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KFX 700V FORCE

1. 3 16 3 16 3 17 3 18 3 20 3 21 3 21 3 22 3 23 3 25 3 25 3 25 3 25 3 25 3 27 3 28 3 28 3 28 3 29 3 29 3 30 3 30 3 31 3 31 3 31 3 32 3 32 E 3 2 FUEL SYSTEM Exploded View PO FUEL SYSTEM 3 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Throttle Limiter Screw 3 7 2 Throttle Limiter Locknut 3 7 33 in Ib 3 Throttle Case Assembly Screws 3 7 33 in Ib 4 Choke Lever Mounting Screw 3 5 31 in lb 5 Left Handlebar Switches Assembly Screws 3 5 6 Throttle Lever T Throttle Cable 8 Choke Lever 9 Choke Cable 10 Jet Needle 11 Pilot Jet 12 Main Jet 13 Needle Jet 14 Pilot Screw O Apply engine oil G Apply grease 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Air Cleaner Housing Bolts M5 5 9 0 60 52inlb L 2 Air Cleaner Housing Bolts M6 8 8 78 mb 3 Air Cleaner Element Bracket Screws 4 9 43 in lb 4 Fuel Tap Plate Screws 0 80 7 in lb 5 Fuel Tap Cover Screws 1 0 6 Fuel Pump Bolts 2 0 0 20 17 in lb 7 Fuel Pump 8 Check Valve L Apply a non permanent locking agent G Apply grease R Replacement Part 3 6 FUEL SYSTEM Specifications Standard 2 3 mm 0 08 0 12 in about 3 mm 0 12 in Service Limit KEIHIN CVKR D32 135 140 80 6 NBZH 4
2. NOTE O Be certain that all parts are cleaned thoroughly before assembly O Blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crank shaft A WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or low flash point solvents to clean parts A fire or explo sion could result e Apply a small amount of engine oil to the transmission gears bearings and shift fork e Be sure the mating surfaces of the crankcase halves are clean and dry e Press and insert the new ball bearings until they are bot tomed Special Tool Bearing Driver Set 57001 1129 A Ball Bearing B Ball Bearing sealed side towards crankcase e Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole C Needle Bearing D Needle Bearing Insert it from outside e Apply engine oil to the bearings e Install Oil Pressure Relief Valve E see Engine Lubrication Sys tem chapter e Install Rear Cylinder Camshaft Chain Guide A e Tighten Torque Rear Cylinder Camshaft Chain Guide Bolt B 20 N m 2 0 kgf m 14 ft Ib CRANKSHAFT TRANSMISSION 9 11 Crankcase e Press and insert the new ball bearings A until they are bottomed Special Tool Bearing Driver Se
3. HMOS5011BSi Rear Side F D Ball Joint Bearing G H 13 5 0 1 mm 0 531 0 004 in Circlips J Oil seals K e Apply grease to oil seals Collars L O HMO5012BS1 13 12 SUSPENSION Swingarm Swingarm Removal e Support the vehicle on a stand or a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e Remove Rear Final Gear Case see Final Drive chapter Swingarm Pivot Left Nut A Swingarm Pivot Left Shaft B e Loosen Boot Clamp Screw A e Remove Boot Swingarm Pivot Right Shaft B Swingarm C Swingarm Installation e Apply molybdenum disulfide grease to the spline of the output shaft A e Fit the propeller shaft on the output shaft e Apply a non permanent locking agent Swingarm Pivot Shaft A B e Tighten Torque Swingarm Pivot Right Shaft 152 N m 15 5 kgf m 112 ft lb e Tighten Torque Swingarm Pivot Left Shaft B 20 N m 2 0 kgf m 14 ft lb Swingarm Pivot Left Nut C 152 N m 15 5 kgf m 112 ft lb e Fit the boot on the swingarm and tighten the clamp screw HM06000481 C Swingarm Swingarm Disassembly e Remove Collars A O ring B e Remove Oil Seal A e Remove Tapered Roller Bearing A e Remove Outer Race A SUSPENSION 13 13 13 14 SUSPENSION Swingarm e Remove Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 e Remove
4. 14 15V 36 54 V 3 000 r min rpm 0 33 0 49 Q 0 7 0 8 mm 0 028 0 031 in 3 75 6 25 kQ 7 mm 0 28 in or more 0 09 0 13 Q Sas 3 8 5 8 KQ RN 50 V or more Lc 110 140 0 ERE 1 8 V or more Magnetic flux detection method EE More than 65 5 for each bank EE Within 0 5 1 0 sec EE in the text EE 28 mm 1 10 in 12 mm 0 47 in 27 mm 1 06 in 4 mm 0 16 in 17 7 22 6 kPa a 0 18 0 23 kgf cm 2 6 3 3 psi Switches Brake light switch timing Radiator fan switch resistance Rising temperature ON after 10 mm 0 4 in NE of pedal travel From OFF to ON at 96 100 C 205 212 F Specifications ELECTRICAL SYSTEM 16 11 Item Standard Service Limit Falling temperature Coolant temperature warning light switch resistance Rising temperature Falling temperature From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 Q OFF More than 1 MQ From OFF to ON at 112 118 C 234 244 F From ON to OFF at 108 111 C 226 232 F ON less than 0 5 OFF More than 1 MQ 16 12 ELECTRICAL SYSTEM Special Tools Hook Wrench 57001 1101 SS gt f 5 Timing Light 57001 1241 Compression Gauge Gasket 57001 1314 S Hand Tester 57001 1394 Flywheel Puller Assembly 57001 1405 Needle Adapter Set 57001 1457 Ba T571457ST C
5. ELECTRICAL SYSTEM 16 13 Parts Location Light Dimmer Switch A Engine Stop Switch B Starter Button C Reverse Power Assist Switch Override D Rear Brake Light Switch E Ignition Switch F Indicator Unit G Front Brake Light Switch H Battery A Fuel Pump Fuel Reserve Switch B in fuel tank Main Fuse 30 A C Starter Relay D Vehicle Down Sensor E Igniter F Ignition Coil Rear G Rear Brake Light Switch H Water Temperature Switch A Radiator Fan Switch B Ignition Coil Front C Spark Plug D Starter Motor E Oil Pressure Warning Light Switch F Crankshaft Sensor G Alternator H Reverse Position Switch A Neutral Position Switch B Regulator Rectifier C Starter Circuit Relays D Radiator Fan Fuse E 16 14 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be taken when servicing electrical systems Learn and ob serve all the rules below O Do not reverse the battery lead connections This will burn out the diodes in the electrical parts O Always check battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system tests O The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them O To prevent damaging electrical parts do not disc
6. 1 Radiator Fan Fuse 20A 2 Radiator Fan Switch 3 Radiator Fan 4 Main Fuse 30A 5 Battery ELECTRICAL SYSTEM 16 61 Fuel Pump Fuel Reserve Switch Fuel Pump Inspection Fuel Pump Supply Voltage Inspection e Turn the ignition switch OFF e Remove Seat Fuel Pump Lead Connector A e Connect a hand tester B with suitable leads as shown Hand Tester gt Fuel Pump Connector BR Terminal Hand Tester gt Fuel Pump Connector BK R Termi nal e Turn the ignition switch ON and run the engine with the transmission in neutral e Measure the fuel pump supply voltage Fuel Pump Supply Voltage Standard near the Battery Voltage x lf the reading is not as specified replace the igniter x lf the reading is as specified check the fuel pump Fuel Pump Operational Inspection e Remove Fuel Pump see Fuel System chapter e Prepare a container filled with kerosene e Prepare the rubber hoses and connect them to the pump fitting e Connect a suitable pressure gauge to the outlet hose as shown Fuel Pump A Pressure Gauge B Outlet Hose C Kerosene D Battery E 12V e Connect the pump leads to the battery using auxiliary wires as shown Battery gt Fuel Pump Connector BR Terminal Battery gt Fuel Pump Connector BK R Terminal Alf the pump does not operate the pump is defective Re place the fuel pump lf the pump operates is normal close the outlet hose while operating the
7. 16 48 ELECTRICAL SYSTEM Electric Starter System e Install the washers A e Install the plate A on the left end cover B e Align the mark A on the left end cover with the mark B on the yoke e Tighten Torque Starter Motor Bolts 4 9 N m 0 50 kgf m 43 in Ib LJ Ur Commutator Cleaning Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves GP110610S1 C Electric Starter System e Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 2 range measure the resistance between any two commutator segments A x lf there is a high resistance or no reading oo between any two segments a winding is open Replace the starter motor e Using the highest range measure the resistance between the segments and the shaft B e f there is any reading at all the armature has a short Replace the starter motor Special Tool Hand Tester 57001 1394 NOTE O Even if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over
8. Front Rear 3 e 9 OT e e 9 e HE02009BN5 Exploded View ENGINE TOP END 5 3 No Fastener Torque Remarks N m kgf m ft Ib 1 Rocker Case Bolts 55 mm 2 2 in 78 ml S 2 Rocker Case Bolts 130 mm 5 1 in 87 ml S 3 Rocker Case Bolts 30 mm 1 2 in 87 ml 4 Rocker Case Bolts 25 mm 1 0 in 87 ml S 5 Cylinder Head Bolts M10 First Torque 18 S MO 5 Cylinder Head Bolts M10 Final Torque 36 S 6 Cylinder Head Bolts M6 87 in lb 7 Cylinder Head Jacket Plugs 14 8 Valve Adjusting Cap Bolts 78 in Ib 9 Valve Adjusting Screw Locknuts 104 in Ib 10 Rocker Shaft Bolts 78 in Ib 11 Water Pipe Bolts 87 in lb G Apply grease for oil seal and O ring M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil SS Apply silicone sealant Kawasaki Bond 56019 120 S Follow the specific tightening sequence 5 4 ENGINE TOP END Exploded View ENGINE TOP END 5 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 78 in Ib 16 Intermediate Shaft Sprocket Nut Intermediate Shaft Chain Guide Bolts 0 90 78 in Ib 090 76i 104 in Ib L 78 in Ib 87 in lb 12 Clamp G Apply grease for oil seal and O ring L Apply a non permanent locking agent O Apply engine oil MO Apply molybdenum disulfide oil R Replacement parts 5 6 ENGINE TOP END
9. e Remove the converter intake duct A from the joint duct B e Remove the converter intake duct Converter Intake Duct Installation e Apply grease to the O ring A e Install the joint duct and tighten the joint duct bolts B Torque Joint Duct Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install the converter intake duct A in the joint duct B as shown O When installing converter intake duct fit to aligning mark Converter Intake Duct Aligning Mark C Joint duct Aligning Mark D e Install the damper and collar e Tighten the duct mounting bolt HS04018BS1 C HS04016BS1 C CONVERTER SYSTEM 6 11 Drive Belt Drive Belt Removal e Remove the drive pulley A see Drive Pulley Removal gt NOTE O Before removing the drive belt observe the direction of the informations A Such as manufacturers name and arrow marks printed on the belt so that it may be reinstalled on the pulleys as originally e Lift the drive belt B off the driven pulley C Drive Belt Installation NOTE O Be sure the printed information faces the same direc tion so the belt rotates in the same direction as origi nally installed When installing a new belt install it so the printed information A can be read from beside the vehicle e Installation is basically the reverse of removal e Loop the belt B over the driven pulley C e Install the drive pulley see Drive Pulley Installation e Pu
10. Assemble the final gear case completely HK14008BS1 C FINAL DRIVE 11 31 Final Gear Case Final Gear Case Backlash related Parts 1 Pinion Gear 5 Ring Gear 2 Pinion Gear Bearing Holder 6 Pinion Gear Shim s 3 Gear Case Right Cover 7 Ring Gear Shim s 4 Ball Bearings 11 32 FINAL DRIVE Final Gear Case 6 Pinion Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1320 0 2 mm 0 008 in 92180 1319 0 5 mm 0 020 in 92180 1321 0 8 mm 0 031 in 92180 1322 1 0 mm 0 039 in 92180 1345 1 2 mm 0 047 in 92180 1346 7 Ring Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1318 0 2 mm 0 008 in 92180 1316 0 5 mm 0 020 in 92180 1317 0 8 mm 0 031 in 92180 1315 1 0 mm 0 039 in 92180 1343 1 2 mm 0 047 in 92180 1344 Backlash Adjustment e Clean any dirt and oil off the bevel gear teeth e Install the pinion gear assembly with the primary shim 1 0 mm 0 039 in thickness e Assemble the final gear case see Final Gear Case As sembly O Install the ring gear with the primary shim 1 0 mm 0 039 in thickness O Check the backlash during tightening the cover bolts and stop to tighten them immediately if the backlash disap pears Then change the ring gear shim to a thinner one e Temporarily install the rear axle in the gear case and hold it with a vise so that the ring gear is lower than
11. C Spring 2 If compression is released while the engine is running the weights are not swinging out e Remove the spring and move the weights back and forth lf the weights do not move easily from the retracted po sition replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Running Position compression is not released B Weights C Spring KACR Removal e Remove Camshaft see Camshaft Removal Camshaft Sprocket Bolts A KACR Unit B HE09000BS1 C HE09001BS1 C HE09002BS1 C RO P ENGINE TOP END 5 21 Camshaft e Remove Circlips A Weights B Spring C NOTE O Do not remove the shaft A and pin B O If the parts are removed they cannot be reinstalled Rm P KACR Installation e Install Weights Circlips Spring A O Hook the spring from the outside with the open side of the hook inwards e Install KACR Unit e Hook the arms B on the pins e Apply a non permanent locking agent to the camshaft sprocket bolts C and tighten them Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 in Ib Camshaft Chain Removal e Remove left side view Rear and Front Camshafts see Camshaft Removal Alternator Rotor see Electrical System chapter Oil Pump see Engine Lubrication System chapter Intermediate Shaft Chain Tensioner A Circlip B and Washer Special Tool Outs
12. e Turn the idle adjusting screw A until the idle speed is correct O Open and close the throttle a few times to make sure that the idle speed is within the specified range Fuel System Cleanliness Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Place the suitable container under the drain plugs A e Turn out the carburetor drain plug a few turns and drain the fuel system Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 e Check to see if water or dirt comes out e Tighten the drain plug lf any water or dirt appears during the above inspection clean the fuel system carburetor fuel tank fuel hose Air Cleaner Element Cleaning and Inspection NOTE O In dusty areas the element should be cleaned more frequently than the recommended interval O After riding through rain or muddy terrains the element should be cleaned immediately O Also if there is a break in the element material or any other damage to the element replace the element with a new one Clean the element in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any appliance with a pilot light
13. i Kawasaki KFx 700V FORCE All Terrain Vehicle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure e Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page e Refer to the sectional table of con tents for the exact pages to locate the specific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Converter System Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System sch ch aaa a a l O AJIO IN e Il Il ol IN IO or B Oo NB9 lech Appendix Kawasaki KFX 700 V FORCE All Terrain Vehicle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time wi
14. 87 in Ib Rocker Case Bolts A L 30 mm 1 2 in L 25 mm 1 0 in 9 8 N m 1 0 kgf m 87 in Ib e Check the valve clearance and adjust it if necessary HE10003BS1 C ON P K N ALAA e a HE10000881 ENGINE TOP END 5 15 Rocker Case e Apply grease to the O ring A e Tighten Torque Valve Adjusting Cap Bolts B 8 8 N m 0 90 kgf m 78 in lb HE100013S1 Rocker Arm Removal e Remove Rocker Case Rocker Shaft Bolts A see Rocker Case Removal Rocker Shaft B Washers O Mark and record the rocker arm location so it can be in stalled in the original position O The rocker arms come off with the rocker shafts Rocker Arm Installation e Apply molybdenum disulfide oil Rocker Shaft A Hole in Rocker Arm B e Apply grease to the O rings C e Install Wave Washers D as shown Rocker Arms as shown Rocker Shafts and O rings e Tighten Torque Rocker Shaft Bolts E 8 8 Nm 0 90 kgf m 78 in Ib HE10001052 C 5 16 ENGINE TOP END Rocker Case Rocker Arm Inspection e Inspect the area A on the rocker arm where the cam rubs xIf the rocker arm is scored discolored or otherwise dam aged replace it Also inspect the camshaft lobes e Inspect the end of the valve clearance adjusting screws B where it contacts the valve stem x lf the end of the adjusting screw is mushroomed or dam aged in any way or if the screw will not tur
15. A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics The carburetor has been calibrated to provide lean air fuel mixture characteristics and opti mum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufac
16. Brake Fluid Level Inspection Brake Fluid Change Brake Line Air Bleeding Master Cylinder Inspection Visual Inspection ettet Caliper Fluid Seal Replacement Caliper Dust Seal and Friction Boot Replacement Rear Brake Plates Replacement Rear Brake Lever Free Play Inspection Rear Brake Pedal Free Play Inspection Rear Brake Lever and Pedal Free Play Adjustment aeeeeee SUSPENSION ccccccocccnnnncccnnnnnnnnnnnnonanenens Knuckle Joint Inspection Steering EE Steering Inspection Tie Rod End Inspection Electrical System Spark Plug Cleaning Inspection Spark Plug Gap Inspection Brake Light Switch Inspection Brake Light Timing Adjustment General Lubrication Lubrication ococcccccccccccncincnnnnnns 2 28 2 28 2 29 2 29 2 29 2 29 2 30 2 30 2 30 2 30 2 30 2 31 2 31 2 32 2 33 2 34 2 34 2 34 2 34 2 34 2 35 2 35 2 35 2 36 2 36 2 36 2 37 2 37 2 37 2 37 2 37 2 37 2 37 2 2 PERIODIC MAINTENANCE Bolts and Nuts Tightening PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglec
17. C CAUTION Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Master Cylinder Installation e The master cylinder clamp must be installed with the UP mark A upwards e Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line after master cylinder installation see Brakes in the Periodic Maintenance chapter e Check the brake for good braking power no braking brag and no fluid leakage A WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done Master Cylinder Disassembly e Remove Master Cylinder see Master Cylinder Removal Brake Lever Pivot Nut A Brake Lever Pivot Bolt B Brake Lever C Dust Cover D Circlip E Piston F Spring G Special Tool Inside Circlip Pliers 57001 143 CAUTION Do not remove the secondary cup H from the pis ton since removal will damage it BRAKES 12 9 HL07010281
18. Camshaft chain sprocket guides worn Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Troubleshooting Guide Drive pulley weight or roller worn Wear guides worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Final gear case noise Insufficient lubricant Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Rear brake noise Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level too high Black Smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Tire air pressure too low Steering ste
19. Drive Pulley Alf the sheave bushing is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 37 985 38 085 mm 1 4955 1 4994 in Service Limit 38 12 mm 1 501 in x lf the spider shoes A are damaged replace them e Check the spider shoe side clearance see Spider Shoe Side Clearance Inspection lf the ramp weights A in the movable sheave are dam aged or worn replace them Alf the pins B are damaged or worn replace them xIf the rollers A are damaged or worn replace the spider B If the washers C are damaged or worn replace the spi der CONVERTER SYSTEM 6 17 Drive Pulley lf the spring is worn or damaged replace the spring Spring Free Length A Standard 60 4 mm 2 38 in HS0601168S1 Spider Shoe Side Clearance Adjustment e Remove Drive Pulley see Drive Pulley Removal Drive Pulley Cover and Spring see Drive Pulley Disas sembly e Temporarily install Dowel Pins 2 Drive Pulley Cover Two Bolts at dowel pins e Turn the movable sheave clockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at all four arms Shoe Side Clearance Standard 0 15 0 30 mm 0 0059 0 0118 in lf any of the measurements are greater than the maxi mum replace all shoes with standard shoes see Drive Pulley Disassembly HS06001BSi 6 18 CONVERTER SYSTEM Drive Pulley e Turn
20. HLOTOGOBS1 C 12 10 BRAKES Master Cylinder Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake e Take care not to scratch the piston or the inner wall of the cylinder e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in Ib Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib Master Cylinder Inspection Visual Inspection e Refer to the Brakes in the Periodic Maintenance chapter Calipers Caliper Removal e Remove the front wheel see Wheels Tires chapter e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts B e Detach the caliper C from the disc e Unscrew the banjo bolt and remove the brake hose D from the caliper CAUTION Immediately wash away any brake fluid that spills NOTE O If the caliper is to be disassemble
21. Inspection ssssesususs Air Cleaner Draining Fuel Hoses and Connections Inspection sssssessssss Fuel Hose and Fuel Filter Replacement Cooling System Radiator Cleaning Radiator Hose and Connection Inspection ssessssssuss Coolant Change Coolant Filter Cleaning Engine Top End EE Valve Clearance Inspection Valve Clearance Adjustment Spark Arrester Cleaning Converter System Drive Belt Inspection Drive Belt Deflection Inspection Drive Belt Deflection Adjustment Engine Lubrication System Engine Oil Change Oil Filter Change Crankshaft Transmission 2 19 2 20 2 22 2 22 2 22 2 23 2 24 2 24 2 24 2 25 2 26 2 27 2 27 2 27 2 28 Shift Control Grip Free Play Inspection Shift Control Grip Free Play Adjustment ssss Wheels Tires ssssseneee reenn renren Tire Inspection Final Drive Final Gear Case Oil Change Propeller Shaft Joint Boot Inspection Front Brake Pad Wear Inspection Front Brake Hoses and Connections Inspection Front Brake Hose Replacement
22. NOTE O Do not tilt the container as the electrolyte flow may be interrupted e Make sure air bubbles A are coming up from all six filler ports OLeave the container this way for 5 minutes or longer NOTE O f no air bubbles are coming up from a filler port tap B the bottom of the bottle two or three times Never remove the container from the battery CAUTION Fill the electrolyte into the battery until the con tainer is completely emptied e Be certain that all the electrolyte has flowed out e Tap the bottom the same way as above if there is any electrolyte left in the container e Now pull the container gently out of the battery e Let the battery sit for 20 minutes During this time the electrolyte permeates the special separators and the gas generated by chemical reaction is released GP08030281 C ffe TS E GP08030381 C GP08030481 C ELECTRICAL SYSTEM 16 19 Battery e Fit the seal caps A tightly into the filler ports until the seal caps are at the same level as the top of the battery NOTE O Do not hammer Press down evenly with both hands Q e SRSRSRSRSRE Toy 3 Mel CAUTION Once you installed the seal caps after filling the bat tery never remove it nor add any water or elec trolyte 6P08010BS1i Initial Charge While an sealed battery can be used after only filling with electrolyte a battery may not be able to suffi
23. Output Bevel Gear Adjustment Procedure Adjust gear backlash Adjust tooth contact pattern Assemble the output bevel gear completely HKi16005BSi 11 18 FINAL DRIVE Output Bevel Gears Output Bevel Gear Backlash related Parts 1 Ball Bearings 5 Output Driven Bevel Gear 2 Drive Bevel Gear Shims 6 Output Driven Shaft 3 Output Drive Bevel Gear 7 Driven Bevel Gear Shims 4 Bearing Housings FINAL DRIVE 11 19 Output Bevel Gears Drive Bevel Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1311 0 2 mm 0 008 in 92180 1312 0 5 mm 0 020 in 92180 1313 0 8 mm 0 031 in 92180 1314 1 0 mm 0 039 in 92180 1351 1 2 mm 0 047 in 92180 1352 Driven Bevel Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1307 0 2 mm 0 008 in 92180 1308 0 5 mm 0 020 in 92180 1309 0 8 mm 0 031 in 92180 1310 1 0 mm 0 039 in 92180 1349 1 2 mm 0 047 in 92180 1350 Bevel Gear Backlash Adjustment O The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position e Remove the output drive idle gear see Output Drive Bevel Gear Removal e Set up a dial gauge A against the output drive shaft spline groove to check gear backlash OTo measure the backlash turn the shaft clockwise and counterclockwise slightly so as not to move the mate gea
24. compression is head and in combustion chamber possibly and replace damaged parts if higher than usable due to damaged valve stem oil seal and or necessary range damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket thickness Damaged or missing compression release cam spring Replace the gasket with a standard part Replace the spring Compression release weights do not move smoothly Cylinder Gas leakage around cylinder head compression is Replace the compression release unit Replace damaged gasket and check cylinder head warp lower than usable Bad condition of valve seating Repair if necessary range Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Piston seizure Bad condition of piston ring and or piston ring grooves Compression release weights do not move smoothly Replace the piston and or cylinder Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Replace the piston and or the piston rings Replace the compression release unit 5 28 ENGINE TOP END Cylinder Head Cylinder Head Removal e Drain the coolant see Cooling System chapter e Remove Carburetor see Fuel System chapter Exhaust Pipe see Exhaust Pipe Removal Water Pipe A Spark Plug Cap B Rocker Case C Camshaft see Camshaft Removal Exhaust P
25. grind until the seat is slightly too wide and then return to the seat O D measurement step above GE15011981 C GE15012181 C O GE15012281 ENGINE TOP END 5 35 Valves x lf the seat width is too wide make the 60 A grind de scribed below lf the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range O To make the 60 grind fit 60 cutter into the holder and slide it into the valve guide O Turn the holder while pressing down lightly O After making the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the seat once the seat width and O D are within the ranges specified above O Put a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve O Repeat the process with a fine grinding compound A Lubber B Valve Seat C Valve e The seating area should be marked about in the middle of the valve face If the seat area is not in the right place on the valve check to be sure the valve is the correct part If itis it may have been refaced too much replace it e Be sure to remove all grinding compound before assem bly e Whe
26. should move freely A within the cable housing Alf 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 C Points Lubricate with Grease Throttle Inner Cable Ends A Choke Cable Lower End Brake Cable Ends Shift Control Cable Upper Ends 6004040381 C Slide Points Lubricate with Grease Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Bolts and Nuts Tightening Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition x lf there are loose fasteners retorque them to the speci fied torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not listed in the appropriate chapter see the Basic Torque Table see Torque and Locking Agent For each fastener first loosen it by 1 2 turn then tighten it lf cotter pins are damaged replace them with new ones Bolts Nuts and Fasteners to be checked Wheels Front Axle Nuts and Cotter Pins Rear Axle Nuts and Cotter Pins Wheel Nuts Brakes Front Brake Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Brake Lever Pivot Nut Front Brake Caliper Mounting Bolts Brake Pedal Cot
27. the oil seal If the inspection hole is blocked the coolant may pass through the oil seal and flow into the crankcase e Apply heat resistance grease on the oil seal lip e From outside the alternator cover press and insert the oil seal A flush B in the direction as shown Special Tool Bearing Driver Set 57001 1129 COOLING SYSTEM 4 11 Hp06000781 Hp060008S1 HpOo60009S1 4 12 COOLING SYSTEM Water Pump e From inside the alternator cover press and insert the ball bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Using a suitable socket A and the bearing driver B press and insert a new mechanical seal C until its flange stops at the step D of the hole Special Tool Bearing Driver Set 57001 1129 e Clean the sliding surface of a new mechanical seal with a high flash point solvent and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica tion e Apply coolant to the surfaces of the rubber seal and seal ing seat A and press the rubber seal B and sealing seat into the impeller by hand until the seat bottoms out e Tighten the water pump impeller by turning the bolt clock wise Torque Water Pump Impeller 7 9 N m 0 80 kgf m 69 in Ib HD06001081 C C Hm EE COOLING SYSTEM 4 13 Radiator Radiator Removal The rad
28. 17 Initial Charge seee 16 19 Precautions ccccccccccncnncnnnnnnnnnnnns 16 19 Interchange 16 20 Charging Condition Inspection 16 21 Refreshing Charge 16 21 Charging System 16 23 Alternator Cover Remowval 16 23 Alternator Cover Installation 16 24 Alternator Rotor Removal 16 25 Alternator Rotor Installation 16 26 Alternator Stator Removal 16 26 Alternator Stator Installation 16 26 Regulator Rectifier Output Voltage Inspection eeesssuss 16 27 Alternator Inspection 16 28 Regulator Rectifier Inspection 16 29 Ignition System 16 32 Spark Plug Removal 16 32 Spark Plug Installation 16 33 Spark Plug Cleaning Inspection 16 33 Spark Plug Gap Inspection 16 33 Ignition Coil Removal 16 33 Ignition Coil Installation 16 34 Ignition Coil Inspection 16 34 Ignition Coil Primary Peak Voltage Inspection seeesssssss 16 36 Crankshaft Sensor Removal 16 36 Crankshaft Sensor Installation 16 37 Crankshaft Sensor Inspection 16 37 Crankshaft Sensor Peak Voltage Inspection sssesssssuss 16 38 Alternator Rotor Inspection Ignitio
29. 21 93 mm 0 863 in If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again lf the clearance still remains out of the limit replace the cylinder head and the rocker case CAUTION The cylinder head and rocker case are machined as a set and must be replaced as a set ENGINE TOP END 5 19 5 20 ENGINE TOP END Camshaft KACR Inspection The Kawasaki Automatic Compression Release KACR momentarily opens the exhaust valves on the compression stroke at very low speeds This allows some of the com pression pressure to escape making it easy to turn over the engine during starting Due to the simplicity of the mechanism no periodic main tenance is needed There are only two symptoms of prob lems with the KACR mechanism A compression is not re leased during starting and compression is released during running 1 If compression is not released during starting the weights are not returning to their rest position e Remove the camshaft see Camshaft Removal e Remove the KACR unit e Visually inspect the spring lf damaged deformed or missing replace the spring e Remove the spring and move the weights back and forth lf the weights do not move smoothly replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Rest Position compression is released B Weights
30. 27 mm 1 06 in remove the spacers to decrease it O The rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 3 mm 0 051 in change in belt deflection x lf the belt deflection is less than 22 mm 0 87 in add the spacers A to increase it O The rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 6 mm 0 063 in change in belt deflection Spacers Part No Thickness 92026 1569 0 6 mm 0 024 in 92026 1617 0 8 mm 0 032 in 92026 1565 1 0 mm 0 039 in 92026 1570 1 4 mm 0 055 in e Assemble the driven pulley see Converter System chap ter e With the transmission in neutral rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection e Measure the belt deflection again and repeat the above procedures until it is within the standard range e Using the flywheel amp pulley holder and adapter tighten the driven pulley nut Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft lb PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change e Support the vehicle so that it is level side to side and front to back after warming up the engine e Remove the engine drain plug A to drain the oil OThe oil in the filter can be drained by removing th
31. 4 Fuel Hose 5 Fuel Filter 6 To Fuel Tank 7 Face the clamp as shown 17 16 APPENDIX Cable Wire and Hose Routing D 7 1 Front Brake Switch Lead T Left Handlebar Switch Lead 2 Throttle Cable 8 Parking Brake Cable 3 Front Brake Hose 9 Choke Cable 4 Indicator Unit Lead 10 Shift Control Cable 5 Ignition Switch Lead 11 Shift Control Cable 6 Brake Switch Lead ZA y GEA aa LAN EA HB09057BN4 C APPENDIX 17 17 Cable Wire and Hose Routing Gi if EA Wi HS NER oes MEG a PEE SS e e rU A 2 mm a 9 a ZII K o LO eg TS EN fs LP HB09058BN4 C 1 Throttle Cable 2 Choke Cable 3 Shift Control Cable 4 Clamp the choke cable only with the band 5 Band 6 To Front Side of Shift Control Grip 17 18 APPENDIX Cable Wire and Hose Routing 1 Final Gear Case Breather Hose 2 Band 3 Reverse Lock Cable 4 Clamp 5 Rear Brake Cable 6 Parking Brake Cable HB09059BN4 C 7 Clamp 8 Band With the Rear Brake Light Switch 9 Through the parking brake cable upper side on the cross pipe 10 Shift Control Cable 11 To Rear Side of Shift Control Grip Cable Wire and Hose Routing APPENDIX 17 19 5 6 CO QD WM sp7 Y 71 Y i ADN A Ig led Sp 41 7 if F Gi A Head Light Lead 11 Horn Connect
32. 600 4 900 ft Rear 138 P No 92063 1015 1 500 2 500 m Front 130 P No 92063 1075 4 900 8 200 ft Rear 135 P No 92063 1014 2 500 3 500 m Front 128 P No 92063 1074 8 200 11 500 ft Rear 130 P No 92063 1075 3 500 4 500 m Front 120 P No 92063 1073 11 500 14 800 ft Rear 125 P No 92063 1069 There is not high altitude setting for belt converter ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System TABLE OF CONTENTS z delere MEE 7 2 eene le d c dada TRE sabia FENCE hens CEDE NR ce EA e ON En RE tease dia Re Dd 7 4 Special Tools and Sealant sisisireiuie praeerant rre ata ea aa ieie eie ai aaen 7 5 Engine Oil Flow Ghart ooi erit aa 7 6 Engine Oil ad ele EE 7 7 Oil Level INSPECHOMN EET EA E AEAT 7 7 Engine OLEA e EE 7 7 Ol Fiter CAN GC EE 7 T Oil Screen Removal ac A A E SERA 7 T OP SESS CISMA DEE 7 8 Oil Pressure Measurement occccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininiinnnis 7 8 Oil Pressure Relief Valve en enn nennen nnne nn nn nnns nsns nnns nnns 7 9 Oil Pressure Relief Valve Removal sssssssssee nnne 7 9 Oil Pressure Relief Valve Installation nsnnsssenesensrrsrrrrrrtrrrrrrrrrrrrrrttrtrrtrrrtnttnnttnnrrennrenn 7 9 Oil Pressure Relief Valve Inepechon eee 7 9 Oll PUNO des iecore a ds 7 10 Oll Purmp FermoVval EEN 7 10 Oll Pump Installation e echec iere et ede ec 7 10 eco dM 7 12 Oi
33. Air Cleaner Housing Bolts M5 A e Remove Air Cleaner Housing Bolts A e Remove Breather Hose A Air Vent Hose B Drain Hose C Air Cleaner Housing D FUEL SYSTEM 3 27 Air Cleaner Air Cleaner Housing Installation e Insert the fitting of the housing in the duct A and fit the projection B under the fitting in the groove C in the duct e Tighten the clamp screws e Install Drain Tube A Grommets B Air Ducts C e Install Breather Hose A Air Vent Hose B Drain Hose C e Insert the carburetor air vent tube D in the fitting E of the housing e Apply a non permanent locking agent to the air cleaner housing bolts M5 A and tighten them Torque Air Cleaner Housing Bolts M5 5 9 N m 0 60 kgf m 52 in Ib e Tighten Torque Air Cleaner Housing Bolts M6 B 8 8 N m 0 90 kgf m 78 in Ib e Install Air Cleaner Element Air Cleaner Housing Cap 3 28 FUEL SYSTEM Fuel Tank Fuel Tank Removal e Remove Rear Fender see Frame chapter Bolts A Seat Bracket B e Disconnect Breather Hose A Fuel Hose B Fuel Pump Lead Connector C e Remove Fuel Tank Bolts A Fuel Tank B Fuel Tank Installation e Check the rubber dampers A lf the dampers are damaged or deteriorated replace them HC08005BS1 C FUEL SYSTEM 3 29 Fuel Tank e Install Fuel Tank Cover A Fuel Tank B Grommets and Collars e Tighten the fue
34. Bearing e Install Reverse Drive Gear A Spacer B e Install Reverse Idle Shaft A 9 24 CRANKSHAFT TRANSMISSION Transmission e Apply molybdenum disulfide oil to the shift shaft A e Install Shift Shaft Spring Bolt B Spring C Guide D e Apply a non permanent locking agent Shift Shaft Spring Bolt e Tighten Torque Shift Shaft Spring Bolt 25 N m 2 5 kgf m 18 ft lb e When a new bushing A and oil seal B are installed in the shift shaft cover C press and insert the new bushing and oil seal so that their surfaces are flush with the end of the each hole e Install Shift Shaft Cover e Tighten Torque Shift Shaft Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib Shift Fork Bending e Visually inspect the shift fork If the fork is bent replace the shift rod with a new one A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 Shift Fork Gear and Shifter Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the gear groove and shifter If the thickness of a shift fork ear is less than the service limit the shift rod must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 2322 0 2362 in Service Limit 5 8 mm 0 228 in x If the groove is worn over the service limit the shifter must be replaced Shifter Groove Width Standard 6 05 6 15 mm 0 2382 0 2421 in
35. Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the foam element e Remove the air cleaner element see Fuel System chap ter PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures e Clean the element A in a bath of high flash point solvent e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Inspect the element for damage lf it is torn punctured or hardened replace it e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess oil then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the element Air Cleaner Draining e f any water or oil accumulates in the tube drain it by taking off the tube plug A After draining be sure to install the tube plug and clamp firmly Fuel Hoses and Connections Inspection e Remove the air cleaner cover see Frame chapter e Turn the fuel tap to the OFF position e Check the fuel hoses A x lf the fuel hose is frayed cranked or bulged replace the fuel hose e Check that the hose is securely connected and clamps B are tightened lf the fuel hose has been sharply bent or kinked replace the fuel hose x lf the clamps are loosened or damaged replace the clamps e When installing the fuel hose route the hose according to Cable Wire and Ho
36. Bolts 8 8 N m 0 90 kgf m 78 in Ib ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation TABLE OF CONTENTS Exploded BET 8 2 Engine Removal lnstalatiON isiin EUR FO o ai 8 4 Engine REMOVAL EE 8 4 Engine Install carnosa idas a oct 8 5 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Engine Mounting Bracket Bolts 52 5 3 38 2 Engine Mounting Nut 62 6 3 46 8 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal e Remove Engine Oil drain Coolant drain and Coolant Hose Front Fender and Rear Fender see Frame chapter Side Inner Covers see Frame chapter Muffler and Exhaust Pipe see Engine Top End chapter Carburetor see Fuel System chapter Intake and Exhaust Converter Duct Alternator Lead Connector Crankshaft Sensor Lead Connector Foot Guards and Guard see Frame chapter Cable Holder A and Reverse Lock Cable B see Crankshaft Transmission chapter Oil Pressure Switch Lead Connector Spark Plug Caps e Remove Starter Motor Cable Battery Negative Cable Neutral Switch Lead Connector Reverse Switch Lead Connector Boat roll up forward A Engine Mounting Bolts B Engine Mounting Bracket C e Put a tape to protect the frame e Move the engine forward to remove the drive shaft A e Remove the engine as shown E
37. Exploded View ENGINE TOP END 5 7 Exploded View No Fastener torque Remarks N m kgf m ft Ib 1 Exhaust Pipe Cover Bolts 88 090 78inlb 2 Muffler Cover Bolts 8 8 0 90 78 ml 3 Muffler Mounting Bolts 20 2 0 14 4 Exhaust Pipe Clamp Bolt 8 8 0 90 78 in Ib R Replacement parts 5 8 ENGINE TOP END Specifications Item Standard Service Limit Rocker Case Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in 12 05 mm 0 474 in KACR Kawasaki Automatic Compression Release KACR operating engine speed Cylinder Head Cylinder compression usable range Electric starter 290 520 kPa 3 0 5 3 kgf cm 43 75 psi 290 r min rpm 760 30 r min rpm Rocker shaft diameter 11 973 11 984 mm 0 4714 0 4718 in 11 95 mm 0 470 in Camshafts Cam height Exhaust 35 363 35 477 mm 1 3932 1 3967 in 35 26 mm 1 388 in Inlet 35 622 35 736 mm 1 4024 1 4069 in 35 52 mm 1 398 in Camshaft bearing clearance 618 0 016 0 052 mm 0 0006 0 0020 in 0 14 mm 0 0055 in 22 0 020 0 062 mm 0 0008 0 0024 in 0 15 mm 0 0059 in Camshaft journal diameter 618 17 966 17 984 mm 0 7073 0 7080 in 17 94 mm 0 706 in 22 21 959 21 980 mm 0 8645 0 8653 in 21 93 mm 0 863 in Camshaft bearing inside diameter 618 18 000 18 018 mm 0 7087 0 7094 in 18 08 mm 0 712 in 22 22 000 22 021 mm 0 8661 0 867
38. Fastener Torque Remarks N m kgf m ft Ib Handlebar Holder Bolts 3 0 S Tie Rod Adjusting Locknuts 16 Tie Rod End Nuts 31 Steering Stem Clamp Bolts Steering Stem Bearing Joint Bolts 18 Steering Stem Bottom End Nut 30 Suspension Arm Pivot Bolts E 31 Knuckle Joint Nuts 22 Master Cylinder Clamp Bolts 0 90 78 in lb L Apply a non permanent locking agent G Apply grease for oil seal and O ring AD Apply adhesive agent AG Apply grease Amoco rykon premium grease No 2 EP Green S Follow the specific tightening sequence 14 4 STEERING Specifications Item Standard Service Limit Tie Rods Tie rod length 387 4 1 5 mm 15 3 0 06 in STEERING 14 5 Steering Steering Stem Removal e Remove Front Fender see Frame chapter Front Wheels see Wheels Tires chapter Cotter Pins A Tie Rod End Nuts B and Tie Rod End Steering Stem Bearing Housing Bolts C right and left CAUTION Do not loosen the tie rod adjusting locknuts D or the toe in of the front wheels will be changed Handlebar Assembly A see Handlebar Removal Screws B Clamp C e Remove Air Cleaner Duct A Converter Intake Duct B Nuts C and Clamp Steering Clamp Bolts D and Plate Steering Clamps E and Collars Grease Seals F upper and lower e Pull the steering stem out of the frame e Remove Cotter Pin A Steering Stem Bottom End
39. Free Play Inspection e Measure the distance the shift control grip moves with the push button depressed e Check the shift control cable free play of both directions x lf the free play is not within the specified range adjust the cable Shift Control Cable Grip Free play A Standard 0 2 mm 0 0 08 in Shift Control Grip Free Play Adjustment e Remove the battery with the battery case see Electrical System e Make sure that the shift control grip is in neutral position e Make sure that the gear change lever is in neutral posi tion O Neutral position is the shift cable lower ends A and re verse lock cable bracket bolt B aligned state Drive Position C Reverse Position D e Turn the adjusting nuts A at shift control cable lower end make the inner cables B tight with no free play e Turn the shift control grip from N to D and to R respec tively and make sure the change lever C works correctly e Tighten the all adjusting nuts securely e Slide back the rubber covers e Loosen the locknuts A and turn the shift cable upper adjusters B to obtain the specified free play e Tighten the locknuts securely and re install the rubber covers ZN 5 gt Cc SAL Z N PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Wheels Tires Tire Inspection e Examine the tire for damage and wear x lf the tire is cut or cracked replace it OLumps or high spots on th
40. Holder A O Hold the final gear case A in a vise and remove the bearing holder using the socket wrench B Special Tool Socket Wrench Hex 50 57001 1478 O If the holder seems too difficult to break free apply heat to softer the locking agent FINAL DRIVE 11 29 Final Gear Case e Remove Pinion Gear Unit A Shim s Final Gear Case Assembly e Visually check the pinion gear and ring gear for scoring chipping or other damage Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact e Install Shim s Pinion Gear Unit OBe sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Final Bevel Gear Adjustment e Apply a non permanent locking agent to the pinion gear bearing holder A and tighten it Special Tool Socket Wrench Hex 50 57001 1478 Torque Pinion Gear Bearing Holder 137 N m 14 kgf m 101 ft lb e Inspect Ball Bearing A see Bearing and Oil Seal section Oil Seals B see Bearing and Oil Seal section lf they are damaged replace the final gear case right cover C e Apply grease to the oil seal lips and O ring D 11 30 FINAL DRIVE Final Gear Case e Install Final Gear Case Right Cover A Final Gear Case Right Cover Bracket B e Apply a non permanent locking agent to the cover bolts and tighten them following the
41. Ib A L 40 mm 1 57 in B L 65 mm 2 56 in e Install the breather tube A on the crankcase fitting O Align the white line on the tube with the mark B on the crankcase O Face the open end of the clamp C towards the left side D as shown e Apply grease to the steel ball A and spring B e Install Steel Ball Spring Gasket C Shift Shaft Positioning Bolt D e Tighten Torque Shift Shaft Positioning Bolt 25 N m 2 5 kgf m 18 ft Ib e Check Crankshaft and driven shaft turn freely lf any of the shafts do not turn freely split the crankcase to locate the problem p H104012BS1 C bue CRANKSHAFT TRANSMISSION 9 13 Crankshaft Connecting Rod Crankshaft Removal e Split the crankcase see Crankcase Disassembly e Remove the crankshaft A from the crankcase using a press Crankshaft Installation e The left shaft A of the crankshaft is longer than the right shaft B e Apply engine oil to the both main journals e Insert the right crankshaft tapered end the shorter end into the right crankcase using a press WiO40014 P Connecting Rod Removal e Remove the crankshaft see Crankshaft Removal e Remove the connecting rods A from the crankshaft NOTE o Mark and record the locations of the connecting rods and their big end caps B so that they can be installed in their original positions O Remove the connecting rod big end nuts and t
42. Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them 5 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 6 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order
43. Nut B Collar C Steering Stem Bearing D HNO4016BSi 14 6 STEERING Steering Steering Stem Installation e Full grease up the seal grooves A in the steering stem bearing B e Install Collar e Tighten Torque Steering Stem Bottom End Nut 40 N m 4 1 kgf m 30 ft lb e Bend both ends of the cotter pin A as shown Steering Stem Bottom End Nut B e Apply a non permanent locking agent Steering Stem Bearing Joint Bolts A e Apply Amoco Rykon Premium Grease No 2 EP Green Inside of Grease Seals A Steering Stem B e Install Grease Seals Steering Clamps C and Collars D Plate E and Steering Stem Clamp Bolts F Clamp G Nuts H and Washers e Tighten Torque Steering Stem Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Tie Rod End Nuts 42 N m 4 3 kgf m 31 ft lb e Inspect the toe in see Wheels Tires chapter HN04021BS1 C EMI 7 YAT D HNO4001BS1 C HNO4017BS1 C HNO4018BS1 C STEERING 14 7 Steering Knuckle Removal e Remove Front Wheel and Hub see Wheels Tires chapter Brake Caliper see Brakes chapter Cotter Pin and A Tie Rod End B CAUTION Do not loosen the tie rod adjusting locknuts C or the toe in of the front wheels will be changed e Remove Cotter Pins and Knuckle Joint Nuts D Brake Hose Clamp upper knuckle joint e Remove the knuckle E from the suspension arms Knuckle Installation e Inspect
44. Nuts F 62 N m 6 3 kgf m 46 ft Ib Rear Shock Absorber Preload Adjustment e Remove Rear Shock Absorber see Rear Shock Absorber Re moval e Loosen the locknut and turn out the adjusting nut to free the spring Special Tools Hook Wrench A 57001 1101 HM04006BS1 C SUSPENSION 13 9 Shock Absorbers e Measure the spring free length e To adjust the spring preload turn in the adjusting nut A to the desired position and tighten the locknut B Adjusting nut position C Spring Preload Setting Position Standard 94 2 mm 3 71 in Usable Range 93 2 mm 3 67 in to 104 3 mm 4 11 in Torque Rear Shock Absorber Spring Locknut 30 N m 3 1 kgf m 22 ft lb lf the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Position Spring Setting Load Terrain Speed Force 94 2 mm Weak Soft Light Smooth Low 3 71 in T T T T T T y 104 3 mm y Re y y 4 11 in Stronger Hard Heavy Rough High Rear Shock Absorber Inspection e Check the upper pivot lf the sleeve needle bearing and oil seals is damaged replace them Oil Seal A Needle Bearing B Sleeve C Rubber Bushing D e Check the lower pivot lf bushing are worn cracked hardened or otherwise damaged replace them Rear Shock Absorber Scrapping Since the reservoir tank of the rear shock absorber contains nitrogen gas do not
45. Oil Seal A e Remove Collar A Oil Seal B Swingarm Assembly e Apply grease Inside A of Oil Seals e Apply MOBIL FLUID 424 or Equivalent Surface of Collar B e Install the following parts as shown Brake Lever Oil Seal C D 14 5 0 1 mm 0 571 0 004 mm Collar level with surface Propeller Shaft Oil Seal E F 25 0 1 mm 0 984 0 004 mm Ball Bearing G level with surface HM06001281 C SUSPENSION 13 15 Swingarm e Apply Amoco Rykon Premium Grease No 2 EP Green Inside of Oil Seals A O rings B e Install the following parts as shown Tapered Roller Bearing C Oil Seal level with surface O ring Collar D Special Tool Bearing Driver Set 57001 1129 Swingarm Bearing Inspection e Remove the final gear case see Final Drive chapter e Move the swingarm up and down to check for abnormal friction and push and pull it back and forth to check for bearing play If abnormal friction is felt the bearings are damaged Re place the oil seals and both left and right bearings e The play developed during use may indicate bearing dam age In this case remove the swingarm and inspect the bearings Replace both left and right bearings if either of the bearings is damaged Swingarm Bearing Lubrication e Remove the swingarm e Using a high flash point solvent wash the bearings clean of grease and dry them e Inspect the bearings and oil seals for abrasion c
46. Pins C and Springs e Remove Brake Cam Plate A e Remove Steel Balls A BRAKES 12 21 12 22 BRAKES Internal Wet Brake e Remove Brake Cam Lever Bolt and Nut A Brake Camshaft B Brake Cam Lever C Internal Wet Brake Assembly e Apply A MOBIL FLUID 424 or equivalent oil to the brake camshaft and the inside of the collar e Install the brake cam lever inserting the camshaft in the swingarm e Align the punch mark A on the brake cam lever with the punch mark B on the brake camshaft e Install the brake cam lever bolt and nut and tighten them e Install Steel Balls Brake Cam Plate A O Fit the cam plate and brake camshaft B as shown BRAKES 12 23 Internal Wet Brake e Install Steel Pressure Plate A and Pins B as shown e Install Steel Pressure Plates A Friction Plates B Steel Plate C Springs D e Install Dowel Pins A New Gasket B e Apply a non permanent locking agent to the gasket screws C and tighten them e Install Rear Final Gear Case see Final Drive chapter SUSPENSION 13 1 Suspension TABLE OF CONTENTS lee 13 2 SPECIICATIONS EE 13 4 lee tee E 13 5 Shock Absorbers EE 13 6 Front Shock Absorber Inspection 13 6 Front Shock Absorber Preload Adustment A 13 6 Front Shock Absorber REMoOval cceccceeceeeeeeeeeeeeeee ce eeeeceee cee seeeseeeseeeseeeeeeeeeeeeeeeeeeees 13 6 Front Shock Absorber Ins
47. Screws 4 9 0 50 43 in lb L 8 Do not apply a non permanent locking agent to this area 2 3 mm 0 08 0 12 in 9 About 12 mm 0 47 in White Mark Face the mark backwards and align it with the crankcase mark Face the seal of the bearing to the left side outward Apply grease for oil seal and O ring Apply a non permanent locking agent Apply liquid gasket Three Bond 1215 Gray Apply molybdenum disulfide grease Apply molybdenum disulfide oil Apply engine oil Follow the specific tightening sequence 9 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 9 5 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Shift Shaft Lever Nut 78 in lb 2 Shift Shaft Positioning Bolt 18 3 Shift Shaft Spring Bolt 18 E 4 Shift Shaft Cover Bolt 78 in lb 5 Neutral Position Switch 11 6 Reverse Position Switch 11 7 Shift Shaft Lever Bolt 10 8 Reverse Cable Bracket Mounting Bolts 78 in lb 9 Reverse Cable Locknut 12 1 2 104 in Ib 10 Cable Holder Mounting Bolts 9 8 1 0 87 in lb 11 Do not apply a non permanent locking agent to this end Apply grease Apply a non permanent locking agent Apply molybdenum disulfide grease Apply molybdenum disulfige oil Apply engine oil Replacement Parts DAOOZr 9 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit C
48. Specifications in this chapter in the cooling system If hard water is used in the system it causes scale accumulation in the water passages considerably reducing the efficiency of the cooling system Water and Coolant Mixture Ratio when shipping Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 2 5 L 2 64 US qt NOTE O Choose a suitable mixture ratio by referring to the coolant manufacturer s directions e Bleed the air from the cooling system as follows O Start the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant O Tap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine e Check the coolant level in the reserve tank after the en gine cools down x lf the coolant level is lower than the low level line add coolant to the full level line CAUTION Do not add more coolant above the full level line 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Filter Cleaning e Drain the coolant see Coolant change e Remove the filter A from the cooling hoses B of carbu retor system e Blow C off dirt and sediment on the filter with com pressed air HC06005BS1 C Engine Top End
49. Tighten Torque Water Pump Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib Impeller Removal e Drain the coolant see Cooling System in Periodic Main tenance chapter e Remove the water pump cover see Water Pump Cover Removal e Loosen the water pump impeller A counterclockwise Water Pump Impeller Installation e Apply a small amount of coolant on the sliding surface A of the mechanical seal and the sealing seat e Install the impeller on the water pump shaft and tighten the impeller Torque Water Pump Impeller 7 8 N m 0 80 kgf m 69 in Ib Water Pump Water Pump Impeller Inspection e Visually inspect the impeller A x lf the surface is corroded or the blades are damaged re place the impeller Mechanical Seal Replacement e Remove Water Pump Impeller see Water Pump Impeller Re moval Alternator Cover see Electrical System chapter e Take the bearing A out of the alternator cover using the bearing remover Special Tools Bearing Remover Shaft 9 57001 1265 B Bearing Remover Head 10 x 612 57001 1266 C e Press out the mechanical seal A and oil seal B from the inside of the alternator cover with the bearing driver set C Special Tool Bearing Driver Set 57001 1129 CAUTION If either the mechanical seal oil seal or the ball bearing is removed make sure to replace all of them simultaneously with a new one Be careful not to block the inspection hole with
50. Tube 3 Clamps 10 Starter Cable 4 Boots 11 Carburetor 5 Clamp 12 Clamps 6 Vent Hose 13 Air Vent Tube 7 To Crankcase 17 12 APPENDIX Cable Wire and Hose Routing ESA NY VIEW B E SES No RKO SP HB09053BN4 C 1 Clamps 7 Drain Plug 2 Bands 8 Drain Hose 3 Ignition Coil Rear 9 Vent Hose 4 Clamp 10 Align the mark 5 Clamp 11 Fit the projection and groove of the each 6 Clamp ducts APPENDIX 17 13 Cable Wire and Hose Routing HB09054BN4 Coolant Temperature Warning Light 7 Radiator Switch 8 Forward Reserve Tank 9 Face the reserve tank breather hose as Reserve Tank Breather Hose shown Cooling Hose 10 Fan Motor Breather Hose Clamp 11 Fan Motor Lead Radiator Hose DIAN 17 14 APPENDIX Cable Wire and Hose Routing HB09055BN4 C 1 Radiator Hose 8 Clamp 2 Cooling Hose 9 Face the white paint upward 3 Reserve Tank 10 To Thermostat 4 Radiator Fan Switch 11 To Water Pump 5 Fan Motor Lead 12 To Fan Motor 6 Fan Motor Breather Hose 13 To Final Gear Case 7 Clamp APPENDIX 17 15 Cable Wire and Hose Routing MU N NE JI CET rr ff A cs REO 4 rf Y icum L DX c x v oz EJ aa Wy Ar X al A PH AN AD e DA RS Ce fo A d A U S G HB09056BW4 C 1 Fuel Tap 2 Fuel Tap Vacuum Hose 3 Clamp
51. Valve Clearance Inspection NOTE O Check the valve clearance only when the engine is cold at room temperature e Remove Air Cleaner Cover see Frame chapter Air Cleaner Housing see Fuel System chapter Front Fender see Frame chapter Valve Adjusting Caps A e Remove the timing inspection plug A Special Tool Filler Cap Driver 57001 1454 e Remove the alternator bolt cover B e Turn the crankshaft counterclockwise with a wrench on 6 the alternator rotor bolt until T F mark A on the alter nator rotor aligns with the notch B as shown the end of the compression stroke in the front cylinder head f kh A HE10001BS1 C PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Measure the clearance for all four valves one at a time between the end of the valve stem and the adjusting screw A with the thickness gauge B Valve Clearance when cold Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in lf the valve clearance is not correct adjust it see Valve Clearance Adjustment e Then turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until T R mark A on the alternator rotor aligns with the notch B as shown the end of the compression stroke in the rear cylinder head A e Measure the clearance for all four valves one at a time between the end of the valve stem and the adjusting screw
52. amount of water Get medical attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electri cal system Therefore replace a sealed battery only on a vehicle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment the sealed battery s life will be shortened ELECTRICAL SYSTEM 16 21 Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage e Remove the battery see Battery Removal CAUTION Be sure to disconnect the negative lead first e Measure the battery terminal voltage NOTE GP08070351 O Measure with a digital voltmeter A which can be read to one decimal place voltage 13 0 lf the reading is below the specified refreshing charge is i8 required 12 0 Battery Terminal Voltage Standard 12 6 V or more 0 25 50 75 100 Battery Charge ke lt gt Terminal Voltage V Refreshing Charge i Good is required GPO801098S1 Refreshing Charge e Remove the battery A see Battery Removal e Refresh charge by following method according to the bat tery terminal voltage A WARNING This battery is sealed type Never remove seal sheet B even at charging Never add water Charge with current and time as
53. and Alternator Bolt Cover B Water Pump Cover C and Impeller see Cooling Sys tem chapter e Remove Torque Converter Cover see Converter System chap ter e Remove the three bolts of the drive pulley cover except for at the dowel pin parts A as shown B Arrow e Install and tighten the drive pulley holder A and the three bolts B Special Tool Drive Pulley Holder 57001 1520 C Arrow e Holding the drive pulley with the drive pulley holder loosen the alternator rotor bolt A e Remove Alternator Rotor Bolt ELECTRICAL SYSTEM 16 23 16 24 ELECTRICAL SYSTEM Charging System e Remove Collar A O Install the M6 bolt B to the collar and remove it e Place an oil pan under the engine left side e Remove Alternator and Crankshaft Sensor Lead Connectors dis connect Alternator Cover Bolts A Alternator Cover B Clamp C Alternator Cover Installation e Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces e Check that the dowel pins A are in place and fit a new gasket on the crankcase e Check that the bearing B is in place e Fit the grommets A into the notch in the cover e Grease the alternator cover oil seal e Tighten Torque Alternator Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib ELECTRICAL SYSTEM 16 25 Charging System e Check that the O ring A in the collar B is in good con dition e Apply gr
54. circuit Meter gt Connector BR Lead C Meter gt Connector BK Y Lead D e Turn the ignition switch ON and measure the power source voltage Vehicle down Sensor Power Source Voltage Standard Battery Voltage 12 5 V or more e Turn the ignition switch OFF lf there is no battery voltage check the following Main Fuse 30A Ignition Switch Wiring for Vehicle down Sensor Power Source HPi0005BSi Il Connections to Connector 5 V circuit Meter gt Connector Y G Lead E Meter Connector BK Y Lead D B e Turn the ignition switch ON and measure the power Si source voltage o o Vehicle down Sensor Power Source Voltage Standard about 5 V e Turn the ignition switch OFF Alf there is no standard voltage check the following Igniter Wiring for Vehicle down Sensor Power Source HPi0006BSi 16 42 ELECTRICAL SYSTEM Ignition System Vehicle down Sensor Output Voltage e Remove the vehicle down sensor see Vehicle down Sensor Removal e Connect the vehicle down sensor A to the connector of the harness e Hold the sensor almost vertical B with the arrow mark pointed up e Connect Vehicle down Sensor Lead Connector C Digital Volt Meter D Needle Adapters E Special Tool Needle Adapter Set 57001 1457 Connection to Connector 5 V circuit Meter Connector Y G Lead F Meter gt Connector BK Y Lead G e Turn the ignition switch
55. continue the test Regulator Circuit Test 3rd Step e Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step e Momentarily apply 24 V to the BR terminal by adding a 12 V battery e Check Y1 Y2 and Y3 terminals CAUTION Do not apply more than 24 V to the regulator recti fier Do not leave the 24 V applied for more than a few seconds or the unit will be damaged Alf the test light did not light when the 24 V was applied momentarily to the BR terminal the regulator rectifier is defective xIf the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit GPOS060581 C ELECTRICAL SYSTEM 16 31 Charging System Charging System Circuit l gt gt e gt gt gt y m ca n gt N EL c m c en 1 Ignition Switch 3 Regulator Rectifier 5 Main Fuse 30A 2 Alternator 4 Battery 6 Load 16 32 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or an
56. defective e Check the stator coil resistance as follows O Stop the engine O Disconnect the alternator connector O Connect a hand tester as shown in the table O Note the readings total 3 measurement Stator Coil Resistance Tester Connections Range Tester to Tester to x 1 One yellow lead Another yellow lead 0 33 0 49 Q x If there is more resistance than shown in the table or no reading infinity for any two leads the stator has an open and must be replaced Much less resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any reading less than infinity co indicates a short neces sitating stator replacement lf the stator coils have normal resistance but the voltage check shows the alternator to be defective then the rotor magnetism has probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Reading ELECTRICAL SYSTEM 16 29 Charging System Regulator Rectifier Inspection e Remove Connectors A disconnect Bolts B and Regulator Rectifier C Rectifier Circuit Check BR e Check conductivity of the following pair of terminals Rectifier Circuit Inspection Tester WIR Y1 WIR Y2 WIR Y3 W R BK connection BK Y1 BK Y2 BK Y3 The resistance should be low in one direction an
57. diluted coolant must be returned to the cor rect mixture ration within a few days If coolant must be added often or the reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant Draining e Refer to the Cooling System in the Periodic Maintenance chapter Coolant Filling e Refer to the Cooling System in the Periodic Maintenance chapter COOLING SYSTEM 4 9 Coolant Pressure Testing l e Remove the upper front cover and radiator cap then in stall a cooling system pressure tester A on the radiator filler neck NOTE O Wet the cap sealing surfaces with water or coolant to prevent pressure leakage e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds xIf the pressure holds steady the system is alright x If the pressure drops soon check for leaks 4 10 COOLING SYSTEM Water Pump Water Pump Cover Removal e Drain the coolant see Cooling System in Periodic Main tenance chapter e Remove Foot Guards Left Side Cooling Hoses A Water Pump Cover Bolts B Water Pump Cover C Water Pump Cover Installation e Install Knock Pins A New Gasket e
58. e Tighten the drain screw e Repeat the same procedure for the other carburetor Service Fuel Level Adjustment Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetors and drain the fuel e Remove the float chamber e Remove the screw A e Slide out the pivot pin B and remove the float C D E HC06001BS2 C FUEL SYSTEM 3 15 Carburetor e Bend the tang A on the float arm very slightly to change the float height Float Height Standard 4 0 1 mm 0 157 0 040 in O Measure the float height A from the mating surface B of float by tilting the carburetor so that the tang of the float C just touches the needle rod D At this time the float valve E rod must not be depressed Olncreasing the float height lowers the fuel level and de creasing the float height raises the fuel level e Assemble the carburetor and recheck the fuel level x lf the fuel level cannot be adjusted by this method the float or the float valve is damaged HCO06002BSi Carburetor Synchronization Inspection e Check idle speed e Remove Converter Exhaust Joint Duct see Converter System chapter Fuel Tap Vacuum Hose A Caps B on the Carburetor Holder
59. gases contain carbon monoxide a colorless odor less poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death e Stop the engine e Install the drain plug Converter System Drive Belt Inspection Inspection of the drive belt is required at least every 90 days of vehicle use average 12 mile day not to exceed 1 700 km 1 100 mile or belt indicator light turn on 100 hours of use counted by the hour meter More frequent inspection is necessary if the vehicle is subjected to hard usage A WARNING Neglect abuse or failure to maintain the transmis sion can result in a severely worn or damaged drive belt locking up the transmission and wheels This can cause the operator to lose control and have an accident resulting in injury or death e Remove the torque converter cover see Converter Sys tem chapter e Measure the height A of the belt paralle portion at sev eral locations If any measurements exceed the service limit replace the belt Belt Height Paralle Portion Standard 1 16 3 48 mm 0 0457 0 1370 in Service Limit 0 64 mm 0 0251 in HUO8001BS1 C PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Check the belt A for abnormal wear B O Measure the width C of the belt at abnormal wear point x lf any measurements exceed 0 5 mm 0 02 in replace the belt E HS05003BSi e Check the belt for cra
60. holder A along with three cover bolts B in the position shown Note the holder s relative position to the arrow mark C e Tighten the three cover bolts to the specified torque Special Tool Drive Pulley Holder 57001 1520 e Tighten Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in Ib Drive Pulley Bolt D New left hand threads 93 N m 9 5 kgf m 69 ft Ib HS06023BS1 C HS06024BS1 C Driven Pulley Driven Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Removal Drive Pulley see Drive Pulley Removal Drive Belt see Drive Belt Removal e Using a flywheel amp pulley holder A and pulley holder at tachments B remove the driven pulley nut C and wash ers Nut has R H threads Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 e Remove Driven Pulley Driven Pulley Disassembly e Hold the drive amp driven pulley holder A in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 e Screw the guide bar B of the spring holder set into the holder Special Tool Spring Holder Set 57001 1483 e Put the driven pulley C on the guide bar e Tighten the nut D and compress the spring with the spring holder E of the spring holder set Special Tool Spring Holder Set 57001 1483 e Remove the circlip A with circlip pliers B Special Tool Circlip Pliers 57001 154 e Remove the n
61. in Ib 6 Neutral Position Switch f 11 7 Reverse Position Switch 11 8 Fuel Pump Mounting Bolts f 17 in lb 9 Regulator Rectifier Bolts 8 8 0 90 78 in lb 10 Vehicle Down Sensor G Apply grease for oil seal and O ring L Apply a non permanent locking agent S Follow the specific tightening sequence SS Apply silicone sealant Kawasaki Bond 56019 120 16 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 9 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Radiator Fan Switch 18 1 8 13 2 Coolant Temperature Warning Light Switch 6 9 0 70 61 in Ib SS SS Apply silicone sealant Kawasaki Bond 56019 120 16 10 ELECTRICAL SYSTEM Specifications Charging voltage Regulator rectifier output voltage Alternator output voltage Stator coil resistance Ignition System Spark plug Spark plug gap Spark plug cap resistance Ignition coil 3 needle arcing distance Primary winding resistance Secondary winding resistance Primary peak voltage Crankshaft sensor resistance Crankshaft sensor peak voltage Vehicle down Sensor Detection method Detection angle Detection time Output voltage Electric Starter System Starter motor Commutator diameter Brush length Fuel Pump Fuel pump pressure Item Standard Service Limit Battery Type Sealed Battery a Capacity 12 V 12 Ah EE Charging System Alternator type Three phase AC EE
62. 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 lfthe 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 Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents xIf 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 668080301 S 7 10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Remove Alternator Rotor and Starter Clutch Gear see Electrical System chapter Oil Pump Drive Chain Tensioner Bolt A Chain Guide Bolts B and Collar Chain Guides C e Remove Oil Pump Bolts A Oil Pump Drive Chain B and Oil Pump Assembly C e Remove Circlip A Inner Rotor B Outer Rotor C Oil Pump Drive Shaft D Oil Pump Cover E Oil Pump Installation e Apply engine oil Oil Pump Shaft Inner and Outer Rotors e Install Oil Pump Drive Shaft Oil Pump Cover Inner Rotor Oute
63. inspect Steering inspect Tire wear inspect Final gear case oil change Front brake fluid level inspect General lubrication an Front brake fluid change Front brake master cylinder piston assembly and dust seal replace Front brake caliper piston seal and dust seal replace Front brake hoses and connections inspect Front brake hose replace 4 years Service more frequently when operated in mud dust or other harsh riding conditions or when carrying heavy loads or pulling a trailer e Clean adjust lubricate torque or replace parts as necessary PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 EO Apply engine oil SS Apply silicone sealant Kawasaki Bond 56019 120 Lh Left hand Threads R Replacement Parts S Follow the specific tightening sequence Torque Fastener N m kgf m ft Ib Remarks Fuel System Throttle Limiter Screw 3 7 0 38 33 in Ib Throttle Limiter Locknut 3 7 0 38 33 in Ib Throttle Case Assembly Screws 3 7 0 38 33 in lb Chok
64. is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected for 3 minute HP22006BS1 C ELECTRICAL SYSTEM 16 63 Fuel Pump Fuel Reserve Switch Fuel Pump Fuel Reserve Switch Circuit O BK R BK Y BL BL BK Y BR BK R a 1 Indicator Unit 5 Reset Connector 2 Fuel Level Sensor 6 Main Fuse 30 A 3 Fuel Pump 7 Battery 4 Igniter 8 Ignition Switch 16 64 ELECTRICAL SYSTEM Indicator Unit Indicator Unit Removal e Remove Air Cleaner Cover see Frame chapter Indicator Unit Lead Connector A Handlebar Cover and Indicator Unit B e Remove Bolts A Handle Holders B Handlebar Assembly e Remove the indicator unit from handlebar cover CAUTION Do not drop the indicator unit Indicator Unit Installation e Install Indicator Unit Lead Connector Handlebar Assembly O Be sure the indicator unit lead A placed under the han dlebar B e Install the removed parts CAUTION Do not drop the indicator unit Indicator Unit Inspection e Remove Indicator Unit see Indicator Unit Removal ELECTRICAL SYSTEM 16 65 Indicator Unit Check1 Indicator Light Inspection e Using the auxiliary leads connect a 12 V battery to the indicator unit connector as follows Fuel Indicator Light A Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 2 x
65. isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning of these parts Gasoline engine oil or any other petro leum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rub ber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 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 Brake Fluid Recommendation Use extra heavy duty brake fluid only from a container marked DOT3 or DOT4 Recommended Disc Brake Fluid Type DOT 3 or DOT 4 Brake Fluid Level Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brakes in the Periodic Maintenance chapter Brake Line Air Bleeding e Refer to the Brakes in the Periodic Maintenance chapter Master Cylinder Master Cylinder Removal e Remove Brake Hose Banjo Bolt A Master Cylinder Clamp Bolts B Master Cylinder
66. it clockwise and release it It should lock in position ELECTRICAL SYSTEM 16 59 Lighting System Lighting System Circuit TH H EEH TH BH R W 9 BR BL Y BR BL BR BL R BK R BK 6 R Y R Y BK Y BK Y R BK R BK O R Y R Y BK Y BK Y BK Y 2L BK ie HP12008BN4 C 1 Reverse Switch 5 Rear Brake Light Switch 11 Main Fuse 30A 2 Reverse Indicator Light 6 Headlight Right 12 Battery LED 7 Headlight Left 13 Tail Brake Light 3 Front Brake Light Switch 8 Reset Connector 4 Parking Brake Light 9 Light Dimmer Switch Switch 10 Ignition Switch 16 60 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection e Disconnect the leads from the radiator fan switch A e Using an auxiliary wire B connect the radiator fan switch leads lf the fan rotates inspect the fan switch Alf the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Radiator Fan Motor Inspection e Disconnect the connector A in the fan lead e Using two auxiliary wires supply battery B voltage to the fan motor x lf the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Motor Leads BL Battery BK Battery Radiator Fan Circuit BL W gt BL W S al BL W kk w BL BE Nd BK BK Y ETA HP13000BW2
67. kgf m 33 ft lb 5 24 ENGINE TOP END Camshaft Front Camshaft Chain e Rotate the crankshaft clockwise 270 e Align the key groove A on the crankshaft with the em bossed line B on the crankcase e Move the intermediate shaft A to the right side of the engine e Engage the front camshaft chain B with the sprocket on the intermediate shaft e Install left side view Position Plate A e Tighten Torque Position Plate Bolts B 8 8 N m 0 90 kgf m 78 in Ib e Install Intermediate Shaft Chain Guide A front e Tighten Torque Intermediate Shaft Chain Guide Bolts B 8 8 N m 0 90 kgf m 78 in Ib Camshaft e Install Intermediate Shaft Chain Guide A Rear Washer B Circlip C Special Tool Outside Circlip Pliers 57001 144 e Install the intermediate shaft chain tensioner A as fol lows e Release the stopper B and push the push rod C into the tensioner body e Insert a wire D into the rod hole to hold the rod in place e Install Intermediate Shaft Chain Tensioner A e Tighten Torque Intermediate Shaft Chain Tensioner Bolts B 8 8 N m 0 90 kgf m 78 in Ib e Remove the wire C to free the push rod e Confirm that the punch mark A on the intermediate shaft sprocket Right Side is aligned with the embossed mark B on the crankcase ENGINE TOP END 5 25 5 26 ENGINE TOP END Camshaft e Face the arrow mark A upward e
68. lb 87 in lb 31 16 58 38 195 20 78 in lb 101 116 20 89 116 22 14 31 Remarks MO 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Pinion Gear Bearing Holder Final Gear Case Left Cover Bolts Final Gear Case Right Cover Bolts M8 Final Gear Case Right Cover Bolts M10 Final Gear Case Right Cover Bolts M12 Pinion Gear Bearing Holder Nut Brakes Reservoir Cap Screws Bleed Valves Master Cylinder Clamp Bolts Brake Switch Mounting Bolt Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Caliper Mounting Bolts Disc Mounting Bolts Parking Brake Lever Screw Gasket Screws Brake Pedal Bolt Suspension Front Shock Absorber Clamp Bolts and Nuts Front Shock Absorber Mounting Nuts Rear Shock Absorber Mounting Nuts Suspension Arm Pivot Bolts Steering Knuckle Joint Nuts Swingarm Pivot Right Shaft Swingarm Pivot Left Shaft Swingarm Pivot Left Nut Steering Steering Stem Bottom End Nut Steering Stem Clamp Bolts Tie Rod End Nuts Steering Knuckle Joint Nuts Tie Rod Adjusting Locknuts Handlebar Lower Holder Nuts Handlebar Holder Bolts Master Cylinder Clamp Bolts Frame Engine Mounting Bracket Bolts Torque N m 137 49 24 49 94 157 1 9 7 9 8 8 1 2 25 5 9 5 9 25 37 8 8 47 42 62 42 29 152 20 152 40 25 42 29 22 37 29 8 8 52 kgf m 14 5 0 2 4 5 0 9 6 16 0 15 0 80 0 90 0 12 2 5 0 60 0 6
69. mm 3 232 in 81 949 81 964 mm 3 2263 3 2269 in 81 80 mm 3 220 in Exhaust 41 3 mm 1 626 in 39 5 mm 1 555 in 0 030 0 057 mm 0 0012 0 0022 in EE clearance Top 0 040 0 080 mm 0 0016 0 0032 in 0 18 mm 0 0071 in Second 0 030 0 070 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Piston ring groove width Top 1 030 1 050 mm 0 0405 0 0413 in 1 13 mm 0 0445 in Second 1 020 1 040 mm 0 0402 0 0409 in 1 12 mm 0 0441 in Piston ring thickness Top 0 97 0 99 mm 0 0382 0 0390 in 0 9 mm 0 035 in Second 0 97 0 99 mm 0 0382 0 0390 in 0 9 mm 0 035 in Piston ring end gap Top 0 20 0 30 mm 0 0079 0 0118 in 0 60 mm 0 0236 in Second 0 30 0 45 mm 0 0118 0 0177 in 0 75 mm 0 0295 in Oil 0 20 0 70 mm 0 0079 0 0276 in 1 00 mm 0 0394 in 5 10 ENGINE TOP END Special Tools and Sealant Outside Circlip Pliers 57001 144 Compression Gauge 57001 221 Valve Spring Compressor Assembly 57001 241 Piston Pin Puller Assembly 57001 910 Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 28 57001 1119 Valve Seat Cutter 60 30 57001 1123 R Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 45 30 57001 1187 Valve Seat Cutter 32 33 57001 1199 Special Tools and Sealant
70. not available do as follows with the brake hose connected to the caliper O Prepare a container for brake fluid O Remove the pads and spring see Brake Pad Removal o Pump the brake lever to remove the caliper piston e Remove Dust Seal A Fluid Seal B Bleed Valve C and Rubber Cap D Boots E and Caliper Holder F Caliper Assembly e Replace the fluid seal A with a new one OApply brake fluid to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one if it is damaged OApply brake fluid to the dust seal and install it into the cylinder by hand HL06000281 C 6L05040281 C Calipers e Apply brake fluid to the outside of the pistons A and push them into the cylinder by hand Take care that nei ther the cylinder nor the piston skirt gets scratched e Replace the rubber boots B if they are damaged e Apply a thin coat of silicone grease to the caliper holder shafts C and holder holes D Silicone grease is a spe cial high temperature water resistant grease e Install Caliper Holder E Bleed Valve F and Rubber Cap Torque Bleed Valve 7 9 N m 0 80 kgf m 69 in Ib e Install the anti rattle spring A in the caliper as shown e Install the pads see Brake Pad Installation Piston and Cylinder Damage e Visually inspect the pistons A and cylinder surfaces Replace the caliper if the cylinder and piston are badl
71. of Pressure L x 0 2642 gal US ES S n o d ew Em Iq kPa x Ee 3o m ECCE kPa xo 07 a SH L x 0 8799 ot imp a JS ___emHg L x 2 113 pint US Karem x 98 07 kPa L x 1 816 pint imp se bie e mL x 0 03381 oz US cm Hg 333 a mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force N x 0 0020 kg N x 0 2248 Ib Units of Power kg x 9 807 N kW x 1 360 PS kg x 2 205 Ib kW x 1 341 HP PS x 0 7355 kW PS x 0 9863 HP Units of Temperature 9 C 40 o S GRE 5c nes sT O Fas ae 9 oF oF 4 32 68 176 212 248 284 40 20 0 20 40 40 20 60 20 26 7 48 9 104 80 100 120 140 160 180 200 220 240 260 280 300 320 i i 400 i 420 714 93 3 1440 160 116 138 PERIODIC MAINTENANCE 2 1 Periodic Maintenance TABLE OF CONTENTS Periodic Maintenance Chart Torque and Locking Agent Specifications sssssss Special Tools Periodic Maintenance Procedures Fuel Vasari ita Throttle Lever Free Play Inspection sseessssssss Throttle Lever Free Play Adjustment Choke Lever Free Play Check Choke Lever Free Play Adjustment Idle Speed Inspection Idle Speed Adjustment Fuel System Cleanliness Inspection ssussssssuss Air Cleaner Element Cleaning and
72. particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Pos itive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed There fore always replace these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing needle bearing grease seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Wires All the electrical wires are either one color or two color A two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless in structed otherwise electrical wires m
73. shaft with a new one e Visually inspect the splines B on the propeller shaft lf they are badly worn chipped or loose replace the pro peller shaft e Also inspect the splines on the rear end of the output shaft and the pinion gear joint in the final gear case x lf splines are badly worn chipped or loose replace the output shaft and the pinion gear joint FINAL DRIVE 11 23 HKi17000BSi 11 24 FINAL DRIVE Rear Axle Rear Axle Removal e Drain the final gear case oil see Final Drive in the Periodic Maintenance chapter e Remove Rear Wheels see Wheels Tires chapter Rear Hub see Wheels Tires chapter Rear Bottom Guard A see Frame chapter Cap B Final Gear Case Left Cover Bolts C Final Gear Case Left Cover Bracket D Final Gear Case Left Cover E e Tap A the right end of the rear axle B and pull it out from the left O The left axle bearing comes off with the axle Rear Axle Installation e Install the rear axle from the left side with the left bearing installed while aligning the splines e Apply grease O ring A Oil Seal Lips in Final Gear Case Left Cover e Install Final Gear Case Left Cover A Final Gear Case Left Cover Bracket B e Apply a non permanent locking agent to the cover bolts and tighten them Torque Final Gear Case Left Cover Bolts 49 N m 5 0 kgf m 36 ft Ib e Install the cap C Rear Axle Ball Bearing Wear CAUTION Do not r
74. small amount of engine oil to the O ring 16 46 ELECTRICAL SYSTEM Electric Starter System e Install Starter Motor A Clamp B as shown Starter Motor Cable C e Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib A Ln Starter Motor Terminal Nut 4 9 N m 0 50 kgf m NES into Jo e Apply grease to the O ring D in the joint duct E e Install Joint Duct and Collars F Clamp G as shown e Tighten Torque Joint Duct Bolts H 8 8 N m 0 90 kgf m 78 in Ib HP11001BS1 C Starter Motor Disassembly e Remove Starter Motor Bolts A Left End Cover B Right End Cover C Yoke D e To remove the brush plate assembly A remove the ter minal nut B Electric Starter System e Hold the brush spring A with needle nose pliers and pull the brush B off the holder Starter Motor Assembly e Replace the O rings e Install the brush plate assembly to the right end cover so that the projection A on the brush plate fits into the groove on the right end cover e Install the O ring insulators B and washer C in that order on the terminal bolt e Tighten Torque Starter Motor Terminal Locknut 6 9 N m 0 70 kgf m 61 in Ib e Install the washers A e Install the armature B between the brushes e Install the yoke A onto the right end cover B aligning the marks C on the yoke and right end cover ELECTRICAL SYSTEM 16 47
75. stated below GP080705S1 Terminal Voltage 11 5 less than 12 5 V Standard Charge 1 4 Ax 5 10 h see following chart Quick Charge 60Ax1 0h CAUTION If possible do not quick charge If the quick charge Bete TORO ES SCH tere is done due to unavoidable circumstances do the P08011191 6 standard charge later on Charge Time h Terminal Voltage less than 11 5 V Charging Method 1 4A x 20h 16 22 ELECTRICAL SYSTEM Battery NOTE O Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current D 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 e Determine battery condition after refreshing charge O Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement 12 0 12 5 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable gt Replace GPO8011381 C Charging System Alternator Cover Removal e Drain the coolant see Cooling System chapter e Remove Bolts A
76. stem as shown A Parallel e Install the handlebar holder A e Tighten the holder front bolts B first and then the rear bolts C Torque Handlebar Holder Bolts 29 N m 3 0 kgf m 22 ft Ib Olf the holder is correctly installed there will be no gap at the front and an even gaps D at the rear after tightening OBe sure the indicator unit lead place under the handlebar E STEERING 14 11 14 12 STEERING Handlebar e Install the left switch housing C on the handlebar B so that the opening angle is 40 A or less NOTE ODo not open the housing more than 40 the built in parts in the housing may be damaged e Install Rear Brake Lever Assembly A Left Switch Housing B Shift Grip C D 2 3 mm 0 08 0 12 in HNO6004BS1 C HNOG008BS1 C FRAME 15 1 Frame TABLE OF CONTENTS Exploded VieW rien fae e aie tes AS BARRE RoR o e a O Seat Removal ee ee e eet oe Aes Seat Installation citet E dee EE Front Guard Remo Front Guards Instalaton HH Engine Bottom Guard Removal ccscseseencceeeeeeeeeeeeeceeeeeeeeeeseseneeeee Engine Bottom Guard Installation nn Rear Bottom Guard Remova eee Rear Bottom Guard Installatton FoDt Guard and Slayer aec beu teat tea peces a ml buds Foot Guard and Stay Removal seeeeeeeeeee Foot Guard and Stay Installation endete al 1 OO CO cO oO OO OO JJJ OO
77. temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the connector and the body at the temperatures shown in the table If the hand tester does not show the specified values re place the switch Coolant Temperature Warning Light Switch Resistance ORising temperature From OFF to ON at 112 118 C 234 244 F C Falling temperature From ON to OFF at 108 111 C 226 232 F ON Less than 0 5 Q OFF More than 1 MQ Switch Inspection e Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms O For the handlebar switches ignition switch refer to tables in the Wiring Diagram Alf the switch has an open or short repair or replace it with a new one HP14000BS2 C ELECTRICAL SYSTEM 16 69 Switches Neutral Switch Connection When transmission is in neutral eee When transmission is not in neutral AA ae A Neutral Switch Reverse Switch Connections When transmission is in reverse EE When transmission is not in reverse B Reverse Switch Oil Pressure Switch Connections Engine lubrication system is in good condition 16 70 ELECTRICAL SYSTEM Fuses 30 A Main Fuse Removal e Remove Seat see Frame chapter Starter Relay and 30A Main Fuse Connector A e Pull out the main fuse B from the starter relay with a needle nose
78. the Periodic Maintenance Chart In dusty areas they should be cleaned more frequently than the recommended interval After riding through muddy terrains the radiator screen and the radiator should be cleaned immediately e Remove Radiator Cover see Frame chapter Radiator Screen Mounting Screws A Radiator Screen B With the Shroud C e Clean the radiator screen in a bath of tap water and then dry it with compressed air or by shaking it e Clean the radiator CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun away more than 0 5 m 20 in from the radiator core A Hold the steam gun perpendicular to the core sur face Run the steam gun following the core fin direction Radiator Hose and Connection Inspection OThe high pressure inside the radiator hose can cause coolant to leak A 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 swollen Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly HUOGOOOBS1 C 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change A WARNING To avoid burns do not remove the radiator cap or try t
79. the pinion gear e Mount a dial gauge A so that the tip of the gauge is against the splined portion B of the pinion gear joint e To measure the backlash move the pinion gear shaft back and forth C while holding the rear axle steady The difference between the highest and the lowest gauge reading is the amount of backlash O Measure backlash at three locations equally spaced on the splines Final Bevel Gear Backlash 0 07 0 14 mm 0 003 0 006 in at pinion gear spline x lf the backlash is not within the limit replace the ring gear shim s To increase backlash decrease the thickness of the shim s To decrease backlash increase the thick ness of the shim s Change the thickness a little at a time e Recheck the backlash and readjust as necessary Final Gear Case Tooth Contact Adjustment e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth of the pinion gear NOTE O Apply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear O The checking compound must be smooth and firm with the consistency of tooth paste O Special compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact e Assemble the final gear case see Final Gear Case As sembly e Turn the pinion gear for one revolution in the
80. the spherical bearing A lf roughness excessive play or seizure is found replace the knuckle joint B e Clean the shanks C of the knuckle joint e Check that the joint boot D is not torn worn deteriorated or is leaking grease e Install the knuckle e Tighten Torque Knuckle Joint Nut 29 N m 3 0 kgf m 22 ft lb Tie Rod End Nut 42 N m 4 3 kgf m 31 ft lb Tie Rod Removal e Remove Front Wheel see Wheels Tires chapter Cotter Pins and Tie Rod End Nuts A Tie Rod B CAUTION When removing the tie rod be careful not to bend it Do not loosen the tie rod adjusting locknuts C or the toe in of the front wheels will be changed Tie Rod Installation e The right and left tie rods are identical e Tighten Torque Tie Rod End Nuts 42 N m 4 3 kgf m 31 ft lb Wheel Nuts 52 N m 5 3 kgf m 38 ft Ib e Inspect the toe in see Wheels Tires chapter 14 8 STEERING Steering Tie Rod End Removal e Remove the tie rod see Tie Rod Removal e Holding the width across flats A on the tie rod loosen the locknut B and unscrew the tie rod end C NOTE O The locknut near the flattened area on the tie rod has left hand threads Turn the wrench clockwise as viewed from the joint end for loosening CAUTION Do not remove the grease seal It is packed with grease Tie Rod End Installation e Check that the seal lip A is on the shank B e Install the tie rod en
81. the vacuum piston These can be detached together with the spring seat E O Do not remove the pilot screw if possible synchronization ofthe carburetors is necessary if pilot screws are removed see Pilot Screw Adjustment e Remove Screws A Float Chamber B Carburetor e Remove Screw A Float Pivot Pin B Float C and Float Needle Valve Pilot Jet D Main Jet E e Remove Screws A Coasting Enricher Cover B e Remove Diaphragm A O ring B FUEL SYSTEM 3 19 3 20 FUEL SYSTEM Carburetor Carburetor Assembly A WARNING Fuel spilled from the carburetors is hazardous CAUTION Do not apply force to the jet or overtighten it or this could damage the jet or the carburetor body requiring replacement e Install the float valve needle in the valve seat and hook the needle hanger A onto the float tang e Insert the float pivot pin B into the pivot post and the float e Tighten the screw C e Set the float to the standard height see Service Fuel Level Adjustment e Insert the jet needle A into the hole in the center of the vacuum piston B and place the spring seat C over the needle e Slip the needle through the hole in the center of the vac uum piston and put the spring seat A on the top of the needle Turn the seat so that it does not block the hole B at the bottom of the vacuum piston e After installing the upper chamber cover check that
82. the wheel see Wheel Removal e Remove the caliper A by taking off the mounting bolts and let the caliper hang free e Remove the axle nut B and pull off the front hub C and brake disc e Separate the brake disc from the front hub Front Hub Installation e Install the brake disc see Brakes chapter e Tighten Torque Front Axle Nut 52 N m 5 3 kgf m 38 ft Ib e Insert a new cotter pin A and bend it over the nut B NOTE O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise up to next alignment Olt should be within 30 degree O Loosen once and tighten again when the slot goes past the nearest hole HJ07002BS1 C Front Hub Disassembly Assembly e Do not press the hub bolts A out xlf any hub bolt is damaged replace the hub B and bolts as a unit HJ07006BS1 C WHEELS TIRES 10 13 Rear Hub Rear Hub Removal e Remove Cotter Pin A e Loosen the axle nut B e Remove Wheel see Wheel Removal Axle Nut A Rear Hub B MJOBBOO7 P Rear Hub Installation e Tighten Torque Rear Axle Nuts 265 N m 27 kgf m 195 ft lb e Insert a new cotter pin A and bend it over the nut B NOTE O When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise up to next alignment O It should be within 30 degree eee O Loo
83. this is not done Brake Pad Wear Inspection e Refer to the Brakes in the Periodic Maintenance chapter BRAKES 12 15 Brake Discs Disc Cleaning Poor braking can be caused by oil on a disc Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone A WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Disc Removal e Remove Front Hub see Wheels Tires chapter Brake Disc Mounting Bolts A Brake Disc B Disc Installation e The disc must be installed with the marked side A facing toward the steering knuckle e Apply a non permanent locking agent Disc Mounting Bolts e Tighten Torque Disc Mounting Bolts 37 N m 3 8 kgf m 27 ft lb e After installing the discs check the disc runout Com pletely clean off any grease that has gotten on either side of the disc with a high flash point solvent Do not use one which will leave an oily residue D OO Lo nC O MIN TH 3MM O HL09000281 Disc Wear e Measure the thickness of each disc at the point A where it has worn the most Replace the disc if it has worn past the service limit Disc Thickness Standard 3 3 3 7 mm 0 130 0 146 in Service Limit 3 mm 0 12 in HLO9000BSi C 12 16 BRAKES Brake Discs Disc Runout e Jack up the vehicle so that the wheels a
84. to avoid damaging the screw heads 7 Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent Gasket O Ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks C 8 x GENERAL INFORMATION 1 3 Before Servicing 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious dam age 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufa
85. vernier calipers lf the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE O Remove all pittings of flaws from 45 ground surface O After grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier o When the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x lf the outside diameter A of the seating surface is too large make the 32 grind described below xIf 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 O To make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide Turn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to prevent overgrinding O After making the 32 grind return to the seat O D mea surement step above e To measure the seat width use vernier calipers to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x lf the seat width is too narrow repeat the 45
86. weakly replace the starter motor with a new one ELECTRICAL SYSTEM 16 49 GP110608S1 16 50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Brush Length e Measure the overall length A of each brush Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 4 mm 0 16 in lf any is worn down to the service limit replace the brush plate assembly Brush Assembly Inspection e Using the x 1 Q range measure the resistance as shown A Terminal Bolt and Positive Brush B Brush Plate and Negative Brush x lf there is not close to zero ohms the brush lead has an open Replace the brush plate assembly Special Tool Hand Tester 57001 1394 Brush Plate and Terminal Bolt Inspection e Using the highest range measure the resistance as fol lows A Terminal Bolt and Right Hand End Cover B Terminal Bolt and Brush Plate lf there is any reading the brush holder assembly has a short Replace the brush plate assembly Special Tool Hand Tester 57001 1394 Starter Relay Inspection e Remove Seat see Frame chapter Starter Relay A Electric Starter System e Connect the hand tester A and a 12 V battery B to the starter relay C as shown lfthe relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 range Criteria When battery is connected gt 0 2 When battery is disconnected gt o 2 Specia
87. 0 130 1 1 2 turns out less than 2 7 kPa 2 cmHg difference between carburetors 95 1100 50 r min rpm 12 1 mm 0 47 0 04 in below the punch mark 4 0 1 mm 0 16 0 04 in 135 92063 1014 140 92063 1013 132 92063 1076 138 92063 1015 130 92063 1075 135 92063 1014 128 92063 1074 130 92063 1075 120 92063 1073 125 92063 1069 Item Throttle Case and Cable Throttle lever free play Choke Lever and Cable Choke lever free play Carburetor Make Type Main jet Front Rear Main air jet Needle jet Jet needle Pilot jet Pilot air jet Pilot screw Carburetor synchronization vacuum Starter jet Idle speed Service fuel level Float height Optional parts Main jet Altitude 0 500 m 0 1600 ft Front Rear 500 1500 m 1600 4900 ft Front Rear 1500 2500 m 4900 8200 ft Front Rear 2500 3500 m 8200 11500 ft Front Rear 3500 4500 m 11500 14800 ft Front Rear Air Cleaner Air cleaner element oil High quality foam air filter oil FUEL SYSTEM 3 7 Special Tools Fuel Level Gauge Carburetor Drain Plug Wrench Hex 3 57001 1017 57001 1269 s Pilot Screw Adjuster A 57001 1239 3 8 FUEL SYSTEM Throttle Lever and Cable Throttle Lever Free Play Inspection e Refer to the Fuel System in the Periodic Maintenance chapter Throttle Lever Free Play Adjustment e Refer to the Fuel System in the Periodic Maintenan
88. 0 2 5 3 8 0 90 4 8 4 3 6 3 4 3 3 0 15 5 2 0 19 9 4 1 2 5 4 3 3 0 2 2 3 8 3 0 0 90 5 3 ft lb 101 36 17 36 69 116 13 in lb 69 in lb 78 in lb 10 in lb 18 52 in lb 52 in lb 18 27 78 in lb 35 31 46 31 21 112 14 112 30 18 31 22 16 27 22 78 in lb 38 Remarks PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Engine Mounting Nut 62 6 3 46 Footrest Mounting Bolts 44 4 5 33 Electrical System Alternator Cover Bolts 8 8 0 90 78 in Ib Alternator Rotor Bolts 127 13 94 Alternator Stator Bolts 13 1 3 113 in Ib Alternator Cover Plugs 18 1 8 13 Spark Plug 13 1 3 113 in Ib Crankshaft Sensor Mounting Bolts 5 9 0 60 52 in lb Starter Motor Mounting Bolts 8 8 0 90 78 in Ib Starter Motor Terminal Nut 4 9 0 50 43 in lb Starter Motor Terminal Locknut 6 9 0 70 61 in Ib Starter Motor Bolts 4 9 0 50 43 in lb Starter Motor Clutch Bolts 34 3 5 25 L Reverse Position Switch 15 1 5 11 Neutral Position Switch 15 1 5 11 Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in Ib Radiator Fan Switch 18 1 8 13 Coolant Temperature Warning Light Switch 6 9 0 70 61 in Ib SS 2 10 PERIODIC MAINTENANCE Torque and Locking Agent The tables below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not
89. 0 0028 in 0 0067 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 Piston Ring Groove Width e Measure the piston ring groove width O Use a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top 1 030 1 050 mm 0 0405 0 0413 in 1 020 1 040 mm 0 0402 0 0409 in Second Service Limit 1 13 mm 0 0445 in 1 12 mm 0 0444 in lf the width of any of the two grooves is wider than the service limit at any point replace the piston ENGINE TOP END 5 41 Cylinder and Piston Piston Ring Thickness e Measure the piston ring thickness OUse a micrometer to measure at several points around the ring Piston Ring Thickness Standard Service Limit Top 0 97 0 99 mm 0 9 mm 0 0382 0 0390 in 0 035 in Second 0 97 0 99 mm 0 9 mm 0 0382 0 0390 in 0 035 in lf any of the measurements is less than the service limit on either of the rings replace all the rings NOTE O When using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder w
90. 0 in 22 08 mm 0 870 in Camshaft runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 0039 in Cylinder head war Valve Valve clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in EE Inlet 0 10 0 15 mm 0 0039 0 0059 in EE Valve head thickness Exhaust 0 8 mm 0 031 in 0 5 mm 0 020 in Inlet 0 5 mm 0 020 in 0 3 mm 0 012 in Valve stem bend EE TIR 0 05 mm 0 002 in Valve stem diameter Exhaust 4 955 4 970 mm 0 1951 0 1957 in 4 94 mm 0 1945 in Inlet 4 975 4 990 mm 0 1959 0 1965 in 4 96 mm 0 1953 in Valve guide inside diameter Exhaust 5 000 5 012 mm 0 1969 0 1973 in 5 08 mm 0 20 in Inlet 5 000 5 012 mm 0 1969 0 1973 in 5 08 mm 0 20 in ENGINE TOP END 5 9 Specifications Item Standard Service Limit Valve valve guide clearance wobble method Exhaust 0 09 0 17 mm 0 0035 0 0067 in 0 34 mm 0 0133 in Inlet 0 03 0 11 mm 0 0012 0 0043 in 0 28 mm 0 0110 in Valve seat cutting angle 45 32 60 Valve seating surface Outside diameter Exhaust 25 2 25 4 mm 0 992 1 000 in Inlet 29 4 29 6 mm 1 157 1 165 in Width Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in Valve spring free length Inlet 41 3 mm 1 626 in 39 5 mm 1 555 in Cylinder Piston Cylinder inside diameter Piston diameter Piston cylinder clearance Piston ring groove 81 994 82 006 mm 3 2281 3 2286 in 82 09
91. 00 6017036682 Vehicle down Sensor A Constant Voltage Circuit E Ground Terminal B BK Y Hall IC Integrated Circuit F Output Terminal C Y G Vehicle down Sensor Circuit G Power Source Terminal D BR Front H Vehicle down Sensor Removal CAUTION Never drop the down sensor especially on a hard surface Shock to the sensor can damage it e Remove Rear Fender see Frame chapter Fuel Tank see Fuel System chapter Vehicle down Sensor Lead Connector A Screws B Vehicle down Sensor C Vehicle down Sensor Installation e Install the vehicle down sensor A so that the sensor lead faces backwards B and the arrow mark C on the sen sor points upward e Tighten the screws securely A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by the sensor brackets ELECTRICAL SYSTEM 16 41 Ignition System Vehicle down Sensor Inspection NOTE O Be sure the battery is fully charged Vehicle down Sensor Power Source Voltage e Remove Seat see Frame chapter Vehicle down Sensor Lead Connector e Connect Vehicle down Sensor Lead Connector A harness side Digital Volt Meter B l Connections to Connector 12 V
92. 01 1394 NOTE O The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage HP10008BS2 C ELECTRICAL SYSTEM 16 35 Ignition System e Measure the primary winding resistance A as follows O Connect the tester between the coil terminals O Set the tester to the x 1 range e Measure the secondary winding resistance B as follows O Remove the plug cap by turning it counterclockwise O Connect the tester between the spark plug lead and ter minal O Set the tester to the x 1 KQ range Ignition Coil Winding Resistance Primary windings 0 09 0 13 Secondary windings 3 8 5 8 kQ xIf the hand tester does not read as specified replace the coil OTo install the plug cap turn it clockwise HPi0008BSi 16 36 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE O Be sure the battery is fully charged e Remove the spark plug cap see Spark Plug Removal but do not remove the spark plug e Measure the primary peak voltage as follows O Connect a commercially peak voltage adapter A to the hand tester B 250 V DC range Install the needle adapters C on the peak voltage adapter leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI O Insert the needle adapter inside
93. 1 To Tail Brake Light 8 2 Clamp 9 3 Run the main harness under the seat 10 bracket 11 NOOA Clamp With the Fuel Hose 12 Igniter 13 Ignition Coil Rear Band Face the end of the band upward Clamp Clamp Clamp To Right Headlight Rear Brake Light Switch Band With the Final Gear Case Breather Hose APPENDIX 17 23 Cable Wire and Hose Routing HB09064BW4 C 1 Clamp 5 Clamp the fuel hose and main harness 2 Clamp 6 Through the hoses above the main har 3 Fuel Tank Breather Hose ness 4 Fuel Hose 7 Clamp 17 24 APPENDIX Cable Wire and Hose Routing HB09085BW3 1 Through the brake hose to the clamp Left Side Only 2 Through the brake hose to the clamp on the left side suspension arm 3 Fit the grommet to the frame clamp MODEL APPLICATION Beginning Frame No JKASV700AAB600001 or 2004 GE JKASV6A1114B500001 This digit in the frame number changes from one machine to another H E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1315 01 Printed in Japan
94. 1 144 Mae P e Remove Circlip A Spring Holder B Spring C Cam Damper D Output Driven Bevel Gear E HK16003081 C FINAL DRIVE 11 15 Output Bevel Gears e Hold the housing assembly A with the output shaft holder y B amp spacer C in a vise LY Special Tool Output Shaft Holder amp Spacer 57001 1479 e Remove Oil Seal D e Remove Output Shaft Holder Nut A Special Tool Socket Wrench B 57001 1482 e Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476 e Remove Bearing Holder C Special Tool Socket Wrench D Hex 50 57001 1478 Olf the holder seems too difficult to break free apply heat to softer the locking agent e Remove Ball Bearing Special Tool Oil Seal amp Bearing Remover 57001 1058 11 16 FINAL DRIVE Output Bevel Gears Output Driven Bevel Gear Assembly e Press the new ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476 e Apply a non permanent locking agent to the threads of the bearing holder C and tighten it Special Tool Socket Wrench Hex 50 57001 1478 Torque Bearing Holder 137 N m 14 kgf m 101 ft Ib e Hold the housing assembly A with the output shaft holder B amp spacer C in a vise Special Tool Output Sha
95. 1012281 C Camshaft Camshaft Bearing Wear OThe journal wear is measured using plastigage press gauge which is inserted into the clearance to be mea sured The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled e Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case e Install the rocker case tightening the bolts in the correct sequence to the specified torque see Rocker Case In stallation NOTE O Do not turn the camshaft when the plastigage is be tween the journal and rocker case e Remove the rocker case and measure the plastigage width A to determine the clearance between the journal and the rocker case Measure the widest portion of the plastigage Camshaft Bearing Clearance 018 Standard 0 016 0 052 mm 0 0006 0 0020 in Service Limit 0 14 mm 0 0055 in Camshaft Bearing Clearance 022 Standard 0 020 0 062 mm 0 0008 0 0024 in Service Limit 0 15 mm 0 0059 in lf any clearance exceeds the service limit measure the diameter of the camshaft journal Camshaft Journal Diameter 018 Standard 17 966 17 984 mm 0 7073 0 7080 in Service Limit 17 94 mm 0 706 in Camshaft Journal Diameter 022 Standard 21 959 21 980 mm 0 8645 0 8653 in Service Limit
96. 16 Cylinder and Piston 5 37 Rocker Shaft Diameter Cylinder Removal 5 37 Measurement sssseen renren 5 16 Piston HRemoval 5 37 Camada 5 17 Cylinder Piston Installation 5 37 Camshaft Removal 5 17 Cylinder Wear 5 39 Camshaft Installation 5 17 Piston Wear 5 40 Camshaft Assembly 5 18 Piston Cylinder Clearance 5 40 Cam West tias 5 18 Piston Ring Piston Ring Groove Camshaft Bearing Wear 5 19 Wea iicet uo ERE REM 5 40 KACR Inspection 5 20 Piston Ring Groove Width 5 40 KACR Remowval 5 20 Piston Ring Thickness 5 41 KACR Installation 5 21 Piston Ring End Gap 5 41 Camshaft Chain Removal 5 21 Exhaust System ssss 5 42 Camshaft Chain Installation 5 22 Spark Arrester Cleaning 5 42 Cylinder Head 5 27 Muffler and Exhaust Pipe Cylinder Compression Removal ts 5 42 Measurement 5 27 Muffler and Exhaust Pipe Cylinder Head Removal 5 28 Installation eue 5 43 Cylinder Head Installation 5 28 Exhaust System Inspection 5 43 5 2 ENGINE TOP END Exploded View
97. 2 041 mm 1 6545 1 6552 in 42 08 mm 1 6567 in CRANKSHAFT TRANSMISSION 9 7 Specifications Item Standard Service Limit Transmission Shift fork ear thickness 5 9 6 0 mm 0 2322 0 2362 in 5 8 mm 0 228 in Shifter groove width 6 05 6 15 mm 0 2382 0 2421 in 6 25 mm 0 246 in 9 8 CRANKSHAFT TRANSMISSION Special Tools and Sealant Outside Circlip Pliers Bearing Driver Set 57001 144 57001 1129 Three Bond 1215 Gray CRANKSHAFT TRANSMISSION 9 9 Crankcase Crankcase Disassembly e Remove Engine see Engine Removal Installation chapter Starter Motor see Electrical System chapter Oil Filter see Engine Lubrication System chapter Cylinder Blocks and Pistons see Engine Top End chap ter Intermediate Shaft and Chain see Engine Top End chapter Right Crankcase Bolts M6 A Right Crankcase Bolts M8 B e Remove Shift Shaft Positioning Bolt A Washer Spring and Steel Ball Left Crankcase Bolts M6 B Left Crankcase Bolts M8 C e Wrap the teeth on the sprockets A by taping for protect ing the bushing in the crankcase e Using the pry points B split the crankcase halves e Lift off the left crankcase half 9 10 CRANKSHAFT TRANSMISSION Crankcase Crankcase Assembly CAUTION The right and left crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set
98. 38 12 mm 1 501 in Shoe side clearance 0 15 0 30 mm 0 0059 0 0118 in Spring free length 60 4 mm 2 38 in SE Driven Pulley Sheave bushing inside diameter 40 000 40 039 mm 1 5748 1 5763 in 40 079 mm 1 5779 in Spring free length 99 5 mm 3 92 in CONVERTER SYSTEM 6 7 Special Tools Circlip Pliers Drive Pulley Holder 57001 154 57001 1473 7571473ST Flywheel 8 Pulley Holder Drive Pulley Wrench 57001 1343 57001 1474 S g ST571474ST Drive amp Driven Pulley Holder Spring Holder Set 57001 1412 57001 1483 ST571483ST C Drive Pulley Puller Bolt Drive Pulley Holder 57001 1429 57001 1520 d 7571520ST Pulley Holder Attachment 57001 1472 75714728T 6 8 CONVERTER SYSTEM Torque Converter A WARNING Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death The pulleys of the belt drive torque converter are precision balanced components de signed to operate within certain rpm limits Disas sembly assembly and servicing procedures of the pulley assemblies must be followed closely Modi fications to the engine or pulleys that increase rpm may cause failure Torque Converter Cover Removal e Turn the ignition switch OFF e Remove Clamp Screw A and Clamp B Joint Duct C e Remove Torque Converter Cover Bolts A Torque
99. 45W Fuel Indicator Light Neutral Indicator Light LED Reverse Indicator Light LED Water Temperature Warning Light LED Oil Pressure Warning Light LED Belt Indicator Light LED 12V45 45W Headlight Right Headlight Left Frame Ground Terminal Igniti g oe ON Reverse Neutral Switch Radiator CE BL W Switch Switch Fan Switch BL 2 ES x Ou a Radiator SNE BL Fan BK BK Y a s lt 3 z Horn DI BR 12V18W lt lt Bk Y gt a o R BK R BK R Y R Y BK Y BK Y Indicator Unit 12V3 48 ar E 12V30nW Se i 12V30nN afk ds 12V30m a 12V30m P 12V30nW we En R BK R BK a 2x R Y R Y eS g BK Y BK Y x gt uru DS Sea p SE m a E P Ss may M emper E d Water m Temperature Switch mp we d Left Handlebar Switches leet e o f C f 1 Light Dimmer Switch rankshaft 2 Engine Stop Switch Ge r Pressuer Sensor 3 Starter Button Switch 4 Reverse Power ssist Switch Alternator Left Handlebar Switch Connections ht Dimmer Engine Stop Switch Starter Button Reverse Power Assist Sw Color R Y R BK Color Y R Color Y R Color Y BK OFF OFF Released OFF W2LO008AN5 ELECTRICAL SYSTEM 16 73 Wiring Diagram gt 0000000000 Radiator Fuel Front Parking Rear Fan Fuse Pump Brake Brake Brake Light Light Light Switch Switch Switch 20A Starter Circuit Relay Brake L I5 BK BK BK Y BL BL BR BL BR
100. 5002BS1 C CRANKSHAFT TRANSMISSION 9 17 Crankshaft Connecting Rod Crankshaft Runout e Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 04 mm 0 0016 in or less Service Limit TIR 0 10 mm 0 0039 in HI04002081 Crankshaft Main Bearing Journal Wear e Measure the diameter A of the crankshaft main journal Crankshaft Main Journal Diameter Standard 41 984 42 000 mm 1 6529 1 6535 in Service Limit 41 96 mm 1 652 in elf any journal has worn past the service limit replace the crankshaft with a new one HI04002181 e Measure the main bearing bore diameter A in the crankcase halves Crankcase Main Bearing Bore Diameter Standard 42 025 42 041 mm 1 6545 1 6552 in Service Limit 42 08 mm 1 6567 in xIf there is any signs of seizure damage or excessive wear replace the crankcase halves as a set HI05015BS1 9 18 CRANKSHAFT TRANSMISSION Transmission Shift Lever Removal e Remove Seat and Rear Fender see Frame chapter Air Cleaner Cover and Right Side Inner Cover see Frame chapter Battery and Rear Ignition Coil see Electrical System chapter e Make sure that the shift control grip is in neutral position e Make sure that the shift lever is in neutral position O Neutral position is the shift control cable lower ends A and reverse cable bracket mounting bolt B align
101. 58 527 11 904 Final gear case oil Type MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Capacity 900 mL 0 95 US qt Frame Type Double cradle tubular steel Caster rake angle 4 5 Camber 0 5 King pin angle 12 5 Trail 20 mm 0 79 in Tread Front 1 000 mm 39 37 in Rear 900 mm 35 43 in Front tire Type Tubeless Size AT22 x 7 10 Rear tire Type Tubeless Size AT22 x 11 10 Suspension Front Type Double A arms Wheel travel 236 mm 9 29 in Rear Type Swingarm Wheel travel 200 mm 7 87 in Brake Front Disc x 2 Rear Enclosed wet multi plate Electrical Equipment Battery 12 V 14 Ah Headlight Type Semi sealed beam Bulb 12 V 45 45 W x 2 1 8 GENERAL INFORMATION General Specifications Items KSV700 A1 Tail brake light Alternator Bulb 12 V 5 21 W Alternator Type Three phase AC Rated output 25 A 14 V 6 000 r min rpm Specifications subject to change without notice and may not apply to every country US United States model Unit Conversion Table Prefixes for Units GENERAL INFORMATION 1 9 Units of Length Prefix Power km x 0 6244 mile mega M x 1000 000 m x 32801 ft kilo k x 1000 mm x 0 03937 in centi C x 0 01 milli m x 0 001 micro x 0 000001 Units of Torque N m x 0 0020 kg m N m x 0 7376 ft lb Units of Mass N m x 8 851 in Ib kg x 2 205 Ib Sch i is E g x 0 03527 Oz gm 7 233 ft b kom x 86 80 in lb Units of Volume Units
102. 6 20 ELECTRICAL SYSTEM Battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal caps during refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 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 lead re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal
103. 9 L 2 01 US qt When filter is removed 2 2 L 2 33 US qt When engine is completely dry 0 0251 in Capacity Wheels Tires Tire tread depth Front 3 mm 0 12 in Rear 3 mm 0 12 in Standard tire Front AT 22 X 7 10 EE CARLISLE HOLE SHOT XC Rear AT 22 x 11 10 CARLISLE HOLE SHOT XCT EE Final Drive Final Gear Case Gear Case Oil Type MOBIL Fluid 424 or CITGO EE TRANSGARD TRACTOR HYDRAULIC FLUID Oil level Filler opening bottom EE 900 mL 0 95 US at 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Brakes Front Brake Fluid Type DOT 3 or DOT 4 Front Disc Brake Pad lining thickness 4 mm 0 16 in Rear Brake Lever Pedal and Cables Rear brake lever free play 1 2 mm 0 04 0 08 in Brake pedal free play 15 25 mm 0 6 1 0 in Electrical System Spark plug gap 0 7 0 8 mm 0 028 0 031 in Rear brake light switch timing On after 10 mm 0 4 in of pedal travel 1 mm 0 04 in Special Tools Oil Filter Wrench 57001 1249 Carburetor Drain Plug Wrench Hex 3 57001 1269 Flywheel amp Pulley Holder 57001 1343 PERIODIC MAINTENANCE 2 13 Pulley Holder Attachment 56 Filler Cap Driver 57001 1454 57001 1472 75714728T 7571454ST 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection e
104. AL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage lf the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity O Use the wiring diagram to find the ends of the lead which is suspected of being a problem O Connect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 O Set the tester to the x 1 range x lf the tester does not read 0 9 the lead is defective Re place the lead or the wiring harness B if necessary HP07000BS1 C Battery Battery Removal e Turn off the ignition switch e Remove the seat see Frame chapter e Loosen the bolts A of the battery holder B e Remove the battery with the holder and the case e Disconnect the battery negative cable C first and then the positive cable D e Take out the battery E Battery Installation e Turn off the ignition switch e Put the battery with the case and the holder in place e Connect the positive cable first and then the negative ca ble e Put a light coat of grease on the terminals to prevent cor rosion e Tighten the battery holder bolts Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer mat
105. ANCE 2 7 Fastener Oil Pump Drive Chain Tensioner Bolt Engine Removal Installation Engine Mounting Bracket Bolts Engine Mounting Nuts Crankshaft Transmission Crankcase Bolts M8 Crankcase Bolts M6 Shift Shaft Positioning Bolt Shift Shaft Spring Bolt Shift Shaft Cover Bolts Connecting Rod Big End Cap Nuts Engine Drain Plug Position Plate Mounting Screws Shift Shaft Lever Nut Shift Shaft Lever Bolts Neutral Position Switch Reverse Position Switch Reverse Cable Locknut Cable Holder Mounting Bolts Wheels Tires Tire Rod End Nuts Tie Rod Adjusting Locknuts Wheel Nuts Front Axle Nuts Rear Axle Nuts Final Drive Output Bevel Gears Output Drive Bevel Gear Cover Bolts Bearing Holder Bevel Gear Holder Nut Bearing Holder Output Shaft Holder Nut Final Gear Case Oil Filler Cap Oil Drain Plug Final Gear Case Bolts Reverse Cable Bracket Mounting Bolts Output Driven Bevel Gear Housing Bolts Output Drive Bevel Gear Housing Bolts Torque N m 25 52 62 20 9 8 25 25 8 8 34 20 4 9 8 8 14 8 8 8 8 15 12 9 8 42 22 78 52 265 26 8 8 13 157 26 120 157 29 20 42 kgf m 2 5 5 3 6 3 2 0 1 0 2 5 2 5 0 90 3 5 2 0 0 50 0 90 1 4 0 90 0 90 1 5 1 2 1 0 4 3 2 2 8 0 5 3 27 2 7 0 90 14 16 2 7 12 16 3 0 2 0 4 3 ft lb 18 38 46 14 87 in lb 18 18 78 in lb 25 14 43 in lb 78 in lb 10 78 in lb 78 in lb 11 104 in
106. AUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Using the piston pin puller assembly special tool re move the piston pins Special Tools Piston Pin Puller Assembly A 57001 910 Piston Pin Puller Adapter B 57001 1211 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 3 piece oil ring with your thumbs in the same manner Cylinder Piston Installation NOTE O If a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston rings WI P 6E16020381 GEI60606S1 5 38 ENGINE TOP END Cylinder and Piston NOTE O The oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it O Spread the rail with your thumbs but only enough to fit the rail over the piston O Release the rail into the bottom piston ring groove e Do not mix up the top ring and second ring e Install the top ring A so that the R mark B faces up e Install the second ring C so that the RN mark D faces up e The piston ring openings must be positioned as shown in the figure Th
107. Align the marks B on the weights with the front cylinder head upper surface C e Place the front camshaft chain on the front camshaft sprocket e Apply grease to the O ring A and install the cover B into the right side of the crankcase so that the tapped hole C faces outward e Install Both Rocker Cases see Rocker Case Installation Both Camshaft Chain Tensioners see Camshaft Chain Tensioner Installation e Check the valve clearances see Valve Clearance Inspec tion Cylinder Head Cylinder Compression Measurement NOTE O Use the battery which is fully charged e Warm up the engine thoroughly and stop the engine e Remove the spark plug see Electrical System chapter e Attach the compression gauge A and adapter B firmly into the spark plug hole Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1486 e Hold the throttle wide open and crank the engine with the electric starter or the recoil starter several times When the gauge stops rising stop cranking and read the gauge Cylinder Compression Usable Range Electric Starter 290 520 kPa 3 0 5 3 kgf cm 43 75 psi 290 r min rpm ENGINE TOP END 5 27 The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston cylinder Remove the carbon deposits
108. BR BL BL W Etat og BR BK R BK Y Fuel Reserve Switch Regulator Rectifire UN Tail Brake Light R 12V 21 5W Starter Motor Y R G N BK Y BR BR Y G BK Y dE BR R Y G BK Y 1O O Starter Vehicle down Circuit Sensor Relay Neutral Color Code BL Blue LB Light Blue prse Pink RENI White Y Yellow Ignition Switch Connections Color BR av on Oran 98052 0008A W2RO0OBAN5 C APPENDIX 17 1 Appendix TABLE OF CONTENTS Troubleshooting BET 17 2 Cable Wire and Hose ROUUFrig eoo e Ee et epis ite ii br cn t ste Ee 17 6 17 2 APPENDIX Troubleshooting Guide NOTE O This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big en
109. Bottom 4 CP Bott d Pinion Gear Top Toe Heel n Bottom Ring Gear Example 2 Increase the thickness of the ring gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary dil Heel Bottom Bottom E d Top Toe Bottom Pinion Gear Toe Top i Heel Y ee Bottom e Ring Gear HK14010B S 11 36 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close toler ances the clearance cannot normally be measured CAUTION Do not remove any bearings for inspection except the right rear axle bearing e Turn each bearing in the case or hub back and forth A while checking for plays roughness or binding lf bearing play roughness or binding is found replace the bearing e Check the needle bearings A in the final gear case O The rollers in the needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If the bearing is damaged replace the rear final gear case Oil Seal Inspection e Inspect the oil seals A Replace any if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged 6114010181 C BRAKES 12 1 Brakes TABLE OF CONTENTS Exploded View 12 2 Specific
110. C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing OThree new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 6114060581 Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol 6113014951 vent dry it do not spin the bearing while it is dry and oil it with engine oil O Spin A the bearing by hand to check its condition If the bearing is noisy does not spin smoothly or has any rough spots replace it e Check the needle bearings O The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage Alf there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seals A Replace it if the lips are misshapen discolored indicating tha
111. Check that the throttle lever A moves smoothly from full open to close and the throttle closes quickly and com pletely in all steering positions by the return spring lf the throttle lever does not return properly check the throttle cable routing lever free play and possible cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If the idle speed increases check the throttle lever free play and the cable routing e Stop the engine and check the throttle lever free play B x lf the free play is not within the specified range adjust the cable Throttle Lever Free Play Standard 2 3 mm 0 08 0 12 in Throttle Lever Free Play Adjustment e Slide the rubber cover off the adjuster at the throttle case e Loosen the locknut A and turn the throttle cable upper adjuster B until the cable has proper amount of play e Tighten the locknut and reinstall the rubber cover x lf the free play cannot be adjusted by using the upper cable adjuster remove the air cleaner cover and then use the cable adjusting nuts A at the lower end of the throttle cable and make the necessary free play PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Choke Lever Free Play Check e Check if the choke lever A returns properly and if the inner cable slides smoothly e Make sure t
112. Converter Cover B Torque Converter Cover Installation e Fit the trim seal into the converter cover O Set trim seal juncture in area A when insert trim seal in the cover 10 mm B HS04014BS1 C CONVERTER SYSTEM 6 9 Torque Converter e Tighten the cover bolts following the tightening sequence as shown Torque Converter Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib Converter Exhaust Duct Removal e Remove Clamp Screw A Clamp B e Remove the idle adjuster from the converter exhaust duct e Remove the duct mounting bolt A and collar e Remove the converter exhaust duct Converter Exhaust Duct Installation e Install the converter exhaust duct collar and tighten the duct mounting bolt e Install the converter exhaust duct A in the joint duct B as shown OWhen installing converter exhaust duct fit to aligning mark Converter Exhaust Duct Aligning Mark C Joint Duct Aligning Mark D OWhen installing joint duct do not twist and deformation e Install the joint duct to the converter cover e Install the clamp and tighten the clamp screw e Install the idle adjuster to the converter exhaust duct e Adjustthe idle speed see Periodic Maintenance chapter HS04017BS1 6 10 CONVERTER SYSTEM Torque Converter Converter Intake Duct Removal e Remove Seat and Air Cleaner Cover see Frame chapter Front Fender see Frame chapter e Remove the duct mounting bolt A collar and damper
113. Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive pulley spring incorrect installed too tight Driven pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift shaft bent or seized Gear stuck on the shaft Shift control grip damaged Shift control cable maladjusted Reverse lock maladjusted Jumps out of gear Shifter groove worn Gear dogs worn Shift block worn Shift fork worn Shift shaft spring weak or broken Shift control cable maladjusted Drive shaft output shaft and or gear splines worn Overshifts Shift shaft spring weak or broken Shift control cable maladjusted Abnormal Engine Noise Knocking Igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble
114. EASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM US MODEL only To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any which results in an increase in noise level Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the wa
115. EEN 4 20 Co lant Filter Cleaning EE 4 20 Coolant Valve Inspection oococcccccncncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnnnininins 4 20 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Fastener Torque Remarks N m kgf m ft Ib Radiator Fan Switch z 9 1 2 Water Pump Fitting Bolt 9 8 1 0 87 in lb 3 Water Pump Impeller 7 8 0 80 69 in Ib 4 Thermostat Housing Cover Bolts 8 8 0 90 78 in lb 5 Coolant Temperature Warning Light Switch SS 6 Radiator Fan Assembly Bolts 8 8 0 90 78 in lb 7 Radiator Mounting Bolts 8 8 0 90 78 mb 8 Water Pump Cover Bolts 8 8 0 90 78 in Ib 3 coolant Drain Plug se 090 78inib 10 Thermostat 11 Coolant Valve 12 Coolant Filter SS Apply silicone sealant Kawasaki Bond 56019 120 4 4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and cor rosion When the engine starts the water pump coupled with the oil pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 69 5 72 5 C 157 162 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole
116. EL SYSTEM 3 31 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Remove Seat Bracket Fuel Hose A Fuel Pump Lead Connector B Breather Hose C e Unscrew the fuel pump bolts D and take out the fuel pump assembly and gasket O Do not contact the fuel filter with the fuel tank e Discard the fuel pump gasket Pump Filter Cleaning A WARNING Clean the pump filter in a well ventilated area and take care that there are no sparks or flame any where near the working area Because of the dan ger of highly flammable liquids do not use gasoline or low flash point solvent to clean the pump filter e Remove the fuel pump A along with the pump filter B e Prepare a container C filled with a high flash point sol vent e Dip and shake the fuel filter only in the solvent to remove dirt and fuel deposits from the filter e Dry the pump and filter
117. Gears e Apply a non permanent locking agent to the threads of f the bevel gear holder nut A and tighten it so that the projection side B faces outward Special Tool Socket Wrench 57001 1482 C Torque Bevel Gear Holder Nut 157 N m 16 kgf m 116 ft lb e Press the new outer ball bearing until it is bottomed Output Driven Bevel Gear Removal e Remove Swingarm see Suspension chapter and Propeller Shaft see this chapter or Engine see Engine Removal In stallation chapter Output Driven Bevel Gear Housing Bolts A Output Driven Bevel Gear Housing B e Tap lightly the front end A of the output driven bevel gear shaft using a plastic mallet O The output driven bevel gear shaft assembly comes off with the housing 11 14 FINAL DRIVE Output Bevel Gears Output Driven Bevel Gear Installation e Apply grease O ring A e Install the output driven bevel gear shaft assembly e Tighten Torque Output Driven Bevel Gear Housing Bolts 26 N m 2 7 kgf m 20 ft Ib mde P Output Driven Bevel Gear Disassembly e Remove Output Driven Bevel Gear Housing Assembly see Out put Driven Bevel Gear Removal e Hold the holder in a vise and set the housing assembly A on the holder Special Tools Damper Spring Compressor Set B 57001 1475 Holder amp Guide Arbor C 57001 1476 e Tighten the nuts D and compress the damper spring E e Remove Circlip A Special Tool Outside Circlip Pliers 5700
118. It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE O Prior to grinding apply engine oil to the cutter and 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 Deeg eebe ts Cutter angle B SOO ae Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced ENGINE TOP END 5 33 GE150118S1 5 34 ENGINE TOP END Valves Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F e Measure the outside diameter of the seating surface with
119. NE LUBRICATION SYSTEM Engine Oil Flow Chart Se EDI D O OO O O H T e H604003BN4 1 Oil Screen 6 Oil Pipe 11 Transmission Drive Shaft 2 Oil Pump 7 Crankshaft 12 Front Cylinder Head 3 Relief Valve 8 Rear Cylinder Head 13 Front Camshaft 4 Oil Pressure Switch 9 Rear Camshaft 5 Oil Filter 10 Transmission Idle Shaft ENGINE LUBRICATION SYSTEM 7 7 Engine Oil and Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e If the oil has just been changed start the engine and run it for several minutes to fill the oil filter CAUTION Allow the engine to idle for several minutes so that oil may reach all parts of the engine Racing a dry engine may cause severe damage e Stop the engine and wait several minutes for all the oil to drain back to the sump e Unscrew the oil filler cap A wipe its dipstick B dry and tighten it into the filler opening e Unscrew the oil filler cap and check the oil level The oil level should be between the upper H level line C and lower L level line D xIf the level is too high suck the excess oil out the filler hole with a syringe or other suitable device x lf th
120. NGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Installation e Roll up the boot A toward the engine e Insert the drive shaft in the rear propeller shaft joint A e Tighten Torque Engine Mounting Bracket Bolts 52 N m 5 3 kgf m 38 ft lb Engine Mounting Nut 62 N m 6 3 kgf m 46 ft lb CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission TABLE OF CONTENTS Exploded E 9 2 A EE EBENE 9 6 Special Tools and Gealant drna e a a e e a a a a 9 8 SEENE E E O E E E A T 9 9 Crankcase Disaster iaa 9 9 Crankease Assembly tantito iii 9 10 Crankshaft Connecting Rod rhet ide ata 9 13 Crankshaft Removal 5 i ette m ae cest Rp e EN M S E E AE A a E 9 13 Crankshaft Installation oooooonccncccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininins 9 13 Connecting Rod Removal ce sia aa Gu Paglia 9 13 Connecting Rod Installatiofi 7 1 1r dies 9 13 Crankshaft Connecting Rod Cleaning Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Cearance cnn 9 15 Connecting Rod Big End Bearing Crankpin West 9 15 ANSIA E te Pe nerd ede 9 17 Crankshaft Main Bearing Journal Wear oooonocnnncnccoccccncccnnnnononnnnncnonnnnnnno nn nenne 9 17 TRANS MISSION EE 9 18 Shift Eever Removal unitaria ia taa 9 18 shiftLever Installation uoto ee testet dee Ja el da td dedos 9 18 Shift Control Cables HRemoval ee nene eene nennen nene nannan rnnr rnea 9 19 Shi
121. NSMISSION Crankshaft Connecting Rod l the measured crankpin diameter A is not less than the service limit but does not coincide with the original diameter marking on the crankshaft make a new mark on it Crankpin Diameter Marks None 39 984 39 992 mm 1 5742 1 57449 in Q 39 993 40 000 mm 1 57452 1 5748 in Crankpin Diameter Mark B mark or no mark e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter e Tighten the big end nuts to the specified torque Torque Connecting Rod Big End Cap Nuts 34 N m 3 5 kgf m 25 ft lb NOTE O The mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Inside Diameter Marks None 43 000 43 008 mm 1 6929 1 69323 in O 43 009 43 016 mm 1 69326 1 6935 in Diameter Mark A mark or no mark e Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Big End Bearing Insert Selection Con rod Big Bearing Insert End Bore aad j Diameter Diameter Marking Mark Size Color Part Number None Brown 92028 1963 Yellow 92028 1962 None O Green 92028 1961 e Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage HI05001BS1 C HI0
122. O TRANSGARD TRACTOR HYDRAULIC FLUID Capacity 900 mL 0 95 US qt e Be sure the O ring is in place Torque Oil Filler Cap B 29 N m 3 0 kgf m 22 ft Ib 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Propeller Shaft Joint Boot Inspection e Visually inspect the rear propeller shaft joint boot A in accordance with the Periodic Maintenance Chart or if the shaft is noisy during operation If the joint boot is torn worn or deteriorated replace the joint boot and check the propeller shaft see Final Drive chapter Brakes Front Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard 4 mm 0 16 in Service Limit 1 mm 0 04 in Front Brake Hoses and Connections Inspection e Inspect the brake hose and fittings for deterioration cracks and signs of leakage O The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed e Tighten any loose fittings Front Brake Hose Replacement e Pump the brake fluid out of the line as explained in the Brake Fluid Change e Remove the banjo bolts at both ends of the brake hose and pull the hose off the v
123. ON and measure the output volt age with the connector joined Vehicle down Sensor Power Output Voltage Standard 0 4 1 4 V with sensor arrow mark pointed up e Tilt the sensor 60 70 or more H right or left and mea sure the output voltage O The time lag is from 0 5 to 1 second Vehicle down Sensor Power Output Voltage Standard 3 7 44V with sensor tilted 60 70 or more right or left x lf the output voltage is out of the specified replace the vehicle down sensor HP10007BS2 C ELECTRICAL SYSTEM 16 43 Ignition System Ignition System Troubleshooting Faulty ignition No spark Battery Inspection Charge or replace battery Ignition system wiring and connector inspection Repair prreplace damaged part Good No good Replace spark plug No good Replace plug cap Spark plug inspection Plug cap inspection Good Vehicle down sensor inspection Replace vehicle down sensor Good No good i Ignition coil primary peak voltage inspection Ne Ee than the Good i Ignition coil is defective Voltage is zero or Inspect Replace ignition coil almost zero y lower tai ina hand tester Use No good KAWASAKI Hand Tester Inspect 2 Crankshaft sensor peak No good 1 Adapter connection is voltage incorrect or adapter is defective 2 Ignition switch and engine stop switch 3 Crankshaft sensor peak voltage Igniter is defective
124. Oh 15 2 FRAME Exploded View SS 2 lun Zoe Ae ae 5 RE E Gren S a a be n H002019BN4 1 Canada Model FRAME 15 3 Exploded View AD Apply adhesive agent to outside 15 4 FRAME Exploded View of Y AN Y gt V eX ve y As FRAME 15 5 Exploded View No Fastener Torque N m kgfm ft lb 52 5 3 38 62 6 3 46 44 4 5 33 Remarks 1 Engine Mounting Bracket Bolts 2 Engine Mounting Nut 3 Footrest Mounting Bolts AD Apply adhesive agent 15 6 FRAME Seat Seat Removal e Push down the seat latch A and then remove the seat B by pulling it up to the rear Seat Installation e Slip the front seat hooks A into the button B on the air cleaner cover and the brace C on the frame e Put the stoppers D into the holes E in the frame e Push down the rear part of the seat until the lock F clicks Fenders Front Fender Removal e Remove Seat see Seat Removal Air Cleaner Cover see Air Cleaner Cover Removal Screw and Collar A Upper Front Cover B e Remove Screws and Collars A both side Screws and Collars B e Remove Bolts A both side Screws and Collar B both side Headlight Connector C both side Front Fender Front Fender Installation e Install Grommets A Clamp Nut B Damper C Stay D Front Fender Up
125. Position Adjustment Rear Brake Lever Free Play Inspection Brake Pedal Free Play Inspection Rear Brake Lever and Pedal Free Play Adjustment aeeeee Brake Pedal Removal Brake Pedal Installation Brake Cable Removal Brake Cable Installation Brake Cable Lubrication Brake Pedal Shaft Removal Brake Pedal Shaft Installation Internal Wet Brake Internal Wet Brake Disassembly Internal Wet Brake Assembly 12 21 12 22 12 2 BRAKES Exploded View oy BRAKES 12 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Reservoir Cap Screws 1 5 0 15 13 in lb 2 Brake Lever Pivot Bolt 5 9 0 60 52 in lb 3 Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb 4 Master Cylinder Clamp Bolts 8 8 0 90 78 in lb 5 Brake Switch Mounting Bolt 1 2 0 12 10 in Ib 6 Brake Hose Banjo Bolts 25 2 5 18 7 Caliper Mounting Bolts 25 2 5 18 8 Bleed Valves 7 9 0 80 69 in lb 9 Disc Mounting Bolts 37 3 8 27 L B Apply brake fluid L Apply a non permanent locking agent Si Apply silicone grease 12 4 BRAKES Exploded View HLO2012BW5 BRAKES 12 5 Exploded View No Fastener Remarks 1 Parking Brake Lever Screw L 2 Gasket Screws L 3 Brake Pedal Bolt 8 8 0 90 78 in
126. Rep lace igniter Replace bad parts or inspect them with KAWASAKI Hand Tester HP10004B F Replace bad parts 16 44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit Y G BR R R W JB 10 SLE BK R BR zu Y BK BR Y G R W BK R BR 1 Y G R W BK R BR BK Y Y G BR BK Y ME e O R Y W oo BR Y R GY W T TUE BR Y R BL BL BK W i BK W eo 1 Reverse Switch 2 Fuel Pump 3 Reverse Power Assist Switch Override 4 Engine Stop Switch Y G R W BK R BK W BL Y BK 5 Ignition Switch 6 Reset Connector G W BK Y BL 4 BK Y 7 Vehicle down Sensor 8 Crankshaft Sensor 9 Igniter BK Y wW W HP10024BN4 C 10 Ignition Coils 11 Spark Plugs 12 Battery 13 Main Fuse 30A ELECTRICAL SYSTEM 16 45 Electric Starter System Starter Motor Removal e Remove Converter Intake Duct A Joint Duct B and Collars e Remove Starter Motor Cable A Starter Motor Mounting Bolts B Clamp C Starter Motor D CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged Starter Motor Installation e When installing the starter motor clean the starter mo tor lugs A and crankcase B where the starter motor is grounded x lf the O ring A shows wear or damage or if it is hard ened replace it with a new one e Apply a
127. Service Limit 6 25 mm 0 2460 in mi100020 P HI10002181 C HI10002281 Ona CRANKSHAFT TRANSMISSION 9 25 Transmission Transmission and Shift Mechanism Inspection e Visually inspect Gears Dogs of Gear and Shifter xf they are damaged or worn excessively replace them HI10015BS1 9 26 CRANKSHAFT TRANSMISSION Transmission 0000 0 O 9 C0 9 9 4 E y ae EA Sie Sai Me i I a iz L F 71 4 m m m XC E E NA 49 oOo D x Lb Ni G3 D OU E 3 1 Driven Shaft 10 Reverse Idle Shaft 2 Spacer 17 3 x 30 x 2 0 11 Reverse Driven Gear 16T 3 Reverse Gear 12T 12 Reverse Driven Output Gear 14T 4 Spacer 21 2 x 29 x 1 6 13 Idle Shaft 5 Shifter 14 Spacer 20 3 x 33 x 2 0 6 Snap Ring 15 Driven Output Gear 20T 7 Washer T 1 5 16 Driven Hi Gear 29T 8 Spacer 28 x 39 x 8 17 Needle Bearing 9 Drive Hi Gear 27T 18 Spacer 25 x 32 x 13 CRANKSHAFT TRANSMISSION 9 27 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or three needle bearings NOTE O In the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93
128. Valve Spring Compressor Adapter 22 57001 1202 Valve Guide Arbor 5 57001 1203 Valve Guide Reamer 5 57001 1204 Valve Seat Cutter Holder 5 57001 1208 ENGINE TOP END 5 11 Piston Pin Puller Adapter 57001 1211 Filter Cap Driver 57001 1454 7571454ST Compression Gauge Adapter M10 x 1 0 57001 1486 7571486ST Kawasaki Bond Silicone Sealant 56019 120 5 12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type cam chain tensioner The push rod does not return to its original position once it moves out to take up cam chain slack Ob serve all the rules listed below When removing the tensioner do not take out the mounting bolts only partway 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 cam chain timing and damage the valves e Remove Cap Bolt A and Washer Pin and Spring e Remove Tensioner Mounting Bolts A Camshaft Chain Tensioner B Camshaft Chain Tensioner Installation e Push the stopper A to release the ratchet and push the push rod B into the tensioner body e Tighte
129. a eee ar eaae aeea aiee iEn ean ena Eana aaen Ea na aiaa aE aaae 1 OO OO Ob 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper ation on a vehicle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following 1 Dirt Before removal and disassembly clean the vehicle Any dirt entering the engine will shorten the life of the vehicle For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Disconnect the ground wire from the battery before performing any disassembly operations on the vehicle This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive wire to the positive terminal of the battery Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it
130. a set in the factory to get the best tooth contact They must be re placed as a set e Visually inspect the bearing for abrasion color change or other damage Alf there is any doubt as to the condition of a bearing re place the bearing e Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced e Press the bearing A on the pinion gear until it is bot tomed e Install the pinion gear bearing holder nut B so that the projection C faces outward e Apply a non permanent locking agent to the pinion gear bearing holder nut A and tighten it Special Tools Socket Wrench B 57001 1363 Pinion Gear Holder C 57001 1480 Torque Pinion Gear Bearing Holder Nut 157 N m 16 kgf m 116 ft Ib Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged HK14001381 C HK14001781 FINAL DRIVE 11 35 Final Gear Case Correct Tooth Contact Pattern No adjustment is required Heel Bottom Bottom PL lop Bottom Toe m E Toe Pinion Gear Heel S m Bottom Ec Incorrect Tooth Contact Patterns Example 1 Decrease the thickness of the ring gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Bottom mom Heel To
131. ads Crankshaft Sensor Inspection e Remove the rear fender see Frame chapter e Disconnect the crankshaft sensor lead connector A e Measure the crankshaft sensor resistance OConnect a hand tester between the BK W lead and the BL lead O Set the tester to the x 10 range Crankshaft Sensor Resistance 110 140 Q x lf the tester does not read as specified replace the crank shaft sensor ELECTRICAL SYSTEM 16 37 16 38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE O Be sure the battery is fully charged e Remove the spark plug caps but do not remove the spark plugs e Disconnect Crankshaft Sensor Wire Connector A e Set the hand tester B to the 10 V DC range e Connect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tool Hand Tester 57001 1394 Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connections Crankshaft Sensor Wire Adapter Hand Tester Blue c Red gt Black White lt Black gt e Turn the ignition switch on and rotate the engine for 4 5 seconds with the transmission gear in neutral to measure the pickup coil peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 1 8 V or more Alf the peak voltage is lower than the standard inspect the crankshaft sensor Alternator Rotor Inspection e Check the timin
132. air whenever brake parts are replaced or re assembled e Remove the reservoir cap and fill the reservoir with new brake fluid e Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir This bleeds the air from the master cylinder and the brake line NOTE O Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container e Bleed the brake line and the caliper as follows O Hold the brake lever applied A O Quickly open and close the valve B O Release the brake lever C e The fluid level must be checked several times during the bleeding operation and replenished as necessary NOTE O If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have en tered the line O If the brake lever action still feels soft or spongy tap the brake hose from bottom to top and air will rise up to the top part of the hose Slowly pump the brake lever in the same manner as above e Tighten Torque Bleed Valves 7 9 N m 0 80 kgf m 69 in Ib e Apply the brake lever forcefully for a few seconds and check for fluid l
133. ake off the rod and cap with the bearing inserts ou P Connecting Rod Installation CAUTION If the connecting rods bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling the engine to be sure the correct bear ing inserts are installed e Apply molybdenum disulfide oil Inner Surface A of Bearing Inserts e Face the OUT marks B of both connecting rods to wards the outsides of the crankshaft e Fit the connecting rod cap so that the grooves C of the cap and connecting rod are on the same side Hp P 9 14 CRANKSHAFT TRANSMISSION Crankshaft Connecting Rod e Apply molybdenum disulfide oil Threads A of Connecting Rod Big End Cap Bolts Seating Surface B of Connecting Rod Big End Cap Nuts C e Tighten Torque Connecting Rod Big End Cap Nuts 34 N m 3 5 kgf m 25 ft lb Crankshaft Connecting Rod Cleaning e After removing the connecting rods from the crankshaft clean them with a high flash point solvent e Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend e Remove the connecting rod big end bearing inserts and reinstall the connecting rod big end cap e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an ar
134. allation e Make sure that the shift lever is in neutral position O Neutral position is the shift control cable lower ends A and reverse cable bracket mounting bolt B aligned state e Lubricate the shift control cables before installation e Route the shift control cables correctly according to the Appendix chapter A WARNING Operation with an improperly adjusted incorrectly NEE routed or damaged cables could result in an unsafe riding condition e Adjust the shift control cables free play see Periodic Maintenance chapter 9 20 CRANKSHAFT TRANSMISSION Transmission Reverse Lock Cable Removal e Remove Right Foot Guard see Frame chapter Converter Cover see Converter System chapter e Remove the reverse lock cable locknut A eg ec So M toog N N N d e Remove the cotter pin A washer B and pin C e Remove the reverse lock cable from the lever D e Loosen the locknuts A and remove the reverse lock ca ble from the frame Reverse Lock Cable Installation e Lubricate the reverse lock cable before installation e Install the reverse lock cable to the frame e Tighten the locknuts temporarily e Install the reverse lock cable A to the lever e Replace the cotter pin with a new one e Install the pin washer and cotter pin HI10018BS1 C CRANKSHAFT TRANSMISSION 9 21 Transmission e Install the reverse lock cable in the reverse lock cable bracke
135. alve seat with vernier calipers elt the width is too wide too narrow or uneven repair the seat see Valve Seat Repair F Good G Too Wide H Too Narrow J Uneven Valve Seating Surface Width Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in Valve Seat Repair Valve Lapping e Using the valve seat cutters A repair the valve seat Special Tools Valve Seat Cutters Exhaust Valves Valve Seat Cutter 45 427 5 57001 1114 Valve Seat Cutter 32 428 57001 1119 Valve Seat Cutter 60 430 57001 1123 Inlet Valves Valve Seat Cutter 45 430 57001 1187 Valve Seat Cutter 32 433 57001 1199 Valve Seat Cutter 60 430 57001 1123 Holder amp Bar Valve Seat Cutter Holder 5 57001 1208 B Valve Seat Cutter Holder Bar 57001 1128 C If the manufacturer s instructions are not available use the following procedure GE15011782 C Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve seat for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE O Do not use a wire brush to remove the metal particles from the cutter
136. ar HK16003582 C Incorrect Tooth Contact Patterns 2 Bottom Heel Top Toe Bottom Drive Gear Bo ttom Toe Heel b Toe Top Bottom N Heel SS N Driven Gear HK160036S2 C 11 22 FINAL DRIVE Output Bevel Gears Bevel Gears Inspection e Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged Cam Damper Inspection e Visually inspect Bevel Gear Cam A Cam Follower B Spring C Shaft D Replace any part if it appears damaged HK16006BS1 C Propeller Shaft Propeller Shaft Removal e Drain the final gear case oil see Final Drive in the Periodic Maintenance chapter e Remove Swingarm A see Suspension chapter Propeller Shaft B Propeller Shaft Installation e Wipe the old grease off the front and rear end splines A of the propeller shaft B and apply new molybdenum disulfide grease in those e Be sure to install the spring C on the pinion gear nut of the final gear case e Install the propeller shaft while aligning the splines Propeller Shaft Joint Boot Inspection e Refer to the Final Drive in the Periodic Maintenance chap ter Propeller Shaft Inspection e Remove the propeller shaft see Propeller Shaft Re moval e Check that the universal joint A works smoothly without rattling or sticking x lf it does rattle or stick the universal joint is damaged Replace the propeller
137. ar camshaft chain with the rear camshaft sprocket e Align the marks B on the weights with the rear cylinder head upper surface HEO9008BSi C 5 18 ENGINE TOP END Camshaft e Using a wrench on the alternator bolt turn the crankshaft clockwise 270 O Align the T F mark A with the notch B in the inspection window e Face the arrow A of the front camshaft sprocket upward right side view e Engage the front camshaft chain with the front camshaft sprocket e Align the marks B on the weights with the front cylinder head upper surface e Install Rocker Cases see Rocker Case Installation Camshaft Chain Tensioners see Camshaft Chain Ten sioner Installation e Check the valve clearance see Valve Clearance Inspec tion Camshaft Assembly e Install the KACR unit A sprocket on the camshaft so that the unit fits onto the camshaft pins B e Apply a non permanent locking agent to the camshaft sprocket bolts C e Tighten Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 in Ib Cam Wear e Remove the camshaft e Measure the height A of the cam with a micrometer Alf the cams are worn past the service limit replace the camshaft Cam Height Standard Service Limit Exhaust 35 363 35 477 mm 35 26 mm 1 3932 1 3967 in Inlet 35 622 35 736 mm 35 52 mm 1 4024 1 4069 in 1 398 in HE10001BS1 C HE09010BS1 C MEO90006 P GE1
138. ash MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Filler opening bottom 900 mL 0 95 US qt 0 07 0 14 mm 0 003 0 006 in at pinion gear spline Special Tools Bearing Puller 57001 135 Outside Circlip Pliers 57001 144 57001 1058 Oil Seal amp Bearing Remover Bearing Driver Set 57001 1129 Socket Wrench 57001 1363 FINAL DRIVE 11 7 Damper Spring Compressor Set 57001 1475 CV ST5714758T Holder 8 Guide Arbor 57001 1476 SEO ST5714768T Socket Wrench Hex 50 57001 1478 S 7571478ST Output Shaft Holder amp Spacer 57001 1479 e lt gt 7571479ST Pinion Gear Holder 57001 1480 Ke 7571480ST Nut Holding Bolts 57001 1481 ST5714818T 11 8 FINAL DRIVE Special Tools Socket Wrench 57001 1482 Q Pinion Gear Holder 57001 1485 T5714828T Socket Wrench Hex 41 57001 1484 C 7571484ST C Oil Seal Driver 57001 1487 S 7571485ST 7571487ST Hexagon Wrench Hex 44 57001 1491 g 7571491ST Output Bevel Gears Output Drive Bevel Gear Removal e Remove Oil Pipe see Engine Lubrication System chapter Output Drive Bevel Gear Cover Bolts A Output Drive Bevel Gear Cover B e Remove Circlip A Special Tool Outs
139. ations sssssss 12 6 Special Tool 12 7 Brake Flug 12 8 Brake Fluid Recommendation 12 8 Brake Fluid Level Inspection 12 8 Brake Fluid Change n 12 8 Brake Line Air Bleeding 12 8 Master Cylinder 12 9 Master Cylinder Removal 12 9 Master Cylinder Installation 12 9 Master Cylinder Disassembly 12 9 Master Cylinder Assembly 12 10 Master Cylinder Inspection Visual Inspection ilie ensis 12 10 Calipers ec o ds 12 11 Caliper Removal 12 11 Caliper Installation 12 11 Caliper Disassembly 12 12 Caliper Assembly 12 12 Piston and Cylinder Damage 12 13 Caliper Holder Shaft Wear Inspection ssessessssss 12 13 Brake Pads anodne aa 12 14 Brake Pad Removal 12 14 Brake Pad Installation 12 14 Brake Pad Wear Inspection 12 14 Brake DISCS nnannnnnnnnnnneneaeennnnneeneene Disc Cleaning Disc Removal Disc Installation Disc Wear niiin eiia Disc Runout suesssss Brake Hoses Brake Hose Inspection Brake Hose Replacement Rear Brake Lever Pedal and Cables Brake Pedal Position Inspection Brake Pedal
140. ator Fan Fuse Removal 16 70 Main Fuse Inspection 16 70 Radiator Fan Fuse Inspection 16 71 Wiring Diagram eeesssse 16 72 16 4 ELECTRICAL SYSTEM Exploded View Exploded View ELECTRICAL SYSTEM 16 5 No Fastener EE Remarks N m kgf m ft Ib 1 Battery Cable Bolts 59 060 52inlb 2 Starter Motor Mounting Bolts 8 8 0 90 78 in Ib 3 Starter Motor Terminal Nut 4 9 0 50 43 in Ib 4 Starter Motor Terminal Locknut 6 9 0 70 61 in Ib 5 Starter Motor Bolts 4 9 43 in lb 6 Starter Motor Clutch Bolts 34 3 5 25 L 7 Alternator Stator Bolts 13 1 3 113 in Ib 8 Crankshaft Sensor Mounting Bolts 5 9 0 60 52 in lb 9 Alternator Cover Plugs 18 13 10 Alternator Rotor Bolt 127 13 94 11 Alternator Bolt Cover Bolts 8 8 0 90 78 in Ib 12 Alternator Cover Bolts 8 8 0 90 78 in lb DOS lt FrO Apply grease for oil seal and O ring Apply a non permanent locking agent Apply molybdenum disulfide grease Apply engine oil Replacement Parts 16 6 ELECTRICAL SYSTEM Exploded View HP02019BN5 ELECTRICAL SYSTEM 16 7 Exploded View No Fastener Sorque Remarks N m kgf m ft Ib 1 Spark Plugs 13 1 3 113 in Ib 2 Ignition Coil Mounting Bolts 48 in lb 3 Igniter Mounting Bolts 20 in lb 4 Oil Pressure Switch i 11 SS 5 Oil Pressure Switch Terminal Bolt 1 5 0 15 13
141. b 115 kg 254 Ib 135 kg 298 lb 12 L 3 2 US gal Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil Type Viscosity Capacity Performance Minimum turning radius 3 2 m 10 50 ft Engine Type 4 stroke SOHC V2 cylinders Liquid cooled 82 0 x 66 0 mm 3 23 x 2 60 in 697 mL 42 5 cu in 9 9 1 36 3 kW 49 4 PS 6 500 r min rpm US 59 2 N m 6 04 kgf m 43 67 ft lb 5 000 r min rpm Carburetor Keihin CVKR D32 Electric Starter Digital DC CDI Electronically advanced From 5 BTDC 21 100 r min rpm to 28 BTDC 95 000 r min rpm NGK CR7E 20 BTDC 44 ABDC 244 44 BBDC 20 ATDC 244 Forced lubrication wet sump API SF or SG API SH or SJ with JASO MA class SAE 10W 40 2 2 L 2 33 US qt GENERAL INFORMATION 1 7 General Specifications Items KSV700 A1 Drive Train Primary reduction system Type Belt converter Reduction ratio 3 122 0 635 Transmission Type 1 speed and reverse Gear ratios Forward 2 416 29 27 x 27 20 x 20 12 Reverse 4 285 16 12 x 20 14 x 27 20 x 20 12 Final drive system Type Shaft 2WD Reduction ratio 4 375 35 8 Overall drive ratio Forward 32 999 6 711 Reverse
142. ble Cable Wire and Hose Routing 17 6 APPENDIX tod 1 Tube 2 Clamp 3 Align the white paint mark on the tube with the adjustment mark on the crankcase 4 Electric Starter APPENDIX 17 7 Cable Wire and Hose Routing 1 Cooling Hoses 2 Clamps Install the clamps with the tabs direction as shown 3 Coolant Valve 4 Position the white marks on the tube as shown 5 Damper 6 Clamps 17 8 APPENDIX Cable Wire and Hose Routing HB09050BN4 C 1 Clamp 2 Engine Ground Lead 3 Install the clamp on the engine ground lead Cable Wire and Hose Routing APPENDIX 17 9 VIEW A 1 Water Pipe 2 White Paint 3 Clamps 4 Cooling Hoses 5 Coolant Filter Body 6 Coolant Filter FORWARD HB06019BN4 7 Carburetor 8 Mark 9 Cooling Hose 10 Assemble Angle about 45 4 and 9 hoses 11 Cooling Hose 17 10 APPENDIX Cable Wire and Hose Routing HB09051BN4 1 White Paint 8 Tube 2 Water Pipe 9 Breather 3 Clamp 10 Pump Cover 4 Cooling Hose 11 Mark 5 To Carburetor 12 To Radiator 6 Carburetor Overflow Tube 13 Duct 7 Exhaust Pipe Cover 14 Face the clamp screw as shown APPENDIX 17 11 Cable Wire and Hose Routing ETC saa oe ed Eo aS e SN RI 8 6 gt i FL HB09052BN4 C 1 Air Cleaner Duct 8 Coolant Valve 2 Clamps 9 Coolant
143. ble could result in an unsafe riding condition Choke Cable Lubrication Whenever the choke cable is removed lubricate the cable as follows e Lubricate the cable with a penetrating rust inhibitor through the pressure cable lubber Choke Cable Inspection e With the choke cable disconnected at both ends the ca ble should move freely A in the cable housing lf the cable does not move freely after lubricating if the cable is frayed B or if the housing is kinked C replace the cable 6004011481 C 6004020152 C FUEL SYSTEM 3 13 Carburetor Idling Speed Inspection e Refer to the Fuel System in the Periodic Maintenance chapter Idle Speed Adjustment e Refer to the Fuel System in the Periodic Maintenance chapter Pilot Screw Adjustment e Adjust the pilot screw if necessary e Remove the converter exhaust joint duct see Converter System chapter e Turn the carburetor pilot screw A all the way in until it seats lightly Special Tool Pilot Screw Adjuster A 57001 1239 B CAUTION Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement e Back the pilot screw out the specified number of turns Carburetor Pilot Screw Setting Standard 1 1 2 turns out Service Fuel Level Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure t
144. bor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on a V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend lf connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in 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 3 94 in length of the arbor to de termine 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 0 008 3 94 in HIOS000BS1 C CRANKSHAFT TRANSMISSION 9 15 Crankshaft Connecting Rod Connecting Rod Big End Side Clearance e Measure the side clearance of the connecting rod big end A O Insert a thickness gauge B between the big end and ei ther crank web to determine clearance Connecting Rod Big End Side Clearance Standard 0 16 0 46 mm 0 0063 0 0181 in Service Limit 0 7 m
145. by lightly applying compressed air e Install the fuel pump see Fuel Pump Installation HC10001BS2 C 3 32 FUEL SYSTEM Fuel Pump Fuel Pump Installation e Clean the pump filter see Pump Filter Cleaning e Remove dirt or dust from the fuel pump by lightly applying compressed air e Replace the fuel pump gasket A with a new one e Install the fuel pump assembly so that the fuel filter do not contact with the fuel tank Fuel Pump Inspection e Refer to the Electrical System chapter COOLING SYSTEM 4 1 Cooling System TABLE OF CONTENTS O A OA 4 2 Coolant Flow Charts iieri eh te a e RARE aac avis 4 4 jore NS 4 6 Special Tools and Sealant emere nnns 4 7 eel S 4 8 Coolant Deterioration Inspechon eee 4 8 Coolant Level Inspechon a E e a a a a 4 8 Coolant Draining ti ia 4 8 OO TF WING EE 4 8 Pressure Test EE 4 9 Water nM 4 10 Water Pump Cover Removal ooooooooooccooocooncnoncnoncnoncnoncnoncnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnrnnnnnnnrnonnnnnnnns 4 10 Water Pump Cover Installation seeeeeeeeeeeeeeeeeeeeeeneeeseeeereetreesrtestterrtesrtrerererterteerrresereeee eee 4 10 Impeler Rem OVa ier A As 4 10 Water Pump Impeller Installation ooooooonooonnonncoonconccnncnoncnnnnnonnnoncnonnnonnnnnnnnncnnnnononnnns 4 10 Water Pump Impeller Inspection eene 4 11 Mechanical Seal Replacement ooocccccccnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn
146. causing the engine to warm up more quickly When coolant temperature is more than 69 5 72 5 C 157 162 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 96 100 C 205 212 F the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 91 95 C 195 203 F the fan switch opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contract and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 14 18 psi the pressure valve opens and releases the pressure to the res
147. ce chapter Throttle Case Removal Disassembly e Remove the throttle case screws A and pull the case open e Slide the cable adjuster dust cover out of place e Remove the rubber cover A e Pull the cable tip A out of the throttle lever catch with the throttle lever opened e Loosen the locknut B and unscrew the adjuster C e Disassemble the throttle case as follows O Remove the throttle lever screw D lockwasher and flat washer and lift the throttle lever E and return spring from the case O Pull the throttle control lever F out of the case Throttle Case Assembly Installation e Lubricate the throttle case and cable before assembly in stallation e Be certain that the return spring is correctly installed on the throttle lever A e Instal the throttle case so that fit the projection on the lower throttle case and hole on the handlebar e Tighten the throttle case assembly screws Torque Throttle Case Assembly Screws 3 7 N m 0 38 kgf m 33 in Ib WD P Throttle Lever and Cable e Swing the throttle control lever so that the carburetor throt tle valve is fully open Turn the throttle limiter screw A until it is spaced about 1 mm 0 04 in B away from the throttle lever stop C Tighten the locknut D Torque Throttle Limiter Screw 3 7 N m 0 38 kgf m 33 in Ib Throttle Limiter Locknut 3 7 N m 0 38 kgf m 33 in Ib NOTE O Refer to the Owner s Ma
148. ches the model name B of the battery These names must be the same Battery Model Name KMX 14 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance e Check to see that there is no peeling tears or holes in the seal sheet on the top of the battery e Place the battery on a level surface e Remove the seal sheet CAUTION Do not remove the aluminum seal sheet A sealing the filler ports B until just before use NOTE OA battery whose seal sheet has any peeling tears holes or from which the air sucking sound was not heard requires a refreshing charge initial charge ELECTRICAL SYSTEM 16 17 6P08040781 gp070004 tif 16 18 ELECTRICAL SYSTEM Battery e Take the electrolyte container out of the vinyl bag e Detach the seal caps A from the container NOTE O Do not discard the seal caps because it is used as the battery plugs later O Do not peel back or pierce the seals B on the container e Place the electrolyte container upside down aligning the six seals with the six battery filler ports e Push the container down strongly enough to break the seals Now the electrolyte should start to flow into the battery
149. ciently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of higher than 12 6 V after 10 minutes of filling Note 1 no initial charge is necessary Condition requiring initial charge Charging method At low temperatures lower than 0 C 1 4 Ax 2 3 hours Battery has been stored in high temperature and humidity Seal has been removed or broken peeling tear or hole If you did not hear the air sucking sound Shoosh as you removed the seal 1 4 A x 15 20 Battery as old as 2 years or more after manufacture hours Battery manufacturing date is printed on battery top Example 12 10 99 T1 Day Month Year Mfg location Note 1 Terminal voltage To measure battery terminal voltage use a digital voltmeter 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 sealing plug to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery 1
150. cks breaks or peeling x lf necessary replace the belt with a new one Belt A Crack B Broken C Peeling D NOTE O Whenever the belt is replaced inspect the drive and the driven pulleys HS05002BSi Drive Belt Deflection Inspection e Remove the torque converter cover see Converter Sys tem chapter e Putthe transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley e Measure the belt deflection A as shown O Place a straightedge B on top of the belt between the drive pulley C and the driven pulley D OUse a ruler to push the belt away from the straightedge Push hard but with no more force than 59 N 6 kgf 13 Ib Belt Deflection Standard 22 27 mm 0 87 1 06 in lf the belt deflection is not within the specified range first measure the height of the belt pralle portion see Drive 150500085058 Belt Inspection Adjust the deflection by adding or re moving spacers on the fixed sheave e When adjusting the deflection less is better than more Less deflection will maintain better performance for more time as the belt width decreases by normal wear which causes the deflection to increase with usage 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Deflection Adjustment e Disassemble the driven pulley see Converter System chapter x If the belt deflection is more than
151. counterclockwise 270 until T R mark A is aligned with the notch B in the inspection window and the cam lobes are pointing away from the rocker arms the end of the compression stroke CAUTION Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case The rocker arms could bend the valves HEi10002BSi 5 14 ENGINE TOP END Rocker Case e Remove Rear Camshaft Chain Tensioner see Camshaft Chain Tensioner Removal Rocker Case Bolts A Rear Rocker Case B e Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame Rocker Case Installation e Install the rear camshaft and then the front camshaft see Camshaft Installation in this chapter e Check that the crankshaft is positioned at TDC and at the end of the compression stroke CAUTION Be sure to position the crankshaft is at TDC of the end of the compression stroke The rocker arms could bend the valves e Apply silicone sealant to the outer surface of the cap A and the cylinder head upper surface B as shown Sealant Kawasaki Bond Silicone Sealant 56019 120 e Tighten the rocker case bolts following the tightening se quence shown Torque Rocker Case Bolts 1 4 L 55 mm 2 2 in with washers 8 8 N m 0 90 kgf m 78 in Ib Rocker Case Bolts 5 6 L 130 mm 5 1 in 9 8 N m 1 0 kgf m
152. cturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as re moval weakens and deforms them If old ones are reused they could become detached while the vehicle is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign
153. d after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Caliper Disas sembly Caliper Installation e Install the caliper and brake hose lower end O Replace the washers that are on each side of hose fitting with new ones e Tighten Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb e Check the fluid level in the brake reservoir e Bleed the brake line see Brakes in the Periodic Mainte nance chapter e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done BRAKES 12 11 12 12 BRAKES Calipers Caliper Disassembly e Remove Caliper see Caliper Removal Pads see Brake Pad Removal Anti rattle Spring e Using compressed air remove the piston O Cover the caliper opening with a clean heavy cloth A O Remove the piston by lightly applying compressed air B to where the brake line fits into the caliper A WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers NOTE O If compressed air is
154. d fins A are deformed carefully straighten them xIf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one Radiator Cleaning e Refer to the Cooling System in the Periodic Maintenance chapter Radiator Cap Inspection e Check the condition of the top and bottom valve seals of the radiator cap lf any one of them shows visible damage replace the cap Bottom Valve Seal A Top Valve Seal B Valve Spring C e Install the cap A on a cooling system pressure tester B NOTE O Wet the cap sealing surfaces with water or coolant to prevent pressure leakage e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The relief valve opens indicated by the gauge hand flicks downward O The relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgficm 14 18 psi If the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one COOLING SYSTEM 4 15 6p07010481 6D070107Si 4 16 COOLING SYSTEM Thermostat Thermostat Removal e Drain the coolant see Cooling System in Periodic Main tenance chapter e Remove Front Fender see Frame chapter Thermos
155. d more than ten times as much in the other direction If any two Y2 Y3 leads are low or high in both directions the rectifier is HPO900BBS1 defective and must be replaced NOTE O The actual meter reading varies with the meter and the individual rectifier Generally speaking the lower read ing should be from zero to one half of the scale Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is correct before con tinuing Regulator Circuit Test 1st Step e Connect the test light and the 12 V battery to the regula tor rectifier as shown e Check Y1 Y2 and Y3 terminal respectively xf the test light turns on the regulator rectifier is defective xIf the test light does not turn on continue the test GP090603S1 16 30 ELECTRICAL SYSTEM Charging System Regulator Circuit Test 2nd Step e Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step e Apply 12 V to the BR terminal e Check Y1 Y2 and Y3 terminals x If the test light turns on the regulator rectifier is defective x lf the test light does not turn on
156. d seizure Transmission gear or bearing seizure Camshaft seizure No fuel flow Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Crankshaft Sensor trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or
157. drive and reverse coast direction while creating drag on the ring gear e Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth O The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe lf the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown e Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE O f the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern Pinion Gear Unit Disassembly e Remove Pinion Gear Unit A see Final Gear Case Disassembly e Hold the pinion gear bearing holder nut B with the socket wrench C in a vise and loosen the pinion gear shaft using the pinion gear holder D Special Tools Socket Wrench 57001 1363 Pinion Gear Holder 57001 1480 e Remove the ball bearing E as necessary Special Tool Bearing Puller 57001 135 FINAL DRIVE 11 33 11 34 FINAL DRIVE Final Gear Case Pinion Gear Unit Assembly O The pinion gear and ring gear are lapped as
158. ds so that width across flats on the tie rod face to the knuckle arm the tie rod has the correct length A and both visible thread lengths B are approx imately equal Tie Rod Length Standard 387 4 1 5 mm 15 3 0 06 in e Tighten Torque Tie Rod Adjusting Locknuts 22 N m 2 2 kgf m 16 ft lb a Fra Gen l Ab P HN04005BS1 C HN04020BS1 C Steering Maintenance Steering Inspection e Refer to the Steering in the Periodic Maintenance chapter Steering Stem Straightness e Remove the steering stem see Steering Stem Removal e Check the steering stem for straightness O Use a straightedge along the stem xf the steering stem is bent replace the steering stem Steering Lubrication e Lubricate the steering stem clamps O Remove the steering stem see Steering Stem Removal OWipe all the old grease off the steering stem bearing sleeves and out of the grease seals OApply Amoco Rykon Premium Grease No 2 EP Green to the steering stem A grease seals B and mating sur face C of the clamp e Lubricate the steering stem bearing A O Remove the steering stem bearing OPack the grease seal lips with grease Steering Stem Clamp Inspection e Inspect the steering stem clamps A x lf roughness excessive play or seizure is found replace both clamps STEERING 14 9 HNOS5005BSi 14 10 STEERING Steerin
159. e Spark Plug Cap A Primary Lead Connectors B Bolt C Ignition Coil D 16 34 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation e Connect the primary leads to the ignition coil terminals as shown Front Side G W Lead gt Mark A BK Y Lead gt Mark Rear Side BL W Lead gt Mark A BK Y Lead gt Mark Ignition Coil Inspection e Remove the ignition coil e Measure the arcing distance with a coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance Ignition Coil Arcing Distance 7 mm or more A WARNING To avoid extremely high voltage shocks do not touch the ignition coil body or leads x lf the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclock wise lf the arcing distance is as before the trouble is with the ignition coil If the arcing distance is normal the trouble is with the spark plug cap Alf a coil tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester Special Tool Hand Tester 570
160. e Connect the battery wires to the battery e Attach a suitable vacuum gauge A to the fitting on the carburetor holder e Start the engine and read the intake vacuum of each car buretor when idling xIf the vacuum is out of the specified range adjust it Carburetor Synchronization Vacuum Standard Less than 2 7 kPa 2 cmHg difference between carburetors 3 16 FUEL SYSTEM Carburetor Carburetor Synchronization Adjustment e Remove the air cleaner cover see Frame chapter e Turn the adjust screw A to synchronize the carburetors x If the carburetor synchronization cannot be obtained by using the adjusting screw check for dirt or blockage and then check the pilot screw settings e Check the carburetor synchronization again NOTE O Do not turn the pilot screws carelessly during carburetor synchronization You may cause poor running at low engine speed e Check idle speed Fuel System Cleanliness Inspection e Refer to the Fuel System in the Periodic Maintenance chapter Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Drain the coolant see Cooling System chapter e Remove Air Cleaner Housing see Air Cleaner Housing Removal Side Inner Cover see Fra
161. e Lever Mounting Screw 3 5 0 36 35 in Ib Left Handlebar Switches Assembly Screws 3 5 0 36 35 in Ib Air Cleaner Housing Bolts M5 5 9 0 60 52 in lb L Air Cleaner Housing Bolts M6 8 8 0 90 78 in Ib Air Cleaner Element Bracket Screws 4 9 0 60 43 in lb Fuel Tap Plate Screws 0 80 0 080 7 in lb Fuel Tap Cover Screws 1 0 0 10 8 in Ib Fuel Pump Bolts 2 0 0 20 17 in Ib Cooling System Radiator Fan Switch 18 1 8 13 Water Pump Fitting Bolt 9 8 1 0 87 ml Water Pump Impeller 7 8 0 80 69 in Ib Thermostat Housing Cover Bolts 8 8 0 90 78 in Ib Coolant Temperature Warning Light Switch 7 8 0 80 69 in Ib SS Radiator Fan Assembly Bolts 8 8 0 90 78 in Ib Radiator Mounting Bolts 8 8 0 90 78 in Ib Water Pump Cover Bolts 8 8 0 90 78 in lb Coolant Drain Plug 8 8 0 90 78 in Ib Engine Top End Water Pipe Bolts 9 8 1 0 87 in lb Rocker Case Bolts 55 mm 2 2 in 8 8 0 90 78 in Ib S Rocker Case Bolts 130 mm 5 1 in 9 8 1 0 87 in lb S Rocker Case Bolts 30 mm 1 2 in 9 8 1 0 87 in Ib Rocker Case Bolts 25 mm 1 0 in 9 8 1 0 87 in lb S Cylinder Head Bolts M10 First Torque 25 2 5 18 S MO 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Cylinder Head Bolt M10 Final Torque Cylinder Head Bolts M6 Cylinder Head Jacket Plugs Valve Adjusting Cap Bolts Valve Adjusting Screw Locknuts Rocker Shaft Bolts Chain Tensioner Mounting Bolts Chain Tensioner Cap Bolt Intermediate Shaft Sprocket Nut Intermediate Shaft Chain Guide Bolts Camshaft Sprocket Bo
162. e disconnected at both ends the ca ble should move freely within the cable housing Alf the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable 6004011481 C DA a GCO4000BS1 C Choke Lever and Cable Choke Lever Free Play Check e Refer to the Fuel System in the Periodic Maintenance chapter Choke Lever Free Play Adjustment e Refer to the Fuel System in the Periodic Maintenance chapter Choke Lever and Cable Removal e Remove the air cleaner housing see Air Cleaner Housing Removal e Remove the carburetor from the carburetor holder e Remove the cooling hoses and fuel hose e Remove the screws A and holder plates e Pull out the starter plungers e Hold the starter plunger springs compressed and free the choke cable lower ends A from the plungers B e Remove Choke Lever Mounting Screw A Plane Washer and Wave Washer Switch Case Mounting Screws B e Free the choke cable upper end A from the choke lever B FUEL SYSTEM 3 11 3 12 FUEL SYSTEM Choke Lever and Cable e Pull off the retaining clip A e Pull the cable out of the vehicle Choke Lever and Cable Installation e Lubricate the choke cable before installation e Install the wave washer plain washer and screw in that order e Route the choke cable according to the Appendix chapter A WARNING Operation with an incorrectly routed or damaged ca
163. e filter see Oil Filter Change Replace the drain plug gasket with a new one e Tighten Torque Engine Drain Plug 20 N m 2 0 kgf m 14 ft lb e Pour in the specified type and amount of oil Engine Oil SAE 208 50 gt Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W 40 Amount 1 7 L 1 80 US qt When filter is not removed 1 9 L 2 01 US qt When filter is removed 2 2 L 2 33 US qt When engine is completely dry NOTE O Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area Oil Filter Change e Drain the engine oil e Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 SAE 104 50 SAE 10W 40 AAA SAE 104 30 20 i0 0 10 20 30 40 e A A A A Se 4 14 32 50 68 86 104CF E E AAA HUO9002BS1 e Replace the filter with a new one e When installing the oil filter be careful of the following O Apply oil to the gasket A before installation O Tighten the filter with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 18 N m 1 8 kgf m 13 ft lb O Pour in the specified type and amount of oil 6805040281 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Crankshaft Transmission Shift Control Grip
164. e level is too low add oil through the filler hole Use the same type and make of oil that is already in the engine Engine Oil Change e Refer to the Engine Lubrication System in the Periodic Maintenance chapter Oil Filter Change e Refer to the Engine Lubrication System in the Periodic Maintenance chapter Oil Screen Removal e Split the crankcase see Crankshaft Transmission chap ter e Pull the oil screen A out of the crankcase 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning e Clean the oil screen A thoroughly whenever it is removed for any reason e Clean the oil screen with a high flash point solvent and remove any particles stuck to it A WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE o While cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes broken wires or gasket pulling off lf the screen is damaged replace it Oil Pressure Measurement NOTE O Measure the oil pressure after the engine is warmed up e Remove the oil pressure switch and attach the oil pres sure gauge A and adapter B Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapt
165. e nose scriber make a thin mark near the center of the chalk coating while turning the wheel e With the front wheels on the ground set the handlebar straight ahead e At the level of the axle height measure the distance be tween the scribed or painted lines for both front and rear of the front tires e Subtract the measurement of the front from the measure ment of the rear to get the toe in x lf the toe in is not in the specified range go on to the Toe in Adjustment procedure Toe in of Front Wheels Standard 10 10 mm 0 39 0 39 in at 1G HJ04011BS1 C WHEELS TIRES 10 7 Wheel Alignment Toe in Adjustment e Loosen the locknuts A B and turn the adjusting tie rods C the same number of turns on both sides to achieve the specified toe in NOTE O The locknut A on the tie rod has left hand threads Turn the locknut clockwise for loosening O The toe in will be near the specified value if the tie rod length D is 386 389 mm 15 2 15 3 in on each tie rod CAUTION Adjust the tie rod length so that the visible thread length E is even on both ends of the tie rod Un even thread length could cause tie rod end damage e Check the toe in e Tighten Torque Tie Rod Adjusting Locknuts 22 N m 2 2 kgf m 16 ft lb HJ04010BS1 e Test ride the vehicle 10 8 WHEELS TIRES Wheels Rims Wheel Removal e Loosen the wheel nuts A e Support the veh
166. e openings of the oil ring steel rails must be about 30 40 F of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails C Oil Ring Expander D F mark E must be faced toward Front Side for front and rear pistons Opening Positions G 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 O When installing the piston pin snap ring compress it only enough to install it and no more e Apply engine oil to the cylinder bore and piston skirt GE16040481 C GE16060481 C c Da of HE14000BS1 C HE14002BS1 C Cylinder and Piston e Install Dowel Pins A New Cylinder Base Gasket B e Install Cylinder Clamp A rear only e Tighten Torque Cylinder Bolts B 9 8 N m 1 0 kgf m 87 in Ib e Install Chain Guide C Oil Pipe D Cylinder Wear e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the three locations total of six measure ments shown in the figure x If any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 4 in A 60 mm 2 4 in B 20 mm 0 8 in C Standard 81 994 82 006 mm 3 2281 3 2286 in and less than 0 01 mm 0 0004 in difference bet
167. e spring preload of the shock absorber can be adjusted or the spring can be replaced Also the damping force can be adjusted easily so changing oil viscosity unnecessary Compression Damping Adjustment e Turn the compression damping adjuster A on the rear shock absorber gas reservoir with a flat bead screwdriver lf the damping feels too soft or too stiff adjust it in accor dance with the following table Seated position adjuster turned fully clockwise A Counterclockwise Clockwise Softer erc Harder Compression Damping Standard 14 clicks STD NOTE 19181716151413121110 9 O Always make any damping adjustments in small steps fe and test their effects before using them in competition wN e a a w w HM04004BSi 13 8 SUSPENSION Shock Absorbers Rear Shock Absorber Removal e Remove Seat see Frame chapter Rear Fender see Frame chapter e Support the vehicle on a stand or a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e While holding the rear wheels remove the lower and up per shock absorber mounting bolts A nuts and wash ers e Remove the rear shock absorber B Rear Shock Absorber Installation e Apply plenty of grease to the inside of the needle bearing sleeve and oil seals e Install Oil seals A Needle Bearing B Sleeve C Collars D Rubber Bushing E e Tighten Torque Rear Shock Absorber Mounting
168. e tread or sidewalls indicate internal damage requiring tire replacement ORemove any foreign objects from the tread After re moval check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places lf any measurements are less than the service limit re place the tire Tire Tread Depth Service Limit Front 3 mm 0 12 in Rear 3 mm 0 12 in Standard Tire Front AT 22 x 7 10 CARLISLE HOLE SHOT XC Rear AT 22 x 11 10 CARLISLE HOLE SHOT XCT Final Drive Final Gear Case Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Park the vehicle so that it is level both side to side and front to rear e Place an oil pan beneath the rear final gear case and remove the drain plug A A WARNING When draining or filling the final gear case be care ful that no oil gets on the tire or rim because oil will deteriorate the tire Clean off any oil that inadver tently gets on them with a high flash point solvent e After the oil has completely drained out install the drain plug with a new aluminum gasket Torque Oil Drain Plug 20 N m 2 0 kgf m 14 ft Ib e Fill the final gear case up to the bottom of filler opening with the oil specified below Final Gear Case Oil Type MOBIL Fluid 424 or CITG
169. eakage around the fittings Master Cylinder Inspection Visual Inspection e Disassemble the master cylinder see Brakes chapter e Check that there are no scratches rust or pitting on the inner wall of the master cylinder A and on the outside of the piston B Alf the master cylinder or piston shows any damage re place them e Inspect the primary C and secondary D cups lf a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x lf fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups e Check the dust cover E for damage x lf it is damaged replace it e Check that the relief F and supply G ports are not plugged x lf the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air e Check the piston return spring H for any damage xIf the spring is damaged replace it 6L07010481 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Fluid Seal Replacement The fluid seals A around the piston maintain the proper pad disc clearance If the seals are not satisfactory pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Disassemble the brake caliper see Brakes chapter e Replace the fluid seals under any of the following condi tions a fluid leakage around the
170. ear is low e Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Service Limit Top 0 20 0 30 mm 0 60 mm 0 0079 0 0118 in 0 0236 in Second 0 30 0 45 mm 0 75 mm 0 0118 0 0177 in 0 0295 in Oil 0 20 0 70 mm 1 00 mm 0 0079 0 0276 in 0 0394 in x lf the end gap of either ring is greater than the service limit replace all the rings EEN SN EN N SSNS lt SSSSSSSENY SSS SSS SS GEN RETO SSA SSSSSSNN NS HE14005BS1 5 42 ENGINE TOP END Exhaust System This vehicle is equipped with a spark arrester approved for off road use by the U S Forest Service It must be prop erly maintained to ensure its efficiency In accordance with the Periodic Maintenance Chart clean the spark arrester Spark Arrester Cleaning e Refer to the Engine Top End in the Periodic Maintenance chapter Muffler and Exhaust Pipe Removal e Remove Rear Fender see Frame chapter Battery and Battery Case see Electrical System Left Side Inner Cover Rocker Case Bolts A Cable Holder B Rear Exhaust Pipe Nuts A e Remove Front Exhaust Pipe Nuts A ENGINE TOP END 5 43 Exhaust System e Remove Muffler Clamp Bolt A Muffler Mounting Bolts B Muffler C and Rear Exhaust Pipe Front Exhaust Pipe D Muffler and Exhaust Pipe Installation e f the exhaust pipe cover A or muffler cover B were removed tighte
171. ease to the O ring e Install the collar on the alternator cover e Install the alternator rotor bolt C HPO9008BSi e Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1520 e Tighten Torque Alternator Rotor Bolt 127 N m 13 kgf m 94 ft Ib Alternator Bolt Cover Bolts 8 8 N m 0 90 kgf m 78 in lb e Add engine oil Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Ball Bearing A e Thread the flywheel puller A onto the alternator rotor Special Tool Flywheel Puller 57001 1405 e Holding the flywheel puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft CAUTION If the rotor is difficult to remove turn the puller while tapping the end of the puller Do not strike the alternator rotor Striking the rotor can cause the magnets to lose magnetism 16 26 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation e Clean A the inside of the rotor and the end of the crank shaft e Fit the rotor onto the crankshaft so that woodruff key B fits in the groove C in the hub of the rotor e Install the torque limiter A e Install the alternator rotor B while turning the starter clutch gear C Alternator Stator Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor A see Crankshaft Sensor Re moval Bolts B and Alt
172. ect each other make them at the same time Rear Brake Lever e Loosen the knurled locknut A and turn the adjuster B at the rear brake lever in as far as it will go e Tighten the locknut e Turn the brake lever adjuster A at the rear end of the brake cable until the rear brake lever has the correct amount of play Brake Pedal e Turn the brake pedal adjuster B at the rear end of the brake cable until the brake pedal has the correct amount of play e Operate the pedal a few times to see that it returns to its rest position immediately upon release e Rotate the rear wheels to check for brake drag e Check braking effectiveness xIf there is any doubt as to the conditions of the brake check the brake parts for wear or damage Suspension Knuckle Joint Inspection e Visually inspect the boot A of knuckle joint lf damage wear or deterioration is found replace the knuckle joint 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Turn the handlebar left and right and check the steering action x If the steering action is not smooth or if the steering binds or catches before the stop lubricate the steering stem bearing NOTE O The cables and wires will have some effect on the steer ing action which must be taken into account e Check the steering action again Alf steering stem bearing lubrication does not remedy the problem inspect the steering s
173. ed state O At neutral position 1 mm A e Remove the cable holder mounting bolts A e Remove the shift control cables B from the shift shaft lever e Remove the shift shaft lever bolt C e Remove the shift shaft lever D from the shift shaft Shift Lever Installation e Install the shift shaft lever to the shift shaft O When installing shift shaft lever align the mark A on the shaft end with the slit B of the shift shaft lever e Tighten the shift shaft lever bolt Torque Shift Shaft Lever Bolt 14 N m 1 4 kgf m 10 ft Ib e Install the shift control cables to the shift shaft lever e Install the cable holder and tighten the cable holder mounting bolts Torque Cable Holder Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Adjust the shift control cables free play see Periodic Maintenance chapter HI10014BS1 C CRANKSHAFT TRANSMISSION 9 19 Transmission Shift Control Cables Removal e Remove Seat see Frame chapter Battery and Rear Ignition Coil A see Electrical System chapter e Loosen the adjusting nuts B e Remove the cable holder mounting bolts C e Remove the shift control cables D from the shift shaft lever e Remove the shift control cables from the cable holder E e Remove the band A and clamp B e Remove the shift control grip screws A e Remove the shift control cables from the shift control grip Shift Control Cables Inst
174. eene le Suenan iaa dad di di idad Special TOONS ita ai ds Torque Conve EE Torque Converter Cover Removal ooooocoooococoooooncnoncnonononnnncnnnnnonnnonnnonnnonnnnnnnnnnnnnnnnnnnnonennnnnns Torque Converter Cover Installation seeseessssesssesssssesssesseeee enne nnne Converter Exhaust Duct Removal Converter Exhaust Duct Installaton Converter Intake Duct Removal Converter Intake Duct Installaton eee BIR EEN Drive Belt Removal cocccncncicononnnocnnnnnnnnnnnnnnnnnnononononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininss Drive Belt Installation sssssssss mmm nnne EEEE EEEE Drive Belt Inspection ener rete A E RR ERRARE eS Drive Belt Deflection Inspection sssssssssR HR Hee Drive Belt Deflection Adjustment ccseeseceeccceeeeeeeeeseneeeeeeeeeeeeseeeaaenneeeeseeeeeseessneeeeeee A EA EE ENEE EE Drive Pulley Remo ninia e at Drive Pulley Disassembly oo Ra Drive Pulley Ins Pecos A ia ide rane Spider Shoe Side Clearance Adjustment eene 6 17 Drive Pulley Assembly coin A re crece eva leote niece alee 6 18 Eemer Fillettes Eeer Getae Go C sombre 6 20 Driven aum r SEA ebe 6 21 Driven Pulley Removal triste tite meter I get Egeter 6 21 Driven Pulley Disassembly ee cios 6 21 Driven Pulley Inspection ccu eo cs ceo e A bo i ARR E ed oss 6 22 Driven Pulley ASsembly dti er a e ite inb Fea s d bl een roa b qus ete
175. ege Urbes 6 24 Driven Pulley InstallatiOri uero ere Eb etu di Pact re e rade 6 26 High Altitude Setting Information eeeeeeeeseseieeeeeeeeeee eese nnne 6 27 Specification a ds 6 27 6 2 CONVERTER SYSTEM Exploded View ei O LS Lis 7 z Y SOs YA HS02007BW5 CONVERTER SYSTEM 6 3 Exploded View No Fastener Remarks 1 Drive Pulley Bolt Lh R 2 Driven Pulley Nut 3 Drive Pulley Cover Bolts 113 in Ib 4 Ramp Weight Nuts 3 61 in Ib 5 Spider Lh G Apply grease for oil seal and O ring Lh Left hand Threads M Apply molybdenum disulfide grease R Replacement Parts 6 4 CONVERTER SYSTEM Exploded View HSO2008BW5 CONVERTER SYSTEM 6 5 Exploded View Torque N m kgf m ft Ib 1 Converter Cover Bolts 8 8 0 90 78 in Ib S 2 Joint Duct Bolts 8 8 0 90 78 in Ib No Fastener Remarks G Apply grease for oil seal and O ring S Follow the specific tightening sequence 6 6 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt Belt deflection 22 27 mm 0 87 1 06 in 0 64 mm Belt height Parallel portion 1 16 3 48 mm 0 046 0 137 in 0 0252 in Drive Pulley Cover bushing inside diameter 27 985 28 085 mm 1 1018 1 1057 in 28 12 mm 1 107 in Sheave bushing inside diameter 37 985 38 085 mm 1 4955 1 4994 in
176. ehicle e Immediately wipe up any brake fluid that spills CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e Use a new flat washer for each side of the hose fittings e Install the new brake hose in its place see Appendix chapter and tighten the banjo bolts Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb HU13000BS1 C GL10020181 C PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Brake Fluid Level Inspection e Position the reservoir horizontal and check that the fluid level in the reservoir is higher than the lower level line A If the fluid level is lower than the lower level line check for fluid leakage of the brake line and add the fluid as follows O Remove the reservoir cap and fill the reservoir to the up per level line A in the reservoir with the same type and brand of the fluid that is already in the reservoir And then install the reservoir cap A WARNING Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified HL05010281 e Tighten Torque Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib Brake Fluid Change e Remove the reservoir cap and the rubber cap on the bleed valve e Attach a clear plastic hose to the bleed valve on the caliper and run t
177. emove Radiator Fan Switch see Cooling System chapter e Suspend the fan switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant NOTE O The switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table l the hand tester does not show the specified values re place the switch Radiator Fan Switch Resistance ORising temperature From OFF to ON at 96 100 C 205 212 F Falling temperature From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 OFF More than 1 MQ ELECTRICAL SYSTEM 16 67 HP14012B52 C 16 68 ELECTRICAL SYSTEM Switches Coolant Temperature Warning Light Switch Inspection e Remove Coolant Temperature Warning Light Switch see Cooling System chapter e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant NOTE O The switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the
178. emove the bearing A for inspection Re moval may damage it e Check the ball bearing OSince the ball bearing is made to extremely close toler ances the wear must be judged by feel rather than mea surement O Spin the bearing by hand to check its condition Alf the bearing is noisy does not spin smoothly or has any rough spots replace the rear axle shaft Rear Axle Runout Inspection e Visually inspect the axle for damage xIf the axle is damaged or bent replace it e Set the rear axle in an alignment jig or on V blocks and place a dial gauge A against the middle point e Turn the axle slowly The difference between the highest and lowest dial gauge readings is the axle runout TIR If the runout exceeds the service limit replace the axle Rear Axle Shaft Runout Standard TIR 1 mm 0 04 in or less Service Limit TIR 2 mm 0 08 in FINAL DRIVE 11 25 HK13000581 11 26 FINAL DRIVE Final Gear Case Final Gear Case Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove the filler cap CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case e Check the oil level The oil level should come to the bot tom of the filler opening A xIf it is insufficient first check the final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same t
179. engine left side e Inspect the coolant valve at room temperature Alf the valve is closed replace the valve with a new one O To check valve opening just blow through the valve Valve Closing Temperature for reference Standard 80 C 176 F or more at 24 5 kPa 0 25 kgf cm 3 6 psi ENGINE TOP END 5 1 Engine Top End TABLE OF CONTENTS Exploded View 5 2 Cylinder Head Cleaning 5 28 Specifications ssssssss 5 8 Cylinder Head Warp 5 29 Special Tools and Sealant 5 10 VAIV S wi ives M 5 30 Camshaft Chain Tensioner 5 12 Valve Clearance Inspection 5 30 Camshaft Chain Tensioner Valve Clearance Adjustment 5 30 Remowval esses 5 12 Valve Removal ss 5 30 Camshaft Chain Tensioner Valve Installation 5 30 Installation ssuss 5 12 Valve Guide Removal 5 31 Rocker Case 5 13 Valve Guide Installation 5 31 Rocker Case Removal 5 13 Valve to Guide Clearance Rocker Case Installation 5 14 Measurement sssus 5 31 Rocker Arm Remowval 5 15 Valve Seat Inspection 5 32 Rocker Arm Installation 5 15 Valve Seat Repair Valve Lapping 5 32 Rocker Arm Inspection 5
180. er 57001 1033 Oil Pressure Standard 480 kPa 4 9 kgf cm 69 7 psi 4 500 r min rpm 110 C 230 F of oil temp x lf the oil pressure is much lower than the standard inspect the relief valve oil pump and or crankshaft bearing insert wear lf the oil pressure is much higher than the standard in spect the oil filter oil screen and other areas of the lubri cation system for clogging e Stop the engine e Remove the oil pressure gauge and adapter WARNING Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed e Apply silicone sealant to the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb Oil Pressure Switch Terminal Bolt 1 5 N m 0 15 kgf m 13 in Ib ENGINE LUBRICATION SYSTEM 7 9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal e Split the crankcase see Crankshaft Transmission chap ter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e See crankcase assembly See Crankshaft Transmission chapter e Apply a non permanent locking agent to the threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib Oil Pressure Relief Valve Inspection e Remove the relief valve e Using a wooden stick push the
181. er seated Adjust both headlights to the same an gle Headlight Bulb Replacement e Remove Front Fender see Frame chapter Mounting Screws A Headlight Unit B e Remove Headlight Bolts A and Washer Vertical Adjustment Screw B Spring and Nut Headlight Body C e Remove Headlight Connector A Dust Cover B 16 56 ELECTRICAL SYSTEM Lighting System e Push the holder A and turn it counterclockwise e Remove Holder Headlight Bulb B e Insert the new bulb A by aligning the projection B with the notch C in the headlight unit e Push the bulb holder A in turn it clockwise and release it It should lock in position e Fit the dust cover A O Face the TOP mark B upward Lighting System e Install Grommet A Vertical Adjustment Screw Spring and Nut B Damper Collar and Bolt C Taillight Bulb Replacement e Remove Rear Fender see Frame chapter Tail Light Connector A Screws and Collars B Tail Light Assembly C with Cover e Remove Screw A Screw and Collar B Tail Light Cover C e Remove the screws A e Remove the taillight lens B from the taillight assembly ELECTRICAL SYSTEM 16 57 16 58 ELECTRICAL SYSTEM Lighting System e Push the bulb A in turn it counterclockwise and pull it out e Be sure the socket is clean e Insert the new bulb by aligning the pins A with the grooves B in the walls of the socket e Push the bulb in turn
182. ernator Stator C Alternator Stator Installation e Tighten Torque Alternator Stator Bolts 13 N m 1 3 kgf m 113 in Ib e Install Crankshaft Sensor see Crankshaft Sensor Installation e Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads ELECTRICAL SYSTEM 16 27 Charging System Regulator Rectifier Output Voltage Inspection e Remove the seat see Frame chapter e Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions e Check that the ignition switch is turned off and connect a hand tester to the battery terminals Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off The readings should show nearly battery voltage when the engine speed is low and as the engine speed in creases the readings should also increase Regulator Rectifier Output Voltage Connections Tester Range Reading Tester to Tester to Battery Battery e Turn off the ignition switch and disconnect the hand tester lf the regulator rectifier output voltage is between the val ues given in the table the charging system is working nor mally lf the output voltage is much higher than the values spec ified in the table the regu
183. erve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 14 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator COOLING SYSTEM 4 5 Coolant Flow Chart HDO4001BH3 1 Radiator 6 Reserve Tank 2 Water Pump 7 Cylinder Cylinder Head 3 Radiator Cap 8 Carburetor 4 Thermostat 9 Radiator Fan 5 Coolant Temperature Warning Light 10 Radiator Fan Switch Switch Black Painted Arrow Hot Coolant White Painted Arrow Cold Coolant 4 6 COOLING SYSTEM Specifications Item Standard Service Limit Coolant provided when shipping Type Color Mixed ratio Freezing point Total amount Radiator cap Relief pressure Thermostat Valve opening temperature Valve full opening lift Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Green Soft water 50 coolant 50 35 C 31 F 2 5 L 2 64 US qt reserve tank full level including radiator and engine 93 123 kPa 0 95 1 25 kgf cm 14 18 psi 69 5 72 5 C 157 162 F 8 mm or more 85 C 185 F Coolant Filter Valve Coolant valve closing temperature for re
184. essure to seat beads when cold Front and Rear 250 kPa 2 5 kgf cm 36 psi Do not inflate the tire to more than the maximum tire air pressure Overinflation can explode the tire with possibility of injury and loss of life e Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B lfthe rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire e After the beads are properly seated check for air leaks OApply a soap and water solution around the tire bead and check for bubbles e Deflate the tire to the specified pressure e Check the tire pressure using an air pressure gauge NOTE O Kawasaki provides the air pressure gauge P N 52005 1082 with the owner s tool kit Tire Air Pressure when cold Front 28 kPa 0 28 kgf cm 4 0 psi Rear 35 kPa 0 35 kgf cm 5 0 psi e Install the wheel see Wheel Installation e Wipe off the soap and water solution on the tire and dry the tire before operation A WARNING Do not operate the vehicle with the water and soap still around the tire beads They will cause tire sep aration and a hazardous condition may result Tire Inspection e Refer to the Wheels Tires in Periodic Maintenance chap ter WHEELS TIRES 10 11 HJ050098B S 10 12 WHEELS TIRES Front Hub Front Hub Removal e Remove Cotter Pin A e Loosen the axle nut B e Remove
185. f indicator light does not go on replace the indicator unit Check2 LED light Emitting Diode Light Inspection e Using the auxiliary leads connect a 12 V battery to the indicator unit connector as follows Neutral Indicator Light LED B Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 3 Reverse Indicator Light LED C Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 4 HP20036BS2 Water Temperature Warning Light LED D Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 5 Oil Pressure Warning Light LED E Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 6 Belt Indicator Light LED F Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 7 lf each LED light does not go on replace the indicator unit 16 66 ELECTRICAL SYSTEM Indicator Unit Indicator Unit Circuit BL BK Y un o HP20035BN4 C 1 Indicator Unit 5 Igniter 8 Ignition Switch 2 Neutral Switch 6 Oil Pressure Switch 9 Main Fuse 30A 3 Reverse Switch 7 Water Temperature 10 Battery 4 Fuel Reserve Switch Switch Switches Brake Light Switch Adjustment e Refer to the Brake Light Switch Inspection in the Periodic Maintenance chapter Radiator Fan Switch Inspection e R
186. ference 80 C 176 F or more 24 5 kPa 0 25 kgf cm 3 6 psi Special Tools and Sealant Bearing Driver Set 57001 1129 Bearing Remover Shaft 9 57001 1265 Oh COOLING SYSTEM 4 7 Bearing Remover Head 10 x 12 57001 1266 Ce Kawasaki Bond Silicone Sealant 56019 120 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Visually inspect the coolant in the reserve tank A If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system x If the coolant gives off an abnormal smell check for cool ing system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection NOTE O Check the level when the engine is cold room or ambi ent temperature e Check the coolant level in the reserve tank with the vehi cle held perpendicularly Reserve Tank A F full Mark B L low Mark C lf the coolant level is lower than the L mark Remove the upper front cover and reserve tank cap A then add coolant to the F mark B CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attach the aluminum engine parts In an emergency soft water can be added But the
187. ft Control Cables Installaton nennen 9 19 Reverse Lock Cable Removal essseseesese e em enne neneennhenerrsse nnns erase nnana n nns 9 20 Reverse Lock Cable Installation eeeseeesseeen ona nano nano narran rn nana ranas 9 20 Transmission REMOVAL A ds 9 21 Transmission Installation eeseeeeeeeen eene nnne nnn nennen nnne 9 22 Shift Fork Bending usura dd da 9 24 Shift Fork Gear and Shifter Groove Wear essen nnne rennen 9 24 Transmission and Shift Mechanism Inspection 9 25 Ball Bearing Needle Bearing and Oil Gezai 9 27 Ball and Needle Bearing Replacement ooooonnninnncccnnncnonononnoncnnnnn cnn nace nn 9 27 Ball and Needle Bearing Wear coord ii 9 27 Oil Seal Inspection tette ete ed ce eet reta Pee uen tendo acia 9 27 9 2 CRANKSHAFT TRANSMISSION Exploded View 3 Si KE Os LX D d Le ei z ESA NN ext We A A AN NS A N SA SS NO MAL Clive a H102009BW5 Exploded View CRANKSHAFT TRANSMISSION 9 3 No Fastener Torque Remarks N m kgf m ft lb 1 Connecting Rod Big End Cap Nuts 34 3 5 25 MO 2 Engine Drain Plug 20 2 0 14 3 Crankcase Bolts M8 75 mm 2 95 in 20 2 0 14 S 4 Crankcase Bolts M8 110 mm 4 33 in 20 2 0 14 L 1 S 5 Crankcase Bolts M6 40 mm 1 57 in 9 8 1 0 87 ml 6 Crankcase Bolts M6 65 mm 2 56 in 9 8 1 0 87 ml 7 Position Plate Mounting
188. ft Holder amp Spacer 57001 1479 e Insert the output shaft D in the housing e Apply a non permanent locking agent to the threads of the output shaft holder nut E and tighten it so that the projection side F faces outward Special Tool Socket Wrench 57001 1482 Torque Output Shaft Holder Nut 157 N m 16 kgf m 116 ft lb e Apply grease to the oil seal and press it Hold the holder A in a vise and set the housing assembly B on the holder Special Tool Holder amp Guide Arbor 57001 1476 e Install Output Driven Bevel Gear C Cam Damper D Spring E Spring Holder F Circlip G WI P Output Bevel Gears e Install Guide Bars A Damper Spring Compressor Set B Special Tools Holder amp Guide Arbor 57001 1476 Damper Spring Compressor Set 57001 1475 e Tighten the nuts C and compress the damper spring e Install Circlip Special Tool Outside Circlip Pliers 57001 144 Output Bevel Gears Adjustment The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged When replacing any one of the backlash related parts be sure to check and adjust the backlash and tooth contact First adjust the backlash and then tooth contact by replac ing shims These two adjustments are of critical importance and must be carried out in the correct sequence using the procedures shown FINAL DRIVE 11 17
189. fuel pump e When the pump stops read the pressure gauge lfthe pressure gauge reading is out of the specified pres sure the pump is defective Replace the fuel pump HP22000BSi Fuel Pump Pressure Standard 17 7 22 6 kPa 0 18 0 23 kgf cm 2 6 3 3 psi e Install the fuel pump and tighten it Torque Fuel Pump Mounting Bolts 2 N m 0 2 kgf m 17 in Ib 16 62 ELECTRICAL SYSTEM Fuel Pump Fuel Reserve Switch Fuel Reserve Switch Inspection 1 e Fill the fuel tank with fuel e Close the fuel tank cap surely e Remove the fuel tank see Fuel System chapter e Connect the test light A 12 V 3 4 W bulb a socket with leads and the 12 V battery B to the fuel pump connector C Connections Battery gt 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side gt BL Lead Terminal Battery gt BK Y Lead Terminal Special Tool Needle Adapter Set 57001 1457 x lf the test light turn on the reverse switch is defective Replace the fuel pump Fuel Reserve Switch Inspection 2 e Remove Fuel Pump see Fuel System chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump connector as shown 12 V Battery A Test Light B Fuel Pump Connector C Fuel Reserve Switch D x lf the test light doesn t light replace the fuel pump NOTE O lt may take a long time to turn on the test light in case that the fuel reserve switch
190. g Maintenance Steering Stem Bearing Inspection e Inspect the spherical bearing A If roughness excessive play or seizure is found replace the steering stem bearing e Inspect the upper and lower grease seals B lf damage wear or deterioration is found replace the steering stem bearing Steering Knuckle Bearing Inspection CAUTION Do not remove any bearings for inspection e Remove the steering knuckle see Steering Knuckle Re moval e Examine the bearing seal B for tears or leakage Alf the seal is torn or is leaking replace the bearing e Turn A the bearing back and forth while checking for roughness or binding If roughness or binding is found replace the bearing Tie Rod End and Steering Knuckle Joint Inspection e Inspect each spherical bearing A If roughness excessive play or seizure is found replace the tie rod end or steering knuckle joint e Inspect each grease seal B If damage wear or deterioration is found replace the tie rod end or steering knuckle joint HNO5006BS1 C 6J06002BS1 C Handlebar Handlebar Removal e Remove Throttle Case Front Brake Master Cylinder Left hand Switch Housing Rear Brake Lever Assembly Handlebar Cover and Indicator Unit A as a set Handlebar Holder Bolts A Handlebar Holders B Handlebar C Handlebar Installation e Install the handlebar so that the angle of the handlebar matches the angle of the steering
191. g projection A for damage such as chip ping or grooving lf the timing projection on the rotor is visibly damaged replace the alternator rotor ELECTRICAL SYSTEM 16 39 Ignition System Ignition Timing Test e Remove the ignition timing inspection plug e Attach a timing light A and a tachometer in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light atthe timing mark on the alternator rotor e Run the engine at the speeds specified and note the align ment of the timing marks A F or R mark Ignition Timing Engine speed r min rpm Slot B aligned with Advanced mark C on alternator 1 100 and below rotor Q gt amp Q0d a6d above Advanced mark D on alternator E rotor NOTE O Do not mix up the timing marks with mark A HPi0001BSi lf the ignition timing is incorrect replace the igniter and the crankshaft sensor Vehicle down Sensor Outline This sensor has a weight A with two magnets inside and sends a signal to the igniter But when the vehicle banks 60 70 or more to either side in fact falls down the weight turns and shuts off the voltage in the vehicle down sensor circuit The igniter senses this change and stops the fuel pump and the ignition system Hall IC B 6617063881 16 40 ELECTRICAL SYSTEM Ignition System
192. h contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and a little closer to the toe of the tooth x lf the tooth contact pattern is incorrect replace the shim s at the drive bevel gear and shim s at the driven bevel gear following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shims are replaced Repeat the shim change procedure as necessary NOTE Of the backlash is out of the standard range after chang ing shims correct the backlash before checking the tooth contact pattern Correct Tooth Contact Patterns No adjustment is required Bottom Toe Bottom Drive Gear Bottom Heel Driven Gear HK16003492 C Output Bevel Gears Example 1 Decrease the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or increase the thickness of the driven bevel gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Example 2 Increase the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or decrease the thick ness of the driven bevel gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary FINAL DRIVE 11 21 Incorrect Tooth Contact Patterns 1 Bottom e Toe Bottom Toe Ss A Heel Drive Gear Driven Ge
193. hat the choke lever returns to its released po sition all the way e To determine the amount of choke cable play at the lever pull the choke lever to the left until feeling the operation of the lever tough the amount of choke lever is equivalent to that of cable play e The proper amount of play ranges about 3 mm 0 12 in at the choke lever x lf the free play is not within the specified range adjust the cable Choke Lever Free Play B Standard about 3 mm 0 12 in Choke Lever Free Play Adjustment e Loosen the locknut A of the choke cable e Turn the adjuster B until the cable has proper amount of play e Tighten the locknut securely Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides to check for any changes in the idle speed If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted incorrectly routed or damaged Be sure to correct any of these conditions before riding A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition e Check idle speed with a suitable tachometer xIf the idle speed is out of the specified range adjust it Idle Speed Standard 1 100 50 r min rpm 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment e Start the engine and warm it up thoroughly
194. he area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal 3 14 FUEL SYSTEM Carburetor e Set the carburetor A fuel level gauge B and fuel C as follows Special Tool Fuel Level Gauge 57001 1017 OPlace the additional graduation D 10 mm 0 39 in higher than the top graduation E O Put the carburetor horizontally and so that the outlet side faces downward O Connect the fuel gauge and hose to the drain fitting of the carburetor O Connect the fuel to the fuel inlet fitting 210 mm 8 27 in F 12 mm 0 47 in G O Hold the gauge so that the additional graduation is placed slightly higher than the punch mark H O Feed the fuel into the carburetor then loosen the carbu retor drain screw Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 e Wait until the fuel level in the gauge settles e Hold the gauge vertically and lower it slowly so that the additional graduation aligns with the punch mark NOTE O Do not align the additional graduation on the gauge lower than the punch mark If it is lowered and then raised the gauge will show a fluid level that is higher than the actual level which will require a remeasure ment e Read the fuel level G xIf the fuel level is incorrect adjust it Service Fuel Level Standard 12 1 mm 0 47 0 04 in below the punch mark
195. he new rim see Tire Installation e Install the wheel see Wheel Installation 10 10 WHEELS TIRES Tires Tire Removal e Remove the wheel e Unscrew the valve core to deflate the tire O Use a proper valve core tool A e Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE O The tires cannot be removed with hand tools because they fit the rims tightly Tire Installation e Inspect the rim see Wheel Rim Inspection e Replace the air valve with a new one CAUTION Replace the air valve with whenever the tire is re placed Do not reuse the air valve e Check the tire for wear and damage see Tire Inspection e Lubricate the tire beads and rim flanges with a soap and water solution or water Do notuse the lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation HJOS006B S HJ05007B S Tires e Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pr
196. he other end of the hose into a container e Fill the reservoir with new brake fluid e Change the brake fluid as follows O Open the bleed valve A O Apply the brake lever and hold it B OClose the bleed valve C ORelease the brake lever D e Check the fluid level in the reservoir often replenishing it as necessary NOTE O If the fluid in the reservoir runs completely out any time during fluid changing air will enter the line and the sys tem must be bled 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid changes A WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are not known e Tighten Torque Bleed Valves 7 9 N m 0 80 kgf m 69 in Ib e Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings If necessary bleed the air from the brake line see Brake Line Air Bleeding A WARNING If the brake lever has a soft or spongy feeling when it is applied there might be air in the brake line or the brake may be defective Since it is dan gerous to operate the vehicle under such condi tions bleed the air from the brake line immediately Brake Line Air Bleeding e Bleed the
197. heave Spider A and Shoes B O Align the arrow C on the spider with the arrow D on the movable sheave O Insert the guides so that the rubber side small diameter faces inward e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 e Turn the wrench counterclockwise for tightening Torque Spider 275 N m 28 kgf m 203 ft lb e Remove the drive pulley wrench e Install the spacer e Put the spring A in the groove of the spider e Align the arrows B on the drive pulley cover and spider e Install Dowel Pins C Drive Pulley Cover e Tighten Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in Ib e Clean the surface of the sheaves with an oil less cleaning fluid CONVERTER SYSTEM 6 19 HS0601068S1 6 20 CONVERTER SYSTEM Drive Pulley Drive Pulley Installation e Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone Fixed Sheave Tapered Portion A Crankshaft Tapered Portion B These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings e Install the drive pulley stepped washer and two washers on the drive pulley bolt as shown Crankcase Side A Stepped Washer B Two Washer C Bolt Head D e Install the drive pulley cover and be sure to install the drive pulley
198. holding bolt and look at through the hole lf the groove of the bevel gear holder nut is not seen loosen the other three bolts e Drive the gear shaft end using a copper mallet until the grooves of the bearing holder nut can be seen again e Retighten the nut holding bolts 4 securely into the groove of the bevel gear holder nut in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 e Repeat the above procedure and remove the bevel gear from the housing e Remove the bearing holder A using the hexagon wrench B Special Tool Hexagon Wrench Hex 41 57001 1491 OH the holder seems too difficult to break free apply heat to softer the locking agent e Remove Outer Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 FINAL DRIVE 11 11 11 12 FINAL DRIVE Output Bevel Gears e Remove Output Drive Bevel Gear Holder Nut Inner Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 Output Drive Bevel Gear Assembly e Press the new inner ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 e Apply a non permanent locking agent to the threads of the bearing holder A and tighten it so that the deep side B faces outward Torque Bearing Holder 120 N m 12 kgf m 89 ft lb e Press the output drive bevel gear until it is bottomed Wun P FINAL DRIVE 11 13 Output Bevel
199. iator fan is connected directly to the bat tery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS CONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES e Drain the coolant see Cooling System in the Periodic Maintenance chapter e Remove Front Fender see Frame chapter Radiator Cover see Frame chapter Radiator Screen Mounting Screws A Radiator Screen B With the Shroud C e Remove Radiator Hoses A Radiator Fan Wire Connector B Radiator Fan Switch Connectors C e Remove Radiator Mounting Bolts A Radiator B CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency 4 14 COOLING SYSTEM Radiator Radiator Fan Removal e Remove Radiator see Radiator Removal Radiator Fan Assembly Bolts A Fan Assembly B e Remove Radiator Fan Mounting Nut A Radiator Fan B NOTE O When removing and installing the fun motor tube A do not crush the tube Radiator Fan Installation e Install Radiator Fan Radiator Fan Assembly e Tighten Torque Radiator Fan Assembly Bolts 8 8 N m 0 90 kgf m 78 in Ib Radiator Radiator Inspection e Check the radiator core x lf there are obstructions to air flow remove the radiator and remove obstructions lf the corrugate
200. icle on a stand or a jack so that the wheels are off the ground Special Tool Jack 57001 1238 e Remove Wheel Nuts Wheel Wheel Installation e Position the wheel so that the air valve A is toward the outside of the vehicle e Tighten the wheel nuts in a criss cross pattern Torque Wheel Nuts 78 N m 8 0 kgf m 58 ft lb Wheel Rim Inspection e Examine both sides of the rim for dents A If the rim is dented replace it x lf the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing sur faces with fine emery cloth if necessary HJ05012BS1 C HJ05013BS1 C WHEELS TIRES 10 9 Wheels Rims Wheel Rim Replacement e Remove the wheel see Wheel Removal e Disassemble the tire from the rim see Tire Removal O Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve Plastic Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F 6J05010881 e Install a new air valve in the new rim O Remove the valve cap lubricate the stem with a soap and water solution and pull the stem A through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber HJO05005B S e Mount the tire on t
201. ide Circlip Pliers 57001 144 e Remove Output Drive Idle Gear B e Remove Output Drive Bevel Gear Housing Bolts A Output Drive Bevel Gear Housing B Output Drive Bevel Gear Installation e Install the output drive bevel gear housing e Tighten Torque Output Drive Bevel Gear Housing Bolts 26 N m 2 7 kgf m 20 ft Ib e Install Output Drive Idle Gear New Circlip Special Tool Outside Circlip Pliers 57001 144 FINAL DRIVE 11 9 11 10 FINAL DRIVE Output Bevel Gears e Apply grease O rings A e Install Output Drive Bevel Gear Cover B e Tighten Torque Output Drive Bevel Gear Cover Bolts C 8 8 N m 0 90 kgf m 78 in Ib Output Drive Bevel Gear Disassembly e Remove Output Drive Bevel Gear Housing A see Output Drive Bevel Gear Removal e Look through the hole B in the housing e Turn the bevel gear C until the groove of the output drive bevel gear holder nut is seen e Tighten the nut holding bolts A 4 securely into the grooves B of the bevel gear holder nut C in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 D Output Drive Bevel Gear Housing E Outer Ball Bearing F Inner Ball Bearing G Bearing Holder H Output Drive Bevel Gear HK16001682 C Output Bevel Gears e Hold the output drive bevel gear housing A in a vise e Loosen the bevel gear B using an Allen wrench about four rotations e Remove one nut
202. ide Circlip Pliers 57001 144 e Remove Intermediate Shaft Chain Guides C Position Plate Bolts D and Position Plate 5 22 ENGINE TOP END Camshaft e Remove right side view Torque Converter see Converter System chapter e Using a M6 bolt A pull out the cover B e Using an Allen wrench hold the intermediate shaft A e Remove left side view Intermediate Shaft Sprocket Nut A Intermediate Shaft Sprocket B Intermediate Shaft Drive Chain C Rear Camshaft Chain D Front Camshaft Chain Camshaft Chain Installation Rear Camshaft Chain e Align the key groove A on the crankshaft with the em bossed line B on the crankcase left side view ENGINE TOP END 5 23 Camshaft e Face the arrow A of the rear camshaft sprocket upward e Align the marks B on the weights with the rear cylinder head upper surface C e Place the rear camshaft chain D onto the rear camshaft sprocket e Engage the camshaft and intermediate shaft chains on the intermediate shaft sprocket A left side view e Align the punch mark B on the intermediate shaft sprocket with the embossed mark C on the crankcase e Install the intermediate shaft and align the punch mark A on the intermediate shaft with the punch mark B on the intermediate sprocket nut e Using an Allen wrench hold the intermediate shaft e Tighten Torque Intermediate Shaft Sprocket Nut A 44 N m 4 5
203. imit replace the guide NOTE O The reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Service Limit Exhaust 0 09 0 17 mm 0 34 mm 0 0035 0 0067 in 0 0133 in Inlet 0 03 0 11 mm 0 28 mm 0 0012 0 0043 in 0 0110 in ENGINE TOP END 5 31 HE13002BS1 P 5 32 ENGINE TOP END 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 O Coat the valve seat with machinist s dye O Push the valve into the guide O Rotate the valve against the seat with a lapping tool O Pull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around e Measure the outside diameter D of the seating pattern on the valve seat xIf the outside diameter of the valve seating pattern is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Exhaust 25 2 25 4 mm 0 992 1 000 in Inlet 29 4 29 5 mm 1 157 1 165 in NOTE O The valve stem and guide must be in good condition or this check will not be valid lf the valve seating pattern is not correct repair the seat see Valve Seat Repair e Measure the seat width E of the portion where there is no build up carbon white portion of the v
204. incinerate the reser voir tank without first releasing the gas or it may explode 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 Since the high pressure gas is dangerous do not point the valve toward your face or body HM04007BSi HM040011S1 13 10 SUSPENSION Suspension Arms Suspension Arm Removal e Remove Brake Hose Banjo Bolt Caliper side Front Wheel see Wheels Tires chapter Knuckle Joint Nuts and Cotter Pin A Knuckle Joints B from Knuckle Tie Rod End Nut C Suspension Arm Pivot Bolts D Suspension Arms E Suspension Arm Installation e Tighten Torque Suspension Arm Pivot Bolts 42 N m 4 3 kgf m 31 ft Ib Knuckle Joint Nuts 29 N m 3 0 kgf m 21 ft Ib Tie Rod End Nut 42 N m 4 3 kgf m 31 ft Ib Suspension Arm Disassembly e Remove Oil Seals A Sleeve B Collars C HM05009BS2 C SUSPENSION 13 11 Suspension Arms e Remove Circlip A Snap Ring B e Press out the ball joint bearing C and needle bearing D Knuckle joint E Special Tools Inside Circlip Pliers 57001 143 Outside Circlip Pliers 57001 144 Suspension Arm Assembly e Install the following parts as shown Front Side A Needle Bearing B C 7 5 0 1 mm 0 295 0 004 in Oil seals D Sleeve E
205. ipe see Exhaust System e Remove Cylinder Head Bolt M6 A Cylinder Head Bolts M10 B and Washers Cylinder Head C and Gasket O Lift the cylinder head to clear the dowel pins in the cylin der and slide the cylinder head out of the frame Cylinder Head Installation e Install Dowel Pins A New Cylinder Head Gasket B Oil Pipe C Camshaft Chain Guides D e Tighten Torque Front Cylinder Camshaft Chain Guide Bolt 20 N m 2 0 kgf m 14 ft Ib e Apply molybdenum disulfide oil to the threads and seating surface of the cylinder head bolts and both sides of the washers e Tighten the cylinder head bolts following the tightening sequence as shown First Torque Cylinder Head Bolts M10 A 25 N m 2 5 kgf m 18 ft Ib Final Torque Cylinder Head Bolts M10 A 49 N m 5 0 kgf m 36 ft lb e Tighten the cylinder head bolts M6 Torque Cylinder Head Bolts M6 B 9 8 N m 1 0 kgf m 87 in lb Cylinder Head Cleaning e Remove the cylinder head see Cylinder Head Removal e Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool e Wash the head with a high flash point solvent e Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air P Cylinder Head Cylinder Head Warp e Clean the cylinder head see Cylinder Head Cleaning e Lay astraightedge across the lower surface of the cylinder head e Use a thic
206. itch leads A e Remove the radiator fan switch B Radiator Fan Switch Installation e Tighten Torque Radiator Fan Switch 18 N m 1 8 kgf m 13 ft Ib e Fill the coolant see Cooling System in Periodic Mainte nance chapter Radiator Fan Switch Inspection e Refer to the Electrical System chapter Coolant Temperature Warning Light Switch Coolant Temperature Warning Light Switch Removal CAUTION The coolant temperature warning light switch should never be allowed to fall on a hard surface Such a shock to the part can damage it e Drain the coolant see Cooling System in Periodic Main tenance chapter e Disconnect the switch lead A e Remove the switch B Coolant Temperature Warning Light Switch Installation e Apply silicone sealant to the threads of the switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Coolant Temperature Warning Light Switch 7 8 N m 0 80 kgf m 69 in Ib e Fill the coolant see Cooling System in Periodic Mainte nance chapter Coolant Temperature Warning Light Switch Inspection e Refer to the Electrical System chapter COOLING SYSTEM 4 19 4 20 COOLING SYSTEM Coolant Filter Valve Coolant Filter Cleaning e Refer to the Cooling System in the Periodic Maintenance chapter Coolant Valve Inspection e Drain the coolant see Cooling System in Periodic Main tenance chapter e Remove the coolant valve A on the
207. k the operation of the rear brake light switch by de pressing the brake pedal A If it does not as specified adjust the brake light timing Brake Light Timing Standard On after about 10 mm 0 4 in of pedal travel B Brake Light Timing Adjustment e Remove the foot guard see Frame chapter e Adjust the brake light switch A up or down To change the switch position turn the adjusting nut B CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment General Lubrication Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE oWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation WSO AO SOS SN N ki ay y GP100108S1 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables Lubricate with Cable Lubricant Brake Cables Throttle Cable Choke Cable Shift Control Cables e Lubricate the cables by seeping the oil between the cable and housing O The cable may be lubricated by using a pressure cable lubber with an aerosol cable lubricant 6004011481 C e With the cable disconnected at the both ends the cable
208. kgf m ft Ib 1 2 Rear Shock Absorber Mounting Nuts 6 3 3 Suspension Arm Pivot Bolts 4 SEHR Knuckle Joint Nuts 5 L 6 Swingarm Pivot Left Shaft L 7 Swingarm Pivot Left Nut 152 15 5 112 G Apply grease L Apply a non permanent locking agent AG Apply grease Amoco rykon premium grease No 2 EP Green MF Apply MOBIL FLUID 424 or equivalent oil R Replacement parts 13 4 SUSPENSION Specifications Item Standard Service Limit Front Shock Absorbers Usable Range Spring preload setting position No 2 1 5 Rear Shock Absorber Spring preload adjustment Adjusting nut position from the center Adjustable Range of the mounting hole upper 94 2 mm 3 71 in 93 2 104 3 mm 3 67 4 11 in Gas Reservoir Compression damping Adjustment from the seated position adjuster Adjust Range tuned fully clockwise 14 clicks counter clockwise 19 clicks Gas pressure 980 kPa 10 kgf cm 142 psi Special Tools Inside Circlip Pliers 57001 143 Outside Circlip Pliers 57001 144 Oil Seal amp Bearing Remover 57001 1058 SUSPENSION 13 5 Hook Wrench 57001 1101 bus gt f NL Bearing Driver Set 57001 1129 Jack 57001 1238 13 6 SUSPENSION Shock Absorbers Front Shock Absorber Inspection Since the front shock absorbers are sealed units which cannot be disassembled only external checks are neces sary If one unit is damaged replace bo
209. kness gauge A to measure the space between the straightedge B and the head at several locations Cylinder Head Warp Service Limit 0 05 mm 0 002 in lf the cylinder head is warped more than the service limit replace it lf the cylinder head is warped less than the service limit repair the head by lapping the lower surface with emery paper secured to a surface plate first No 200 then No 400 ENGINE TOP END 5 29 5 30 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Engine Top End in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Engine Top End in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal O Mark and record the valve location so it can be installed in the original position e Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 022 57001 1202 B Valve Installation e Replace the valve stem oil seal lf a new valve is to be used check the valve to guide clearance see this chapter x lf there is too little clearance ream the valve guide see Valve Guide Installation xIf there is too much clearance install a new valve guide see Valve Guide Removal and Valve Guide Installation e Check the valve seat see Valve Seat Inspection e Apply a thin coat of molybdenum disulfide grease to
210. l Pipe oce E Wes 7 12 Oil PipeInstallatio E 7 13 7 2 ENGINE LUBRICATION SYSTEM Exploded View d ZA e Ke Es SN SS A X 3 D LTA DD H6802004BN5 ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque N m kgf m ft Ib R Oil Pressure Switch 11 SS Oil Pipe Bolts 0 90 78 in Ib Remarks No Fastener Engine Drain Plug Cil Pressure Relief Valve L Oil Pump Bolts 78 in Ib Chain Guide Bolts 78 in Ib Oil E Drive Chain Tensioner Bolt 18 EE L 15 mm 10 Oil Pressure Switch Terminal Bolt 0 15 13 in lb G Apply grease for oil seal and O ring L Apply a non permanent locking agent O Apply engine oil SS Apply silicone sealant Kawasaki Bond 56019 120 R Replacement Parts 7 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 1 7 L 1 80 US qt when filter is not removed 1 9 L 2 01 US qt when filter is removed 2 2 L 2 33 US qt when engine is completely dry Oil Pressure Measurement Oil Pressure 4 500 r min rpm oil temp 480 kPa 4 9 kgf cm 69 7 psi 110 C 230 F ENGINE LUBRICATION SYSTEM 7 5 Special Tools and Sealant Oil Pressure Gauge 10 kgf cm Kawasaki Bond Silicone Sealant 57001 164 56019 120 Oil Pressure Gauge Adapter PT 1 8 57001 1033 7 6 ENGI
211. l Tool Hand Tester 57001 1394 Starter Circuit Relay Inspection e Remove Seat see Frame chapter Rear Fender see Frame chapter Starter Circuit Relays A Brake and Neutral Switch Cir cuit O The starter circuit relays for the brake and neutral switch circuits are identical e Connect the hand tester A and a 12 V battery B to the starter circuit relay C as shown xIf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 12 Criteria When battery is connected gt 0 Q When battery is disconnected gt o 2 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 ELECTRICAL SYSTEM 16 51 GP12070382 16 52 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit SSES Red 3 M 5 1 Engine Stop Switch 6 Starter Circuit Relay 11 Battery 2 Starter Button Brake 12 Starter Circuit Relay 3 Front Brake Light Switch 7 Ignition Switch Neutral 4 Parking Brake Light 8 Starter Motor 13 Neutral Switch Switch 9 Starter Relay 5 Rear Brake Light Switch 10 Main Fuse 30A Starter Motor Clutch Removal e Remove the alternator rotor see Alternator Rotor Re moval e Hold the rotor with the flywheel holder and take out the starter motor clutch bolts A Special Tool Flywheel Holder 57001 1313 Wwip P ELECTRICAL SYSTEM 16 53 Electric Starter System e Take
212. l tank bolts e Connect Breather Hose C Fuel Pump Lead Connector D Fuel Hose E e Be sure the fuel hose is clamped to the fuel pump fitting Fuel Tank Cleaning e Remove the fuel tank and drain it see Fuel Tank Re moval e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits A WARNING Clean the tank in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank A fire or explosion could result e Pour the solvent out the tank e Install the fuel tank see Fuel Tank Installation Fuel Tap Removal e Remove Fuel Hoses A Fuel Tap Mounting Bolts B e Remove Fuel Tap Vacuum Hose A 3 30 FUEL SYSTEM Fuel Tank Fuel Tap Installation e Connect the fuel hoses to the fuel tap as follows Fuel Filter Hose to Fitting A Fuel Tank Hose to Fitting B Fuel Tap Vacuum Hose to Fitting C e Be sure to clamp the fuel hoses to the fuel tap to prevent leakage Fuel Tap Inspection e Be sure the O ring A is in good condition to prevent leak age e Apply grease to the lever B e Tighten Torque Fuel Tap Plate Screws C 0 80 N m 0 080 kgf m 7 in Ib Fuel Tap Cover Screws D 1 0 N m 0 10 kgf m 8 in Ib HC08006BS1 C FU
213. lator rectifier is defective or the regulator rectifier leads are loose or open lf the battery voltage does not increase as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective 16 28 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures short open or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromag netic field or just by aging will result in low output e To check the alternator output voltage perform the follow ing procedures O Remove the rear fender see Frame chapter O Disconnect the alternator connector A O Connect a hand tester as shown in the table O Start the engine O Run it at the rpm given in the table O Note the voltage readings total 3 measurements Alternator Output Voltage Tester Reading Range Tester to Tester to 93 000rpm 250 V AC One yellow lead Another yellow lead 36 54 V x If the output voltage is within the values in the table the alternator is operating correctly and the regulator rectifier is damaged A much lower reading indicates that the al ternator is
214. lb G Apply grease L Apply a non permanent locking agent MF Apply MOBIL FLUID 424 or equivalent oil 12 6 BRAKES Specifications Item Standard Service Limit Brake Fluid Type DOT 3 or DOT 4 SE Front Disc Brake Pad lining thickness 4 0 mm 0 16 in 1 mm 0 04 in Disc thickness 3 3 3 7 mm 0 130 0 146 in 3 mm 0 12 in Disc runout TIR 0 2 mm 0 008 in or less TIR 0 3 mm 0 012 in Rear Brake Lever Pedal and Cables Rear brake pedal position 35 40 mm 1 38 1 57 in above footboad Rear brake lever free play 1 2 mm 0 04 0 08 in Rear brake pedal free play 15 25 mm 0 6 1 0 in BRAKES 12 7 Special Tool Inside Circlip Pliers 57001 143 me 12 8 BRAKES Brake Fluid 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
215. lts Position Plate Bolts Cylinder Bolts 40 mm 1 6 in Cylinder Bolts 30 mm 1 2 in Exhaust Pipe Cover Bolts Muffler Cover Bolts Muffler Mounting Bolts Exhaust Pipe Clamp Bolts Converter System Converter Cover Bolts Driven Pulley Nut Ramp Weight Nuts Spider Drive Pulley Cover Bolts Drive Pulley Bolt Joint Duct Bolts Engine Lubrication System Engine Drain Plug Oil Filter Oil Pressure Switch Oil Pressure Relief Valve Oil Pump Bolt Oil Pipe Bolts Oil Filter Mounting Bolt Oil Pressure Switch Terminal Bolt Chain Guide Bolts Intermediate Shaft Chain Tensioner Bolts Front Cylinder Camshaft Chain Guide Bolt Rear Cylinder Camshaft Chain Guide Bolt Torque N m 49 9 8 20 8 8 12 8 8 8 8 22 44 8 8 8 8 12 8 8 9 8 9 8 20 8 8 8 8 20 8 8 8 8 93 6 9 275 13 93 8 8 20 18 15 15 8 8 8 8 25 1 9 8 8 kgf m 5 0 1 0 2 0 0 90 1 2 0 90 0 90 2 2 4 5 0 90 0 90 1 2 0 90 1 0 1 0 2 0 2 0 0 90 0 90 2 0 0 90 0 90 9 5 0 70 28 1 3 9 5 0 90 2 0 1 8 1 5 1 5 0 90 0 90 2 5 0 15 0 90 ft lb 36 87 in lb 14 78 in lb 104 in lb 78 in lb 78 in lb 16 33 78 in lb 78 in lb 104 in lb 78 in lb 87 in lb 87 in lb 14 14 78 in lb 78 in lb 14 78 in lb 78 in lb 69 61 in lb 203 113 in Ib 69 78 in lb 14 13 11 11 78 in lb 78 in lb 18 13 in lb 78 in lb Remarks Lh R Lh SS L 15mm Torque and Locking Agent PERIODIC MAINTEN
216. lts 26 2 7 20 3 Bearing Holder 137 14 101 L 4 Bevel Gear Holder Nut 157 16 116 L 5 Bearing Holder 120 89 L 6 Output Shaft Holder Nut 157 16 116 L 7 Output Drive Bevel Gear Cover Bolts 8 8 0 90 78 in lb G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil 11 4 FINAL DRIVE Exploded View Nopi HKO2014BW5 FINAL DRIVE 11 5 Exploded View No Fastener Totdug Remarks N m kgf m ft Ib Oil Drain Plug 20 2 0 14 Pinion Gear Bearing Holder 137 14 101 L Pinion Gear Bearing Holder Nut 157 16 116 L L Final Gear Case Bolts 42 4 3 31 S Final Gear Case Right Cover Bolts M8 24 24 17 L S Final Gear Case Right Cover Bolts M10 49 5 0 36 L S Final Gear Case Right Cover Bolts M12 o 96 69 Ls G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease MF Apply MOBIL FLUID 424 or equivalent oil S Follow the specific tightening sequence 11 6 FINAL DRIVE Specifications Item Standard Service Limit Output Bevel Gear Case Output bevel gear backlash 0 05 0 11 mm 0 0020 0 0043 in at output drive shaft spline Rear Axle Shaft Rear axle shaft runout TIR 1 mm 0 04 in or less TIR 2mm 0 08 in Final Gear Case Gear case oil Type Oil level Capacity Final bevel gear backl
217. m 0 028 in xIfthe clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Crankpin Wear e Measure the bearing insert crankpin A clearance with plastigage B O Tighten the big end nuts to the specified torque Torque Connecting Rod Big End Nuts 34 N m 3 5 kgf m 25 ft lb NOTE O Do not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 028 0 052 mm 0 0011 0 0020 in Service Limit 0 09 mm 0 0035 in xIf the clearance is within the standard no bearing insert replacement is required lf the clearance is between 0 052 mm 0 0020 in and the service limit 0 09 mm 0 0035 in replace the bear ing inserts A with inserts painted green B Check in sert crankpin clearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure xIf the clearance exceeds the service limit measure the diameter of the crankpin Crankpin Diameter Standard 39 984 40 000 mm 1 5742 1 5748 in Service Limit 39 97 mm 1 5736 in lf the crankpin has worn past the service limit replace the crankshaft with a new one MIO P 9 16 CRANKSHAFT TRA
218. m Guard B Engine Bottom Guard Installation e Confirm Damper C e Install Engine Bottom Guard Bolts Rear Bottom Guard Removal e Remove Bolts M6 A Bolts M8 B Rear Bottom Guard C Rear Bottom Guard Installation e Confirm Dampers D e Install Rear Bottom Guard Bolts M8 Bolts M6 FRAME 15 11 H009015BSi H009016BSi 15 12 FRAME Foot Guard and Stay Foot Guard and Stay Removal E e Remove Screws and Collars A Foot Guards B e Remove Bolt and Nut A Bolts B Guard Stays C Footrest D e For left side remove guard E Foot Guard and Stay Installation e For left side install the guard and tighten it e Install the footrest A and foot stay B e Tighten the footrest mounting bolt C and the bolts D Torque Footrest Mounting Bolt 44 N m 4 5 kgf m 33 ft Ib e Install the foot guard E and tighten the screws F H008007BS1 C ELECTRICAL SYSTEM 16 1 Electrical System TABLE OF CONTENTS Exploded View 16 4 Specifications sssssss 16 10 Special Tools 16 12 Parts Location 16 13 PreCaUutiOns cccccceeceeeeeeeeeeeeeeeeeeeeees 16 14 Electrical VWumg 16 16 Wiring Inspection 16 16 A dete ata 16 17 Battery Removal 16 17 Battery Installation 16 17 Electrolyte Filling 16
219. m bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Damage tie rod end not properly APPENDIX 17 5 Handlebar shakes or excessively vibrates Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem clamp bolt loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm bent or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Brake Doesn t Hold Front brake Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad overworn or worn unevenly Oil grease on pads and disc Disc worn or warped Brake overheated Rear Brake Brake not properly adjusted Plates worn Brake parts worn or damaged Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator rectifier trouble Battery trou
220. m idling smoothly Re place it e Check that the vacuum piston moves smoothly in the car buretor body The surface of the piston must not be ex cessively worn lf the vacuum piston does not move smoothly or if it is very loose in the carburetor body replace both the body and the vacuum piston 6006014351 C 6006014451 C FUEL SYSTEM 3 25 Air Cleaner Air Cleaner Element Removal e Remove Air Cleaner Cover see Frame chapter Clips A Air Cleaner Housing Cap B e Remove Thumbscrews A Metal mesh B with element e After removing the element stuff pieces of lint free clean cloth into the air cleaner ducts to keep dirt out of the car buretor and engine A WARNING If dirt or dust is allowed to pass through into the carburetors the throttle may become stuck possi bly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur e Separate metal mesh A and element B Air Cleaner Element Cleaning and Inspection e Refer to the Fuel System in the Periodic Maintenance chapter Air Cleaner Draining e Refer to the Fuel System in the Periodic Maintenance chapter Air Cleaner Housing Removal e Remove Air Cleaner Cover see Frame chapter Air Cleaner Housing Cap Air Cleaner Element Air Cleaner Element Removal 3 26 FUEL SYSTEM Air Cleaner e Remove Screws A Element Bracket B e Remove
221. me chapter Fuel Hose A Coolant Hoses B e Loosen the clamp screws A on the carburetor holders e Remove the carburetor out of the frame FUEL SYSTEM 3 17 Carburetor e Remove the throttle cable cover screw A and throttle cable cover B e Loosen the nut A on the throttle cable e Remove the throttle cable lower end B e Remove the screws A and holder plates B e Pull out of the starter plungers Carburetor Installation e Check fuel leakage from the carburetors A WARNING Fuel spilled from the carburetors is hazardous e Adjust the idle speed see Fuel System in Periodic Main tenance chapter e Check the throttle cable see Fuel System in Periodic Maintenance chapter 3 18 FUEL SYSTEM Carburetor Carburetor Disassembly e Remove the carburetors see Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTE O The carburetors can be disassembled in the joined state e Remove the upper chamber cover A spring B and vac uum piston C CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm e Remove the jet needle D from
222. ment parts 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheel Alignment Toe in of front wheels 10 10 mm 0 39 0 39 in Tires Standard tire Front AT 22 x 7 10 HOLESHOT XC Tubeless Rear AT 22 x 11 10 HOLESHOT XCT Tubeless Tire air pressure when Front 28 kPa 0 28 kgf cm 4 0 psi cold Rear 35 kPa 0 35 kgf cm 5 0 psi ee Maximun tire air pressure to seat beads when cold Tire tread depth Front 250 kPa 2 5 kgf cm 36 psi 3 mm 0 12 in 3 mm 0 12 in WHEELS TIRES 10 5 Special Tool Jack 57001 1238 10 6 WHEELS TIRES Wheel Alignment Toe in is the amount that the front wheels are closer to gether in front than at the rear at the axle height When there is toe in the distance A Rear is the greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slip ping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are build in and require no adjust ment A Rear B Front Amount of Toe in Distance A and B are measured at axle height with the vehicle sitting on the ground or at 1G Toe in Inspection e Apply a heavy coat of chalk or a paint line near the center of the front tires e Using a needl
223. mm 0 366 in Circlip F e Tighten the nut A and compress the spring with the spring holder B Special Tool Spring Holder Set 57001 1483 e Install the circlip C with the circlip pliers D Special Tool Circlip Pliers 57001 154 e Remove the driven pulley from the spring holder set e Clean the surface of the sheaves with an oil less cleaning fluid 6 26 CONVERTER SYSTEM Driven Pulley Driven Pulley Installation e Clean the transmission driven shaft A e Install Driven Pulley NOTE O When engaging the spline on the driven pulley with the spline B on the shaft do not damage the pulley s spline If any damage occurs remove it with a file e Clean the driven shaft and driven pulley ends to open the air vent passage Wipe off any extra grease O Wipe off any protruding grease A e Install the washers A on the shaft as shown Crankcase Side B Bolt Head C e Using a flywheel amp pulley holder A and pulley holder at tachments B tighten the driven pulley nut C Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft lb CONVERTER SYSTEM 6 27 High Altitude Setting Information Specifications Carburetor Altitude Main Jet 0 500 m Front 135 P No 92063 1014 STD 0 1 600 ft Rear 140 P No 92063 1013 STD 500 1 500 m Front 132 P No 92063 1076 1
224. n Torque Chain Tensioner Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib e Install Pin A and Spring B Washer C and Chain Tensioner Cap Bolt D e Tighten Torque Chain Tensioner Cap Bolt 22 N m 2 2 kgf m 16 ft Ib ENGINE TOP END 5 13 Rocker Case Rocker Case Removal Front Rocker Case e Remove Air Cleaner Cover see Frame chapter Front Fender see Frame chapter Side Inner Cover see Frame chapter Timing Inspection Plug A Valve Adjusting Caps Converter Intake Duct Exhaust Duct see Converter System Special Tool Filler Cap Driver 57001 1454 e Using a wrench on the alternator bolt turn the crankshaft counterclockwise until T F mark A is aligned with the notch B in the inspection window and the cam lobes are pointing away from the rocker arms the end of the compression stroke CAUTION Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case The rocker arms could bend the valves HEi10001BSi e Remove Front Camshaft Chain Tensioner see Camshaft Chain Tensioner Removal Rocker Case Bolts A Front Rocker Case B e Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame Rear Rocker Case e Remove Front Rocker Case see this section Converter Exhaust Joint Duct e Using a wrench on the alternator bolt turn the crankshaft
225. n Timing Test Vehicle down Sensor Outline Vehicle down Sensor Removal Vehicle down Sensor Installation Vehicle down Sensor Inspection Electric Starter System Starter Motor Removal Starter Motor Installation Starter Motor Disassembly Starter Motor Assembly Commutator Cleaning Inspection Armature Inspection Starter Motor Brush Length Brush Assembly Inspection Brush Plate and Terminal Bolt Inspection Starter Relay Inspection Starter Circuit Relay Inspection Starter Motor Clutch Removal Starter Motor Clutch Installation Starter Motor Clutch Inspection Torque Limiter Inspection Lighting System eee Headlight Beam Vertical Adjustment Headlight Bulb Replacement Taillight Bulb Replacement Radiator Fan Gvstem Radiator Fan Circuit Inspection Radiator Fan Motor Inspection Fuel Pump Fuel Reserve Switch Fuel Pump Inspection Fuel Reserve Switch Inspection Indicator Unit Inspection e Le iii 16 2 ELECTRICAL SYSTEM Brake Light Switch Adjustment Radiator Fan Switch Inspection Coolant Temperature Warning Light Switch Inspection 30 A Main Fuse Removal 16 70 Radi
226. n smoothly replace it Also inspect the end of the valve stem e Measure the inside diameter C of the rocker arm with a dial bore gauge x If the rocker arm inside diameter is larger than the service limit replace it Also check the rocker shaft diameter see Rocker Shaft Diameter Measurement Rocker Arm Inside Diameter Standard 12 000 12 018 mm 0 4724 0 4731 in Service Limit 12 05 mm 0 474 in Rocker Shaft Diameter Measurement e Measure the diameter A of the rocker shaft where the rocker arm pivots on it with a micrometer lf the rocker shaft diameter is smaller than the service limit replace it Also check the rocker arm inside diameter see Rocker Arm Inspection Rocker Shaft Diameter Standard 11 973 11 984 mm 0 4714 0 4718 in Service Limit 11 95 mm 0 470 in Mo P ENGINE TOP END 5 17 Camshaft Camshaft Removal e Remove Both Camshaft Chain Tensioners see Camshaft Chain Tensioner Removal Both Rocker Cases see Rocker Case Removal Both Camshafts A e Support the chain using a suitable tool Camshaft Installation e Using a wrench on the alternator bolt turn the crankshaft clockwise until T R mark A is aligned with the notch B in the inspection window A FO A HEi10002BSi e The rear camshaft A has a groove B e First install the rear camshaft e Face the arrow A of the rear camshaft sprocket upward left side view e Engage the re
227. n the engine is assembled be sure to adjustthe valve clearance see Valve Clearance Adjustment GE15012381 GEi5012081 5 36 ENGINE TOP END Valves Valve Seat Repair START Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Vernier Caliper Purpose check seat O D against spec 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase O D of 32 Grind seat area to spec Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seat Width Tool Vernier Caliper Purpose check seat width against spec 45 Grind Machinist s Tool 45 Cutter dye on seat Purpose increase width of seat area beyond spec to increase O D 60 Grind Tool 60 Cutter Purpose reduce seat width to specification Lap Valve Tools Valve Lapper Grinding Compound Purpose perfectly match valve FINISHED and seat area check valve head for damage ENGINE TOP END 5 37 Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Oil Pipe A Chain Guide B Cylinder Bolts C Cylinder D Cylinder Base Gasket Piston Removal e Remove the cylinder block see Cylinder Removal e Place a piece of clean cloth under the piston and remove the piston pin snap rings A from the outside of each pis ton C
228. n them Torque Exhaust Pipe Cover Bolts C 8 8 N m 0 90 kgf m 78 in lb Muffler Cover Bolts D 8 8 N m 0 90 kgf m 78 in Ib Exhaust Pipe Clamp Bolt 8 8 N m 0 90 kgf m 78 in Ib e Replace the exhaust pipe holder gaskets E and clamp gasket F with new ones e Install But do not tighten the following nuts and bolts Front Exhaust Pipe G Clamp H Muffler and Nuts Rear Exhaust Pipe I and Nuts Muffler Mounting Bolts J e Tighten Exhaust Pipe Holder Nuts evenly Muffler Clamp Bolt Torque Muffler Mounting Bolts 20 N m 2 0 kgf m 14 ft Ib Rocker Case with Cable Holder Bolts 9 8 N m 1 0 kgf m 87 in Ib HE15006B52 C Exhaust System Inspection e Before removing the exhaust system check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp lf there are signs of leakage around the exhaust pipe gas ket it should be replaced If the muffler to exhaust pipe joint leaks tighten the clamp e Remove the exhaust pipe and muffler see Exhaust Pipe and Muffler Removal e Inspect the gasket for damage and signs of leakage lf the gasket is damaged or has been leaking replace it e Check the exhaust pipe and muffler for dents cracks rust and holes x lf the exhaust pipe or muffler is damaged or has holes it should be replaced for best performance and least noise CONVERTER SYSTEM 6 1 Converter System TABLE OF CONTENTS Exploded Vlew EET
229. needle or needle jet worn Main air jet clogged Bleed holes of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking APPENDIX 17 3 Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Igniter trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged C
230. nnnnnnnnnininis 4 11 RA A AA 4 13 ese Eege EE 4 13 Radiator Fan ue isis ada one ayant lave e e de da a ps 4 14 Radiator Fan Installation m emnes 4 14 Radiator Inspections eoe xe ne Stes dns ova e E Rae eva TEE TN ETE E YET EUN 4 15 Radiator CleaniNg uds toten on b Sod c sed aue COE Gat Sch gia al osos dte 4 15 Radiator Cap Inspection seiri i aeea aapa eem ene nnn nnnnn nnns nennen 4 15 stuer ET 4 16 Thermostat HRemoval rhet rhe rre rre rre ren ren enr ren arena 4 16 Thermostat Installaton aeaee eeee rererere trrererertrerteerteertrerteertresreesreeseeerreere eee 4 16 Thermostat Inspection sirrcna anena eah eaa ae a A a pae E aaa raa arra Ea 4 16 Radiator Fan SWCNT E EEE EE EE E E p en E EE erer 4 18 Radiator Fan Switch Removal oooocccccncncnciconnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninininins 4 18 Radiator Fan Switch Installation ccccceeceeeceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeess 4 18 Radiator Fan Switch Inspection 4 18 Coolant Temperature Warning Light Switch eeeeesesseeeeeeeeee eren 4 19 Coolant Temperature Warning Light Switch Removal sene 4 19 Coolant Temperature Warning Light Switch Installation seesseeeeeeesees 4 19 Coolant Temperature Warning Light Switch Inspection ssssssesseeeeeeeseersrerresesrsrrrrrreessee 4 19 Coolant Filter ValVe in teh rh bn ER ERR E S RR n RA ee EE CERA TUR AR Fe EXTR YER baa FE PY RA
231. nual for the function of the throt tle limiter and adjustment procedure of it A WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition e Check the throttle lever free play see Fuel System in Pe riodic Maintenance chapter e Slide back the cable adjuster dust cover to the original position Throttle Cable Installation e Lubricate the throttle cable before installation e Route the cable correctly according to the Appendix chap ter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition e Check the throttle cable see Fuel System in Periodic Maintenance chapter Throttle Case Inspection e With the throttle cable disconnected from the throttle lever the lever should move freely and return smoothly by spring xIf the lever is heavy disassemble the throttle case clean and lubricate the throttle case e Examine the lever and case for cracks Replace the case assembly if it is cracked FUEL SYSTEM 3 9 3 10 FUEL SYSTEM Throttle Lever and Cable Throttle Cable Lubrication Whenever the throttle cable is removed lubricate the ca ble as follows e Apply a small amount of multi purpose grease to the cable both ends e Lubricate the cable with a penetrating rust inhibitor through the pressure cable lubber Throttle Cable Inspection e With the throttle cabl
232. o change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wash away any coolant that spills on the frame engine or wheels Since coolant is harmful to the human body do not use for drinking e Remove Front Fender see Frame chapter Reserve Tank Cap e Place the container under the reserve tank e Pull off the cooling hose A and drain the coolant e Place a container under the drain plug A at the bottom of the water pump B then remove the drain plug e Remove the radiator cap A in two steps First turn the cap counterclockwise to the first step Then push and turn it further in the same direction and remove the cap e The coolant will drain from the radiator and engine PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures e Install the cooling hose A e Tighten the drain plug Torque Coolant Drain Plug 8 8 N m 0 90 kgf m 78 in Ib e Support the vehicle on a stand or the jack so that the front wheels are offthe ground This makes air bleeding easier e Fill the radiator up to the radiator filler neck B with coolant NOTE O Pour in the coolant slowly so that the air in the engine and radiator can escape e Fill the reserve tank up to the full level line with coolant and install the reserve tank cap CAUTION Soft or distilled water must be used with antifreeze see
233. ocknut and the adjusting bolt e Remove the brake switch spring A e Loosen the brake pedal bolt B e Remove Washers C Brake Pedal D KA 71 Lam Rear Brake Lever Pedal and Cables Brake Pedal Installation e Apply grease to the tip of the brake pedal shaft e Install the brake pedal e Align the punch mark A on the brake pedal shaft with the punch mark B on the brake pedal e Install the washers A e Tighten Torque Brake Pedal Bolt B 8 8 N m 0 90 kgf m 78 in Ib e Install the brake switch spring C e Adjust the brake pedal position see Brake Pedal Posi tion Brake Cable Removal e Remove Right Foot Guard see Frame chapter e Unscrew the adjusters A at the rear ends of the cables and pull the cables out of the joints B e Remove the circlip C and pull the cables out of the cable mount D e Loosen the knurled locknut B at the rear brake lever and screw in the adjuster C e Line up the slots A in the brake lever knurled locknut and adjuster and then free the cable from the lever e Remove the brake lever cable from the frame BRAKES 12 19 HLi1007BS1 GFO40607S1 12 20 BRAKES Rear Brake Lever Pedal and Cables e Remove Swingarm see Suspension chapter e Remove Circlip A Cotter Pin Washer and Pin B Brake Pedal Cable C Brake Cable Installation e Grease the brake cable front ends e Replace the cot
234. olor change or other damage e Apply grease to the outer races A and pack the tapered roller bearings B with the same grease e Apply Amoco Rykon Premium Grease No 2 EP green to the inside of the oil seals e Install the swingarm see Swingarm Installation HM06000BS1 C HMOGOO03BSi C STEERING 14 1 Steering TABLE OF CONTENTS Exploded MEE 14 2 eene le Susini alada ad dni dd id hal 14 4 lee EE 14 5 Steering Stem Removal cant ding li wedges 14 5 Steering Stem Installation Aia 14 6 A EE EE 14 7 IG FUCK LEAS UA AO m EET 14 7 HS Rod En EE 14 7 ele Bil crue DP 14 7 Te Rod End REMO ducados iR 14 8 Tie Rod End Installation vecina id 14 8 le He Ee e ntetagtatectyta be otbtyatatyatataatatiatetagaat 14 9 Steering d Iae Tel foii o TE 14 9 Steering Stem Talgo aii Pe 14 9 Steering Lubricante 14 9 Steering Stem Clamp Inspection sssssssssse eee 14 9 Steering Stem Bearing Inspection oococonnononnnccccccnnnnnnnnnccccnrcnnnn nn 14 10 Steering Knuckle Bearing Inspection ceecsecceecceeeeeseseceeneeeeeeeeeeesesenaneeeeeeeensenneaeneeees 14 10 Tie Rod End and Steering Knuckle Joint Inspechon 14 10 HO ii a A nee et nat ee he dees ae eee 14 11 Handlebar Removal ai a id devi de 14 11 Handlebar Installation menaa a e a e a a ie aa aae Ea E a 14 11 14 2 STEERING Exploded View HNO2008BN5 STEERING 14 3 Exploded View No
235. ompression high Carbon built up in combustion chamber Compression release cam K A C R sticks close Engine load faulty Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Final gear case overheating Insufficient oil Bevel gears maladjusted Coolant incorrect Coolant level too low Coolant deteriorated 17 4 APPENDIX Troubleshooting Guide Thick coolant Cooling system component incorrect Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Cooling system component incorrect Radiator fan switch trouble Thermostat trouble Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly in stalled too loose Shifting too slowly Belt dirty or worn
236. onnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running O Because of the high current never keep the starter button depressed when the starter motor will not turn over or the current may burn out the starter motor windings O Only use an illumination bulb rated for the voltage or wattage specified in the wiring diagram or the handle cover could be warped by excessive heat radiated from the bulb O Take care not to short the leads that are directly con nected to the battery positive terminal to chassis ground O Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc De fective wires and bad connections will affect electrical sys tem operation O Measure coil and winding resistance when the part is cold at room temperature O Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Lightgreen W White DG Darkgreen O Orange Y Yellow ELECTRICAL SYSTEM 16 15 Precautions O Electrical Connectors Female Connectors A Male Connectors B GP06010281 16 16 ELECTRIC
237. ons Always follow safe operating and maintenance practices This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE o This note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done O Indicates 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 ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information TABLE OF CONTENTS Before Servich g era o 1 Model efecto Lc 1 General Specifications eR rere ee dada 1 Unit Conversion Tap ese eera
238. or Clamp 12 Clamp 13 Convertor Duct 14 Indicator Unit Lead Connector 15 Rear Brake Switch Lead Connector Front Brake Switch Lead Connector 16 Ignition Switch Lead Connector 17 Left Handlebar Switch Lead Connector VIEW A HB09060BN4 C Reverse Power Assist Switch Lead Con nector Clamp Clamp Radiator Fan Connector Ground Tighten with the thermostat cover bolt Water Temperature Warning Switch Lead Radiator Fan Switch Lead 17 20 APPENDIX Cable Wire and Hose Routing 1 Left Head Light Lead Connector 2 Radiator Fan Connector 3 Radiator Fan Switch Connector 4 Water Temperature Warning Switch Lead 5 Ground Tighten with the thermostat cover bolt 6 Clamp 7 Ignition Coil Front 8 Clamp 9 Band 10 Regulator Rectifier 11 Clamp 12 Starter Circuit Relays 13 Clamp HBOSO61BW4 APPENDIX 17 21 Cable Wire and Hose Routing gt WE 1 call gt di V n NS VIEW A 1 To Engine Ground 8 To Regulator Rectifier 2 Main Harness 9 To Reverse Neutral Switch 3 Clamp Main Harness Accessory 10 Battery 4 Fuel Tank Breather Hose 11 Fuse Case For Radiator Fan 5 To Tail Brake Light 12 Spare Fuse 6 Vehicle down Sensor 13 Reset Connectors 7 Starter Relay Main Fuse 17 22 APPENDIX Cable Wire and Hose Routing SS RNR lt HB09083BW3
239. out the one way clutch A Starter Motor Clutch Installation e Install the one way clutch so that the flange A fits on the recess B of the race e Apply a non permanent locking agent Starter Motor Clutch Bolts e Tighten Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft Ib Rimm P Starter Motor Clutch Inspection e Remove Alternator Rotor see Alternator Rotor Removal e Fit the starter clutch gear into the starter motor clutch x lf the alternator rotor turns counterclockwise A freely from the starter clutch gear but not clockwise B the clutch is operating correctly x lf the clutch does not operate correctly or if it makes noise disassemble it and examine each part visually Re place any worn or damaged parts NOTE o Examine the starter clutch gear A Replace it if it is worn or damaged 16 54 ELECTRICAL SYSTEM Electric Starter System Torque Limiter Inspection e Remove Alternator Rotor see Alternator Rotor Removal e Remove the torque limiter A and visually inspect it lf the limiter has wear discoloration or other damage replace it as a unit Wb P ELECTRICAL SYSTEM 16 55 Lighting System Headlight Beam Vertical Adjustment e Turn the adjusting screw A on each headlight rim in or out to adjust the headlight vertically NOTE O On high beam the brightest point should be slightly be low horizontal with the vehicle on its wheels and the rid
240. pad b brakes over heat c there is a large difference in inner and outer pad wear d the seal is stuck to the piston eee If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Caliper Dust Seal and Friction Boot Replacement e Disassemble the brake caliper see Brakes chapter e Check that the dust seals A and friction boots B are not cracked worn swollen or otherwise damaged x lf they show any damage replace them HU13002BS1 C Rear Brake Plates Replacement e Disassemble the internal wet brake see Brakes chapter e Replace the steel pressure plates steel plates and friction plates in accordance with the specified interval Rear Brake Lever Free Play Inspection e Check the rear brake lever free play A O Pull the rear brake lever lightly until the brake is applied xIf the play is incorrect adjust it Rear Brake Lever Free Play Standard 1 2mm 0 04 0 08 in Rear Brake Pedal Free Play Inspection e Check the brake pedal free play A O Depress the brake pedal lightly by hand until the brake is applied xIf the free play is incorrect adjust it Brake Pedal Free Play Standard 15 25 mm 0 6 1 0 in PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Rear Brake Lever and Pedal Free Play Adjustment NOTE O Since the rear brake lever and pedal free play adjust ments aff
241. per Front Cover Air Cleaner Cover see Air Cleaner Cover Installation Seat see Seat Installation FRAME 15 7 H004005BS1 15 8 FRAME Fenders Rear Fender Removal e Remove Seat see Seat Removal Bolts and Collars A both side Bolts and Plats B both side e Remove Bolts and Collars A Tank Cap Cover B e Remove Fuel Tank Cap A Rear Fender e Install the fuel tank cap at once Rear Fender Installation e Remove the fuel tank cap e Install Rear Fender Fuel Tank Cap e Install the removed parts FRAME 15 9 Covers Side Inner Cover Removal e Remove Air Cleaner Cover see Air Cleaner Cover Removal Screws and Collars A Side Inner Cover B Side Inner Cover Installation e Install Collars A Screws B Air Cleaner Cover see Air Cleaner Cover Installation SS EN V ioosoosss c Air Cleaner Cover Removal e Remove Seat see Seat Removal Knobs A Air Cleaner Cover B Air Cleaner Cover Installation e Insert the tabs A of the cover into the recesses both sides e Install the removed parts 15 10 FRAME Covers Radiator Cover Removal e Remove Screws and Collars A Quick Rivet B Radiator Cover C Guards Front Guard Removal e Remove Front Guard Bolts A Front Guard B Front Guards Installation e Install the front guard e Tighten the front guard bolts Engine Bottom Guard Removal e Remove Bolts A Engine Botto
242. pliers Radiator Fan Fuse Removal e Remove Seat see Frame chapter Fuse Case Cover A e Pull out the fuse from the fuse case Spare Fuse B Main Fuse Inspection e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP19040181 C Fuses Radiator Fan Fuse Inspection e Remove the fuse see Radiator Fan Fuse Removal e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Fuse Element A Blown Element B CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components ELECTRICAL SYSTEM 16 71 GP20000BSi 16 72 ELECTRICAL SYSTEM Wiring Diagram 12V45
243. r A rod can be inserted through the lower hole of the hous ing and into contact with driven gear This may help to hold it still The difference between the highest and low est gauge reading is the amount of backlash If the backlash is not within the limit replace the shim s at the driven bevel gear Change the thickness a little at a time e Recheck the backlash and readjust as necessary Output Bevel Gear Backlash Standard 0 05 0 11 mm 0 0020 0 0043 in at output drive shaft spline 11 20 FINAL DRIVE Output Bevel Gears Tooth Contact Adjustment O Tooth contact location is influenced by drive gear position more than by driven gear position e Clean any dirt and oil off the bevel gear teeth e Apply checking compound to 4 or 5 teeth on the output driven bevel gear NOTE O Apply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear O The checking compound must be smooth and firm with the consistency of tooth paste O Special compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use this for checking the bevel gears e Turn the output driven shaft for 3 or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear shaft e Check the drive pattern and coast pattern of the bevel gear teeth The toot
244. r Rotor New Circlip ENGINE LUBRICATION SYSTEM 7 11 Oil Pump e Check to see that the dowel pins A are in place e Apply engine oil to the oil pump hole B e Install the oil pump drive chain A with the oil pump as sembly B e Tighten Torque Oil Pump Bolts C 8 8 N m 0 90 kgf m 78 in Ib e Install Upper Chain Guide A Face the tab B downward Lower Chain Guide C and Collar D e Tighten Torque Chain Guide Bolts 8 8 N m 0 90 kgf m 78 in Ib H806000BSi e Apply grease to the O ring A e Install Pin B Spring C O ring Oil Pump Drive Chain Tensioner Bolt D e Tighten Torque Oil Pump Drive Chain Tensioner Bolt 25 N m 2 5 kgf m 18 ft lb H806001BSi 7 12 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal Engine Left Side Oil Pipe e Remove Alternator Cover see Electrical System chapter Oil Pipe Bolts A Oil Pipe B Oil Pump see Oil Pump Removal Oil Pipe Bolts C Oil Pipe D Engine Right Side Oil Pipe e Remove Drive Pulley see Torque Converter chapter Plate Bolts A Plate B e Remove Oil Pipe Bolt A Oil Pipe B Engine Inside Oil Pipe e Remove Cylinder Head see Engine Top End chapter Oil Pipe A ENGINE LUBRICATION SYSTEM 7 13 Oil Pipe Oil Pipe Installation e Replace the O ring A with new ones e Apply engine oil to the O rings before installation e Tighten Torque Oil Pipe
245. rankshaft Connecting Rods Connecting rod bend Connecting rod twist Connecting rod big end side clearance Connecting rod big end bearing insert crankpin clearance Crankpin diameter None O Connecting rod big end inside diameter Marking Marking None O Connecting rod big end bearing insert thickness Brown Yellow Green 0 16 0 46 mm 0 0063 0 0181 in 0 028 0 052 mm 0 0011 0 0020 in 39 984 40 000 mm 1 5742 1 5748 in 39 984 39 992 mm 1 5742 1 57449 in 39 993 40 000 mm 1 57452 1 5748 in 43 000 43 016 mm 1 6929 1 6939 in 43 000 43 008 mm 1 6929 1 69323 in 43 009 43 016 mm 1 69326 1 6935 in 1 482 1 486 mm 0 05835 0 05850 in 1 486 1 490 mm 0 05850 0 05866 in 1 490 1 494 mm 0 05866 0 05882 in TIR 0 2 100 mm 0 008 3 94 in TIR 0 2 100 mm 0 008 3 94 in 0 7 mm 0 028 in 0 09 mm 0 0035 in 39 97 mm 1 5736 in Connecting rod big end bearing insert selection Con rod Big End Crankpin e i Bearing Insert Bore Diameter Diameter Marking Marking Size Color Part Number None O 92028 1963 None Ione Yellow 92028 1962 O O O None Green 92028 1961 Crankshaft runout TIR 0 04 mm 0 0016 in or less TIR 0 10 mm 0 0039 in Crankshaft main journal diameter 42 Side 41 984 42 000 mm 1 6529 1 6535 in 41 96 mm 1 652 in Crankshaft main bearing bore diameter 42 Side 42 025 4
246. re off the ground e Remove the front wheels and turn the handlebar fully to one side e Set up a dial gauge against the disc A and measure the disc runout If the runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 2 mm 0 008 in or less Service Limit TIR 0 3 mm 0 012 in HLO9001BS1 C Brake Hoses Brake Hose Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Hose Replacement e Refer to the Brakes in the Periodic Maintenance chapter BRAKES 12 17 12 18 BRAKES Rear Brake Lever Pedal and Cables Brake Pedal Position Inspection e Check that the brake pedal B is in the correct position as shown A Converter Cover Pedal Position C Standard 35 40 mm 1 38 1 57 in x lf it is incorrect adjust the brake pedal position Brake Pedal Position Adjustment e Loosen the locknut A and turn the adjusting bolt B until the brake pedal is correctly positioned e Tighten the locknut e Check the brake pedal free play see Brakes in the Peri odic Maintenance chapter Rear Brake Lever Free Play Inspection e Refer to the Brakes in the Periodic Maintenance chapter Brake Pedal Free Play Inspection e Refer to the Brakes in the Periodic Maintenance chapter Rear Brake Lever and Pedal Free Play Adjustment e Refer to the Brakes in the Periodic Maintenance chapter Brake Pedal Removal e Remove Right Foot see Frame chapter e Loosen the l
247. require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners of Engine Parts Threads dia Mark of Torque mm bolt head N m kgf m ft lb 5 4T 19 23 inb 6 9T 1 2 1 5 104 130 in lb 6 7T 0 80 1 0 69 87 in lb 6 4T 0 40 0 50 35 43 in lb 8 7T 13 16 8 4T 87 122 in lb 10 7T 29 33 10 4T 14 17 Basic Torque for General Fasteners of Frame Parts Threads dia Torque mm N m kgf m ft Ib 5 3 4 4 9 0 35 0 50 30 43 in Ib 6 5 9 7 8 0 60 0 80 52 69 in Ib 8 14 19 10 0 14 10 25 34 19 0 25 12 44 61 33 45 14 73 98 54 72 16 115 155 83 155 18 165 225 17 23 125 165 20 225 325 23 33 165 240 Specifications PERIODIC MAINTENANCE 2 11 Item Standard Service Limit Fuel System Throttle lever free play Air cleaner element oil 2 3 mm 0 08 0 12 in High quality foam air filter oil Engine Top End Valve clearance Exhaust Inlet 0 20 0 25 mm 0 0079 0 0098 in 0 10 0 15 mm 0 0039 0 0059 in Converter System Belt height Parallel portion Belt deflection 1 16 3 48 mm 0 0457 0 1370 in 0 64 mm 22 27 mm 0 87 1 06 in Engine Lubrication System Engine oil Type Viscosity Capacity API SF or SG API SH or SJ with JASO MA class SAE10W 40 1 7 L 1 80 US qt When filter is not removed 1
248. rking area this includes any ap pliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetor CAUTION Do not use compressed air on an assembled carbu retor the float may be crushed by the pressure and the vacuum piston diaphragm may be damaged Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged Disassemble the carburetor and clean all the metal parts in a carburetor cleaning solution Rinse the parts in water and dry them with compressed air Blow through the air and fuel passages with compressed air Remove the float valve spray cleaning solution from the valve seating surface into the fuel passage and clean the strainer press fitted with compressed air A e Assemble the carburetor see Carburetor Assembly FUEL SYSTEM 3 23 Carburetor Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under cer
249. rranty 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 eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructi
250. screw ing the drive pulley puller bolt B clockwise while holding the drive pulley with the drive pulley holder C Special Tool Drive Pulley Puller Bolt 57001 1429 CONVERTER SYSTEM 6 13 6 14 CONVERTER SYSTEM Drive Pulley Drive Pulley Disassembly e Hold the drive pulley holder A and drive amp driven pulley holder B in a vise so that the upper surface on the holder is 7 mm 0 28 in C above the vise Special Tools Drive amp Driven Pulley Holder 57001 1412 Drive Pulley Holder 57001 1473 e Set the pulley onto the pulley holder e Remove Drive Pulley Cover Bolts A Drive Pulley Cover B e Remove Spring A Spacer e Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 e Turn the wrench clockwise and remove the spider with the movable sheave NOTE O The spider has left hand threads Turn the wrench clockwise for loosening CONVERTER SYSTEM 6 15 Drive Pulley e Remove Spider A Shoes B Nuts C Ramp Weight Pin D Ramp Weight E Movable Sheave F Fixed Sheave G HS06000B52 C Drive Pulley Inspection x lf the sheave surfaces A appear damaged replace the sheaves x lf the cover bushing is damaged or worn replace the drive pulley cover Cover Bushing Inside Diameter A Standard 27 985 28 085 mm 1 1018 1 1057 in Service Limit 28 12 mm 1 107 in 6 16 CONVERTER SYSTEM
251. se Routing section in Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose and Fuel Filter Replacement A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the air cleaner cover see Frame chapter e Turn the fuel tap to the OFF position e Remove Clamps A Clamp Fuel Tank Side Fuel Hoses B Fuel Filter C e Replace the fuel hoses and fuel filter with a new one e When installing the fuel hose route the hose according to Cable Wire and Hose Routing section in Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed e Fit the fuel hose A onto the pipe fully and install the clamps B beyond the raised rib C HUOS001BS1 C PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Cooling System Radiator Cleaning CAUTION Clean the radiator screen and the radiator in ac cordance with
252. sen once and tighten again when the slot goes past the nearest hole Rear Hub Disassembly Assembly e Do not press the hub bolts A out lf any hub bolt is damaged replace the hub B and bolts as a unit HJO8OG5BS1 FINAL DRIVE 11 1 Final Drive TABLE OF CONTENTS Exploded VIOW eege E eed aie ade E E 11 2 SD POCITIC le 11 6 Special O Sii ERE 11 7 Output Bevel Gears A 11 9 Output Drive Bevel Gear Removal nnns 11 9 Output Drive Bevel Gear Installaton Ree 11 9 Output Drive Bevel Gear Disassembly coooomononcccnncncnnnnnnnccccnn conc nnnannnnnnn rre 11 10 Output Drive Bevel Gear Asserribly ie ill 11 12 Output Driven Bevel Gear Removal eee 11 13 Output Driven Bevel Gear Installatton HR 11 14 Output Driven Bevel Gear Disassembly cccceeeeeeeeeeeneeeeeeeeenenseeeeceeeeeeeeeseesenseeeeee 11 14 Output Driven Bevel Gear Assembly oooooocioconnicccccccccnononancoconecnnnnnnnnnnnnnr rre 11 16 Output Bevel Gears Adjustment oooooonnncicicocononnnnanccncncnononnnnnccccnnnnnnnnnnnnnnanrrr eran 11 17 Bevel Gears Inspechon nnn a a a nn nnne nsns Cam Damper Inspection ccccccccncnnnonnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnness Propeller Sai A as Propeller Shaft Hemoval enne nnrnnnnnnnn nnns EEEE Propeller Shaft Installation Propeller Shaft Joint Boot Inspection Propeller Shaft Inspection Rea Axle t peu e nt
253. spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Igniter trouble Pickup coil trouble Ignition coil trouble Battery voltage low Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Starter plunger stuck open Air cleaner clogged poorly sealed or miss ing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Troubleshooting Guide Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Other Carburetor vacuum piston doesn t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Final gear case oil viscosity too high Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Pickup coil trouble Igniter trouble Ignition coil trouble Fuel air mixture incorrect Main jet clogged or wrong size Jet
254. t 57001 1129 e Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole B Needle Bearing C Needle Bearing Insert it from outside e Apply engine oil to the bearings e Install the position plates D e Apply a non permanent locking agent to the position plate mounting screws E e Tighten Torque Position Plate Mounting Screws 4 9 N m 0 50 kgf m 43 in Ib HIOA013BS1 e Grease the lip A of the oil seal B and press the seal 3 mm 0 12 in C inwards from the end of the boss e Be sure the following parts are in place in the right crankcase half Crankshaft Transmission Shafts and Shift Rod A Oil Tube B Oil Screen C O ring Apply Grease D Dowel Pins E e Apply liquid gasket A to mating surface of the left crankcase half Sealant Three Bond 1215 Gray e Apply after must be assembled with in 20 min Dd a HIO4009BS1 9 12 CRANKSHAFT TRANSMISSION Crankcase e Apply a non permanent locking agent to the area C 12 mm 0 47 in except for the tip D 2 3 mm 0 08 0 12 in Left Crankcase Bolt M8 3 e Tighten the right and left crankcase bolts M8 following the tightening sequence 1 8 Torque Crankcase Bolts M8 20 N m 2 0 kgf m 14 ft lb 1 2 5 6 L 75 mm 2 95 in 3 4 7 8 L 110 mm 4 33 in e Tighten Torque Crankcase Bolts M6 9 8 N m 1 0 kgf m 87 in
255. t A e Tighten the reverse lock cable locknut B Torque Reverse Lock Cable Locknut 12 N m 1 2 kgf m 104 in Ib e Tighten the locknuts securely Transmission Removal e Remove the shift lever see Shift Lever Removal e Split the crankcase see Crankcase Disassembly e Remove Reverse Lock Cable Bracket Mounting Bolts A Reverse Lock Cable Bracket B Shift Shaft Cover Bolt C Shift Shaft Cover D e Remove Shift Shaft Spring Bolt A Shift Shaft B e Remove Reverse Idle Shaft A Spacer B Reverse Drive Gear C Needle Bearing and Spacer Shifter D Shift Rod E 9 22 CRANKSHAFT TRANSMISSION Transmission e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Spacer A Idle Gear Assembly B and Spacer Washer and Spacer C High Gear D e Remove Needle Bearings A e Remove the driven shaft B from the crankcase using a press Transmission Installation e Insert the driven shaft in the crankcase until it is bottomed using a press e Apply engine oil to the needle bearings and install them e Install Spacer and Idle Gear Assembly A Spacer B High Gear C CRANKSHAFT TRANSMISSION 9 23 Transmission e Install Spacer Toothed Washer A Circlip Special Tool Outside Circlip Pliers 57001 144 e Apply engine oil Shift Rod A and Shift Fork Ear B Needle Bearing C e Install Shift Rod with Shifter Spacer D Needle
256. t the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires TABLE OF CONTENTS Exploded VIEW aiat ea A eet E te 10 2 A LO EE 10 4 ele Mt RE 10 5 de Re e un n E 10 6 Toe in Inspection tcc ere aa 10 6 Joe FAG SUVS IN i cs eae on eae tence fiac istic ag nate cen m DD ear edt uns 10 7 cciam 10 8 Wheel Removal o ee ENTREE ENEE REMAIN REM deg 10 8 Wheel Installaton rerne ae ee aeree a aaee aani a an E rae eE a ee ET 10 8 Wheel Rim REH tt ri tdi aAA et Gal eee aa 10 8 Wheel Rim Replacement cion dni 10 9 RI Tire Inspection Front AUD EE EFrOntiHUb Removal Eu ea etui a eet feasted sbvtactasechines 10 12 ErontEub Installationzzcs eR ene t ni E e Rees 10 12 Front Hub Disassembly Assembly 4 iii ein Rabe lees 10 12 Rear AUD TR EP A ide 10 13 Rear e leg En ne NEE 10 13 Rear Hub Installation tme eR Rem 10 13 Rear Hub Disassembly Assembly eeee esent nnns 10 13 10 2 WHEELS TIRES Exploded View HJ02007BN5 WHEELS TIRES 10 3 Exploded View No Fastener FOrque Remarks N m kgf m ft Ib 1 Wheel Nuts 58 2 Front Axle Nuts 38 3 Tie rod End Nuts 31 4 Tie rod Adjusting Locknuts 16 5 Rear Axle Nuts 195 6 Tie rod Install the width across flats side to the knuckle arm W Apply water or soap and water solution R Replace
257. t the transmission in neutral and rotate the driven pul ley to allow the belt to return to the top A of the sheaves before measuring belt deflection Drive Belt Inspection e Refer to the Converter System in the Periodic Mainte nance chapter Drive Belt Deflection Inspection e Refer to the Converter System in the Periodic Mainte nance chapter 6 12 CONVERTER SYSTEM Drive Belt Drive Belt Deflection Adjustment e Refer to the Converter System in the Periodic Mainte nance chapter Drive Pulley Drive Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Removal e Be sure to remove the three cover bolts A in the positions shown and install the drive pulley holder B in the position shown Note the holder s relative position to the arrow mark C e Tighten the three bolts Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in lb CAUTION Be sure to install three bolts in the specified posi tions shown Otherwise the tapped holes will be damaged Special Tool Drive Pulley Holder 57001 1520 e Loosen the drive pulley bolt D left hand threads hold ing the drive pulley with the drive pulley holder e Remove the drive pulley bolt two washers and the stepped washer but do not remove the drive pulley holder yet NOTE O The drive pulley bolt has left hand threads Turn the wrench clockwise for loosening e Remove the drive pulley A from the crankshaft by
258. tain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Before disassembling the carburetors check the fuel level see Fuel Level Inspection e Turn the throttle cable pulley A to check that the throttle a aey butterfly valve B moves smoothly and return back with the spring tension x lf the throttle valve does not move smoothly replace the carburetor A NA e Y 25 e Disassemble the carburetors see Carburetor Disassem bly e Clean the carburetor see Carburetor Cleaning e Check the vacuum piston diaphragm A and the O rings B on the float bowl pilot screw coasting enricher and starter plunger cap x If any of the diaphragm or O rings are not in good condi tion replace them 3 24 FUEL SYSTEM Carburetor e Check the plastic tip A of the float valve needle It should be smooth without any grooves scratches or tears If the plastic tip is damaged C replace the float valve B e Push the rod D in the other end of the float valve needle and then release it E x lf it does not spring out replace the float valve e Check the tapered portion A of the pilot screw B for wear or damage x lf the pilot screw is worn or damaged on the tapered por tion it will prevent the engine fro
259. tallation cccccceeccee cece cece cece eeee eee tee sge seed ceeeeeeeeeeeeeeeeeeeeeeees 13 7 Rear Shock Absorber te tee Uu re e pe REESE POLI ERR e Ce e REP DEN ah 13 7 Compression Damping Adjustment AA 13 7 Rear Shock Absorber Removal ccociinciinininicocccocccncccnncrcnnn nano rn rr rre 13 8 Rear Shock Absorber Installation ooooocccccccnnccnnccnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnos 13 8 Rear Shock Absorber Preload Adjustment AAA 13 8 Rear Shock Absorber Inspection cecccecceee cee e cece eeee eect eee cece teed seeeeeeeeeeeeeeeeeeeeeeeeneeeeees 13 9 Rear Shock Absorber Scrapping occocccccccccccococonocnncccnncnnnnnnn cnn nr ran 13 9 SUSPENSION Viene 13 10 Suspension Arm Removal ccocccnnccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnss 13 10 Suspension Arm Installation ooonoonncccnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninenss 13 10 Suspension Arm Disassembly n di Re aus 13 10 Suspension Arm ASSIM Vestir pe operta epos 13 11 eei e Swingarm te Al s ta ce e do neca un cob Goll AG te bo sa ae ats Swingarm Installation Swingarm Disass em Diy D 13 13 ee ele EE 13 14 Swingarm Bearing InspectlOn uis eee dod iced cia 13 15 Swingarm Bearing Lubrication E 13 15 13 2 SUSPENSION Exploded View SUSPENSION 13 3 Exploded View No Fastener Torque Remarks N m
260. tat Housing Cover Bolts A Thermostat Housing Cover B Thermostat Installation e Be sure to install the O ring A on the housing cover e Install the ground wire terminal A as shown e Tighten Torque Thermostat Housing Cover Bolts B 8 8 N m 0 90 kgf m 78 in Ib e Add coolant see Cooling System in Periodic Mainte nance chapter Thermostat Inspection e Remove the thermostat and inspect the thermostat valve A at room temperature x If the valve is open replace the valve with a new one HD08000BS1 C COOLING SYSTEM 4 17 Thermostat e To check valve opening temperature suspend the ther mostat A and an accurate thermometer B in a container of water with the heat sensitive portions C in almost the same depth NOTE O The thermostat must be completely submerged and the thermostat and thermometer must not touch the con tainer sides or bottom e Gradually raise the temperature of the water while stirring the water gently for even temperature Alf the measurement is out of the range replace the ther mostat Thermostat Valve Opening Temperature 69 5 72 5 C 157 162 F 6D09020252 C 4 18 COOLING SYSTEM Radiator Fan Switch Radiator Fan Switch Removal CAUTION The fan switch should never be allowed to fall on a hard surface Such a shock to the part can damage it e Drain the coolant see Cooling System in Periodic Main tenance chapter e Disconnect the fan sw
261. ted EES E Regular Service Every 90 days 1 Every Every 700 km 1 After 10 100 mi or hrs or when belt See 100 km indicator ade 60 mi light turns pag of use on 100 hrs of use whichever OPERATION comes first ENGINE Converter drive belt wear inspect 2 24 Converter drive belt deflection inspect 2 25 Air cleaner inspect 2 16 Throttle lever play inspect 2 15 Cable adjustment 2 28 Idle speed inspect 2 15 Valve clearance inspect 2 22 Fuel system cleanliness inspect 2 16 Engine oil change 2 27 Oil filter replace 2 27 Spark plug clean and gap 2 37 Spark arrester clean e 2 24 Fuel hoses and connections inspect e 2 17 Fuel hose and fuel filter replace 4 years 2 18 Radiator clean e Radiator hoses and connections check Coolant change Coolant filter of carburetor clean CHASSIS Joint boots inspect Rear brake pedal and lever play inspect Rear brake plates change Bolts and nuts tighten 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY OPERATION First Service Regular Service Every 90 days 1 Every Every 700 km 1 After 10 100 mi or hrs or when belt 100 km indicator 60 mi light turns of use on 100 hrs of use whichever comes first Front brake pad wear inspect Brake light switch
262. tem for straightness steer ing stem clamps and tie rod bearings lf you feel looseness or if the steering rattles as it turns check the tightness of the steering bolts and nuts e Tighten loose bolts and nuts to the specified torque see Steering chapter and check the steering action again x lf the steering action does not change by tightening the bolts and nuts inspect the steering stem clamps steer ing stem bearings tie rod bearings and steering knuckle joints Tie Rod End Inspection e Visually inspect the grease seal A of tie rod end lf damage wear or deterioration is found replace the tie rod end PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning Inspection e Remove the spark plug see Electrical System chapter e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool x lf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge xIf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Brake Light Switch Inspection e Turn on the ignition switch e Chec
263. ter Pin Steering Suspension Handlebar Clamp Bolts Stem Clamp Bolts Stem Bearing Housing Bolts Tie Rod End Nuts and Cotter Pins Tie Rod Adjusting Sleeve Locknuts Shock Absorber Mounting Bolts and Nuts Suspension Arm Pivot Bolts Engine Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Others Footrest Mounting Bolts Throttle Mounting Bolts FUEL SYSTEM 3 1 Fuel System TABLE OF CONTENTS Exploded View Specifications sseeseesss Special Tools Throttle Lever and Cable Throttle Lever Free Play Inspection suesssssussss Throttle Lever Free Play Adjustment Throttle Case Removal Disassembly Throttle Case Assembly Installation Throttle Cable Installation Throttle Case Inspection Throttle Cable Lubrication Throttle Cable Inspection Choke Lever and Cable Choke Lever Free Play Check Choke Lever Free Play Adjustment Choke Lever and Cable Removal Choke Lever and Cable Installation Choke Cable Lubrication Choke Cable Inspection Carburetor eem Idling Speed Inspection Idle Speed Adjustment Pilot Screw Adj
264. ter pin with a new one e Route the brake cables according to the Cable Wire and Hose Routing section in Appendix chapter e Install the parts removed see the appropriate chapter e Adjust the brake pedal and rear brake lever Brake Cable Lubrication Whenever the brake cable is removed lubricate the cable as follows e Lubricate the cable with a penetrating rust inhibitor Brake Pedal Shaft Removal e Remove Swingarm see Suspension chapter Brake Pedal see Brake Pedal Removal Brake Cable see Brake Cable Removal Reverse Lock Cable see Crankcase Transmission chapter e Remove the brake return spring A with pliers e Remove the brake pedal shaft B Brake Pedal Shaft Installation e Apply grease to the tip of the brake pedal shaft A e Install Brake Return Spring Brake Pedal Shaft e Hook the brake return spring end B to the projection C turn the spring clockwise and hook the other end of the spring D to the brake pedal shaft E with pliers e Install Brake Cable see Brake Cable Installation Reverse Lock Cable see Crankcase Transmission chapter Brake Pedal see Brake Pedal Installation Swingarm see Suspension chapter HL11008BS1 C HL11008BS1 C Internal Wet Brake Internal Wet Brake Disassembly e Remove Rear Final Gear Case see Final Drive chapter Gasket Screws A Gasket B Dowel Pins C e Remove Steel Pressure Plates A and Steel Plates Friction Plates B
265. th shock absorbers as a set If only one unit is replaced and the two are not balanced vehicle instability at high speed may result Front Shock Absorber Preload Adjustment The spring adjusting sleeve A on the rear shock ab sorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions If the spring ac tion feels too soft or too stiff adjust it in accordance with the following table Spring Action Position Spring Setting Load Terrain Speed 1 Force Soft Light Smooth Low 2 STD 1 i A f 3 4 y y y y y 5 Stronger Hard Heavy Rough High e Turn the adjusting sleeve on shock absorber to the de sired position with the hook wrench A Owner s Tool 92110 1129 Front Shock Absorber Removal e Support the vehicle on a stand or a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e While holding the rear wheels remove the lower and up per shock absorber mounting bolts A nuts and wash ers e Remove the front shock absorber B SUSPENSION 13 7 Shock Absorbers Front Shock Absorber Installation e Apply plenty of grease to the inside of the bushing sleeve and oil seals e Install Rubber Bushing A Bushing B Sleeve C Oil Seals D e Tighten Torque Front Shock Absorber Mounting Nuts 42 N m 4 3 kgf m 31 ft lb HMO4005BS1 Rear Shock Absorber To suit to various riding conditions th
266. the vacuum piston slides up and down smoothly without bind ing in the carburetor bore HC06004BS1 C Carburetor e Fit the projection A of the vacuum piston diaphragm in the recess B of the body e After installing the upper chamber cover check to make sure that the vacuum piston moves smoothly in the car buretor body Carburetor Separation e Remove Carburetor see Carburetor Removal Carburetor Joining Bolts A and Nuts e Separate the carburetors Carburetor Joining e The center lines of the carburetor bores must be parallel both horizontally and vertically If they are not loosen the mounting screws and align the carburetors on a flat surface e Retighten the carburetor joining bolts e Visually synchronize the throttle butterfly valves OCheck to see that all throttle valves open and close smoothly without binding when turning the pulley OVisually check the clearance A between the throttle valve and the carburetor bore in each carburetor lf there is a difference between two carburetors turn the balance adjusting screw B to obtain the same clearance e Install the carburetors see Carburetor Installation e Adjust the synchronization see Synchronization Adjust ment FUEL SYSTEM 3 21 3 22 FUEL SYSTEM Carburetor Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there are no sparks or flame any where near the wo
267. the valve stem e Install each spring so that the closed coil end faces down wards O The green paint on the spring faces upwards Valve Stem A Oil Seal B Spring Seat C Spring D Retainer E Split Keepers F Closed Coil End G HE13000BS2 C Valves Valve Guide Removal e Remove Valve see Valve Removal Valve Stem Oil Seal e Hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 5 57001 1203 Valve Guide Installation e Lightly oil the valve guide outer surface e Using the valve guide arbor drive the valve guide until its flange touches the cylinder head Special Tool Valve Guide Arbor 5 57001 1203 e Ream the valve guide with the valve guide reamer A if may be necessary to ream the guide even if the old guide is reused Special Tool Valve Guide Reamer 5 57001 1204 Valve to Guide Clearance Measurement If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move C the stem back and forth to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first If the reading exceeds the service l
268. the movable sheave clockwise e Measure the resulting clearance A between the shoe B and the post C on the movable sheave at two positions as shown Arrow Mark D x lf the clearance is not within the specified range adjust it according to following chart Clearance Present Shoes Measurement Part Number Less than 0 15 mm 49048 1087 7 2 mm 0 283 in 0 0059 in 49048 1088 7 3 mm 0 287 in 0 15 0 30 mm no change 0 0059 0 0118 in 49048 1089 7 4 mm 0 291 in standard clearance 49048 1090 7 5 mm 0 295 in 49048 1091 7 6 mm 0 299 in Over 0 30 mm 49048 1092 7 7 mm 0 303 in 0 0118 in 49048 1093 7 8 mm 0 307 in 49048 1094 7 9 mm 0 311 in 49048 1095 8 0 mm 0 315 in e Check that the movable sheave A moves smoothly after the shoe side clearance adjustment O The movable sheave must move freely towards the fixed sheave B lf the movable sheave does not move smoothly readjust the shoe side clearance Drive Pulley Assembly e Install the ramp weight A as shown e Tighten Torque Ramp Weight Nuts B 6 9 N m 0 70 kgf m 61 in Ib e Check that the ramp weights swing smoothly HSO6002BS2 C Drive Pulley e Hold the fixed sheave A with the drive pulley holder B in a vise Special Tool Drive Pulley Holder 57001 1473 e Clean the threads of the fixed sheave and spider e Install Movable S
269. the seal of the G W front or BL W rear lead in the ignition coil D until the needle reaches the terminal in the ignition coil O Install a new spark plug E into the spark plug cap and ground it to the engine A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch ON rotate the engine for 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one ignition coil Ignition Coil Primary Peak Voltage Standard 50 V or more e Repeat the test for the other ignition coil x lf the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection x If the ignition coils and crankshaft sensor are normal see the Ignition System Troubleshooting chart Crankshaft Sensor Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Mounting Bolts A Plate B Crankshaft Sensor C HP10025BS1 Ignition System Crankshaft Sensor Installation e Install Stator Coil Leads A Plate B Crankshaft Sensor C e Tighten Torque Crankshaft Sensor Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib e Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Le
270. thout prior notice and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2003 Kawasaki Heavy Industries Ltd First Edition 1 Feb 28 2003 M LIST OF ABBREVIATIONS A ampere s Ib pounds s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celcius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable regulations of the California Air Resources Board 1 Crankcase Emission Control System
271. tightening sequence 1 8 Torque Final Gear Case Right Cover Bolts M8 24 N m 2 4 kgf m 17 ft Ib Final Gear Case Right Cover Bolts M10 49 N m 5 0 kgf m 36 ft Ib Final Gear Case Right Cover Bolts M12 94 N m 9 6 kgf m 69 ft Ib e Install Final Gear Case Left Cover Rear Axle see Rear Axle Installation Oil Seal Installation e Press the oil seals in the right and left covers to the spec ified positions as shown A Left Cover B Outside Oil Seal C 31 5 32 5 mm 1 24 1 28 in D Inside Oil Seal E 21 3 22 3 mm 0 84 0 88 in OUse the oil seal driver A for the outside oil seals of the right and left covers Special Tool Oil Seal Driver 57001 1487 Final Bevel Gear Adjustment O The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash related parts be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth con tact by replacing shims O The amount of backlash is influenced by the ring gear position more than by the pinion gear position O Tooth contact locations is influenced by the pinion gear position more than by the ring gear position HK18001BS1 C HK18002BS1 C HI P Final Bevel Gear Adjustment Procedure Adjust gear backlash Adjust tooth contact pattern
272. turer 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 o The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of 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 vehicle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION PL
273. u ne a eet du E e E eet Rear Axle Removal icit ect i eA n ka PRX Ea PATERE EEXR ERAN E EREE VER TR VENAE GR AER ENEE Rear Axle InstallatiOris 55 ceret eere E oe ane erbe e eet Ph etie et alanine Ball zi RI npe Rear Axle Runout Inspechon s i a e nennen nennen nennen nenne 11 25 IERT 11 26 Final Gear Case Oil Level Inspection ccecccee cece cece cece eeee tees eeee tees eeeeeeeeseeeeseeeeeeeeneeeeees 11 26 Final Gear Case Oil Change acicate daros IA ME cuc PRO AE E age 11 26 Final Gear Case Removal ssssssssssssssssssssseeeeemeeem eene nen nennen eren en nennen 11 26 Final Gear Case lnstallaton eene nennen nens 11 27 Final Gear Case Disassembly i io irte erret itk Cu bia nuda Dang UHR Gen 11 28 Final ear Gase Assembly fee Des fra ot pencas ao e bf piter tu Sem etae tenete dle uada 11 29 Oil Seal Installati n Asir arnee aa e aea eae EE E a AE aea eaa anaE i 11 30 Final Bevel Gear AQUUSs Mets ni tai 11 30 Pinion Gear Unit DisassoMmblVo vacia ali ita 11 33 Pinion Gear Unit Assembly di A Seege 11 34 Bevel Gear A EE 11 34 Bearingiand Olla EA ee Ee 11 36 Ball or Needle Bearing InSpectiON oooomnmcononnononcnrnnnnnnncnnrnncnnnn nan rre 11 36 Oil S al In ee 11 36 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View No Fastener morgue Remarks N m kgf m ft Ib 1 Output Driven Bevel Gear Housing Bolts 26 20 2 Output Drive Bevel Gear Housing Bo
274. ust be connected to wires of the same color 1 4 GENERAL INFORMATION Before Servicing Two Color Electrical Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Y Rass Yellow Red 6B020601w1 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification KSV700 A1 Left Side View W030018 P KSV700 A1 Right Side View HECIBO1S P 1 6 GENERAL INFORMATION General Specifications Ground clearance Rear final gear case Center of frame Seat height Dry mass Curb mass Front Rear Fuel tank capacity Items KSV700 A1 Dimensions Overall length 1 985 mm 78 15 in Overall width 1 195 mm 47 05 in Overall height 1 170 mm 46 06 in Wheelbase 1 285 mm 50 60 in 160 mm 6 30 in 245 mm 9 65 in 850 mm 33 46 in 234 kg 516 I
275. ustment Service Fuel Level Inspection Service Fuel Level Adjustment Carburetor Synchronization Inspection sssessususss 3 3 3 3 0 Y OM 3 3 3 O O qo 3 10 3 11 3 11 Pow ah a os C9 Q Gi CO Co ai ai ai C9 m IX Dx 3 X LX 0X LX X RWWWWWHNYD DY 1 zx al Carburetor Synchronization Adjustment Fuel System Cleanliness Inspection Carburetor Removal Carburetor Installation Carburetor Disassembly Carburetor Assembly Carburetor Separation Carburetor Joining Carburetor Cleaning Carburetor Inspection Air tla Air Cleaner Element Removal Air Cleaner Element Cleaning and Inspection Air Cleaner Draining Air Cleaner Housing Removal Air Cleaner Housing Installation Fuel Tank Fuel Tank Remowval Fuel Tank Installation Fuel Tank Cleaning Fuel Tap Remowval Fuel Tap Installation Fuel Tap Inspection Fuel PUMP aeeie Fuel Pump Removal Pump Filter Cleaning Fuel Pump Installation Fuel Pump Inspection
276. ut and spring holder C e Remove Spring Seats A Spring B Thrust Plate C CONVERTER SYSTEM 6 21 6 22 CONVERTER SYSTEM Driven Pulley e Make match marks A and B on the sheaves so that it can be installed later in the same position Movable Sheave C Fixed Sheave D e Wipe off the molybdenum disulfide grease e Remove the four pins A with a thin standard tip screw driver B e Remove the movable sheave from the fixed sheave e Remove Spacer s A for Drive Belt Deflection Adjustment Driven Pulley Inspection Alf the sheave surfaces A appear damaged replace the sheaves CONVERTER SYSTEM 6 23 Driven Pulley e Replace the sheave with uneven wear on the belt con tacting surfaces Sheave Surface A Straight Edge B HS07008BSi lf the sheave bushings A are damaged or worn replace the movable sheave Sheave Bushing Inside Diameter Standard 40 000 40 039 mm 1 5748 1 5763 in Service Limit 40 079 mm 1 5779 in e Inspect seals for damage lf seals are damaged replace the movable sheave lf the splines A are damaged or worn replace the fixed sheave Alf the spring is damaged or worn replace the spring Spring Free Length A Standard 99 5 mm 3 92 in If the spring coils are distorted replace the spring j h AA ALTA LS Ff 6 24 CONVERTER SYSTEM Driven Pulley Driven Pulley Assembly e Clean off an
277. ween any two measurements Service Limit 82 09 mm 3 232 in or more than 0 05 mm 0 0020 in difference between any two measurements ENGINE TOP END 5 39 EN SS w SSSSSSXN GS A HE14003BS1 5 40 ENGINE TOP END Cylinder and Piston Piston Wear e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard Service Limit 81 949 81 964 mm 3 2263 3 2269 in 81 80 mm 3 220 in Piston Cylinder Clearance e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 030 0 057 mm 0 0012 0 0022 in Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance HE14004BS1 C GE16020881 C Standard Service Limit Top 0 040 0 080 mm 0 18 mm 0 0016 0 0032 in 0 0071 in Second 0 030 0 070 mm 0 17 mm 0 0012
278. with the thickness gauge Valve Clearance when cold HE100028S1 Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in lf the valve clearance is not correct adjust it see Valve Clearance Adjustment Valve Clearance Adjustment e Remove the valve adjusting caps e Loosen the locknut A and turn the adjusting screw B until the clearance is correct e Hold the adjusting screw from turning and tighten the lock nut to the specified torque Torque Valve Adjusting Screw Locknuts 12 N m 1 2 kgf m 104 in Ib e Recheck the clearance Alf the clearance is incorrect repeat the adjustment proce dure x lf the clearance is correct perform the adjustment proce dure on the other valve e Apply grease to the O rings A Torque Valve Adjusting Cap Bolts 8 8 N m 0 90 kgf m 78 in Ib 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Arrester Cleaning A WARNING To avoid burns wear gloves while cleaning the spark arrester Since the engine must be run during this procedure the muffler will become hot e Remove the drain plug A on the muffler e n an open area away from combustible materials start the engine with the transmission in neutral e Raise and lower engine speed while tapping on the muf fler with a rubber mallet until carbon particles are purged from the muffler A WARNING Do not run the engine in a closed area Exhaust
279. y scored or rusty Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts B 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 brake and brake fluid tem perature e Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber friction boots are not damaged lf the rubber friction boot is damaged replace the rubber friction boot lf caliper holder shaft is damaged replace the caliper holder shaft and rubber friction boot as a unit BRAKES 12 13 HL06000381 HLOGO008BSi C 12 14 BRAKES Brake Pads Brake Pad Removal e Remove the front wheel see Wheels Tires chapter e Detach the caliper from the disc see Caliper Removal e Draw out the clip A and remove the pad holder pin B e Remove the pad A on the outside e Push the holder B towards the piston and remove the pad C on the piston side Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Be sure that the anti rattle spring is in place e Install Brake Pads Pad Holder Pin and Clip O The clip must be outside of the pads Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brake will not function on the first application if
280. y grease or dirt on the movable and fixed sheaves and dry them with a clean cloth e Install Spacers A for Drive Belt Deflection Adjustment e Apply grease to the oil seal lips A e Press the oil seals B in the movable sheave assembly so that the oil seal surface is flush C with the sleeve end e Apply D molybdenum disulfide grease to the inner sur faces of the bushings e Align the match marks on the sheaves made when disassembled and the opening A and hole B will be matched easily e Apply molybdenum disulfide grease to the seating surface A of the pins and insert them into the holes in the mov able sheave HS07006BS1 C CONVERTER SYSTEM 6 25 Driven Pulley e Draw the movable sheave onto the fixed sheave and ap ply molybdenum disulfide grease of 1 g 0 035 oz to all openings A NOTE O Do not heap up the grease out of the openings e Check that the O rings A are in good condition xIf any of the O rings are damaged replace them e Apply grease to the O rings e Hold the drive pulley holder in a vise Special Tool Drive Pulley Holder 57001 1473 e Screw the guide bar of the spring holder set into the holder Special Tool Spring Holder Set 57001 1483 e Put the driven pulley A onto the guide bar e Put the thrust plate B so that the alloy side gray faces the movable sheave e Install Spring Seat C 18 5 mm 0 728 in Spring D Spring Seat E 9 3
281. y other electrical connections when the ignition switch is on or while the engine is running This is to prevent igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and igniter Use the standard regulator rectifier or the igniter will be damaged Spark Plug Removal Front Side e Remove Spark Plug Cap A Spark Plug B Rear Side e Remove Rear Fender see Frame chapter Air Cleaner Cover see Frame chapter Inner Side Cover see Frame chapter Clamp Screws A and Clamps Converter Exhaust Joint Duct B ELECTRICAL SYSTEM 16 33 Ignition System e Remove Spark Plug Cap A Spark Plug B Spark Plug Installation e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Fit the spark plug caps securely e Pull up the spark pug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning Inspection e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Inspection in the Periodic Main tenance chapter Ignition Coil Removal Front Side e Remove Spark Plug Cap A Primary Lead Connectors B Bolt C Ignition Coil D Rear Side e Remove Rear Fender see Frame chapter Air Cleaner Cover see Frame chapter Inner Side Cover see Frame chapter Converter Exhaust Joint Duct see Spark Plug Removal Rear Sid
282. ype and brand of oil that is already in the final gear case e Apply grease to the O ring e Be sure the O ring is in place Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft Ib Final Gear Case Oil Change e Refer to the Final Drive in the Periodic Maintenance chap ter Final Gear Case Removal e Remove Lower Rear Shock Absorber Mounting Bolts Nuts and Washers see Suspension chapter Rear Brake Cable Ends A see Brake chapter Final Gear Case Breather Hose B Rear Bottom Guard see Frame chapter FINAL DRIVE 11 27 Final Gear Case e Remove Brake Cable Mount Bolts A Brake Cam Lever Cover and Cable Mount B HKi18003BSi e Remove Final Gear Case Bolts A 10 Final Gear Case B Final Gear Case Installation e Install Spring A Dowel Pins B New Gasket C see Brake System chapter e Insert the pinion gear shaft of the final gear case in the plate assembly OAlign the splines by rotating the axle shaft e Tighten the final gear case bolts following the tightening sequence 110 Torque Final Gear Case Bolts 42 N m 4 3 kgf m 31 ft lb HK14000BS1 11 28 FINAL DRIVE Final Gear Case Final Gear Case Disassembly e Remove Final Gear Case see Final Gear Case Removal Final Gear Case Right Cover Bolts A Final Gear Case Right Cover Bracket B Final Gear Case Right Cover C HK18000BS1 C e Remove Shim s A Ring Gear B e Remove Pinion Gear Bearing

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