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2004 KX250F & RM-z250 Service Manual

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Contents

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2. sise 10 7 Rear Wheel Installation cggeceeeseeeeseeeeeeeeseeeseeeseeeees 10 8 Wheels Inspection seen 10 9 Spoke Tightness Inspection 10 9 Rim R nout INSp ctiOn session denim enaar arean Ers 10 9 Axle Inspection AE D CUT TR EN AE ER D PE EE Tire Removal Installation Hub Bearings Hub Bearing Removal surn inen ib 10 13 Hub Bearing instalation ess gt te te Ten etat a tests 10 13 Hub Bearing Inspection a rt ane de Re 10 13 10 2 WHEELS TIRES Exploded View 6J02017BW5 WHEELS TIRES 10 3 Exploded View re Fastener Remarks Spoke Nipple 19 in lb Front Axle Nut k 58 1 2 3 4 Rear Axle Nut 110 10 2802 Spokes Front Tire Rims Front Axle Swingarm 10 11 AL Apply Grease WL YX O O1 Front Axle Clamp Bolts 14 5 Rear Tire Rear Axle Tighten the two clamp bolts alternately two times to ensure even tightening torque Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim runout Axial 1 0 mm 0 039 in or less 2 mm 0 08 in Radial 1 0 mm 0 039 in or less 2 mm 0 08 in Axle runout 100 mm 0 1 mm 0 004 in 0 2 mm 0 008 in Tires Air Pressure Front and Rear Tires Standard tire Front 100 kPa 1 0 kgf cm 14 psi 80 100 21 51M
3. 5 12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e Remove Carburetor see Fuel System chapter Cap Bolt A Washer B e Remove the tensioner mounting bolts C and remove the chain tensioner body D Camshaft Chain Tensioner Installation e Replace the O ring A with new one and apply grease e Release the stopper and push the pushrod B into the tensioner body C fully e Install the tensioner body so that the stopper faces D up ward e Tighten the tensioner mounting bolts A Torque Camshaft Chain Tensioner Mounting Bolts 9 8 N m 1 0 kgf m 87 ft Ib e Install the spring B and rod C e Tighten the cap bolt D with the washer E Torque Camshaft Chain Tensioner Cap Bolt 20 N m 2 0 kgf m 15 ft lb
4. ELECTRICAL SYSTEM 16 19 Ignition System Crankshaft Sensor Peak Voltage Check e To check the peak voltage do the following procedures ODisconnect the connector of the magneto lead connector from the main harness NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder heaa OSet the hand tester to DC 10 V range OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connection Adapter Positive Green Lead C Adapter Negative Red Lead D OCrank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Peak Voltage 1 4 V or above WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock x lf the voltage is less than the specified check the crank shaft sensor 6P10124BS1 16 20 ELECTRICAL SYSTEM Ignition System Exciter Coil Peak Voltage Check e Disconnect the connector of the magneto lead connector from the main harness e To check the peak voltage do the following procedures NOTE OMeasure the vol
5. 4 2510 4mm 4 45 0 4mm GMO7012BW2 Needle Bearing Inspection xf there is any doubt as to the condition of either needle bearing replace the bearing and sleeve as a set 13 32 SUSPENSION Uni Trak Maintenance Uni Trak Linkage Inspection e Referto the Uni Trak Linkage Inspection in Periodic Main tenance chapter Tie Rod and Rocker Arm Sleeve Wear e Pull out the sleeves A of the tie rod and rocker arm e Measure the outside diameter of the sleeve lf the sleeve is worn past the service limit replace the sleeve Sleeve Outside Diameter Tie rod Standard 19 987 20 000 mm 0 7869 0 7874 in Service Limit 19 85 mm 0 781 in Rocker Arm Large Standard 19 987 20 000 mm 0 7869 0 7874 in Service Limit 19 85 mm 0 781 in Small Standard 15 995 16 000 mm 0 6297 0 6299 in Service Limit 15 85 mm 0 624 in Tie Rod and Rocker Arm Mounting Bolt Bend A bent bolt causes vibration poor handling and instabil ity e To measure the bolt runout remove the bolt place it in V blocks and set a dial gauge to the bolt at a point halfway between the blocks Turn A the bolt to measure the runout The amount of dial variation is the amount of runout lf runout exceeds the service limit replace the bolt Bolt Runout Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in 6M07001BS1 6M07013BS1 6M07002BS1 STEERI
6. ENGINE TOP END 5 13 Camshaft Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Cap A Flywheel Cap B e First bring the piston to the TDC of either the compres sion or exhaust stroke OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts 1 4 sequence numbers Camshaft Caps A e Remove Positioning Rings A e Disengage the Camshafts B from camshaft chain C e Staff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crank shaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could dam age both the chain and the sprocket 5 14 ENGINE TOP END Camshaft e Remove Bolt A Auto Decompressor B Spring Camshaft Installation e Install Spring A Auto Decompressor B Bolt C Torque Auto Decompressor Bolt 12 N m 1 2 kgf m 104 in Ib e Apply molybdenum disulfide oil to the ball bearing all cam and journal surfaces of the camshaft elf the camshaft is replaced with a new part apply a thin coat of molybdenum disulf
7. 1 2 3 4 5 6 7 8 9 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View No Fastener Remarks Rear frame mounting bolts 25 Air cleaner duct clamp screw E 17 in lb Fuel tap plate mounting screws 7 in lb 4 Fuel Tank Cap 5 Fuel Tank 6 Fuel Tap 7 Element 8 Frame 9 Holder 10 Air Cleaner Duct 11 Air Cleaner Housing 12 Rear Frame G Apply grease O High quality foam air filter oil 3 6 FUEL SYSTEM Specifications Item SRE Service Limit KX250 N1 Carburetor Make Type KEIHIN FCR37 Starter Jet 68 Leak Jet 60 Main jet 178 Throttle valve cutaway 1 5 Jet needle OBEKS Jet needle clip position 3rd groove from the top Slow jet 40 Slow Air Jet 100 Pilot Air Screw turns out 2 1 4 gt Service fuel level above the bottom edge of the carb body Float height 6 5 1 mm 0 256 0 039 in 8 1 mm 0 315 0 039 in FUEL SYSTEM 3 7 Special Tools Fuel Level Gauge M18 x 1 0 57001 122 3 8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hana if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check th
8. NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap and check that there is plenty of fluid in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Install the reservoir cap e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close the bleed valve while holding the brake applied B 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs almost out any time during bleeding operation the bleeding opera tion must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for easier bleeding e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps To
9. 6K04030351 6ko050611S1 6S12010BS1 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Brakes Brake Lever and Pedal Adjustment WARNING Always maintain proper brake adjustment If ad justment is improper the brake could drag and overheat This could damage the brake assembly and possibly lock the wheel resulting in loss of control e Adjust the front brake lever A to suit you e Slide the brake lever dust cover B out of place e Loosen the adjuster locknut C and turn the adjuster D to either side e After adjustment tighten the locknut NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the master cylinder is disas sembled or pedal position is incorrect e Measure the length indicated in the figure Length A Standard 68 5 1 mm 3 09 0 04 in x lf it is not specified length the brake pedal may be de formed or incorrectly installed xf it is not within the specified length adjust the push rod in the master cylinder as following OLoosen the push rod locknut A OReplace the cotter pin with a new one ORemove Cotter Pin B Washer Joint Pin C OTurn the bracket D to obtain the specified length OTighten the locknut Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 12 5 ft lb 6S13044BS1 2 34 PERIODIC MAINTENANCE Periodic Maintenance P
10. 6114060581 Bearing Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil to it OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it 6113014981 9 20 CRANKSHAFT TRANSMISSION Bearings Oil Seals e Check the needle bearing OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection Replace the oil seal if the lips are deformed discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents Exploded Vie Wisin aliadas 10 2 SPCCITICATONS 45225468 sabes da a ad 10 4 Special TOS iii iia 10 5 Wheels RMS A de Au RS eme Sn te 10 6 Front Wheel Removal see 10 6 Front Wheel Installation a 10 6 Rear Wheel Removal
11. Kickshaft Installation e Apply a non permanent locking agent to the ratchet guide bolt e Install the ratchet guide A Torque Ratchet Guide Bolt 9 8 N m 1 0 kgf m 83 in Ib e Apply molybdenum disulfide grease to the end of the kick shaft e Insert the kick shaft assembly B into the crankcase OSecurely engage the stopper portion C of the ratchet gear with the guide e Insert the spring end D into the hole E e Install Idle Gear see this chapter Clutch Housing see this chapter Right Engine Cover see this chapter 6 22 ENGINE RIGHT SIDE Kickstarter Kickstarter Assembly Disassembly Assembly e The kickstarter assembly consists of the following parts e Check the kickstarter assembly parts for damage Any damaged parts should be replaced with new ones A Kick Gear E Ratchet Gear B Circlip F Kick Shaft C Washer G Kick Spring D Spring H Spring Guide e Apply molybdenum disulfide grease to the inside of the kick gear and ratchet gear e When assembling the ratchet gear A onto the kick shaft B align the punch mark C on the ratchet gear with the punch mark C on the kick shaft e Replace the circlips that were removed with new ones Special Tools Outside Circlip Pliers 57001 144 GROSO11BS1 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents Exploded MI A o conte dvatetcatsseavshedeeunctsnat 7 2 Lubrication ISO TCM A A A A
12. GMO5066BS1 PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Push the bladder into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil CAUTION Ensure that no air remains in the system e Check the circlip for weakening deformity and flaws x lf necessary replace it with a new one CAUTION Ifweakened deformed or flawed circlip is used the gas reservoir cap may not hold when injecting the nitrogen gas This would allow oil and internal parts to explode out of the reservoir e Mount the circlip A in the groove in the gas reservoir e Pull up the gas reservoir cap A against the circlip The end of the gas reservoir cap must align B with the end of the gas reservoir C WARNING If the end of the gas reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitting in the groove in the gas reservoir or is deformed In this case the oil and internal parts could explode out of the reservoir when injecting the nitrogen gas or while riding the motorcycle 6M05011BS1 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the rear shock body to 55 mm 1 77 in A from the lower end B of the rear shock body B O Xx Dx MU LIT EE E GMO5068BS2 C e
13. Lower front fork clamp bolts Upper front fork bolts Push rod nut 8 0 Front axle clamp bolts Front fork cylinder valve assembly Screw O Rings Fork Spring Seat Spring Rebound Damping Adjuster Rod Spring Guide Piston Rod Assy O ring Nut Snap Rings Stopper Holder Fork Cylinder Outer Tube Fork Guide Guide Bush Washer Oil Seal Retaining Ring Dust Seal Guide Bush Fork Inner Tube Gasket Plug Steering Stem Head Steering Stem Fork Protector Apply a non permanent locking agent to the threads Replacement Parts Tighten the two clamp bolts alternately two times to ensure even tightening torque 13 4 SUSPENSION Exploded View sa a 6M02082BW5 SUSPENSION 13 5 Exploded View Torque No Fastener Remarks Swingarm pivot shaft nut 10 Rocker arm pivot nut 8 5 Tie rod mounting nut front rear 8 5 4 0 5 Rear shock absorber mounting nut lower 34 3 5 25 6 Air bleed bolt 6 5 0 65 56 in lb 7 8 Pivot Shaft Swingarm 9 Rocker Arm 10 Tie Rod 11 Rear Shock Absorber Cylinder 12 O Ring 13 Bladder 14 Cap 15 Circlip 16 Valve Cap 17 Locknut 18 Adjusting Nut 19 Spring 20 Spring Guides 21 Circlip 22 Piston Rod Assembly 23 Piston 24 O Ring 25 Oil Seal 26 Stopper 27 Rear Shock Absorber G Apply grease L Apply a
14. Water Pump e Apply plenty of high temperature grease to the oil seal lips e Press in the oil seals direction as shown OPress in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the right engine cover Flat Side A Water Pump Oil Seals B Crankshaft Oil Passage Oil Seal C Circlip D Kickshaft Oil Seal E Special Tools Bearing Driver Set 57001 1129 C e Press the ball bearing F into the hole until the face of the bearing is even with the end of the hole Special Tools Bearing Driver Set 57001 1129 GDO6030B 1 COOLING SYSTEM 4 13 Radiator Radiator Removal e Drain the coolant see Coolant Draining e Drain the engine oil from the oil filter oil chamber see Water Pump Removal e Remove Radiator Shrouds see Fuel System chapter Fuel Tank see Fuel System chapter e Loosen Clamp Screws A e Remove Radiator Hoses B Bolts C Right Radiator Screen D e Unscrew the bolts A e Loosen Clamp Screw A e Remove Right Radiator B e Loosen Clamp Screw A e Remove Radiator Hose B Bolts C Left Radiator Screen D 4 14 COOLING SYSTEM Radiator e Remove Bolts with Clamps A Left Radiator with Hoses B Radiator Installation e Hold the clutch cable with clamps e Fit the projections A of the screen in the holes B of the radiator Torque Radiator Hose Clamp Screws 1 5 N m
15. e Remove the exhaust pip holder nut B e Remove the exhaust pipe C e Remove Seat see Frame chapter Right Side Cover see Frame chapter e Remove the muffler mounting bolts A e Remove the muffler B from the back Muffler Installation e Check the exhaust pipe holder gasket A and replace it if it is damaged e Check the gasket B at the clamp and replace it if it is damaged Make sure that the gasket is placed securely outside the exhaust pipe 6E18011BS1 e First tighten all the bolts and nuts to a snug fit e Next tighten the exhaust pipe holder nuts evenly to avoid exhaust leaks e Lastly tighten the rest of the bolts and clamp bolt securely Torque Exhaust Pipe Holder Nuts 21 N m 2 1 kgf m 15 ft lb Muffler Mounting Bolts 21 N m 2 1 kgf m 15 ft lb e Thoroughly warm up the engine wait until the engine cools down and then retighten the exhaust pipe holder nuts and the clamp bolt securely ENGINE RIGHT SIDE 6 1 Engine Right Side Table of Contents EXPIOded VIEW ES RER Acca ose RSR Ne ce enr mers teens te Matt conte T E Specifications A A er Rene es PE son SA se soue sueseaues nciduh aa ethen tases tuceags ag neteuteacd shecasgutan A Clutch Lever and Cable muii A ne at Clutch Lever Free Play Inspection titane atar Clutch Lever Free Play Adjustment sun Clutch Lever Installation ss Clutch Cable Removal sise Clutch Cable Installation Clutch Cable Inspection an
16. Exploded View 5 2 Valve Installation 5 22 Specifications cccccccnccononccncnncnnnn 5 6 Valve Guide Removal 5 23 Special Tools Sealants 5 9 Valve Guide Installation 5 23 Cylinder Head Cover 5 11 Valve Valve Guide Clearance Cylinder Head Cover Removal 5 11 Measurement Wobble Method 5 24 Cylinder Head Cover Installation 5 11 Valve Seat Inspection 5 25 Camshaft Chain Tensioner 5 12 Valve Seat Repair o oo o o o 5 25 Camshaft Chain Tensioner Cylinder and Piston 5 30 REMOVAL moco td 5 12 Cylinder Removal 5 30 Camshaft Chain Tensioner Piston Removal 5 30 Installation ss nus 5 12 Cylinder and Piston Installation 5 30 Cam Misc 5 13 Cylinder Wear 5 32 Camshaft Removal 5 13 Piston Wear sua ruse 5 32 Camshaft Installation 5 14 Piston Cylinder Clearance 5 32 Camshaft and Camshaft Cap Piston Ring Ring Groove WAR cj lalalala aos 5 16 Clearance sis seat 5 32 Camshaft Chain Removal 5 17 Piston Ring Groove Width 5 32 Camshaft Chain Installation 5 17 Piston Ring Thickness 5 33 Cylinder Head 5 18 Piston Ring End Gap Cylinder Compression Measurement 5 33 Measurement
17. OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat O D mea surement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat xlf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above lf the seat width is too wide make the 60 A grind de scribed below x lf the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit a 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B GE15012181 A GE15012281 GE15012381 5 28 ENGINE TOP END Valves e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it
18. 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 225 325 23 33 165 240 2 8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle grip free play 2 3 mm 0 08 0 12 in Hot start lever free play 0 5 1 0 mm 0 02 0 04 in wiser Air cleaner element oil High quality foam air filter oil Cooling System Coolant Type recommended Permanent type antifreeze Color Green Mixed ratio Soft water 50 and coolant 50 Freezing point 35 C 31 F Total amount 1 20 L 1 27 US qt Engine Top End Valve clearance Exhaust 0 17 0 22 mm 0 0067 0 0087 in Inlet 0 10 0 15 mm 0 0039 0 0059 in Cylinder head warp 0 05 mm 0 0020 in Cylinder inside diameter see text 77 000 77 012 mm 77 06 mm 3 0315 3 0320 in 3 0339 in Piston cylinder clearance 0 030 0 057 mm 0 0012 0 0022 in Engine Right Side Clutch Lever free play 2 3 mm 0 08 0 12 in Friction plate thickness 2 72 2 88 mm 0 107 0 113 in 2 6 mm 0 102 in Steel plate thickness 1 46 1 74 mm 0 057 0 069 in 1 36 mm 0 054 in Friction plate warp Not more than 0 15 mm 0 006 in 0 3 mm 0 012 in Steel plate warp Not more than 0 2 mm 0 008 in 0 3 mm 0 012 in Engine Lubrication System Engine oil Type
19. 4 512 mm 0 1772 0 1776 in 4 500 4 512 mm 0 1772 0 1776 in 0 08 0 16 mm 0 0031 0 0063 in 0 03 0 10 mm 0 0012 0 0039 in 45 32 60 33 84 mm 1 3322 in 34 54 mm 1 3598 in 0 15 mm 0 0059 in 21 93 mm 0 8634 in 22 08 mm 0 8693 in TIR 0 1 mm 0 0039 in 0 05 mm 0 0020 in TIR 0 05 mm 0 0020 in 4 44 mm 0 1748 in 4 46 mm 0 1756 in 4 57 mm 0 1779 in 4 57 mm 0 1779 in 0 32 mm 0 0126 in 0 26 mm 0 0102 in ENGINE TOP END 5 7 Specifications Item Standard Service Limit Valve Seat Surface Outside Diameter Exhaust 24 62 24 82 mm 0 9693 0 9772 in Inlet 30 62 30 82 mm 1 2055 1 2134 in Valve Seat Surface Width Exhaust 0 5 1 0 mm 0 0197 0 0394 in Inlet 0 5 1 0 mm 0 0197 0 0394 in Valve Spring Free Length Inlet Exhaust 37 88 mm 1 4913 in 37 0 mm 1 4567 in Cylinder and Pistons Cylinder Inside Diameter 77 000 77 012 mm 77 06 mm 3 0315 3 0320 in 3 0339 in Piston Diameter 76 955 76 970 mm 76 82 mm 3 0297 3 0303 in 3 0244 in Piston Cylinder Clearance 0 030 0 057 mm 0 0012 0 0022 in Piston Ring Ring Groove Clearance Top 0 04 0 08 mm 0 18 mm 0 0016 0 0031 in 0 0071 in Piston Ring Groove Width Top 0 83 0 85 mm 0 93 mm 0 0327 0 0335 in 0 0366 in Piston Ring Thickness Top 0 77 0 79 mm 0 70 mm 0 0303 0 0311 in 0 0
20. B Kawasaki KX250F Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System ajaja lla a NIO BA QO N O O O0O0 mon AON Appendix Kawasaki KX250F Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation t
21. More than 44 5 mm Too big 1 0 mm Less than 36 7 mm Too small 1 0 mm xRemove the push rod holder assy as necessary and re install the clutch Friction and Steel Plates Wear Damage Inspection e Refer to the Friction and Steel Plates Inspection in Peri odic Maintenance chapter Friction and Steel Plate Warp Inspection e Refer to the Friction and Steel Plate Inspection in Periodic Maintenance chapter Clutch Spring Free Length Inspection e Measure the free length A of the clutch springs If any clutch spring is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 46 8 mm 1 843 in Service Limit 44 9 mm 1 768 in GFO6O0303S1 ENGINE RIGHT SIDE 6 15 Clutch Clutch Housing Finger Damage e Visually inspect the clutch housing fingers A that come in contact with the friction plate tangs x If they are damaged or if there are groove cuts it the areas that come in contact with the tangs replace the housing Replace the friction plates if their tangs are damaged as well Friction Plate Clutch Housing Clearance e Measure the clearance between the tangs A on the fric tion plate and the fingers B of the clutch housing lf this clearance is excessive the clutch will be noisy x If the clearance exceeds the service limit replace the fric tion plates Friction Plate Clutch Housing Clearance Standard 0 04 0 55 mm 0 0016 0 02
22. Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 9 4 ft Ib e Fit the plug cap securely OPull the spark plug cap A to make sure the installation of the spark plug cap Cable Inspection Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation REIZXZEZZREZS Y FUEREN INS Sy DSS LL LS ra NN Q SIS i 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Hot Start Inner Cable Upper End Throttle Inner Cable Upper End Cables Lubricate with Rust Inhibitor Throttle Cables Clutch Cable Hot Start Cable e With the cable disconnected at the both ends the cable should move freely A within the cable housing lf cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004011481 6004020152 C PERIODIC MAINTENANCE 2 57 Periodic Maintenance Procedures Nut Bolt and Fastener
23. e Fill the engine with a good quality motor oil specified be low Recommended Engine Type Castrol R4 Superbike 5W 40 or API SH or SJ with JASO MA Viscosity SAE 10W 30 10W 40 10W 50 Capacity 1 3 L 1 4 US qt when filter is not removed 1 35 L 1 43 US qt when filter is remove 1 5 L 1 6 US qt when engine is completely dry NOTE OThe oil viscosity may need to be changed to accommo date atmospheric conditions in your riding area SAE 10W 50 SAE 10W 40 SAE 10W 30 0 10 20 30 40 C 32 50 68 86 104 F 6S09013BS1 e Check the oil level see Engine Lubrication System chap ter Oil Filter Change e Drain Engine oil see Engine Oil change Coolant see Coolant change e Unscrew the water pipe bolt A and pull out the water pipe end B e Unscrew the water pump cover bolts C PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures e Using the pry point A remove the water pump cover B e Remove the oil filter A e Replace the oil filter with a new one e Apply grease to the grommet e Be sure to install the filter with the grommet A facing inside as shown CAUTION Inside out installation stop oil flow causing engine seizure e Install the spring A and dowel pins B Replace the pump cover gasket C with a new one e Apply grease to the pump cover gasket e Install the water pump cover a
24. e Install the engine OFirst insert the front portion of the engine A and then install the rear portion e Install the pivot shaft all engine bracket and mounting bolts temporarily OFor the four locations A shown in the diagram insert the bolts and shaft from the right and attach the nuts from the left OFor other locations insert the engine mounting bolts from the left e Tighten the pivot shaft engine mounting bolts and engine bracket bolts Torque Swing Arm Pivot Nut 98 N m 10 kgf m 72 ft lb Engine Mounting Bolts 49 N m 5 0 kgf m 36 ft lb Engine Bracket Bolt 29 N m 3 0 kgf m 22 ft Ib 6H04018BS1 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the removed parts see Appropriate chapter e Run the cables hoses and leads according to the Cable Wire and Hose Routing section of the Appendix chapter e Fill Engine Oil see Periodic Maintenance chapter Coolant see Periodic Maintenance chapter e Adjust Throttle Cable see Periodic Maintenance chapter Clutch Cable see Periodic Maintenance chapter Drive Chain see Periodic Maintenance chapter e Adjust the idling see Periodic Maintenance chapter e Check the operation of the clutch lever see Periodic Maintenance chapter e Check the brake effectiveness A WARNING Do no attempt to drive the motorcycle until you pump the brake pedal until the pads are against the disc The brake will not func
25. e Remove the throttle pulley cover B 3 16 FUEL SYSTEM Carburetor e Loosen the locknut A e Pull out the end of the throttle cables B e Free the tips C e Remove the carburetor right side of the frame e Drain the fuel from the float bowl by removing the drain plug After draining install the drain plug securely e After removing the carburetor push a clean lint free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Carburetor Installation e Install Throttle Cables see this chapter Hot Start Plunger see this chapter e Tighten Torque Carburetor Throttle Pulley Cover Bolt 3 4 N m 0 3 kgf m 30 in Ib Throttle Cable Locknuts 7 0 N m 0 7 kgf m 61 in Ib e When installing the carburetor into the carburetor holder fit the projection A of the carburetor with the groove B on the holder OFit the claw C of the clamp onto the groove D of the inlet duct e Tighten the clamps securely Torque Carburetor Holding Clamp Screw 2 0 N m 0 2 kgf m 17 in Ib GCO4009BS1 FUEL SYSTEM 3 17 Carburetor e Route the air vent and overfl
26. x lf it is not within the specified voltage range adjust the throttle sensor position see Throttle Sensor Position Ad justment wes P 16 22 ELECTRICAL SYSTEM Ignition System Engine Stop Switch Electric Current Check e Open the clamp A e Disconnect the engine stop switch lead connector B e Start the engine e Ground the stop switch black white lead of the main har ness side while the engine is running x lf does not stop the engine replace the C D I Unit Crankshaft Sensor Inspection e Remove Magneto Lead Connector see Magneto Cover Re moval e Set the hand tester A to the x 1000 range and connect it to the Green B and Red C Leads in the connector Special Tool Hand Tester 57001 1394 x lf there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance 80 180 Q e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground Any tester reading less than infinity indicates a short necessities replacement of the crankshaft sensor assem bly 108272 P E 6P10122BS1 ELECTRICAL SYSTEM 16 23 Throttle Sensor Throttle Sensor Inspection NOTE Olf the variable rheostat is not available refer to throttle sensor output inp
27. 0 15 kgf m 13 in lb Radiator Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Radiator Screen Bolts 9 8 N m 1 0 kgf m 87 in Ib Radiator Shroud Bolts 9 8 N m 1 0 kgf m 87 in Ib e Route the radiator and breather hoses correctly see Ap pendix chapter e Add the engine oil and fill the cooling system with a per manent type coolant Radiator Inspection e Check the radiator core xlf there are obstructions to air flow remove them lf the corrugated fins are deformed carefully straighten them with the thin blade of a screwdriver A CAUTION Do not tear the radiator tubes while straightening the fins xf 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 CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 64 ft B from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun following the core fin direction C 6D07010BS1 COOLING SYSTEM 4 15 Radiator Radiator Cap Inspection e Check the condition of the valve seals A and the top and bottom valve spring B of the radiator cap x If any one of them shows visible damage replace the cap e Wet the top and bottom valve seals with water or coolant to prevent p
28. A and release the nitrogen gas completely from the gas reservoir e Remove the valve WARNING Since the high pressure gas is dangerous do not point the valve toward your face or body GMO5056BS1 13 26 SUSPENSION Swingarm Swingarm Removal e Place the jack A under the frame so that the rear wheel is off the ground Special Tool Jack 57001 1238 e Remove Rear Wheel see Wheels Tires chapter Clamps B Brake Pedal C see Brakes chapter Caps D Disc Protector E e Remove Bolts A Chain Guide Plate B Chain Guide C e Unscrew the rocker arm mounting nut A and pull out the rocker arm bolt CAUTION When pulling out the mounting bolts lift the swingarm wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Unscrew the nut A e Pull out the swing arm pivot shaft and remove the swing arm B e Unscrew the screws A e Separate the chain slipper B from the swing arm SUSPENSION 13 27 Swingarm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and oil seals e Tighten the following Torque Swingarm Pivot Shaft Nut 98 N m 10 0 kgf m 72 ft lb Rocker Arm Mounting Nut 83 N m 8 5 kgf m 61 ft lb e Refer to the Wheels Tires Final Drive and Brakes chap ters for wheel installing Swingarm Bearing Removal e Remove Swingarm Collars A
29. C e Measure the outside diameter D of the seating pattern on the valve seat x lf the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Exhaust 24 62 24 82 mm 0 9693 0 9772 in Inlet 30 62 30 82 mm 1 2055 1 2134 in e Check the seating surface width of the valve seat OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Valve Seating Surface Width Standard Exhaust 0 5 1 0 mm 0 0197 0 0394 in Inlet 0 5 1 0 mm 0 0197 0 0394 in GE15011782 C If the width is too wide G too narrow H or uneven J repair the seat see Valve Seat Repair Valve Seat Repair e For the instructions on how to use the valve seat cutter A follow the operation manual provided by the to man ufacturer Special Tools Valve Seat Cutter Holder 64 5 57001 1330 B Valve Seat Cutter Holder Bar 57001 1128 C Exhaust Valve Seat Cutter 45 627 5 57001 1114 Valve Seat Cutter 32 628 57001 1119 Valve Seat Cutter 60 628 57001 1328 Inlet Valve Seat Cutter 45 35 57001 1116 Valve Seat Cutter 32 633 57001 1199 Valve Seat Cutter 60 633 57001 1334 lf the tool manufacturer s instructions are not available operate in accordance with the following procedure 5 26 ENGINE TOP END Valves Sea
30. Starter plunger stuck open Hot start stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Carburetor holder loose Fuel tank cap air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent de formed worn carbon accumulation on the seating surface Decompression trouble Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat valve Faulty CDI unit Other Throttle valve won t fully open Brake dragging Air cleaner clogged Water or foreign matter in fuel Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Crankshaft bearing worn or damage Engine Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Faulty CDI unit Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carbu
31. and the lever closes quickly and completely in all steering positions by the return spring x lf the hot start lever does not return properly check the hot start cable routing free play and cable damage Then lubricate the hot start cable Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Harness Hose Rout ing in the Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures e Check the idle speed using the engine revolution tester A for high accuracy xf the idle speed is out of specified range adjust it Idle Speed Standard 2 000 50 r min rpm Idle Speed Adjustment e First turn in the air screw A using the pilot screw ad juster A until it seats lightly and back it out the specified number of turns see specifications in the Fuel System chapter Special Tool Pilot Screw Adjuster C 57001 1292 or Pilot Screw Adjuster D 57001 1588 Pilot Screw Adjuster Adapter 4 57001 1371 e Start the engine and warm it up thoroughly e Turn the id
32. e Unscrew the rebound damping adjuster fully then screw the front fork top plug onto the push rod e Holding the top plug A with a wrench B tighten the push rod nut C against the top plug Torque Push Rod Nut 28 N m 2 85 kgf m 20 6 ft lb 6M04171BS1 e Raise the outer tube and screw the top plug into it e After installing the front fork tighten the top plug Torque Fork Top Plug 29 N m 3 0 kgf m 22 ft Ib 13 20 SUSPENSION Front Fork Inner Tube Inspection e Visually inspect the inner tube A repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage xlf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner A and outer tubes B and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bush Inspection e Visually inspect the guide bushes A and replace them if necessary Dust Seal Oil Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary e Replace the oil seal B with a new one whenever
33. secondary cup E primary cup F and return spring G CAUTION Do not remove the secondary cup from the piston since removal will damage it e Remove the rear master cylinder see Brake chapter NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi tion adjustment e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Slide the dust cover A on the push rod B out of place and remove the circlip C Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop D e Take off the piston E secondary cup F primary cup G and return spring H CAUTION Do not remove the secondary cup from the piston since removal will damage it e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning of these parts Gasoline engine oil or any other petroleum distillate will cause de terioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 6S13042BS1 GLO7020BS2 C PERIODIC MAINTENANCE 2 39 Periodic Maint
34. through the valve on the gas reservoir e Check the rear shock body and gas reservoir for oil and gas leaks lf there are no leaks inject the nitrogen gas up to the 980 kPa 10 kgf cm 142 psi pressure Pressurize the gas reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire hazard or substandard performance High pressure gas is dangerous Have a qualified mechanic perform this procedure e Install the spring and spring guide e Adjust spring preload Reinstall the rear shock absorber e Install the parts removed Swingarm and Uni Trak Linkage Inspection e Check the uni trak component parts for wear periodically or whenever excessive play is suspected e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Push and pull on the swingarm A up and down to check for wear xA small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear Swingarm and Uni Track Linkage Pivot Lubricate e Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in Suspension chapter 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 e With t
35. 0 197 in B up from the bottom of the piston at a right angle to the direction of the piston pin x lf the pistons outside diameter is smaller than the service limit replace the piston Piston Diameter Standard 76 955 76 970 mm 3 0297 3 0303 in Service Limit 76 82 mm 3 0244 in Piston Cylinder Clearance e Refer to the Piston Cylinder Clearance in Periodic Main tenance chapter Piston Ring Ring Groove Clearance e Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Ring Groove Clearance Standard Service Limit Top 0 04 0 08 mm 0 18 mm 0 0016 0 0031 in 0 0071 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Piston Ring Groove Width e Measure the groove width at several points around the piston with a vernier caliper Piston Ring Groove Width Standard Service Limit Top 0 83 0 85 mm 0 93 mm 0 0327 0 335 in 0 0366 in x lf any of the groove widths exceeds the service limit re place the piston 6E16054BS1 6E16004BS1 ENG
36. 11 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Check the wheel alignment see Wheel Alignment Inspec tion and adjust it if necessary see Wheel Alignment Ad justment NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest e Measure the space chain slack A between the chain and the swing arm at the rear of the chain slipper as shown If the drive chain slack exceeds the standard adjust it Chain Slack Standard 52 62 mm 2 05 2 44 in Drive Chain Slack Adjustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the axle nut C xlf the chain is too tight back out the left and right chain adjusting bolts D evenly and push the wheel forward until the chain is too loose lf the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch on the left chain adjuster should align with the same swingarm mark E as the right chain adjuster notch F Check the wheel alignment A WARNING Misalignment of the wheel result in abnormal wear and may result in an unsafe riding condition e Tighten
37. 16 ENGINE TOP END Camshaft e Uniformly tighten all bolts and after the camshaft has set tled uniformly tighten all the bolts OBolts A are long OFollowing the sequence numbers on the camshaft caps tighten the cap bolts 1 4 Torque Camshaft Cap Bolts 12 N m 1 2 kgf m 104 in Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation then check the camshaft chain timing CAUTION After this procedure if any resistance is felt while turning over the crankshaft stop immediately and check the camshaft chain timing Valves will be bent if the timing is not properly set e Install the cylinder head cover see Cylinder Head Cover Installation timing inspection cap and the flywheel cap Torque Timing Inspection Cap 4 N m 0 4 kgf m 35 in Ib Flywheel Cap 5 N m 0 5 kgf m 43 in lb Camshaft and Camshaft Cap Wear e Measure each clearance between the camshaft journal and camshaft cap using plastigauge press gauge A OTighten the camshaft cap bolts Torque Camshaft Cap Bolt 12 N m 1 2 kgf m 104 in Ib NOTE ODO not turn the camshaft when the plastigauge is be tween the journal and camshaft cap xlf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Bearing Clearance Standard 0 020 0 062 mm 0 0008 0 0024 in Service Limit 0 15 mm 0 0059 in xlf the camshaft journal diamete
38. 2 Chain tensioner cap 14 5 3 Cylinder head bolts M6 104 in lb Exhaust pipe cover screws 104 in Ib Exhaust pipe holder nuts 15 Muffler mounting bolts a 15 8 Circle Mark 9 Top Ring 10 Oil Ring G Apply high temperature grease O Apply engine oil L Apply non permanent locking agent R Replacement Parts S Follow the specific tightening sequence S Apply silicone sealant 5 6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height Exhaust Inlet Camshaft Journal Clearance Camshaft Journal Diameter Camshaft Journal Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp Valve Valve Clearance Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve valve Guide Clearance wobble method Exhaust Inlet Valve Seat Cutting Angle 33 941 34 057 mm 1 3363 1 3408 in 34 642 34 758 mm 1 3639 1 3684 in 0 020 0 062 mm 0 0008 0 0024 in 21 959 21 980 mm 0 8645 0 8654 in 22 000 22 021 mm 0 8661 0 8670 in TIR 0 02 mm 0 0008 in or less Usable range 431 706 kPa 4 4 7 2 kg cm 62 5 102 psi 5 kicks 0 17 0 22 mm 0 0067 0 0087 in 0 10 0 15 mm 0 0039 0 0059 in TIR 0 01 mm 0 0004 in or less 4 455 4 470 mm 0 1754 0 1760 in 4 475 4 490 mm 0 1762 0 1768 in 4 500
39. 57001 135 57001 1077 Steering Stem Bearing Driver Steering Stem Nut Wrench 57001 137 57001 1100 Steering Stem Bearing Driver Adapter Head Pipe Outer Race Remover 57001 1074 57001 1107 e Head Pipe Outer Race Press Shaft Jack 57001 1075 57001 1238 YS si SY fin t f DS TZ M 5 Ss lt lt 4 Head Pipe Outer Race Driver Bearing Puller 57001 1076 57001 1575 ST5715758T STEERING 14 5 Steering Steering Inspection e Refer to the Steering Inspection in Periodic Maintenance chapter Steering Adjustment e Refer to the Steering Adjustment in Periodic Maintenance chapter Steering Stem Stem Bearing Removal e Remove Front Wheel see Wheels Tires chapter Front Fork see Suspension chapter Front Fender Bolts A Front Fender B e Remove Brake Hose Clamp Bolt A Brake Hose Clamp B Number Plate Bolt C Number Plate D Caliper Mounting Bolts see Brake System chapter Master Cylinder Clamp see Brake System chapter Front Fork see Suspension chapter e Remove Handlebar Mounting Bolts A Handlebar Clamp B Handlebar C see Handlebar Removal e Pull out breather hose D e Remove the steering stem head nut E and washer e Remove the steering stem head F e Pushing up on the stem base A and remove the steering stem locknut B with the steering stem nut wrench C then remove the steering stem D and stem base Spe
40. 8 14 0 mm D Special Tool Valve Guide Driver 44 5 57001 1564 GE15070681 6E15041BS1 5 24 ENGINE TOP END Valves e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 5 57001 1333 Valve Valve Guide Clearance Measurement Wobble Method Olf a small bore gauge is not available inspect the valve guide wear by measuring the valve valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure the valve wobble e Repeat the measurement in a direction at a 90 angle to the first measurement If the reading exceeds the service limit replace the guide NOTE OThe reading is greater than the actual valve valve guide clearance because the measurement is taken outside of the guide Valve Valve Guide Clearance Measurement Wobble Method Standard Service Limit Exhaust 0 08 0 16 mm 0 32 mm 0 0126 in 0 0031 0 0063 in Inlet 0 03 0 10 mm 0 26 mm 0 0102 in 0 0012 0 0039 in GE150306 S GE15010481 ENGINE TOP END 5 25 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
41. A ace 7 4 DPOCIICATIONS 3 2 cscserenaccsseccdnaceutatuneegon se toiaesceseaues nette t case tales ten A TT E tent tnt dla annee Re us 7 6 Sp cial TOOIS A A Bates dow en A A o 7 7 E gine Qil and Oil Fleitas 7 8 Engine Oil Level Inspection iii o ie 7 8 Engine QilChaNgE ii da is 7 8 Oil Filter Change ceuta dia 7 9 ASAS A AE 7 9 Oil Screen Installation 7 9 Qil PUMP ee a A Re SL OR aloe aed PT SaN 7 10 Oil P UMP ReMOVAl EEEE E mens etes entre dar eras en flan Ada cued gute aaedanqalanee densa ced labo mens opinas 7 10 Oil Pump Installation ici Eh Ann ia 7 11 A A RME NON TT stade net deu an eee eee ee nan bcanhs camvecevtas 7 12 Oil Pr sSSUTe at LS EN A de sr 7 13 Oil Pressure Measurement a E a a aa a a a a a Ea ii ian ii aiii 7 13 7 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7 3 Exploded View Torque No Fast Remarks o Han Nm kgfm ftlb 4 Engine oil drain plug M10 for transmission room 15 15 11 oil sump 2 Engine oil drain plug M6 for crank room oil sump 7 0 0 7 61 in lb Engine oil drain plug M6 for oil filter oil chamber 7 0 0 7 Oil Pump mounting bolts Water pump cover bolts Water pump cover bolt with washer Right engine cover bolts Piston oil nozzle Breather fitting Clutch cover bolts Clutch cover bolt with washer Oil pump idle gear shaft screws 13 Inner Rotor scavenging 14 Outer Rotor scavenging 15 Inner Rotor feed 16 Outer Rotor fe
42. BRIDESTONE M601 Tube EU M201 Tube 100 90 19 57M BRIDESTONE M602 Tube EU M202 Tube WHEELS TIRES 10 5 Special Tools Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 Rim Protector Jack 57001 1063 57001 1238 Bead Breaker Assembly 57001 1072 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Using the jack A under the frame and stabilize the mo torcycle Special Tools Jack 57001 1238 e Loosen the left and right axle clamp bolts A e Unscrew the axle nut B e Place a stand under the engine to raise the front wheel off the ground e Remove the axle C and pull out the wheel Take off the collars D and caps E from each side of the front hub CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper posi tion should the brake lever be squeezed accidentally Front Wheel Installation e Apply grease to the seals e Fit the projection on the cap to the groove on the collar e Install the caps A collars on the left longer collar B and right shorter collar C side of the hub e Insert the axle D from right side e Unbolt the right E and left F axle clamp bolts t
43. Cable Installation Torque Hot Start Plunger Cap Bolt 1 0 N m 0 1 kgf m 10 in Ib e Install the hot start cable in accordance with the Cable Wire and Hose Routing section in the appendix chapter e After the installation adjust the cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition GCO4011BS1 FUEL SYSTEM 3 11 Throttle Grip and Cable Hot Start Lever Free Play Inspection e Refer to the Hot Start Lever Free Play Inspection in Peri odic Maintenance Hot Start Lever Free Play Adjustment e Refer to the Hot Start Lever Free Play Inspection in Peri odic Maintenance Hot Start Cable Lubrication e Whenever the hot start cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cable Refer to General Lubrication in the Periodic Main tenance Chapter Hot Start Cable Inspection e Refer to the Cable Inspection in Periodic Maintenance 3 12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine there are two general types of carbure tor trouble too rich a mixture too much fuel and too lean a mixture too little fuel Such trouble can be caused by dirt wear maladjustment or improper fuel level in the float chamber A dirty or damaged air cleaner can also alter the fuel to air ratio Idle Speed Inspection e Refe
44. Castrol R4 superbike 5W 40 or API SH or SJ with JASO MA Viscosity SAE 10W 30 10W 40 or 10W 50 Capacity 1 5 L 0 74 US qt Crankshaft Transmission Connecting rod big end radial 0 002 0 014 mm 0 06 mm clearance 0 00008 0 0006 in 0 0024 in Connecting rod big end side 0 25 0 35 mm 0 55 mm clearance 0 0098 0 0138 in 0 0217 in Crankshaft runout TIR 0 03 mm 0 012 in or less TIR 0 08 mm 0 0031 in ft PERIODIC MAINTENANCE 2 9 Specifications Item Standard Service Limit Wheels Tires Rim Runout Axial Radial Front and rear tires air pressure Standard tire Front Size Make Type Rear Size Make Type Final Drive Drive chain slack Drive chain 20 link length Engine sprocket diameter Rear sprocket diameter Rear sprocket warp Brakes Brake lever free play Brake fluid Type Front Rear Brake pad lining thickness Front Rear Suspension Fork Oil Oil viscosity Oil capacity per unit Oil level fully compressed spring removed Electrical System Spark plug gap Under 1 0 mm 0 039 in Under 1 0 mm 0 039 in 100 kPa 1 0 kgf cm 14 psi 80 100 21 51M BRIDESTONE M601 Tube EU M201 Tube 100 90 19 57M BRIDESTONE M602 Tube EU M202 Tube 52 62 mm 2 05 2 44 in 317 5 318 2 mm 12 50 12 53 in 55 48 55 68 mm 2 184 2 192 in 13T 232 62 233 12 mm 9 158 9 178 in 48T Under 0 4 mm 0 016 in to suit rider DOT3 or DOT4
45. Cylinder Head Oil Passage from Cylinder Oil Passage to Camshaft Oil Shower to Transmission Oil Pump Idle Gear Shaft Oil Pump Gear Kick Starter Idle Gear Kick Starter Idle Gear Shaft Fitting Breather Hose Crank Room Oil Transmission Room Oil Blowby Gas 7 6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade Viscosity Capacity Oil change when filter is not removed Oil change when filter is removed when engine is completely dry Oil level after warm up or driving Castrol R4 Superbike 5W 40 API SH or SJ with JASO MA SAE 10W 30 10W 40 or 10W 50 1 3 L 1 4 US qt 1 35 L 1 43 US at 1 5 L 1 6 US at Upper level Oil Pressure Measurement oil temperature 90 C engine speed 4 000 rpm 19 6 kPa 0 2 kgf cm 2 8 psi ENGINE LUBRICATION SYSTEM 7 7 Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Gear Holder 57001 1557 ST571557ST Outside Circlip Pliers 57001 144 Oil Pressure Gauge Adapter M6 x 1 0 57001 1579 ST5715798T 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury The engine oil level indicated in the clutch cover oil leve
46. Fork Assembly in Suspension chapter Rear Shock Absorber Oil Change The oil should be changed in the rear shock absorber at least once per racing season The frequency for best per formance must be based upon riding conditions and rider ability e Remove the rear shock absorber from the frame see Suspension chapter e Remove the shock absorber spring see Suspension chapter e Point the valve A away from you slowly release nitrogen gas pressure by pushing down the valve core with a screw driver PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures A WARNING Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure An oil mist is often released with the nitrogen Always release nitrogen gas pressure before disassem bling the rear shock absorber to prevent explosive separation of parts e Adjust the gas reservoir damping adjusters A to the soft est position e Remove the air bleeder bolt B and pump the rear shock to drain the oil out the rear shock body e Install the air bleeder bolt e Using the suitable tool A and press push the reservoir cap B in 10 mm 0 39 in e Remove the circlip C from the gas reservoir e Pull the gas reservoir cap B out of the gas reservoir using the pliers A e Pry or tap A at the gaps B in the stop C with suitable tools to free the stop from the rear s
47. Frame Installation e Install the air cleaner housing e Tighten the rear frame mounting bolts Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib e Install the removal parts Engine Guard Installation e Install the engine guard as shown Right Engine Guard A Left Engine Guard B Collars C Damper D Engine Guard E Bolts F 6009007BS2 C FRAME 15 5 Seat Seat Removal e Unscrew the bolts A e Pull the seat B out from the back Seat Installation e Fit the hooks A of the seat under the flange collar B and brackets C 15 6 FRAME Side Cover Side Cover Removal e Unscrew the bolts A and remove the side cover Side Cover Installation e Stick the pads A on the inside of the right side cover B OBend this parts C and stick it to the upper surface of the rib Olnstall the dampers D e Insert the tabs A of the cover into the air cleaner housing B 6006002BS1 FRAME 15 7 Fender Front Fender Removal e Unscrew the bolts A and remove the front fender B Rear Fender Removal e Remove Seat e Unscrew the bolts A and remove the rear fender B Rear Flap Removal e Unscrew the screws A and remove the rear flap B ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents EXPO Mi a A cabin o e O A T E 16 2 SPOCITICATI ONS A A a i 16 4 SA NN 16 5 Wiring Dil amsn A A nes a ed 16 6 A aeea 16 7 Electr
48. GHO2036BW5 ENGINE REMOVAL INSTALLATION 8 3 Exploded View Torque No Fastener HTA ATA Remarks N m kgf m ft Ib Upper engine mounting bolt nut M10 Middle engine mounting bolt nut M10 1 2 3 Lower engine mounting bolt nut M10 Upper engine bracket bolts nuts M8 Middle engine bracket bolts M8 29 3 0 22 Swingarm pivot nut 98 10 72 O O1 8 4 ENGINE REMOVAL INSTALLATION Special Tool Jack 57001 1238 ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Place the jack A under the frame to support the motor cycle Special Tool Jack 57001 1238 WARNING For engine removal the swingarm pivot shaft must be pulled out causing the swingarm and rear wheel assembly to become detached To prevent the mo torcycle from falling make sure to support the fram with a jack e Squeeze the brake lever slowly and hold it with a band A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall over The engine or the motorcycle could be damaged e Drain Engine Oil see Periodic Maintenance chapter Coolant see Periodic Maintenance chapter e Remove the mounting bolt A and remove the engine guard B e Remove Sid
49. Grease Seals B Sleeves C Needle Bearings D e Remove the needle bearings E using the oil seal amp bear ing remover Special Tool Oil Seal amp Bearing Remover 57001 1058 Swingarm Bearing Installation e Replace the needle bearings and grease seals with new ones e Apply plenty of grease to the grease seals and needle bearings A NOTE Olnstall the needle bearings so that the manufacturer s marks face out Olnstall the grease seals so that the deep groove side of the rip in ward Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings A B and grease seals C position as shown OThe installation procedure is the same as the counter side Drive Chain Guide Guide Roller Chain Slipper Wear e Visually inspect the drive chain guide A and replace it if excessively worn or damaged imm 6M06034BS1 C 6S14010BS1 13 28 SUSPENSION Swingarm e Visually inspect the chain slipper A on the swingarm B and replace it if worn or damaged e Visually inspect the upper and lower chain guide rollers A and replace them if excessively worn or damaged Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings installed in the swingarm OThe rollers in a bearing normally wear very little and wear is difficult to measure Instead of measuring visua
50. Hose to cylinder head 3 Hot Start Cable 12 Radiator Hose to water pump 4 Fuel Hose 13 Radiator Hose to water pump 5 Breather Hose 14 Joint Pipe 6 Clamp 15 Lower Engine Bracket 7 Breather Hose 16 Clump Position the clamp claw front 8 Viewed A 17 White Paint Mark 9 Left Radiator APPENDIX 17 7 Cable Wire and Hose Routing GB09385BW4 C 1 Brake Lever 10 Rear Brake Master Cylinder 2 Front Brake Master Cylinder 11 Rear Brake Hose 3 Front Brake Hose 12 Clamps 4 Clamp 13 Rear Brake Caliper 5 Viewed 14 Rear Brake Caliper Guard 6 Clamps 15 Rear Brake Disc 7 Front Brake Caliper 16 Rear Brake Disc Guard 8 Front Brake Disc 17 Cotter Pin 9 Brake Pedal 17 8 APPENDIX Troubleshooting Guide 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 Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end big end seizure Transmission gear or bearing seizure Camshaft seizure Kick shaft return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Fuel tank cap air vent obstructed Fuel tap clogged Fuel tap turned off Fuel line clogged Carburetor float valve clogged Engine flooded Fuel level in carb
51. Insert the piston end A of the piston rod assembly into the rear shock body C slowly Do not insert the seal assembly B yet Pump the piston rod until all the air is forced out of the rear shock body GMO5067BS1 e Push the seal assembly into the rear shock body until it just clears the circlip groove e Check the circlip x If it is deformed or damaged replace it with a new one e Fit the circlip A into the groove in the rear shock body B CAUTION If the circlip is not a certain fit in the groove in the rear shock body the piston rod assembly may come out of the shock absorber when injecting the nitro gen gas or riding the motorcycle GMO5069BS1 e Pull up the piston rod assembly C against the circlip e Force the stop D into the rear shock body by lightly tap ping around the edge of the stop with a mallet e Fully extend the piston rod assembly PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Install the suitable oil cup A to the air bleeder bolt hole and fill the specified oil into the cup e Purge the air from between the gas reservoir B and rear shock body C by slowly pumping the push rod D in and out e Install the air bleeder bolt securely Torque Air Bleeder Bolt 6 4 N m 0 65 kgf m 56 in Ib e Fully extend the push rod assembly 6M05105BS1 e Inject nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi
52. N G y Leg AAA IA G CRANKSHAFT TRANSMISSION 9 3 Exploded View Fastener Crankcase bolts Torque Remarks 87 in lb Gear set lever nut 78 in lb 1 2 3 Neutral switch 4 104 in lb Engine oil drain plug for crank room oil sump 7 0 0 7 61 in lb Engine oil drain plug for transmission room oil sump 11 Shift drum cam bolt 17 Piston oil nozzle Drive shaft bearing retaining screw 22 in lb 56 in lb Output shaft bearing retaining screw 56 in lb Shift dram bearing retaining bolts Breather fitting 13 Reed Valve EO Apply engine oil HG Apply high temperature grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement parts 87 in lb S Tighten the fasteners following the specified sequence 9 4 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Connecting Rods Connecting rod big end radial clearance 0 002 0 014 mm 0 06 mm 0 0024 in 0 00008 0 0006 in Connecting rod big end side clearance 0 25 0 35 mm 0 55 mm 0 0217 in 0 0098 0 0138 in Crankshaft runout TIR 0 03 mm 0 0012 in or TIR 0 08 mm less 0 0031 in Transmission Shift fork ear thickness 4 9 5 0 mm 4 8 mm 0 1890 in 0 1929 0 1969 in Gear shift fork groove width 5 05 5 15 mm 5 25 mm 0 2070 in 0 1988 0 2028 in Shift fork guide pin diameter 5 9 6 0
53. Pivot Nut Others Footpeg Cotter Pins Rear Frame Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents EXPIOded VIEW SRE RER A RSR Ne ce enr ere teens te Matt conte T E SPOECITICATI ONS ii A Sa Seti ere es PM Nos on Sole el MR SR A se A nctduhcaethen tases tucvatscgneteuteach skecasgutan AE Throttle Grip And Cable ai Free Play INSPEGU N namirisan tie idad esco ea Free Play Adjustment siii ie Throttle Cable Replacement ses Throttle Cable Lubrication ss Throttle Cable Inspection ses Hot Start Cable Removal cooccciicciininnococococococoncco nina 3 10 Hot Start Cable Installation dli dei 3 10 Hot Start Lever Free Play Inspection 3 11 Hot Start Lever Free Play Adjustment ooooocccccncnocononiccccccccconnnnnnnnnna nero nnn nn nn nnnnnr nn rra nenas 3 11 Hot Start Cable Lubrication eE N oa a aa iE 3 11 Hot Start Cable Inspection Ea EA 3 11 A NN 3 12 Idle Speed Inspection ss 3 12 Idle Speed AQUSIMEN anterio tte in nn nidesendrtss de eo tient dat Segas 3 12 Service Fuel Level Inspection 3 12 Service Fuel Level Adjustment isa nn me le amant lan Gi 3 13 Carburetor Removal sise 3 14 Carburetor Installation ss 3 16 FUGIMIMS CN ARR ee AN dent ann man dre ant tenant 3 17 Carburetor DiSa
54. Pour the solvent out of the tank e Remove the fuel tap from the tank by taking out the bolts e Clean the fuel tap filter screen in a high flash point sol vent e Pour high flash point solvent through the tap in all lever positions e Dry the tank and tap with compressed air e Install the tap in the fuel tank e Install the fuel tank Fuel Tap Inspection e Remove the fuel tap e Check the fuel tap filter screen A for any breaks or dete rioration x If the fuel tap screen have any breaks or is deteriorated it may allow dirt to reach the carburetor causing poor run ning Replace the fuel tap xlfthe fuel tap leaks or allows fuel to flow when it is at OFF position replace the damaged O ring B GCO9028BS1 6C009029BS1 COOLING SYSTEM 4 1 Cooling System Table of Contents A ARR E ee ME TE DD EU T E 4 2 Specifications A Gs Se VENTE Se Sets bee ae 4 4 DDOCIAITTOON i cccs ics iccccaszccesncntacttetecelancden se totais deseaces A A Musabeck nese bbeccd shes angudan se seuee seus OR 4 5 COGAN E ivedi viewer A A e e E 4 6 Coolant Level InSpectiOn wma dada decada hidra bid n 4 6 Coolant Deterioration Inspection ss 4 6 Coolant Drac la Te Te me Ne nn nds ic 4 6 Coolant Fl ssl la 4 7 A siens Mn RAT ete ee NRA A Adee dog echt lade 4 7 Cooling System Pressure Testing e coronar 4 8 Cooling System FlUS Iscar 4 8 A m ETAn EAE sires ours EEEE E ts tdi es ess Sets d dueatcnm
55. Remove Right Engine Cover see this chapter Clutch Housing see this chapter e Pull out the shift shaft A e Remove the screw B and bolt C take off the shift ratchet assembly D with ratchet plate E e Remove the bolt A and shift dram cam B e Remove the nut C and take off the gear set lever D External Shift Mechanism Installation e Install the gear set lever A OFit each end of the spring B or original positions ODo not forget to install the color C and washer D e Tighten the gear set lever nut E Torque Gear Set Lever Nut 8 8 N m 0 9 kgf m 78 in Ib e Holding the gear set lever A with the driver B and install the shift dram cam C OApply a non permanent locking agent to the shift dram cam bolt OFit the groove D on the pin E e Align the roller of the gear set lever with the slot of the shift dram cam 6 18 ENGINE RIGHT SIDE External Shift Mechanism e Set up the shift ratchet assembly as shown in the figure Ratchet A Pawls B Pins C Springs D Crankcase Side E e Then install the ratchet assembly A to the ratchet plate B as shown in the figure Crankcase Side C e Install the ratchet assembly to the shift drum cam e Apply a non permanent locking agent to the screw e Tighten Torque Ratchet Plate Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb Ratchet Plate Mounting Screw 6 4 N m 0 6 kgf m 87 in lb e Align the middle tooth A
56. Right Engine Cover Clutch Cover Removal e Drain the engine oil see Periodic Maintenance chapter e Set the stand attached e Remove the brake pedal see Brakes chapter e Remove the clutch cover bolts A and remove the clutch cover B Clutch Cover Installation e Apply a non permanent locking agent to the clutch cover bolts e Install the clutch cover C Torque Clutch Cover Bolts A 9 8 N m 1 0 kgf m 87 ft lb Clutch Cover Bolts B with washer 7 0 N m 0 7 kgf m 61 in Ib Brake Pedal Bolt 18 N m 1 8 kgf m 13 ft lb Right Engine Cover Removal e Drain Engine Oil see Periodic Maintenance chapter Coolant see Periodic Maintenance chapter e Remove Brake Pedal A see Brakes chapter Kick Pedal B e Remove Water Pipe Bolt A Water Pipe B see Cooling System chapter Water Pump Cover C see Cooling System chapter e Remove the right engine cover bolts D to remove the right engine E Right Engine Cover Installation e Two dowel pins A are installed at the mating surface between the crankcase and the right engine cover e Replace the engine cover gasket with a new one e Apply a high temperature grease to the kick shaft oil seal lips and kick shaft spline ENGINE RIGHT SIDE 6 11 Clutch Cover and Right Engine Cover e When installing the cover doesn t go well the cover is installed according to the following procedures OThe cover is installed while turning A the
57. Valves Front Rear 7 8 0 8 69 in lb Front Caliper Holder Bolt 27 2 8 20 Rear Caliper Holder Bolt 27 2 8 20 Caliper Pin Bolts 12 1 2 104 in lb Brake Pad Bolt 17 1 7 12 5 Rear Brake Pad Bolt Plug 25 0 25 22 in lb Brake Pedal Mounting Bolt 25 25 18 Suspension Front Fork Clamp Bolts Upper Lower Front Fork Cylinder Valve Assembly Front Fork Top Plug PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Torque Fastener TES kafm ftlb Remarks Push Rod Nut 28 2 85 20 6 Swingarm Pivot Shaft Nut 98 10 72 Rear Shock Absorber Mounting Nuts Upper 39 4 0 29 Lower 34 3 5 25 Air Bleed Bolt 6 4 0 65 56 in lb Tie Rod Mounting Nut Front Rear 83 8 5 61 Rocker Arm Pivot Nut 83 8 5 61 Steering Steering Stem Head Nut Steering Stem Locknut Handlebar Clamp Bolts Front Fork Clamp Bolts Upper Lower Frame Rear Frame Mounting Botls 58 43 in lb 18 14 5 25 Electrical System Neutral Switch Neutral Switch Lead Terminal Screw Flywheel Nut Timing Inspection Cap Stator Bolts Crankshaft Sensor Bolts Spark Plug C D I Unit Bolts Magneto Cover Bolts Ignition Coil Bolts Basic Torque for General Fasteners 104 in lb 12 in lb 36 43 in lb 61 in lb 61 in lb 115 in lb 87 in lb 87 in lb 87 in lb 61 in lb Threads dia Torque mm N m kgf m ft Ib 5 3 4 49 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14
58. a click Adjust the compression damping to suit your preference under special condition NOTE OThe left and right fork legs must have the same shock damping 6M04093BS1 6M04094BS1 y 161514131211 10 9 8 7 6 5 4 3 2 1 GMO5099BS1 da e 6M04008BS1 13 10 SUSPENSION Front Fork Seated positions adjuster turned fully clockwise A E E O Standard 8 clicks B 11 clicks European Model C Softer Counterclockwise D Harder Clockwise E Number of turns counterclockwise usable range 16 clicks or more Counterclockwise from the fully seated position iat St Compression Damping Adjuster Setting 8 e Put the caps into the bottom of the fork tubes Fork Oil Level Adjustment Simplify e Raise the front wheel off the ground using a jack Special Tool Jack 57001 1238 e Remove Front Fender see Frame chapter Brake Hose Clamp Bolts A Brake Hose Clamps B Fork Protector Bolts C Fork Protectors D e Remove Band A Handlebar B Hanging it e Loosen the upper fork clamp bolts C e Disassemble the front fork top plugs from the outer tube D e Slowly compress the front fork fully by pushing up the inner tubes A until they are stepped portion contacts the dust seals B on the lower end of the outer tubes C 6M04144BS1 SUSPENSION 13 11 Front Fork e Place a stand or ot
59. accumulation in the water passages and considerably reduces the efficiency of the cooling system Recommended Coolant Type Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed ratio Soft water 50 Coolant 50 Freezing point 35 C 31 F Total amount 1 2 L 1 27 US qt e Install the drain plug OReplace the gasket with a new one Torque Coolant Drain Plug 7 0 N m 0 7 kgf m 61 in lb e Fill the radiator up to the bottom of the radiator filler neck B with coolant A and install the cap turning it clockwise about 1 4 turn OLean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is lo cated uppermost in order to exhaust the air accumulated in the radiator NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator The radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way e Check the cooling system for leaks Air Bleeding Before putting the motorcycle into operation any air trapped in the cooling system must be removed as follows e Start the engine warm up the engine thoroughly and then stop the engine Wait until the engine cools down e Remove the radiator cap e Check the coolant level see Peri
60. axle for damages lf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 937 in A apart and set a dial gauge on the axle at a point halfway between the blocks Turn the axle to measure the runout The difference between the highest and lowest dial read ings is the amount of runout If runout exceeds the service limit replace the axle Axle Runout 100 mm 3 937 in Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in 604010281 WHEELS TIRES 10 11 Tires Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Remove the wheel from the motorcycle see Wheels Re moval e To maintain front wheel balance mark A the valve stem position on the tire with chalk so that the tire can be rein stalled in the same position e Remove the valve cap B e Take out the valve core A to let out the air e Remove the valve stem nut B OWhen handling the rim be careful not to damage the rim flanges e Loosen the bead protector nut A e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of
61. carefully for any damage holes broken wires gasket pulling off x lf the screen is damaged replace it e Install the oil screens A as shown Longer Outcrop Pipe B Right Crankcase C e Assemble the crankcase see Crankcase Transmission chapter 6113116BS1 7 10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal e Drain Engine Oil see Periodic Maintenance chapter Coolant see Periodic Maintenance chapter e Remove Brake Pedal see Brakes chapter Kick Pedal see Engine Right Side chapter Water Pipe Bolt A Water Pipe B pull out Water Pump Cover C Right Engine Cover Bolts D e Remove the right engine cover E e Remove the clutch see Engine Right Side chapter ODo not remove the clutch housing A OUsing the gear holder B to loosen the primary gear nut C left hand thread e Remove the primary gear D Special Tool Gear Holder 57001 1557 e Remove Circlip A Oil Pump Idle Gear B Special Tool Outside Circlip Pliers 57001 144 e Remove the mounting bolts A and remove the feed oil pump assembly B ENGINE LUBRICATION SYSTEM 7 11 Oil Pump e Remove the inner A and outer B rotors of the scaveng r ing oil pump e Disassembly the feed oil pump assembly Oil Pump Cover A Inner Rotor B Outer Rotor C Pin D Oil Pump Body E Oil Pump Gear F 6609026BS1 Oil Pump Installation e Apply molybdenum disulfid
62. disassemble the caliper before brake hose removal see Caliper Disassembly e Remove the rear wheel see Wheels Tires chapter e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Removal Installation CAUTION Immediately wipe up any brake fluid that is spilled BRAKES 12 13 Caliper Caliper Installation e Tighten the brake pad bolts if it was removed Torque Brake Pad Bolts 18 N m 1 8 kgf m 13 ft Ib Front Brake e Install the caliper and tighten the bolts Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 0 ft lb Rear Brake e Before install the caliper install the rear wheel see Wheels Tires chapter e Install the brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Caliper Disassembly e Refer to the Caliper Piston Seal and Dust Seal Replace ment in Periodic Maintenance chapter Fluid Seal Damage The fluid seal around the piston maintain
63. e Remove Seat Side Covers Carburetor Holder Clamp Screw loosen Muffler see Engine Top End chapter Rear Frame Mounting Bolts A Rear Frame B with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Using the hook wrenches A loosen the locknut B on the rear shock absorber Special Tool Hook Wrench 57001 1101 e Using the stem nut wrench A turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Special Tool Steering Stem Nut Wrench 57001 1100 SUSPENSION 13 23 Rear Suspension Uni Trak Spring Preload Adjustment Adjusting nut position at the lower surface A from the center of the mounting hole Standard 113 mm 4 45 in Adjustable Range 109 129 5 mm 4 29 5 098 in e Tighten the locknut securely e After adjusting move the spring up and down to make sure that the spring is seated e Install the parts removed e Tighten the rear frame mounting bolts Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Spring Tension e Since the spring becomes shorter as it weakens check its free length A to determine its condition xf the spring of either rear shock absorber is shorter than the service limit it must be replaced If the length of re placement spring and that of the remaining spring vary greatly the remaing s
64. inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes past the nearest hole WARNING If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Install disc cover e Check the rear brake for good braking power and no brake drag WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Wheels Inspection e Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings e Visually inspect the front and rear axles for damage lf axle is damaged or bent replace it Spoke Tightness Inspection e Refer to the Spoke Tightness Inspection in Periodic Main tenance chapter Rim Runout Inspection e Refer to the Rim Runout Inspection in Periodic Mainte nance chapter GKO4001BS1 GJ04034BS1 10 10 WHEELS TIRES Wheels Rims Axle Inspection e Visually inspect the front and rear
65. it has been removed Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition xf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability Fork Spring Free Length Standard 460 mm 18 11 in Service Limit 450 mm 17 72 in 6M04169BS1 6M04168BS1 GM040119S1 GM040116S1 SUSPENSION 13 21 Rear Suspension Uni Trak Rear Shock Absorber The rear suspension system of this motorcycle is New Uni trak It consists of a rear shock absorber swing arm tie rod and rocker arm To suit to various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damping force can be adjusted easily so changing oil viscosity unnecessary Rebound Damping Adjustment e Turn the rebound damping adjuster A on the rear shock absorber lower end with the blade of a screwdriver until you feel a click xf the damper setting feels too soft or too stiff adjust it in accordance with the following table Seated position adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 12 clicks B Softer Count
66. it just enough to install it and then use a suitable gear to push the circlip into place Special Tool Outside Circlip Pliers 57001 144 e The drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and the washers are properly in place 61138188 6113116BS1 6113114BS1 CRANKSHAFT TRANSMISSION 9 17 Transmission e The output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is 5th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and washers are properly in place Olnstall the collar A with the flange B facing toward the shifter C side 2nd Gear output D ND CONDO O 40060 O 00d Y y 6113115BS1 D Toothed Washer large Toothed Washer small Circlip Ball Bearing one side sealed 2nd Gear 14T 3rd Gear 18T 4th Gear 20T 5th Gear 19T Ti ES WES UV 29190269 OOOO MENE Ist Gear 14T Ball Bearing Drive Shaft Collar O rings 2 Ball Bearing 2nd Gear 25T Shifter 2nd 3rd four dog recesses faces right 22 23 24 3rd Gear 4th Gear 5th Gear 1
67. kPa 10 kgf cm 142 psi 19 987 20 000 mm 0 7869 0 7874 in 19 987 20 000 mm 0 7869 0 7874 in 15 995 16 000 mm 0 6297 0 6299 in under 0 1 mm 0 004 in Adjustable Range 16 clicks Adjustable Range 109 129 5 mm 4 29 5 02 in 255 mm 10 04 in Adjustable Range 16 clicks 19 85 mm 0 781 in 19 85 mm 0 781 in 15 85 mm 0 624 in 0 2 mm 0 008 in EU European Model SUSPENSION 13 7 Special Tools Oil Seal 8 Bearing Remover Jack 57001 1058 57001 1238 Steering Stem Nut Wrench Bearing Remover Shaft 69 57001 1100 57001 1265 a AJ Hook Wrench Bearing Remover Head 415 x 417 57001 1101 57001 1267 SS gt E f 5 Bearing Driver Set Fork Oil Level Gauge 57001 1129 57001 1290 Fork Outer Tube Weight Fork Oil Seal Driver 648 57001 1218 57001 1509 ST571509 S 13 8 SUSPENSION Special Tools Fork Cylinder Holder 57001 1573 E EN ST5715738ST SUSPENSION 13 9 Front Fork Air Pressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during opera tion Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap e Place the jack under the frame so th
68. less than the service limit the fork must be replaced lf any shift drum groove is worn exceeding the service limit the drum must be replaced Gear Damage e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes e Visually inspect the gear teeth C on the transmission gears Replace lightly damaged gear teeth with an oilstone The gear must be replaced if the teeth are badly damaged When gear is repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary 6113014581 6113110BS1 6113111BS1 6113112BS1 CRANKSHAFT TRANSMISSION 9 19 Bearings Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces sary Removal may damaged them e Remove the ball bearing and or needle bearing outer race using a press or puller NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Install the new bearing until its outer race stops at the bottom of the case using a press and the bearing driver set A Special Tool Bearing Driver Set 57001 1129
69. rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 08 3 94 in Connecting Rod Twist e With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 08 3 94 in 6105040681 6105040781 CRANKSHAFT TRANSMISSION 9 15 Transmission Transmission Shaft Removal e Disassemble the crankcase halves see Crankcase Dis assembly e Pull out the oil screens Crank Room Side Oil Screen A Transmission Room Side Oil Screen B e Pull out the shift rods A allowing the shift fork guide pins to free from the shift drum B e Remove the shift fork C e Remove the shift drum e Pull out the drive shaft A and output shaft B together with their gears meshed O1st gear of the output shaft is left for the crankcase Transmission Shaft Installation e Apply engine oil to the sliding portion of the transmission shaft gears and ball bearings e Install the drive shaft A and output shaft B in the right crankcase C with their gears meshed e Install the shift d
70. s and install them into the cylinder by hand e Apply brake fluid to the outside of the pistons C and push them into each cylinder by hand e Install the anti rattle spring A in the caliper as shown 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the shaft rubber friction boot A and dust boot B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes PBC is a special high temperature water resistance grease e Install the pads see Brakes chapter e Install the caliper see Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth Brake Hose and Connection Check e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings Brake Hose Replacement CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to ke
71. stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearings worn Rim warped or not balanced Spokes loose Wheel bearing worn Handlebar clamp bolt loose Steering stem head bolt loose Front rear axle runout excessive Handlebar pulls to one side Frame bent Rear wheel misalignment Swing arm bent or twisted Swingarm pivot shaft bent Steering maladjusted Steering stem bent Front fork bent Right and left front fork oil level uneven Suspension operation trouble Too hard Tire air pressure too high Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Front fork bent Front fork air pressure too high Too soft Front fork oil insufficient or leaking Front fork oil viscosity too low Rear shock absorber adjusted too soft Front fork rear shock absorber spring weak Rear shock absorber oil or gas leaking Tire air pressure too low Brake Doesn t Hold Air in brake system Pad disc worn Brake fluid leakage Contaminated pad Brake fluid deteriorated Brake master cylinder cups damaged Master cylinder scratched inside Disc warped MODEL APPLICATION Model Beginning Frame No JKAKXMNCO4A000001 or KX250 N1 JKAKX250NNA000001 O This digit in the frame number changes from one machine to another BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1324 02 Printed in Japan
72. the oil seals A so that the seal surface is flush B with the end of the hole e Apply high temperature grease to the oil seal lips Special Tool Bearing Driver set 57001 1129 C Hub Bearing Inspection NOTE Olt is not necessary to remove any bearings for inspec tion If any bearings are removed they will need to be replaced with new ones e Spin A it by hand to check its condition x lf it is noisy does not spin smoothly or has any rough spots it must be replaced e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing 6J06013BS1 GJO6009BS1 6J06008BS1 6J06002BS1 FINAL DRIVE 11 1 Final Drive Table of Contents Exploded View ana a AE AAA A EEN 11 2 SPECITICAIONS O dent dan e ten er ddr Pets Se x 11 4 Special TOONS ii RE PRE PR on A 11 5 NA a E EEA D ES dese aaascedanes 11 6 Drive Chain Slack Inspection 11 6 Drive Chain Slack AQILSIMEN EUR ne een te de ee Ne nl ne 11 6 Wheel Alignment Inspection sis 11 7 Wheel Alignment Adiusim nt s sms niet fiesta tnt ne 11 7 Drive Chain Wear Inspection ooccccccinicicncicncinnninnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnninnnineninns 11 7 Driv Gh in LUbFICATION ist M do errant Fate ds aaa 11 7 Drive Chain Removal sise 11 8 Drive Chain Installation 11 8 o NI 11 9 Engine Sprocket Removal nico e E te ba a
73. the upper hole of the crankcase CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal 6 12 ENGINE RIGHT SIDE Clutch Clutch Removal e Drain the engine oil see Periodic Maintenance chapter e Remove the clutch cover see Clutch Cover Removal e Remove the clutch spring bolts A spring and clutch pressure plate B e Remove the push rod holder assy A friction plates B and steel plates C e Remove steel ball e Remove the clutch hub nut A and washer e Remove the clutch hub C thrust washer and housing D NOTE OUse the clutch holder B to prevent the clutch hub from rotating Special Tools Clutch Holder 57001 1243 e Remove the needle bearing A and sleeve B Clutch Installation e Apply molybdenum disulfide grease to the outside of the sleeve e Apply engine oil to the inside of the clutch housing gear and kickstarter driven gear e Install the sleeve needle bearing clutch housing A and clutch hub ODo not forget to install the thrust washer B before in stalling the clutch hub C ENGINE RIGHT SIDE 6 13 Clutch e Install the toothed washer A e Tighten the clutch hub nut B Torque Clutch Hub Nut 98 N m 10 kgf m 72 ft lb NOTE OUse the clutch holder C to prevent the clutch hub from rotating Special Tool Clutch Holder 57001 1243 e Install the friction plates and steel plates start
74. this chapter Right Engine Cover see Engine Right Side chapter e Pull out the water pump shaft A toward inside of the right engine cover Water Pump Gear Installation e To prevent the oil seal lips from peeling apply thin coat of a molybdenum disulfide grease A to the water pump gear shaft B and insert it into the oil seals C from the inside of the right engine cover D CAUTION Be sure to apply a molybdenum disulfide grease to the water pump shaft when installing If it is in stalled dry the seals may wear excessively e Instal the impeller and check to see that the impeller turn freely Oil Seal and Bearing Removal e Remove Right Engine Cover see Engine Right Side chapter Water Pump Gear e Insert a bar A into the water pump shaft hole from the outside of the right engine cover and remove the ball bearing B by tapping C evenly around the bearing in ner race ORemove the oil seal D from the right engine cover in the same way as ball bearing removal e Insert a bar A into the water pump shaft hole from the inside of the right engine cover and remove the oil seal B by tapping C evenly around the seal lips Oil Seal Installation CAUTION If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Be sure to replace the oil seals 6D06027BS1 6D06028BS1 6D06029BS1 4 12 COOLING SYSTEM
75. to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the spring and pads see Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassembly the caliper e Remove the rear caliper see Brakes chapter e Remove the pads see Brakes chapter e Separate the caliper holder B from the caliper A e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper A WARNING 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 finger e Pull out the piston A by hand e Remove the dust seal B and fluid seal C e Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e The bleed valve was removed install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures e Replace the fluid seal s A with new ones OApply brake fluid to the fluid seal s and install them into the cylinders by hand e Replace the dust seal s B with new ones OApply brake fluid to the dust seal
76. total 2 measurements Special Tool Needle Adapter Set 57001 1457 Table 1 Magneto Output Voltage Tester Connections Reading Range Tester to Tester to 4 000 rpm 250V AC Black Red lead Red White lead 59 V or more 50 V AC Yellow lead Yellow lead 16 V or more x If the output voltage shows the value in the table the mag neto operates properly x If the output voltage shows a much lower reading than that given in the table indicates that the magneto is defective e To check the stator coil resistance as follows OStop the engine ODisconnect the auxiliary leads OConnect the hand tester as shown in the table 2 ONote the readings total 2 measurement 218013 P 16 12 ELECTRICAL SYSTEM Flywheel Magneto Table 2 Stator Coil Resistance Tester Connections Reading Range Tester to Tester to Black Red lead Red White lead 27 2 40 8 Q Yellow White lead Yellow lead 1 76 2 64 Q x 10 lf there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each leads and chas sis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement lf the sta
77. 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 satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in Periodic Main tenance chapter Fluid Change e Refer to the Brake Fluid Change in Periodic Maintenance chapter 12 10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power WARNING Be sure to bleed the air from the brake whenever brake lever or pedal action feels soft or spongy af ter the brake fluid is changed or whenever a brake line fitting has been loosened for any reason
78. 0 N m 0 7 kgf m 61 ft Ib Throttle Pulley Cover Bolt 3 4 N m 0 3 kgf m 30 in Ib e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After the installation adjust each cable properly WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition Throttle Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cables Refer to General Lubrication in the Periodic Main tenance Chapter OApply a thin coating of grease to the cable upper or lower ends OUse a commercially available pressure cable lubricator to lubricate these cables Throttle Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance chapter GCO4009BS1 GCO4010BS1 3 10 FUEL SYSTEM Throttle Grip and Cable Hot Start Cable Removal e Remove Dust Cover A Slide out Locknut B Loosen e Turn in the adjuster C fully e Remove the cable end D from the hot start lever E e Remove Carburetor Inlet side out e Unscrew the plunger cap bolt A and remove the cable end e Cut the band B e Disassemble the cable end from the plunger A Spring B Plunger Cap Assy C e Remove Left Radiator Shround see Fuel Tank Removal Clamps A Open Hot Start Cable B Hot Start
79. 0 kgf m 58 ft Ib Upper Front Fork Clamp Bolts 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again xf the steering is too tight or too loose repeat the adjust ment as mentioned above e Install the handlebar A on the handlebar holder as shown Same Length B Bridge Bar C em ETS 6S15010BS1 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the handlebar clamp A so that the cut side B on the clamp points at the front e Tighten the handlebar clamp bolts C Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib OTighten the clamp bolts rear first and then the front If the handlebar clamp is correctly installed there will be no gap at the rear and a gap at the front after tightening e Install the number plate Stem Bearing Lubrication e Remove the steering stem see Steering chapter e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the rollers Replace the bearing assemblies if they show wear or damage e Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower oute
80. 1 mm 0 10 0 15 mm 2 60 mm 2 81 2 76 mm OExchange the shims for the 2 775 or 2 800 size shim CAUTION Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage Adjustment shims pus P No Mark pes P No Mark 92180 0023 50 3 025 92180 0044 03 92180 0024 3 050 92180 0045 05 92180 0025 3 075 92180 0046 08 92180 0026 3 100 92180 0047 10 92180 0027 3 125 92180 0048 13 92180 0028 63 3 150 92180 0049 15 92180 0029 3 175 92180 0050 18 92180 0030 3 200 92180 0051 20 92180 0031 3 225 92180 0052 23 92180 0032 3 250 92180 0053 25 3 275 92180 0054 28 2775 92180 0034 3 300 92180 0055 30 2 800 92180 0035 3 325 92180 0056 33 2 825 92180 0036 3 350 92180 0057 35 3 375 92180 0058 38 3 400 92180 0059 40 2 900 92180 0039 3 425 92180 0060 43 2 925 92180 0040 3 450 92180 0061 45 2 950 92180 0041 3 475 92180 0062 48 2 975 92180 0042 3 500 92180 0063 50 3 000 92180 0043 6S07008BS1 6S07011BS1 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance Olf there is no valve clearance use a shim that is a few sizes smaller and reme
81. 17 in Service Limit 0 9 mm 0 0354 in Clutch Hub Spline Damage e Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates lf there are notches worn into the clutch hub splines A replace the clutch hub Replace the steel plates if their teeth are damaged as well GFO6O37BS1 GRO50105S1 GRO50140S1 6 16 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal e Remove Right Engine Cover e Remove the clutch see Clutch Removal e Temporarily install the clutch housing A e Using the gear holder B secure the primary gear Special Tool Gear Holder 57001 1557 e Remove the clutch housing e Remove the primary gear nut C washer and the primary gear D OPrimary gear nut is left hand threads Primary Gear Installation e Apply high temperature grease to the oil seal lip e Insert the primary gear A to the crankshaft e Install Washer B Primary Gear Nut C e Using the gear holder A secure the clutch gear and the bottom of the primary gear then tighten the primary gear nut B OPrimary gear nut is left hand threads Torque Primary Gear Nut 98 N m 10 0 kgf m 72 ft lb Special Tool Gear Holder 57001 1557 e Install Clutch see Clutch Installation ENGINE RIGHT SIDE 6 17 External Shift Mechanism External Shift Mechanism Removal e Remove Shift Pedal Bolt A Shift Pedal B e
82. 276 in Piston Ring End Gap Top 0 15 0 25 mm 0 55 mm 0 0059 0 0098 in 0 0217 in Oil 0 20 0 70 mm 1 0 mm 0 0079 0 0276 in 0 0394 in Piston Pin Diameter 15 992 15 997 mm 15 96 mm 0 6296 0 6298 in 0 628 in Piston Pin Hole Diameter 16 004 16 010 mm 16 07 mm 0 6301 0 6303 in 0 633 in Small End Inside Diameter 16 010 16 018 mm 16 05 mm 0 6303 0 6306 in 0 632 in TIR Total Indicator Readings 5 8 ENGINE TOP END Specifications Cam Height Camshaft Runout GE11012281 C 6E11077BS1 C Cam Height A Valve Stem Diameter Valve Stem Bend GE15049BS1 C 6E150112S1 C Valve Stem Diameter A Dial Gauge A 45 B ENGINE TOP END 5 9 Special Tools amp Sealants Compression Gauge 20 kgf cm 57001 221 Valve Seat Cutter 32 628 57001 1119 Valve Spring Compressor Assembly 57001 241 Valve Seat Cutter 32 933 57001 1199 Piston Ring Compressor Grip 57001 1095 Valve Seat Cutter 60 433 57001 1334 Piston Ring Compressor Belt 667 679 57001 1097 Valve Seat Cutter 45 927 5 57001 1114 Valve Seat Cutter Holder Bar 57001 1128 Valve Spring Compressor Adapter 620 57001 1154 Ez 5 10 ENGINE TOP END Special Tools amp Sealants Valve Seat Cutter 45 635 Valve Guide A
83. 5 3 7 V ELECTRICAL SYSTEM 16 5 Special Tools Timing Light 57001 1241 Needle Adapter Set 57001 1457 ST571457ST C Spark Plug Wrench Hex 16 57001 1262 Rotor Puller 57001 1565 ST5715658T Hand Tester 57001 1394 Rotor Holder 57001 1567 Throttle Sensor Setting Adapter 57001 1400 ST571567ST 16 6 ELECTRICAL SYSTEM Wiring Diagram Engine Stop Button lt a7 o x eon m o f o gt Me ao Magneto 6 Throttle Neutral Crankshaft Sensor Switch Sensor 72 Ground Color Code LG Light Green R w White GPOSO36BH3 ELECTRICAL SYSTEM 16 7 Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad
84. 5 18 Piston Piston Pin Connecting Cylinder Head Removal 5 19 Rod Wear Inspection 5 33 Cylinder Head Installation 5 20 Carburetor Holder 5 34 Cylinder Head Cleaning 5 21 Carburetor Holder Installation 5 34 Cylinder Head Warp 5 21 MUST O anpe ieira rae 5 35 Val Ve Saisie solar lan acts 5 22 Muffler Removal 5 35 Valve Clearance Inspection 5 22 Muffler Installation 5 35 Valve Removal ccccseseneeeeeeenes 5 22 5 2 ENGINE TOP END Exploded View ENGINE TOP END 5 3 Exploded View Fastener Remarks Auto decompressor bolt 104 in lb Cylinder head cover bolts 87 in lb Cylinder head bolts M6 104 in lb Carburetor holder clamp screws 17 in lb Plug 14 Lower camshaft chain guide bolt 87 in lb Rear camshaft chain guide bolt Exhaust pipe stud L Planted side 11 Closed coil end faces down EO Apply engine oil L Apply non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil R Replacement Parts S Follow the specific tightening sequence SS Apply silicon sealant 5 4 ENGINE TOP END Exploded View GE02090BN5 ENGINE TOP END 5 5 Exploded View Torque No Fastener Remarks 1 Chain tensioner mounting bolts 87 in lb
85. 7 in lb Radiator screen bolts Radiator Cap Water Pump Cover Impeller Oil Seal Short Oil Seal Long Bearing Water Pump Gear Right Engine Cover Cylinder Head Right Radiator Left Radiator Apply high temperature grease Replacement Parts Apply molybdenum disulfide grease 87 in lb 4 4 COOLING SYSTEM Specifications Item Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50 antifreeze 50 Freezing point 35 C 31 F Total amount 1 2 L 1 27 US qt Radiator Cap relief pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi COOLING SYSTEM 4 5 Special Tool Bearing Driver Set 57001 1129 4 6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor cycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter A WARNING To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down Coolant Level Inspection e Refer to the Coolant Level Inspection in Periodic Mainte nance chapter Coolant Deterioration Inspection e Refer to the Coolant Deterioration Inspection in Periodic Maintenance chapter Coolant Draining The coolant s
86. Cylinder Head Installation e Fit the projection A of the front camshaft chain guide B in the groove C of the cylinder D Olnsert the guide end E into the recess F of the crankcase securely e Install Dowel Pins A New Cylinder Head Gasket B e Install the cylinder head OThe camshaft caps are machined with the cylinder head therefore if a new cylinder head is installed use the caps that are supplied with the new head ENGINE TOP END 5 21 Cylinder Head e Replace all the 10 mm cylinder head bolt washers with new ones OThe 10 mm cylinder head bolt washers are copper plated and they could leak oil if reused e Apply molybdenum disulfide oil to the following areas 10 mm Cylinder Head Bolt Washer both sides A 6E14034BS1 e Tighten the 10 mm cylinder head bolts in the numbered sequence 1 4 Torque 10 mm Cylinder Head Bolt 49 N m 5 0 kgf m 36 ft Ib 6E14033BS1 e Tighten the 6 mm bolts M6 Cylinder Bolt A M6 Cylinder Head Bolt with Clamp B M6 Cylinder Head Bolt C Torque 6 mm Cylinder Bolt 12 N m 1 2 kgf m 104 in 1b 6 mm Cylinder Head Bolt 12 N m 1 2 kgf m 104 in Ib 6E14035BS1 e Install Camshaft see Camshaft Installation Cylinder Head Cover see Cylinder Head Cover Instal lation Engine Bracket see Engine Removal Installation chap ter Torque Engine Bracket Bolts 29 N m 3 0 kgf m 22 ft lb e Tighten the
87. DOT4 3 8 mm 0 150 in 6 4 mm 0 252 in KAYABA 01 or SAE 5W 564 4 mL 19 07 0 14 US oz 95 mm 3 7 in 0 7 0 8 mm 0 028 0 031 in 2 mm 0 08 in 2 mm 0 08 in 323 mm 12 72 in 54 8 mm 2 157 in 232 1 mm 9 138 in 0 5 mm 0 020 in 1 mm 0 04 in 1 mm 0 04 in Adjustable range 70 120 mm 2 8 4 7 in TIR Total Indicator Readings 2 10 PERIODIC MAINTENANCE Special Tools Valve Spring Compressor Assembly Fork Oil Level Gauge 57001 241 57001 1290 Steering Stem Nut Wrench Pilot Screw Adjuster C 57001 1100 57001 1292 Valve Spring Compressor Adapter 620 Pilot Screw Adjuster Adapter 4 57001 1154 57001 1371 Jack Pilot Screw Adjust D 57001 1238 57001 1588 E OE LE gt y AD TRE ST571588ST Spark Plug Wrench M16 57001 1262 PERIODIC MAINTENANCE 2 11 Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the inside the fuel line can cause fuel to leak A or the hose to burst e Check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hose A are securely connected and clamps B are tightened correctly e When installing route the hose according
88. Gear REMO alicia sd A A mi ina 6 20 Idle Gear Installation ss 6 21 Kickshaft Removal sie 6 21 Kickshaft Installation a aia ad old 6 21 Kickstarter Assembly Disassembly ASSeMbly occoccccccccononccocococononnnannoncnoncnnnnnnn nn nccnnnnns 6 22 6 2 ENGINE RIGHT SIDE Exploded View GRO2009BW5 ENGINE RIGHT SIDE 6 3 Exploded View Torque Fastener Primary gear nut 72 Remarks Clutch cover bolts 87 in lb Clutch cover bolt with washer 61 in lb Clutch spring bolts 87 in lb Clutch hub nut 98 10 72 Primary Gear Push Rod Holder Release Lever Shaft Clutch Lever Clutch Cable Clutch Hub Clutch Housing Sleeve Clutch Pressure Plate Friction Plates white paint marked Steel Plate Apply cable lubricant Apply engine oil Apply grease Apply high temperature grease Left hand threads Apply molybdenum disulfide grease Apply molybdenum disulfide oil Replacement Parts Apply a non permanent locking agent 6 4 ENGINE RIGHT SIDE Exploded View ENGINE RIGHT SIDE 6 5 Exploded View No Fastener Ratchet guide bolt Torque 78 in lb Remarks Kick pedal bolt 18 1 2 3 Shift pedal bolt Ratchet plate mounting screw 87 in lb 56 in lb Gear set lever nut 78 in 1b Shift d
89. Holder F O ring G Throttle Valve Plate H OAssemble the valve plate so that the hole side down ward I e Apply a non permanent locking agent to the link screw e Insert the throttle valve assembly Olnsert the link rollers A on the throttle link into the slits B of the throttle valve e Tighten the screw 3 26 FUEL SYSTEM Carburetor e Install O ring A Carburetor Cap B Bolts tighten e Install Starter Jet A Pilot Jet B Baffle Plate C Needle Jet D Main Jet E e Replace the O ring with new one e Install Pilot Air Screw A Spring B Washer C O ring D OTurn in the pilot air screw fully but not tightly and the back it out the counted number of turn see Carburetor Disassembly e Hanging the float valve A on the tang B of the float C e Fit the float valve into the valve seat e Insert the pin D e Install Leak Jet A e Replace the O ring with new one e Fit the O ring B onto the groove of the float bowl FUEL SYSTEM 3 27 Carburetor e Install Float Bowl e Tighten the bolts with hose clamps A and cable holder B as shown e Replace the O rings with new ones e Fit the O rings A e Install Diaphragm B Spring C Acceleration Pump Cover Olnstall the diaphragm so that its mark facing D outward e Tighten the bolts e Install the choke knob starter plunger A e Replace the O rings A with the new ones e Install
90. Hose Fitting P O rings e Pull out the push rod A of the acceleration pump e Unscrew the leak jet A e Remove E clip A Washer B e Pull out the acceleration pump lever assembly C as a set FUEL SYSTEM 3 21 Carburetor e Remove the throttle sensor mounting bolt A e Before removing the throttle sensor B mark C the car buretor body and sensor so that it can be installed later in the same position Carburetor Cleaning Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the carburetor e Make sure the fuel tap is in the OFF position e Remove the carburetor see Carburetor Removal e Drain the fuel in the carburetor e Disassemble the carburetor see this chapter CAUTION Do not use compressed air on an assembled carbu retor the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage or deterioration of the parts Do not use a strong carburetor cleaning solution which could attack the plastic parts instead use a mild high flash point cleaning solution safe for plastic parts Do not u
91. INE TOP END 5 33 Cylinder and Piston Piston Ring Thickness e Measure the thickness at several points around ring with a micrometer Piston Ring Thickness Top Standard 0 77 0 79 mm 0 0303 0 0311 in Service Limit 0 70 mm 0 0276 in lf any of the measurements is less than the service limit on either of the rings replace the rings as a set NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Measurement e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Place the piston ring close to the bottom of the cylinder where cylinder wear is minimal e Measure the gap B between the ends of the ring using a thickness gauge xf the ring end gap exceeds the service limit replace the ring Piston Ring End Gap Standard Service Limit Top 0 15 0 25 mm 0 55 mm 0 0217 in 0 0059 0 0098 in Oil 0 20 0 70 mm 1 0 mm 0 0394 in 0 0079 0 0276 in Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap ring A still fitted in place xf the ring shows weakness or deformation replace the ring Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin B with a microm eter x lf the piston pin diameter is less than the service limit at any po
92. L 1 6 USat Gear 3 350 67 20 Wet multi disc GENERAL INFORMATION 1 9 General Specifications Items KX250 N1 Transmission Type 5 speed constant mesh return shift Gear ratios 1st 2 142 30 14 2nd 1 785 25 14 3rd 1 444 26 18 4th 1 200 24 20 5th 1 052 20 19 Final drive system Type Chain drive Reduction ratio 3 692 48 13 Overall drive ratio 13 020 Top gear Frame Type Steering angle Caster rake angle Trail Front tire Size Make Type Rear tire Size Make Type Front suspension Type Wheel travel Rear suspension Type Wheel travel Brake type Front and Rear Effective disc diameter Front effect dia Rear effect dia Tubular semi double cradle 42 to either side 26 5 110 mm 4 33 in 80 100 21 51M BRIDGESTONE M601 EU M201 Tube type 100 90 19 57M BRIDGESTONE M602 EU M202 Tube type Telescopic fork up side down 300 mm 11 8 in Swingarm New Uni trak 310 mm 12 2 in Single disc 225 mm 8 86 in 215 mm 8 46 in EU European Model Specifications are subject to change without notice and may not apply to every country 1 10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units 104 176 80 100 120 140 160 180 200 220 240 260 280 300 Units of Length 212 248 284 km x 0 6214 mile m x 3 281 ft mm x 0 03937 in Units of Torque N m x 0 1020 kgf m N m x 0 7376 ft lb
93. N m x 8 851 in lb kgf m x 9 807 N m kgf m x 7 233 ft lb kgf m x 86 80 in lb Units of Pressure kPa x 0 01020 kgf cm kPa x 0 1450 psi kPa x 0 7501 cm Hg kgf cm x 98 07 kPa kgf cm x 14 22 psi cm Hg x 1 333 kPa Units of Speed km h x 0 6214 mph Units of Power kW x 1 360 PS kW x 1 341 HP PS x 0 7355 kW PS x 0 9863 HP 5 F 40 AO 9 F 320 Prefix Symbol Power mega M x 1 000 000 kilo k x 1000 centi c x 0 01 milli m x 0 001 micro u x 0 000001 Units of Mass kg x 2 205 Ib g x 0 03527 OZ Units of Volume L x 0 2642 gal US E x 0 2200 gal imp L x 1 057 qt US L x 0 8799 qt imp L x 2 113 pint US L x 1 816 pint imp mL x 0 03381 oz US mL x 0 02816 oz imp mL x 0 06102 cu in Units of Force N x 0 1020 kgf N x 0 2248 Ib kof x 9 807 N kgf x 2 205 Ib Units of Temperature COM ca F 32 68 40 20 i 20 40 60 40 20 0 20 i 40 4 4 26 7 48 9 C i i 400 71 1 93 3 116 120 440 138 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 2 Tires Inspection 2 29 Torque and Locking Agen t 2 4 Spoke Tightness Inspection 2 29 Specifications 2 8 Rim Runout Inspection 2 30 Special Tools 2 10 Wheel Bearing Inspection 2 30 Pe
94. NG 14 1 Steering Table of Contents Exploded MI Acasa A E O eat 14 2 Special TOS ii E et dd on 14 4 A O ue meet 14 5 Steering Inpec a A A AAA At ated 14 5 Steering ACIUSUMEN 22 een letrada colateral 14 5 Steering Stem Stem Bearing Removal ss 14 5 Steering Stem Stem Bearing Installation 14 6 Steering Maintenance mint did iia 14 9 ls A a ded abe nie 14 9 Stem Bearing Wear Damage intssusnnansrninaeremnnaenennttteniennnntnene 14 9 Stem Wars A den nee teed n tune redescend ee 14 9 A a a 14 10 HANS DAREMOS A ns 14 10 Handlebar Installation oooccoocccnccnncccncnnncnononoconnnnnnncnnnrnnncnnnn ocn a a E aaa at a LENS ha 14 10 14 2 STEERING Exploded View GNO2036BW5 STEERING 14 3 Exploded View Fastener Remarks Handlebar clamp bolts 25 25 18 0 S Steering stem head nut 78 8 0 58 Steering stem locknut 4 9 0 5 43 in lb T Handlebar Clamp Handlebar Handlebar Holder Steering Stem Head Bracket Upper Tapered Roller Bearing Head Pipe Lower Tapered Roller Bearing Steering Stem Tighten the two clamp bolts alternately two times to ensure even tightening torque Apply adhesive cement Apply grease Apply 2 Stroke Oil T Tighten all snugly then loosen Retighten to 4 9 N m 0 5 kgf m 43 in Ib S Follow the specific tightening sequence 14 4 STEERING Special Tools Bearing Puller Head Pipe Outer Race Driver
95. Negative Yellow Lead D OCrank the engine by kicking the pedal several time to measure the peak voltage of the charge coil Peak Voltage 8 8 V or Above xf the voltage is less than the specified check the charge coil 6P10123BS1 6P10125BS1 ELECTRICAL SYSTEM 16 21 Ignition System Throttle Sensor Output Input Voltage Check e Remove the carburetor lead connector A e Connect the throttle sensor setting adapter A between carburetor lead connector B and main harness connec tor C Special Tool Throttle Sensor Setting Adapter 57001 1400 e Set the tester D to the DC 10V range and connect it to the adapter leads Hand Tester Blue Lead color of lead on the sensor Hand Tester Black Lead color of lead on the sensor e Start the engine e Check the sensor input voltage with the engine running Throttle Sensor Input Voltage Standard around 5 V x lf it is not within the specified voltage range check the magneto output voltage If it has normal functions re place the C D I Unit e To check the output voltage do the following procedures OConnect the digital voltmeter as follows Tester Yellow Lead Tester Black Lead OStart the engine OMeasure the throttle sensor output voltage with the engine idling speed and with the idle throttle valve opening Throttle Sensor Output Voltage Standard 0 68 0 1 V when engine is idle speed
96. OTE ODo not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again e Read the fuel level in the gauge and compare it to the specification Service Fuel Level above the bottom edge of the carb body Standard 6 5 1 mm 0 256 0 039 in xlf the fuel level is incorrect adjust it e Turn the fuel tap to the OFF position and remove the fuel level gauge e Install the drain plug on the bottom of the float bowl Service Fuel Level Adjustment A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl see Carburetor Disassembly e Drive out the pivot pin A and remove the float B with valve needle C 3 14 FUEL SYSTEM Carburetor e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 8 1 mm 0 315 0 039
97. TE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE 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 Se MIC sti did 1 2 Model Identification sidra a ta diene 1 7 General Specifications 1 8 UnitConversion Table ica a A fa anti dre 1 10 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especiall
98. Tightness Inspection Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature xlfthere are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications For each fastener first loosen it by 1 2 turn then tighten it lf cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknut Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Brake Lever Pivot Nut Front Caliper Mounting Bolts Brake Pedal Bolt Rear Brake Joint Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts Suspension Front Fork Clamp Bolts Front Fender Bolts Rear Shock Absorber Mounting Bolts Nuts Swingarm Pivot Nut Steering Steering Stem Head Bolt Handlebar Clamp Bolts Engine Throttle Cable Adjuster Lock Nuts Engine Mounting Bolts Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Clamp Bolt Clutch Cable Adjuster Locknut Clutch Lever
99. accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B d 6S05009BS1 6S05028BS1 6S05029BS1 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures xlf the throttle grip free play cannot be adjusted with the adjusters at the upper end of the throttle cables use the cable adjusters A at the carburetor e Make the necessary free play adjustment at the lower ca ble adjusters tighten the locknuts B xlf the throttle grip free play cannot be adjusted with the lower adjuster replace the throttle cables e Turn the handlebar from side to side while idling the en gine If idle speed varies the throttle cable may be poorly routed or it may be damaged A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition Hot Start Lever Free Play Inspection e Slide the clutch lever dust cover A back e Check the hot start lever play B when pulling the start lever C lightly Hot Start Lever Free Play Standard 0 5 1 0 mm 0 02 0 04 in xlf the free play is improper adjust the hot start cable e Slide the adjuster cover A back e Loosen the locknut B and turn the adjuster C to obtain the proper lever free play e Tighten the locknut securely e Check that the hot start lever moves smoothly from full open to close
100. ace a clean cloth under the piston and remove the pis ton snap ring A from one end of the piston pin CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Remove the piston pin using a piston pin puller Special Tool Piston Pin Puller Assembly 57001 1564 A e Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the oil ring in the same procedure Cylinder and Piston Installation NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove 6E16013BS1 UVU IIA Sur 6E16044BS1 ENGINE TOP END 5 31 Cylinder and Piston e Install the top ring A so that the R mark B faces up NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston rings e Apply engine oil to the inside wall of the small end of the connecting rod e Face the circle mark A on the top ofthe piston must point toward the front B o
101. ach Tie Rod Rocker Arm 13 29 fork leg she 13 14 Tie Rod Removal i n 13 29 Front Fork Assembly 13 17 Tie Rod Installation 13 29 Inner Tube Inspection 13 20 Rocker Arm Removal 13 29 Guide Bush Inspection 13 20 Rocker Arm Installation 13 30 Dust Seal Oil Seal Inspection 13 20 Tie Rod and Rocker Arm Bearing Spring Tension 13 20 Removal ocio tado weeds 13 30 Rear Suspension Uni Trak 13 21 Tie Rod and Rocker Arm Bearing Rear Shock Absorber 13 21 Installation 13 30 Rebound Damping Adjustment 13 21 Needle Bearing Inspection 13 31 Compression Damping Uni Trak Maintenance 13 32 AQJUS IM batata 13 21 Uni Trak Linkage Inspection 13 32 Spring Preload Adjustment 13 22 Tie Rod and Rocker Arm Sleeve Spring Tension 13 23 Near 13 32 Rear Shock Absorber Removal 13 23 Tie Rod and Rocker Arm Rear Shock Absorber Installation 13 23 Mounting Bolt Bend 13 32 13 2 SUSPENSION Exploded View dy OS S b l e IT i 2 5 OD a 00006 l ES Lil l 9 a TD T ll l D ivy 6M02081BW5 SUSPENSION 13 3 Exploded View Fastener Front fork top plug Torque Remarks
102. amaged Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Hot start stuck open Fuel level in carburetor float bowl too high or too low Fuel tank cap air vent obstructed Fuel tap clogged Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak APPENDIX 17 9 Troubleshooting Guide Valve not seating properly valve bent de formed worn or carbon accumulation on the seating surface Decompression trouble Other Faulty CDI unit Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Flywheel magneto damage Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect
103. anted side Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Chain Tensioner Cap 20 2 0 14 5 PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Fastener ae Remarks N m kgf m ft lb Cylinder Bolt M6 12 1 2 104 in lb S Exhaust Pipe Cover Screws 12 1 2 104 in lb Exhaust Pipe Holder Nuts 21 2 1 15 S Muffler Mounting Bolts 21 2 1 15 S Engine Right Side Primary Gear Nut 98 10 72 Lh Shift Drum Cam Bolt 24 2 4 17 L Clutch Spring Bolts 9 8 1 0 87 in lb Clutch Hub Nut 98 10 72 Gear Set Lever Nut 8 8 0 9 78 in lb Gear Set Lever Pivot Stud L Planted Side Ratchet Plate Mounting Bolt 1 0 87 in lb Ratchet Plate Mounting Screw 0 65 56 in lb L Kick Ratchet Guide Bolt 0 9 78 in lb L Kick Pedal Bolt 2 5 18 L Shift Pedal Bolt 1 0 87 in lb Clutch Cover Bolts 1 0 87 in lb L 1 Clutch Cover Bolt with washer 0 7 61 in lb L Right Engine Cover Bolts 1 0 87 in lb Engine Lubrication System Engine Oil Drain Plug M10 for crank room oil sump f 11 Engine Oil Drain Plug M6 for transmission room oil sump 61 in lb Engine Oil Drain Plug M6 for oil filter oil chamber 61 in lb Oil Pump Mounting Bolts 61 in lb Water Pump Cover Bolts i 87 in lb Water Pump Cover Bolt with washer E 61 in lb Right Engine Cover Bolts l 87 in lb Piston Oil Nozzle 22 in lb Breather Fitting 11 Clutch Cover Bolts f A 87 in lb Oil Pump Idle Gear Shaft Screws 56 in lb Engine Removal Installation Engine Mou
104. ars 2 39 s Brake hoses and pipe replace Every 4 years 2 42 S Brake hoses connections inspect t e 2 42 2 Spoke tightness and rim runout inspect t e 2 29 Wheel bearing inspect t o 2 30 Frame inspect o 2 54 Drive chain wear inspect t o 2 31 Wheels tires inspect e 2 28 Rear sprocket inspect t 2 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 See OPERATION race races races races Page Front fork inspect and clean e 2 44 Front fork oil change Rear shock oil replace Cable inspect Fuel hose replace Fuel hose connections inspect t Steering play inspect t Steering stem bearing grease Swingarm and Uni Trak linkage pivots grease Swingarm and Uni Trak linkage pivots inspect t Nuts bolts fasteners inspect t T Replace add adjust clean or torque if necessary R Replace 2 4 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench If insufficiently tightened a bolt or nut may become damaged strip an internal thread or break and then fall out The following table lists the tightening toque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or liquid gasket When checking the tightening toque of the bolts and nuts first loosen the bolt
105. as shown Acceleration pump lever A Spring B Push Rod Holder C Adjusting Screw with Spring D OFit the spring end on the stopper E of the push rod holder e Install the return spring A to the acceleration pump lever B 3 24 FUEL SYSTEM Carburetor e Install the acceleration pump lever assembly to the car buretor body OFit the end B of the return spring into the recess A on the carburetor body e Install Washer A E clip B e Apply thin coat silicone grease to the shaft e Fit the hook A of the return spring onto the stopper B of the throttle cable pulley e Insert the throttle cable pulley shaft A and install the steel washer D nylon washer C and valve link B OFit the end A of the return spring into the recess B of the carburetor body FUEL SYSTEM 3 25 Carburetor e Turn the pulley counterclockwise A while holding down the acceleration pump lever B and clear the stopper C of the pulley from the throttle stop screw head D e Install the push rod A into the push rod holder B e Apply a grease to the O ring A e Fit the stopper B of the throttle sensor onto the projection C on the throttle cable pulley shaft Olnstall the throttle sensor so that the marks aligns and check it position see Electrical System chapter e Assembly Throttle Valve A Jet Needle B Circlip C Retainer D Spring E Jet Needle
106. asociaron 12 9 Fluid Level Inspection miii ds 12 9 A A et 12 9 Bleeding the Brake eiii ii 12 10 672 E RE A Re 12 12 Galiper Removal A ag alien a ist een 12 12 Galiper InStal lation RS RES ee T EE 12 13 Caliper DISASSEMDIY se ent M PO Nt oe aie Stee 12 13 Fluid Seal Da Mirage avi it bin 12 13 Dust Seal and Cover Damage sec iccisiccsccceneeelad old atetegteadagueseanectactante 12 13 Piston Cylinder Damages aan dd te ner der diet tnt 12 13 Caliper Holder Shaft Wear 12 14 1128 Brake Pad Removal unica Ia eee 12 14 Brake Pad Installation ia da 12 15 Brake PadiInspectionissssa sat etienne ae 12 15 Master Clero conidios decada 12 16 Front Master Cylinder Removal eins ii seasees dl eNsehuedacaieed 12 16 Front Master Cylinder Installation 12 16 Rear Master Cylinder Removal coca ns eh secon aiventiies Uhaweslnpedaut eaeead lense needs 12 17 Rear Master Cylinder Installation 12 17 Front Master Cylinder Disassembly ccceeeeeeeseeneceeeeeeeeeeeseeeeneceeeeseeseeneneeneeeeeenees 12 17 Rear Master Cylinder Disassembly 12 17 Master Cylinder Assembly exc setts caves adi 12 17 Master Cylinder Inspection Visual Inspection 12 18 Brake Disk iii a cada 12 19 Brake DISC INSPECUOM iii A aii 12 19 Brake Hosen RE aii iii haga qeaseaeetsGtaaer 12 20 Brake Hose Removal Inst
107. asure the valve clearance e When installing the shim face the marked side A toward the valve lifter B At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim This may cause it to fracture causing extensive engine damage e Apply engine oil to the valve lifter surface and install the lifter e Install the camshaft see Engine Top End chapter e Recheck the valve clearance and readjust if necessary e Install the cylinder head cover see Engine Top End chap ter timing inspection cap and the flywheel cap Torque Timing Inspection Cap 4 N m 0 4 kgf m 35 in Ib Flywheel Cap 5 N m 0 5 kgf m 43 in lb Cylinder Head Warp Inspection e Remove the cylinder head see Engine Top End chapter e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge between the straightedge and the head lf warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 0020 in e Remove the valves see Engine Top End chapter e Space the carbon out of the combustion chamber and exhaust port with a scraper A
108. at the front wheel off the ground Special Tool Jack 57001 1238 e Remove the screws A at the top of the front fork top plugs to let the air pressure equalize NOTE ODO not use the side stand when adjusting the air pres sure OAdjust the air pressure when the front forks are cold e Replace the O ring with a new one e Install the screw Rebound Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e To adjust rebound damping turn the adjuster A on the front fork top plugs with the blade of a screwdriver until you feel a click Adjust the rebound damping to suit you preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated positions adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 11 clicks B 12 clicks European Model C Softer Counterclockwise D Harder Clockwise E Number of turns counterclockwise usable range 16 clicks or more Counterclockwise from the fully seated position Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e To adjust compression damping turn the adjuster A on the front fork cylinder valve with the blade of a screwdriver until you feel
109. better lubrication e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings e Wipe off any excess oil Oil applied area A Sprocket Wear Inspection e Visually inspect the front and rear sprocket teeth for wear and damage xlf they are worn as illustrated or damaged replace the sprocket A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation e Measure the diameter of the sprocket at the base of the teeth xlf the sprocket is worn down to less than the service limit replace the sprocket Engine Sprocket Diameter Standard 55 48 55 68 mm 2 184 2 192 in 13T Service Limit 54 8 mm 2 16 in Rear Sprocket Diameter 232 62 233 12 mm 9 158 9 178 Standard in 48T Service Limit 232 1 mm 9 138 in NOTE Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain Rear Sprocket Warp Inspection e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Seta dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp If the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard Under 0 4 mm 0 016 in Service Limit 0 5 mm 0 020 in
110. both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 0 kgf m 80 ft Ib e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin A through the axle nut and axle and spread its ends 6S12008BS1 6K04037BS1 6K04001BS1 FINAL DRIVE 11 7 Drive Chain NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes past the nearest hole A WARNING GJ04034BS1 If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Check the rear brake see Brakes chapter NOTE Oln wet and muddy conditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break To prevent this adjust the chain to 62 72 mm 2 44 2 83 in of slack whenever necessary Wheel Alignment Inspection e Check that the rear end A of the left chain adjuster aligns with the same swing arm mark B as the right chain ad juster Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Wheel Alignment Adjustment This procedure
111. c Maintenance Procedures NOTE OThe procedure to change the front brake fluid Chang ing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove the screw A reservoir cap B and diaphragm C e Remove the rubber cap A on the bleed valve B e Attach a clear plastic hose A to the bleed valve on the caliper and run the other end of the hose into a container B e Change the brake fluid as follows ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D OFill the reservoir with fresh specified brake fluid NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line 6S13035BS1 6S13039BS1 GLO9060482 C PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 8 kgf m 69 in Ib Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in 1b e After changing the fluid check the brake for good braking power
112. ce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F GE15011881 GE15011981 ENGINE TOP END 5 27 Valves e Measure the outside diameter of the seating surface with a vernier caliper x lf the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Original Seating Surface B ORemove all pittings of flaws from 45 ground surface OAlter grinding with 45 cutter apply thin coat of machin ist s dye to 45 A seating surface This makes seating surface distinct and 32 and 60 grinding operation eas ier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x lf the outside diameter A of the seating surface is too large make the 32 grind described below If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide
113. cial Tool Steering Stem Nut Wrench 57001 1100 14 6 STEERING Steering e Take off the upper stem bearing inner race tapered roller bearing A e Drive out the bearing outer races from the head pipe ORemove the outer races pressed into the head pipe using the head pipe outer race remover A and hammer the head pipe outer race remover to drive it out Special Tool Head Pipe Outer Race Remover 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearing includ ing outer races should be replaced with new ones e Remove the lower stem bearing inner rase tapered roller bearing A with its grease seal from the stem using bear ing puller Special Tool Bearing Puller 57001 1575 Bearing Puller 57001 135 Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones OApply grease to the outer races and drive them into the head pipe at the same time using the head pipe outer race press shaft A and the drivers Special Tool Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 57001 1076 B Head Pipe Outer Race Driver 57001 1077 C GNO4002BS1 GNO70106S1 GNO4010181 6N05040251 STEERING 14 7 Steering e Replace the lower inner races with new ones OApply grease to the lower tapered roller bearing A and drive it onto the stem using th
114. clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract e Separate the element A from the frame B e Clean the element A in a bath of a high flash point sol vent using a soft bristle brush e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Check all the parts of the element for visible damage x lf any of the parts of the element are damaged replace them e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean towel and squeeze it as dry as possible OBe careful not to tear the sponge filter e Assemble the element e Remove the towel from the carburetor 6S05025BS1 6S05026BS1 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Install the element onto its frame and coat the element lip and lip seat with a thick layer of all purpose grease to assure a compete seal e Install the air cleaner element so that its tab faces A upward and its projections B align with the holes C in the housing e Tighten the wing bolt D e Install the seat Cooling System WARNING To avoid burns do not remove the radiator cap or try to change the c
115. connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors A Female Connectors B Male Connectors Safety Instructions The ignition system produces extremely high volt age Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you could receive a severe electrical shock GPO60101S1 6P0601028S1 16 8 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect an ohmmeter between the ends of the leads OSet the meter to the x 10 range and lead the meter If the meter does not read 0 Q the lead is defective Re place the lead or the wiring harness if necessary 6S17001BS1 ELECTRICAL SYSTEM 16 9 Flywheel Magneto Magneto Cover Removal e Drain the engine oil from the crank room oil sump see Periodic Maintenance chapter e Push down the stopper A e Remove the magneto lead connec
116. cs cuca E erae Smet TT 2 44 Cylinder Wear Inspection 2 20 Rear Shock Absorber Oil Change 2 46 Piston Cylinder Clearance 2 20 Swingarm and Uni Trak Linkage Piston Piston Ring and Piston Inspection 2 51 Pin Replacement 2 20 Swingarm and Uni Track Linkage Exhaust System 2 21 Pivot Lubricate 2 51 Silencer Packing Change 2 21 o manne nl 2 52 Engine Right Side 2 22 Steering Inspection 2 52 Clutch Adjustment 2 22 Steering Adjustment 2 52 Friction and Steel Plates Stem Bearing Lubrication 2 54 Inspection 2 23 FRAME A R Ea 2 54 Engine Lubrication System 2 23 Frame Inspection 2 54 Engine Oil Change 2 23 Electrical System 2 54 Oil Filter Change 2 24 Spark Plug Cleaning and Oil Screen Cleaning 2 26 INSpeCtiON users 2 54 Breather Hose Inspection 2 26 Cable Inspection 2 55 Crankshaft Transmission 2 26 Lubrication 2 55 Crankshaft Inspection 2 26 Nut Bolt and Fastener Tightness Wheel Tires 2 28 Inspection 2 57 Air Pressure Tightness Inspection 2 57 Inspection Adjustm
117. d Rocker Arm Rocker Arm Installation e Apply plenty of grease to the inside of the rocker arm needle bearings oil seals and grease seals outside of the sleeve e Be sure seated the washers e Tighten the following Torque Rear Shock Absorber Lower Mounting Nut 34 N m 3 5 kgf m 25 ft Ib Rocker Arm Pivot Nut 83 N m 8 5 kgf m 61 ft Ib Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft Ib Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rod see Tie Rod Removal Rocker Arm see Rocker Arm Removal Washers A Sleeves B Oil Seal C Grease Seals D e Remove the needle bearings E using the bearing re mover head and bearing remover shaft e Remove the needle bearing F using the oil seal 8 bear ing remover Special Tool Bearing Remover Head 57001 1267 Bearing Remover Shaft 57001 1265 Oil Seal amp Bearing Remover 57001 1058 GMO7011BS2 C Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing grease seals and oil seals with new ones e Apply plenty of grease to the oil seal and needle bearings A NOTE Olnstall the grease seals so that the deep groove side of the rip out ward SUSPENSION 13 31 Tie Rod Rocker Arm e Install the needle bearings A B grease seals C and oil seals D position as shown OThe installation procedure is the same as the counter side Front E Rear Shock Absorber H Right Side F Tie rod I Left Side G Rocker Arm J
118. d Lubrication ococccccnccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenineninnnos 6 9 Clutch Cover and Right Engine Cove hum ia 6 10 Clutch Cover Removal sise 6 10 Clutch Cover Installation 6 10 Right Engine Cover RemOval see iss is o a di 6 10 Right Engine Cover InstallatiON comicios ic 6 10 Release Shaft Removal ss 6 11 Release Shaft Installation 6 11 Clute SP LE RU EE LITE ee 6 12 Clutch Remove es 6 12 Clutch Installation a a ASA ete etn Mere cea 6 12 Friction and Steel Plates Wear Damage Inspection 6 14 Friction and Steel Plate Warp Inspection 6 14 Clutch Spring Free Length Inspection 6 14 Clutch Housing Finger Damage ociosa tes rate nm hein 6 15 Friction Plate Clutch Housing Clearance ooooocccccccccononooacccncncnocnnnnnno nono nnnnnnnnnnnnnnnnnnnnnnnnnnnns 6 15 Clutch Hub Spline Damages dd dic 6 15 PMA e da T 6 16 Primary Gear Removal senii arenie ta et Te US Lait een nat ee Lee 6 16 Primary Gear Installation sida ala 6 16 External Shift Mechanism seen 6 17 External Shift Mechanism Removal rr 6 17 External Shift Mechanism Installation 6 17 External Shift Mechanism Inspection 6 18 LL ET A O T e r r a aE ada ii id 6 20 Kick Pedal Assy Remoyal ua e ia aie EAEE aes 6 20 Kick Pedal Assy Instala cocinada tic EAA aaae nt ti 6 20 Kick Pedal Assy Disassembly iii ii iia 6 20 Kick Pedal Assy AsSemDly di a oo ini 6 20 Idle
119. d crankshaft sensor F as a set ELECTRICAL SYSTEM 16 11 Flywheel Magneto Stator Installation e Route the wires according to the Cable Wiring and Hose Routing section in the Appendix chapter e Install the stator and tighten it Torque Stator Bolts 7 0 N m 0 7 kgf m 61 in Ib e Install the crankshaft sensor and wiring holder A ORun the magneto leads under the holder and sensor Torque Crankshaft Sensor Bolts 7 0 N m 0 7 kgf m 61 in Ib e Apply silicone sealant around the circumference of the wiring grommet e Set the stator wiring grommet B securely in the notch C e Install the magneto cover see Magneto Cover Installa tion Flywheel Magneto Inspection e There are three types of magneto problems short open wire burned out or loss in flywheel 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 flywheel magnetism which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field or just by ag ing will result in low output e Check the magneto output voltage do the following pro cedures OPush down the stopper A and remove the magneto lead connector B OConnect the hand tester A to the connector B as shown in the table 1 using the needle adapter set C OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings
120. dowel pins C are in place in the mating surfaces of the crankcase halves e With the connecting rod positioned at the bottom dead center install the crankshaft jig A Special Tool Crankshaft Jig 57001 1174 e Apply liquid gasket to the mating surface A of the left crankshaft half Sealant Kawasaki Bond Liquid Gasket Gray 92104 1063 NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied gt OMoreover fit the case and tighten the case bolts just Du after finishing the application of the liquid gasket CRANKSHAFT TRANSMISSION 9 11 Crankcase e Using a plastic hammer A press B the rear portion of the crankcase and tap C the area around the crank shaft of the left crankcase While maintaining the mating surfaces of the right and left crankcase halves constantly parallel mate the crankcase halves evenly NOTE OConstantly check the alignment of the two crankcase halves and the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly e Remove the crankshaft jig D e Tighten the crankcase bolts starting with the periphery of the crankshaft then outward Torque Crankcase Bolt 9 8 N m 1 0 kgf m 81 in Ib NOTE OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface espe ciall
121. e temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers are on each side of hose fitting with new ones e Tighten the following Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb Rear Master Cylinder Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage e Check the brake pedal position master cylinder push rod length Front Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in Periodic Maintenance chapter 6L07036BS1 12 18 BRAKES Master Cylinder Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on the outside of each piston B lf a master cylinder or piston shows any damage replace them e Inspect the primary C and secondary D cups lf a cup is worn damaged softe
122. e Apply high temperature grease to the shaft portion of the brake pedal and install the pedal with return spring onto the frame Olnstall the return spring direction A as shown Torque Brake Pedal Mounting Bolt 25 N m 2 5 kgf m 18 ft lb e Check the brake pedal position e Install the joint pin washer and a new cotter pin OBend the ends A of the cotter pin 6L04008BS1 BRAKES 12 9 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 isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber
123. e Covers Seat see Frame chapter Fuel Tank see Fuel System chapter e Disconnect Magneto Lead Connector A Neutral Switch Lead Connector B Spark Plug Cap C Ignition Coil Lead Connector D Ignition Coil with Coil Bracket E 6H04019BS1 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Loosen Carburetor Clamp Bolts A e Remove Inlet Duct B with Rear Frame see Frame chapter Carburetor C hanging it Clutch Cable Lower End D see Engine Right Side chapter Drive Chain E cut out e Remove Bolts A Rear Brake Pedal B Master Cylinder C e Remove Exhaust Pipe Holder Nuts A Exhaust Pipe B Clamp Screws C loosen Radiator Hose D Radiator Pipe Bolt E Radiator Pipe F e Remove Upper Engine Bracket Bolts A Upper Engine Mounting Bolt B Upper Engine Bracket C e Remove Middle Engine Bracket Bolts A Middle Engine Mounting Bolt B Middle Engine Brackets C Lower Engine Mounting Bolts D ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Pull out the carburetor hoses A and breather hose B from the clamp C e Remove the swing arm pivot shaft D OPull out the swing arm pivot shaft half way from right side to free the engine e Remove the engine from the vehicle to right side OClear the engine rear portion from the swingarm and then remove the engine Engine Installation
124. e Press the new output shaft bearings A in the left and right crankcase half B so that the stepped side C faces inside of the engine Special Tool Bearing Driver Set 57001 1129 e Put the output shaft oil seal D in being careful of the proper direction as shown e Apply high temperature grease to the oil seal lip e Install the reed valve A direction as shown Guide B Screws C Torque Read Valve Screws 7 0 N m 0 7 kgf m 61 in lb e Apply a non permanent locking agent to the retaining screw and bolts e Tighten the bearing retaining screws A and bolts B Torque Bearing Retaining Screws 6 4 N m 0 65 kgf m 56 in Ib Bearing Retaining Bolts 9 8 N m 1 0 kgf m 87 in Ib e Apply a non permanent locking agent to the piston oil noz zle C e Tighten Torque Piston Oil Nozzle 2 5 N m 0 25 kgf m 22 in Ib 6104107BS1 6104106BS1 9 10 CRANKSHAFT TRANSMISSION Crankcase e Apply engine oil to the transmission gears bearings shift forks shift drum and crankshaft bearing e Install the drive shaft A and output shaft B in the right crankcase C as a set e Install Shift Drum A see Transmission Installation Shift Forks B see Transmission Installation Shift Rod C see Transmission Installation e Install Crankshaft A Oil Screens B Olnstall the oil screen so that the longer pipe side faces in right crankcase e Check to see that the
125. e Remove the oil drain plug for oil filter oil chamber A e Attach the oil pressure gauge adapter A e Attach the oil pressure gauge B Special Tools Oil Pressure Gauge Adapter 57001 1579 Oil Pressure Gauge 57001 125 e Start the engine and warm up the engine thoroughly e Run the engine at the specified speed and read the oil pressure gauge lf the oil pressure is much lower than the standard check the feed oil pump x If the reading is much higher than the standard check the oil filter first and oil passages for dirt or clogging Oil Pump Pressure oil temperature 90 C 4 000 rpm Standard 19 6 kPa 0 2 kgf cm 2 8 psi NOTE OWarm up the engine thoroughly before measuring the oil pressure e Stop the engine and remove the gauge and the oil pres sure gauge adapter WARNING Take care against burns from hot engine oil that will drain through the oil passage when the oil pressure gauge adapter is removed e Install the oil drain plug see Engine Lubrication System in the Periodic maintenance chapter ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents Exploded View assis a A E ida 8 2 Special Oi A A VEEN eee Pa se on 8 4 Engine R emoval Instalationss ses ess ie at ita 8 5 Engine Removal ai iS Ar MS A a On On tt de des 8 5 Engine Installation Garran ES AA an nee ae aA ee ee 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View
126. e fuel hose fitting B e Unscrew the carburetor cap bolts A e Remove the carburetor cap B e Unscrew the throttle valve link screw A e Pull out the throttle valve assembly B e Disassemble the throttle valve assembly jet needle holder A unscrew spring B retainer C jet needle with circlip D O ring with throttle valve plate E and throttle valve F e Remove the choke knob starter plunger assembly A from the carburetor FUEL SYSTEM 3 19 Carburetor e Remove the throttle pulley shaft A with the spring B steel washer C plastic washer D and throttle valve link E OTurn the throttle pulley shaft A clockwise while holding down the acceleration pump lever B and clear the idle stop screw C to the stopper D of the pulley e Turn in the pilot air screw A fully but not tightly and count the number of turns ORecord this number as the manufacture set number of turns out e Unscrew the pilot air screw e Unscrew the screws A e Remove the acceleration pump cover B from the carbu retor e Remove the spring A diaphragm B and the O ring C 3 20 FUEL SYSTEM Carburetor e Remove the following parts from the carburetor body A Idle Adjusting Screw B Screws C Clamps D Float Bowl E Leak Jet F O ring G Pin H Float I Main Jet J Needle Jet K Starter Jet L Pilot Jet M Pilot Air Jet N Stopper Screw O Fuel
127. e grease to the shaft of the oil pump gear e Apply engine oil to the inner and outer rotors e Assemble the oil pump gear A body B pin C and inner rotor D OFit the slot E of the inner rotor on the pin e Install the outer rotor A and cover B e Install Pin A Inner Rotor B OFit the slot C of the inner rotor on the pin 7 12 ENGINE LUBRICATION SYSTEM Oil Pump e Install the outer rotor A e Install the dowel pin B and dowel pin C e Install the scavenging and feed oil pump assemblies D e Apply a non permanent locking agent to the oil pump mounting bolts e Tighten the oil pump mounting bolts Torque Oil Pump Mounting Bolts 7 0 N m 0 7 kgf m 61 in Ib e Apply engine oil to the shaft sliding surface of the oil pump idle gear e Replace the circlip and install new circlip with its sharp edge facing outward Special Tool Outside Circlip Plier 57001 144 e Install the primary gear and the clutch housing see En gine Right Side chapter e Install the right engine cover see Engine Right Side chap ter Oil Pump Inspection e Disassemble the oil pump assemblies see Oil Pump Re moval e Visually inspect the oil pump body outer rotors and the inner rotors If the oil pump is any damage or uneven wear replace the rotors cover or body or the crankcase ENGINE LUBRICATION SYSTEM 7 13 Oil Pressure Oil Pressure Measurement
128. e old silencer packing and install the new si lencer packing A into the silencer e Install the end A of the inner pipe B to the baffle C e Apply a non permanent locking agent to the pipe mount ing bolts e Install the silencer body 6S07010BS1 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply silicone sealant to the circumference A of the si lencer pipe e Install the muffler see Engine Top End chapter Engine Right Side A WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment Clutch Adjustment Clutch Lever Free Play Inspection e Slide the clutch lever dust cover A out of place e Check that the clutch cable upper end is fully seated in the adjuster B e Pull the clutch lever C just enough to take up the free play D e Measure the gap between the lever and the lever holder xf the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in Clutch Lever Free Play Adjustment e Slide the clutch lever dust cover out of place e Loosen the knurled locknut A e Turn the adjuster B so that the clutch lever will have 2 3 mm 0 08 0 12 in of play C NOTE OBe sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lev
129. e pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it e Remove the float valve needle e Check the plastic tip A of the float valve needle B for wear lf the needle is worn as shown right C replace the valve needle e Push the rod D in the valve needle then release it xlf the rod does not come out fully by spring tension re place the valve needle Push and release E 6006014451 C 6006014351 C FUEL SYSTEM 3 23 Carburetor e Remove the starter jet e Check the slow jet for any damage xf the slow jet is damaged replace it with a new one e Remove the throttle valve and jet needle e Inspect the outside of the throttle valve and plate for scratches and abnormal wear x If it is badly scratched or worn replace the throttle valve or plate e Inspect the inside of the carburetor body for these same faults x If it is badly scratched or worn replace the entire carbu retor e Check the jet needle for wear e For the throttle sensor inspection see the Electrical Sys tem chapter A worn jet needle should be replaced e Clean the fuel and air passages with a high flash point solvent and compressed air Carburetor Assembly e Clean the disassembly parts before assembling OClean the fuel and air passages with a high flash point solvent and compressed air A e Set up the acceleration pump lever assembly
130. e steering stem bearing driver B and adapter C Special Tool Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 57001 1074 e Apply grease to the upper inner race and install it in the head pipe e Install the stem through the head pipe and upper bearing install the stem cap and hand tighten the locknut while pushing up on the stem base e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem locknut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem locknut to the specified torque hook the wrench A on the stem locknut and pull the wrench at the hole by 22 2 kg force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem locknut a fraction of a turn until it turns lightly OTurn the stem locknut lightly clockwise until it just be comes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Locknut 4 9 N m 0 5 kgf m 43 in Ib e Install the front fork see the Suspension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolt Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Front Fork Clamp B
131. e systems be came the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a sin gle chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart is located in the Periodic Maintenance chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for exam ple go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Periodic Maintenance chap ter Then use the Table of Contents on the first page of the chapter to find the Spark Plug sec tion Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol 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 NO
132. e the retaining ring B from the outer tube A OGrasp the outer tube and stroke the inner tube up and down several times The shock to fork seal separates the inner tube from the outer tube lf the tubes are tight use a fork outer tube weight A Special Tool Fork Outer Tube Weight 57001 1218 e Remove the guide bushes A washer B oil seal C retaining ring D and dust seal E from the inner tube Front Fork Assembly e Replace the following with new ones Dust Seal A Retaining Ring B Oil Seal C Guide Bushes D e Place an oil coated plastic bag E over the end of the inner tube to protect the oil seals OThe inner tube guide bush groove has a sharp edge F that can out the sealing lip of the seals as they are pushed down over the inner tube e Install in order these parts on the inner tube 6M040614S1 GM04062281 13 18 SUSPENSION Front Fork e When assembling the new outer tube guide bush A hold the washer against the new one and tap the washer with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 48 57001 1509 e After installing the washer install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 48 57001 1509 e Install the retaining ring to the outer tube e Push the dust seal into the outer tube and put the spring 8H04042081 band on the dust seal e Ins
133. e throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Wire and Hose Routing in the Appendix chapter Free Play Inspection e Refer to the Throttle Grip Free Play Inspection in Periodic Maintenance chapter Free Play Adjustment e Referto the Throttle Grip Free Play Adjustment in Periodic Maintenance chapter Throttle Cable Replacement e Remove the front master cylinder A see Brakes chap ter e Slide out the dust cover B e Pull out the cable housing dust cover C e Unscrew the screws A e Separate the throttle cable housing B e Free the tips A from the grip B FUEL SYSTEM 3 9 Throttle Grip and Cable e Remove the rear frame assy see Frame chapter e Remove the carburetor and move it to the right side of the frame e Unscrew the bolt A e Remove the throttle pulley cover B e Loosen the locknuts A e Remove the cables B from the carburetor e Free the tips C from the pulley e Pull out the cables from the frame e Lubricate the cable e Apply grease to the tips of the cables e Install the throttle cable lower end as shown OTurn out the locknut A fully Olnstall the cable tips B OSet the outer cable ends C to the holder OTurn the adjuster D until the cable is extend e Install the throttle pulley cover Torque Throttle Cable Locknut 7
134. e tire pres sure when the tires are cold x Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure Track Condition Tire Pressure When the track is wet muddy sandy or slippery reduce the tire pressure to increase the tire tread surface on the ground When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily 80 kPa 0 8 kgf cm 11 psi T y 100 kPa 1 0 kgf crr 14 psi 6105004BS2 C GJ05010381 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Tires Inspection As the tire tread wears down the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one Standard Tire Front Size 80 100 21 51M Make BRIDESTONE Type M601 Tube EU M201 Tube Rear Size 100 90 19 57M Make BRIDESTONE Type M602 Tube EU M202 Tube Spoke Tigh
135. eals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing 6602018 Circlips Cotter Pins Replace circlips or cotter pins that were removed with new KS T7 ones Install the circlip with its sharp edge facing outward XW and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded Take care not to open the clip excessively when installing to prevent deformation 602028 Lubrication It is important to lubricate rotating or sliding parts during or lt u aga al N assembly to minimize wear during initial operation Lubri A om cation points are called out throughout this manual apply x YAS A a the specific oil or grease as specified fx 7 Yi 7 j j A SN 66020218 S Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side 68020728 1 6 GENERAL INFORMATION Before Servicing Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color GENERAL INFORMATION 1 7 Model Identif
136. ecessary Gasket Oring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Locking agent clean the surfaces so that no oil residue remains be fore applying liquid gasket or locking agent Do not apply them excessively Excessive application can clog oil pas sages and cause serious damage Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing 020148 S 68020178 S GENERAL INFORMATION 1 5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is AR absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size NA l i NA marks facing out Press the bearing into place by putting Ls pressure on the correct bearing race as shown ST D Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage 68020188 S Oil Seal Grease Seal Do not remove pressed oil or grease s
137. eck both top plug O ring C for damage and replace them if necessary e While holding the push rod nut A with a 19 mm wrench B tighten the top plug C against the push rod e Tighten the fork top plug Torque Push Rod Nut 28 N m 2 85 kgf m 20 6 ft lb Front Fork Top Plug 29 N m 3 0 kgf m 22 ft lb e Assemble the other fork tube in the same way as de scribed above e Tighten the upper fork clamp bolts Torque Front Fork Upper Clamp Blots 20 N m 2 0 kgf m euga 47st 6 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Install the parts removed Oil Change Oil Level Adjustment each fork leg e Refer to the Front Fork Oil Change Oil Level Adjustment in Periodic Maintenance chapter Front Fork Removal e Unscrew the bolts A and remove the front brake hose clamps B SUSPENSION 13 13 Front Fork e Remove Front wheel see Wheels Tires chapter Bolts A e Remove the caliper B from the fork leg to be removed and rest the caliper on some kind of stand so that it doesn t dangle e Loosen the upper A and lower fork clamp bolts B e Remove the front fork OWith a twisting motion A work the fork leg B down and out e Remove Bolts A Fork Protector B Guide C 13 14 SUSPENSION Front Fork Front Fork Installation e f the fork leg was disassembled check the fork oil level e Install the for
138. ed 17 Oil Filler Cap 18 Oil Screen Transmission Room Oil Sump 19 Oil Screen Crank Room Oil Sump 20 Oil Pump Idle Gear 21 Oil Pump Gear 22 Oil Level Gauge 23 Breather Hose G Apply high temperature grease EO Apply engine oil M Apply molybdenum disulfide grease L Apply a non permanent locking agent R Replacement Parts 7 0 0 7 9 8 1 0 7 0 0 7 9 8 1 0 2 5 0 3 15 1 5 9 8 1 0 7 0 0 7 6 4 0 65 61 in lb 61 in lb 87 in lb 61 in lb 87 in lb 22 in lb 11 87 in lb 61 in lb 56 in lb m _ rc r _ E _ m 7 4 ENGINE LUBRICATION SYSTEM Lubrication System Chart N Y E S 6G04028BW5 ENGINE LUBRICATION SYSTEM 7 5 Lubrication System Chart 6G04029B 2 J O O1 ND Oil Screen scavenging Oil Screen feed Oil Pump scavenging Oil Pump feed Right Crankcase Oil Passage from Scavenging Oil Pump to Transmission Oil Shower Passage Right Engine Cover Oil Passage from Feed Oil Pump to Oil Filter Oil Chamber Oil Filter Oil Filter Oil Chamber Oil Chamber Right Engine Cover Oil Passage from Oil Chamber to Crankshaft Crankcase Oil Passage from Oil Chamber to Piston Oil Nozzle Piston Oil Nozzle Crankcase Oil Passage from Oil Chamber to Cylinder Oil Passage Cylinder Oil Passage from Crankcase Oil Passage to Cylinder Head Oil Passage
139. em e Drain the cooling system e Fillthe cooling system with fresh water mixed with a flush ing compound CAUTION Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacture of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding 6D05013BS1 COOLING SYSTEM 4 9 Water Pump Water Pump Cover Removal e Drain the engine oil from the oil filter oil chamber OUnscrew the drain plug A e Drain the coolant see Coolant Draining OUnscrew the drain bolt B e Unscrew the water pipe bolt A and disconnect the water pipe B e Unscrew the cover bolts C e Using the pry points A remove the pump cover B Water Pump Cover Installation e Install Spring A Dowel Pins B e Replace the pump cover gasket with a new one e Apply grease to the pump cover gasket C e Install the water pump cover OReplace the drain bolt washer with a new ones e Tighten Torque Water Pump Cover Bolts 9 8 N m 1 0 kgf m 87 i
140. emporally e Tighten the axle nuts G e Tighten the left axle clamp bolts Torque Front Axle 78 N m 8 0 kgf m 58 ft lb Left Axle Clamp Bolts 20 N m 2 0 kgf m 14 5 ft Ib NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque GJ04067BS1 GJ04068BS1 6J04069BS1 WHEELS TIRES 10 7 Wheels Rims e Remove the jack e Before tightening the clamp bolts on the right fork leg pump the forks up and down A 4 or 5 times to allow the right fork leg to find a neutral position on the front axle NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block B in front of the wheel to stop it from moving e Tighten the right axle clamp bolts Torque Right Axle Clamp Bolts 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the front brake for good braking power and no brake drag A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tools Jack 57001 1238 e Remove the clip A from the master link us
141. enance Procedures e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Rear Dust Covers e Tighten Torque Brake Lever Pivot Bolt 9 8 N m 1 0 kgf m 87 in Ib Caliper Piston Seal and Dust Seal Replacement e Loosen the brake pad pin A and banjo bolt B and tighten them loosely e Remove Front Caliper Mounting Bolts C Banjo Bolt Brake Hose E Front Caliper D see Brakes chapter Brake Pads see Brakes chapter e Separate the caliper holder A from the caliper B and remove the anti rattle spring e Using compressed air remove the pistons One way to remove the pistons is as follows OCover the caliper opening with a clean heavy cloth A ORemove the pistons by lightly applying compressed air B to the hose joint opening A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures OPull out the piston A by hand e Remove the dust seals B and fluid seals C NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected
142. ent 2 28 2 2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQUENCY Each Every 3 Every 6 Every 12 See OPERATION race races Spark plug clean gap t e 2 54 Clutch adjust e 2 22 Clutch and friction plates inspect t e 2 23 Throttle cable adjust o 2 11 Air cleaner element clean e Air cleaner element replace If damaged 2 13 Carburetor inspect and adjust Po 2 12 Engine Oil change 2 23 Piston and piston ring replace 7 Cylinder head cylinder inspect e 220 G Piston pin replace 2 20 Valve clearance inspect t 2 Hot start adjust 2 12 Oil filter replace 2 24 Silencer clean and inspectf e 2 21 Silencer packing change 2 21 Kick pedal and shift pedal clean Engine sprocket inspect t e 2 32 Coolant check t o 2 15 Radiator hoses and connections inspect t e 2 16 Crankshaft inspect 2 26 Oil screen clean 2 26 Breather hose inspect e Brake adjustment inspect e 2 33 Brake pad wear inspect e 2 37 Brake fluid level inspect t e Es Brake fluid change Every 2 years E Brake master cylinder cup and dust seal replace Every 2 years 2 38 A Brake caliper piston seal and dust seal replace Every 2 ye
143. ep fluid loss to a minimum e Immediately wash away any brake fluid that spills 6L100101S1 PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Remove each banjo bolts A and washers B y y e Replace the washers with new ones For Front Brake e Remove Bolts A Brake Hose Clamps B For Rear Brake e Remove Master Cylinder A Hose Clamps B Caliper Cover C e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten the banjo bolts on the hose fittings Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 0 ft lb e Fill the brake line after installing the brake hose see Brake Fluid Changing 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Inspection e Holding the brake lever pump the front fork back and forth manually to check for smooth operation e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube A x lf necessary repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage xf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repai
144. er or it could Slip into the place later creating enough cable play to prevent clutch disengagement e f it cannot be done Turn the adjuster A so that 5 6 mm 0 20 0 24 in B of threads are visible e Tighten the locknut PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures e Slide the adjuster cover A back e f it cannot be done loosen the locknut B at the middle of the clutch cable and turn the adjusting nut C so that clutch lever has 2 3 mm 0 08 0 12 in of play e After the adjustment is made tighten the locknut and start the engine and check that the clutch does not slip and that it release properly Friction and Steel Plates Inspection e Remove the clutch plates see Engine Right Side chapter e Visually inspect the friction and steel plates to see if they show any signs of seizure or uneven wear x lf any plates show signs of damage replace the friction plates and steel plates as a set e Measure the thickness A of the friction and steel plates with vernier calipers lf they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 6 mm 0 102 in Steel Plate Thickness Standard 1 46 1 74 mm 0 057 0 069 in Service Limit 1 36 mm 0 054 in e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and eac
145. erclockwise C Harder Clockwise D Number of turns counterclockwise usable range 16 or more Counterclockwise from the fully seated position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition 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 1615 1413121110 9 iid rd 8 7 6 5 4 3 2 D al A A GM05101BS1 13 22 SUSPENSION Rear Suspension Uni Trak Seated position adjuster turned fully clockwise A O Rebound Damping Adjuster Setting Standard 11 clicks B Softer Counterclockwise C Harder Clockwise D Let MERE Number of turns counterclockwise usable range 16 clicks or more Counterclockwise from the fully seated position 4 a nN ort 6M05102BS1 NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Spring Preload Adjustment
146. ert the push rod and piston assembly A into the fork cylinder B e Install the cylinder unit into the inner tube e Check the O ring A on the cylinder valve assembly B and replace it with a new one e Replace the gasket C with a new one e Apply a non permanent locking agent to the threads D of the cylinder valve assembly and screw the valve assem bly into the bottom of the inner tube 6M04153BS1 C e Hold the cylinder unit A with the fork cylinder holder B and tighten the cylinder valve assembly C Special Tool Fork Cylinder Holder 57001 1573 Torque Cylinder Valve Assembly 54 N m 5 5 kgf m 40 ft Ib 6M04162BS1 e Pour in the type and amount of fork oil specified and adjust the oil level see Periodic Maintenance chapter e Pull up the push rod slowly so as not to spill the fork oil out of the fork tube SUSPENSION 13 19 Front Fork e Fit the circlips A onto the groove of the push rod B e Install the Collar C Holder D and Nut E e Replace the O ring F with a new one e Install the spring guide A so that the thinner portion end B is down e Screw on the push rod nut C fully e Insert the rebound damping adjuster rod A into the push rod 6S14026BS1 e Pull up the push rod A fully up and hold it e Install the fork spring B and spring seat C e Check the O ring D on the top plug and replace it with a new one if damaged
147. ertthe rebound damping adjuster rod into the push rod e Fill the specified oil to the outer tube A Recommended Oil KAYABA 01 or SAE 5W Front Fork Oil Capacity 564 4 mL 19 07 0 14 US oz NOTE OWhile doing this take care to keep the oil level topped off so that it stays above the two large holes A near the top of the inner tube B 6S14025BS1 6S14026BS1 6S14027BS1 My Wy WT gt GS14030BS1 Z Y SNS NN SN y OO E 6S14031BS1 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Purge the air from the fork cylinder by gently moving the piston rod A up and down ten times e Purge the air from between the inner and outer tubes by pumping the outer tube A up and down e After purging the air from the assembly let it sit for about five minutes so that any suspended air bubbles can sur face e Adjust the oil level OWith the fork fully compressed put the oil level gauge A and the stopper B and inspect the distance from the top of the inner tube to the oil Special Tools Fork Oil Level Gauge 57001 1290 Oil Level fully compressed without spring Standard 95 mm 3 7 in Adjustable Range 70 120 mm 2 8 4 7 in lf no oil is drawn out there is insufficient oil in the outer tube Pour in enough oil then drawn out the excess oil e Install the parts removed see Front
148. escaeh sauce necvaneineas tena a 0e las 200 4 9 Water Pump Cover Removal seen 4 9 Water Pump Cover Installation eee 4 9 Impeller REMOVAl t Mes rene Sn eA eels 4 10 Impeller Installation ss 4 10 Water Pump Inspection seems 4 10 Water Pump Gear Removal ses 4 11 Water Pump Gear Installation 4 11 Oil Seal and Bearing Removals ae nine la li 4 11 Oil Seablnstallatio Misina a desde letesensstaeseadecansaceneadvacavandscensondannes 4 11 Radial tardara Leta li caida 4 13 TR A O O 4 13 RadiatorInstallation xfissssssssennisien auras eaten Ade nie nf 4 14 Radiator Inspection semer dater aa E d teste rene sa cauhcute se ane tante delete niet eat 4 14 Radiator Cap NSPE Cti ONda ie pe RE tee Perret 4 15 Filler Neck Inspection 4 15 Radiator Hoses Breather Hose Inspection ss 4 15 Radiator Hoses Breather Hose Installation 4 15 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View No Fastener Water pump cover bolts Torque 87 in lb Remarks Water pump cover bolts with washer 61 in lb 1 2 3 4 Coolant drain plug Right engine cover bolts 61 in lb 87 in lb Water pump impeller bolt 7 0 0 7 61 in lb Cooling hose clamp screws 13 in lb Engine oil drain plug M6 for oil filter chamber Radiator mounting bolts 61 in lb 87 in lb Radiator shround bolts 8
149. f a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract Element Installation e When installing the element coat the lip of the element with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Also coat the base where the lip of the element fits e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Take out the towel from the carburetor securely 6007010351 C 3 30 FUEL SYSTEM Air Cleaner e Install the element so that its tab A faces upward and fit the element projections B to the holes of the housing C e Tighten the wing bolt D e Install the seat see Frame chapter Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in Periodic Maintenance chapter 6007023BS1 FUEL SYSTEM 3 31 Fuel Tank Fuel Tank Removal Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or spar
150. f the engine e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does nat coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install Dowel Pins A New Cylinder Base Gasket B e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be 25 of angle from the opening of the oil ring expander Round Mark A Oil Ring Expander D Top Ring B Lower Oil Ring Steel Rail E Upper Oil Ring Steel Rails C 6E16042BS1 6E16051BS1 6E16053BS1 6E16052BS1 5 32 ENGINE TOP END Cylinder and Piston e Apply engine oil to the cylinder bore e Determine the position of the piston ring ends e Install the cylinder while compressing the piston rings with your fingers or the special tool A Special Tool Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 67 to 79 57001 1097 e Drive the front chain guide in e Install the removed parts Cylinder Wear e Refer to the Cylinder Wear Inspection in Periodic Mainte nance chapter Piston Wear e Using a micrometer measure the outside diameter A of each piston 10 mm
151. h friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp lf any plate is warped over the service limit replace it with a new one Friction and Steel Plates Warp Friction Plate Steel Plate Standard Not more than 0 15 Not more than 0 2 mm 0 006 in mm 0 008 in Service Limit 0 3 mm 0 012 in 0 3 mm 0 012 in Engine Lubrication System Engine Oil Change e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the oil filler cap A e Remove the drain plug B and drain the engine oil in the oil filter oil chamber GFO606028S1 GF13010781 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the engine oil drain plugs on the bottom of the engine and let the oil drain completely Drain Plug for crank room oil sump A Drain Plug for transmission oil sump B NOTE OHold the motorcycle upright so that the oil may drain completely e Replace the gaskets at the drain plugs with a new one e After the oil has completely drained out install the drain plugs with the gaskets and tighten them Torque Engine Oil Drain Plugs Oil Filter Oil Chamber 7 0 N m 0 7 kgf m 61 in Ib Crank Room Oil Sump 7 0 N m 0 7 kgf m 61 in Ib Transmission Oil Sump 15 N m 1 5 kgf m 11 ft lb
152. he flywheel itself Strike the bar can bond it If the flywheel is strike the magnets may lose their magnetism Flywheel Magneto Installation e Using a high flash point solvent clean off any oil or dirt that may be on the crankshaft taper A or in the hole B in the flywheel Dry them with a clean cloth e Fit the woodruff key C securely in the slot in the crank shaft NOTE OConfirm the flywheel fit or not to the crankshaft before tightening it with specified torque Olnstall the flywheel and tighten it with 45 N m 4 5 kgf m 33 ft lb of torque ORemove the flywheel nut OCheck the tightening torque with rotor puller lf the flywheel is not pulled out with 20 N m 2 kgf m 15 ft lb of drawing torque it is installed correctly xlf the flywheel is pulled out with under 20 N m 2 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and flywheel tapered portion and dry them with a clean cloth Then confirm that it is not pulled out with above torque e Holding the flywheel steady with the flywheel holder and tighten the flywheel nut Special Tool Flywheel Holder 57001 1567 Torque Flywheel Nut 49 N m 5 0 kgf m 36 ft lb e Install the magneto cover see Magneto Cover Installa tion Stator Removal e Remove Magneto Cover see Magneto Cover Removal Stator Bolts A Crankshaft Sensor Bolts B Wiring Holder C Wiring Grommet D e Remove the stator E an
153. he front wheel pointing straight ahead alternately nudge each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the steering binds or catches before the stop check the routing of the cables hoses and harnesses xf the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling the forks lf you feel looseness adjust the steering Steering Adjustment e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 e Slide the holder belt A out off e Remove Number Plate Bolt B and number plate C e Remove Handlebar Clamp Bolts A Handlebar Clamp B Handle Bar C 6S15008BS1 GNO4008BS1 PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures e Loosen the front fork upper clamp bolts A and remove the steering stem head nut B and steering stem head C e Turn the steering stem locknut A with the steering stem nut wrench B to obtain the proper adjustment xf the steering is too tight loosen the stem locknut a frac tion of a turn if the steering is too loose tighten the lock nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE OTurn the locknut 1 8 turn at a time maximum e Install the steering stem head e Tighten the following Torque Steering Stem Head Nut 78 N m 8
154. he piston side pad B e Push the caliper holder toward the piston and then re move another pad C from the caliper holder For Rear Brake Pad e Remove Plug A e Unscrew the pad bolt A e Take the piston side pad B e Push the caliper hold toward the piston and then remove another pad C from the caliper holder BRAKES 12 15 Caliper Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the piston side pad first and then another pad OFit the pad end A into the groove B of the anti rattle spring securely e Tighten the brake pad bolt Torque Brake Pad Bolt 18 N m 1 8 kgf m 13 ft Ib e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this is not done Brake Pad Inspection e Refer to the Brake Pad Wear Inspection in Periodic Main tenance chapter 12 16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wished up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the upper brake hose B from the master cylinder C e When remov
155. he valve clearance the posi tion at the end of the compression stroke when the cam lobe faces outside of the camshaft OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the grove B of the inspection hole e Using a thickness gauge A measure the clearance be tween each cam lob and valve lifter for all four valves OFor the purpose of adjusting the valve clearances record the measured values Valve clearance between cam and valve lifter Standard Exhaust 0 17 0 22 mm 0 0067 0 0087 in Inlet 0 10 0 15 mm 0 0039 0 0059 in lf the valve clearance is not within the specified range adjust it Valve Clearance Adjustment e Remove the camshaft caps A see Engine Top End chapter e Remove the camshafts B see Engine Top End chapter e Remove the valve lifters C of the applicable valve e Remove the shim D from the top of the spring retainer GSO7007BS1 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OMark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows A B C D A Replace Shim Thickness B Measured Valve Clearance C Specified Valve Clearance D Present Shim Thickness Example 0 3
156. her suitable support A under the front wheel e While holding the push rod nut with a 19 mm wrench loosen the front fork top plug A from the top of the push rod e Remove the fork top plug with the fork spring seat C and fork spring B 6M04148BS1 e Fill the front fork to the top of the inner tube with specified oil Recommended Fork Oil KAYABA 01 or SAE 5W e Fill the oil to the fork cylinder by gently moving the push rod A up and down five times e Fill oil between the inner tube and outer tube by pumping the outer tube B up and down five times 6M04166BS1 C e Adjust the fork oil level within the adjustable range to suit your preferences Remove the excess oil through the outer tube opening using a oil level gauge OWith the fork fully compressed put the oil level gauge A and the stopper B and adjust the distance from the top of the inner tube to oil Special Tool Fork Oil Level Gauge 57001 1290 Front Fork Oil Level fully compressed without spring Standard 95 mm 3 7 in ae Adjustable Range 70 120 mm 2 8 4 7 in If no oil is drawn out there is insufficient oil in the fork tube Pour in enough oil then pump out the excess oil 13 12 SUSPENSION Front Fork e Hold the push rod with your hand fully up e Insert the fork spring A into the fork tube EAS f XS 6M04101BS1 e Install the fork spring seat A on the fork spring B e Ch
157. hock body D 6M05104BS1 2 48 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm 0 39 in down e Remove the circlip A e Lightly move the piston rod back and forth and pull out the piston rod assembly e Pour the oil out of the rear shock body e Visually inspect the piston A O ring B and oil seal assy C elf the piston O ring and oil seal assy are badly scored rusty or damaged replace them e Using the grinder shave off the stopper portion A of the rod e Remove Nut B Washer C Piston D e Install the new piston and tighten the locknut ODiscard a washer or two e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the gas reservoir to 60 70 mm 2 63 2 76 in A from the gas reservoir upper end e Check that the bladder A on the gas reservoir cap is not partially collapsed x lf it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack lf necessary replace it with a new one CAUTION Do not use a damaged or partially collapsed blad der because it may burst gently reducing rear shock performance e Apply grease to the lip B of the bladder and install the reservoir cap C GMO5065BS1 GM05010481
158. hop having the necessary tools and equipment e f it should be necessary to disassemble the crankshaft use a press to remove the crankpin 9 14 CRANKSHAFT TRANSMISSION Crankshaft Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment e Reassemble the crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist see Periodic Maintenance chapter OConnecting rod big end radial clearance see Periodic Maintenance chapter OCold fitting tolerance between crankpin and flywheels OSide clearance between the connecting rod big end and one of flywheels see Periodic Maintenance chapter OCrankshaft runout see Periodic Maintenance chapter Connecting Rod Bend e Remove the connecting rod e Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and more than 105 mm long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on a V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend If connecting
159. hould be changed periodically to ensure long engine life A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Place a container under the coolant drain plug A and drain the coolant from the radiator and engine by remov ing the drain plug on the water pump cover Immediately wipe or wash out any coolant that spills on the frame or engine e Inspect the old coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Inspec tion COOLING SYSTEM 4 7 Coolant Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale
160. ical WD nee 16 8 Witing Inspection aria fed ee it IA ES 16 8 Flywheel Magneto asirio it 16 9 MERA bonds ls tn Rd nn ales ua en done 16 9 Magneto Cover Installation ii il de 16 9 Flywheel Magneto Removal ssssss toi han dun seront nent etant die 16 9 Flywheel Magneto Installation 16 10 St t ReMOVA iia na 16 10 tato ARE LS UE LU ia a ia 16 11 Flywheel Magneto Inspection 5545 din di 16 11 o EEEE EE AE NS 16 13 Ignition Timing InS pectloni is es st nn dd ii 16 13 A oaa E ee i a Une ee An dd ee AE eae huenak 16 14 Safety INSTUCIONS lt a is 16 14 Ignition Coll Removal e A Nada 16 14 Ignition Coil Inspection ats ELA she AR ne ARR PA en Ati teint ses nn rente 16 14 Spark Plug Cleaning and INS PSCuOM ish ani ARR st ne een aS ae 16 15 Spark Plug Gap Inspection 16 15 CD Oni REM OVA desert ns metre in 16 15 A InspectiOn sriente ne Mers demse ar erns estate odes okie same na obanaasannaces do date de le ttes TAT 16 16 Throttle Sensor Output Input Voltage Check ss 16 21 Engine Stop Switch Electric Current Check 16 22 Crankshaft Sensor Inspection 16 22 ATOS Senso MUR aaa 16 23 Throttle Sensor Inspection see 16 23 Throttle Sensor Position Adjustment nn nn nnnane nena nnn enanas 16 23 Neutral Shc i ses iii ai 16 24 Neutral Switch Inspection see 16 24 16 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 3 Exploded View T
161. ication KX250 N1 Left Side View 098173 P KX250 N1 Right Side View 60308129 P 1 8 GENERAL INFORMATION General Specifications Items KX250 N1 Dimensions Overall length 2 170 mm 85 43 in Overall width 840 mm 33 1 in Overall height 1 270 mm 50 in Wheelbase 1 475 mm 8 07 in Road clearance 340 mm 13 4 in Seat height 960 mm 37 8 in Dry mass 92 5 kg 204 Ib Curb mass Front 49 9 kg 110 Ib Rear 52 6 kg 116 Ib Fuel tank capacity Performance Minimum turning radius Engine Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil Type Viscosity Capacity Drive Train Primary reduction system Type Reduction ratio Clutch type 7 5 L 2 0 US gal 4 stroke single cylinder DOHC 4 valve Liquid cooled 77 0 x 53 6 mm 3 03 x 2 11 in 249 mL 15 2 cu in 12 6 1 31 6 KW 43 0 PS 11 000 r min rpm 28 7 N m 2 93 kgf m 6 45 in lb 8 500 r min rpm Carburetor KEIHIN FCR37 Primary kick Digital AC CDI BTDC 8 2 000 r min rpm NGK CR8EB or NGK CR9EB BTDC 49 ABDC 63 292 BBDC 69 ATDC 49 298 Forced lubrication semi dry sump API SH or SJ with JASO MA SAE 10W 40 1 5
162. ide grease to the cam and jour nal surfaces e First bring the crankshaft to the TDC of either the com pression or exhaust stroke OPlace a wrench over the flywheel nut and turn it counter clockwise to align the TDC mark A with the center of the groove B of the inspection hole e Engage the camshaft chain with the camshaft sprockets OPull the tension side exhaust side of the chain taut to install the chain OThe timing marks on the exhaust sprocket must be aligned with the cylinder head upper surface and pointed toward the front e Pull the chain taut and fit it onto the camshaft sprocket e Starting with the timing mark on the front of the exhaust sprocket count to the 1st pin Feed the exhaust camshaft thought the chain and align the 28th pin with the timing mark on the inlet camshaft sprocket 6E11076BS1 ENGINE TOP END 5 15 Camshaft CES GE11069B 2 Punch Marks exhaust D 1st Pin A 2nd Pin B Punch Marks inlet E 28th Pin C Upper Cylinder Head Surface F e Be sure to install the positioning rings A and dowel pins B e Install the camshaft caps in their original positions by fac ing their triangle marks A face to face as shown in the photograph EX mark B IN mark C CAUTION The camshaft caps are machined with the cylinder head and the camshaft may seize if the caps are installed in a wrong position 5
163. il the output voltage is within the specified voltage range Special Tool Throttle Sensor Setting Adapter A 57001 1400 Throttle Sensor Output Voltage Standard 0 68 0 1 V when engine speed is idle xf it is not within the specified voltage range replace the sensor GP25003BS2 C 16 24 ELECTRICAL SYSTEM Neutral Switch Neutral Switch Inspection e Slide out the dust cover A e Disconnect the connector B OUnscrew the screw e Using a hand tester check to see that only the con nections shown in the table have continuity about zero ohms xlf the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Neutral Switch Connections When transmission is in neutral When transmission is not in neutral ie iii y nae APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing sisas ia si 17 2 Troubleshooting GUJE rr io rod 17 8 17 2 APPENDIX Cable Wire and Hose Routing Ne EZ WH ge AN A A zs E o I 6B09382BW5 APPENDIX 17 3 Cable Wire and Hose Routing _ 2000 J O O1 BON Throttle Cables Clamp Engine Stop Switch Lead Hot Start Cable Clutch Cable Main Harness C D I Unit Throttle Cable accelerator cable Throttle Cable decelerator cable C
164. impeller B e Install Water Pump Cover see Cooling System chapter e Apply a non permanent locking agent to two water pump cover bolts and one right engine cover bolt Torque Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Water Pump Cover Bolts with washer A 7 0 N m 0 7 kgf m 61 in Ib Coolant Drain Plug 7 0 N m 0 7 kgf m 61 in Ib e Apply grease to the water pipe O ring B e Insert the water pipe C into the hole D of the water pump cover Torque Water Pipe Bolt 9 8 N m 1 0 kgf m 87 in lb e Apply grease to the brake pedal bolt and install the brake pedal see Brakes chapter e Install the kick pedal see this chapter e Install the engine oil drain plugs surely see Periodic Main tenance chapter e Pour in the specified type and amount of oil see Periodic Maintenance chapter e Pour in the specified type and amount of coolant see Periodic Maintenance chapter e Check the rear brake see Brakes in the Periodic Mainte nance chapter Release Shaft Removal e Remove the clutch see this chapter e Remove the clutch cable upper end see this chapter e Remove the tips A of the clutch cable see Clutch Cable Removal e Pull the lever and shaft assembly B out of the crankcase Release Shaft Installation e Apply high temperature grease to the oil seal lips e Apply engine oil to the bearing in the hole of the crankcase e Insert the release shaft straight into
165. in NOTE OFloat height A is the distance from the float bowl mat ing surface B of the carburetor body with the gasket removed to the top ofthe float C Measure the height with the carburetor upside down ODo not push the needle rod D in during the float height measurement 6C006088BS1 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 Carburetor Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap lever A to the OFF position OSlid off the clamp C and pull the fuel hose B off the tap FUEL SYSTEM 3 15 Carburetor e Disconnect the throttle sensor connector A e Loosen the clamp screws A and remove the carburetor from the carburetor holder B and then pull it out of the end of the air cleaner duct C x lf necessary do the following procedure e Remove Seat Side Covers Silencer Rear Frame Bolt A e Pull out the rear frame B with the air cleaner housing and remove the carburetor e Unscrew the hot start plunger cap bolt A e Remove the hot start plunger e Unscrew the throttle pulley cover bolt A
166. ince the chain may wear unevenly take O O measurements at several places Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 72 in ETETEN If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Standard Chain Make DAIDO Type D I D 520DMA2 Link 114 Links Drive Chain Lubrication OThe chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain lf the chain is especially dirty it should be washed in diesel oil or kerosene and afterward soaked in a heavy oil Shake the chain while it is in the oil so that oil will pen etrate to the inside of each roller e An effective good quality lubricant specially formulated for chains is best for regular chain lubrication 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e If a special lubricant is not available a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide
167. ing pliers and free the drive chain B from the rear sprocket 6J04006BS1 10 8 WHEELS TIRES Wheels Rims e Remove Cotter Pin A Axle Nut B e Pull out the axle C e Move the rear wheel back with the rear caliper installed e Take off the collar and cap from the each side of the rear hub CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wood wedge between the brake pads This pre vents them from being moved out of their proper position should the brake pedal be squeezed accidentally Rear Wheel Installation e Fit the brake holder stop A with the stop grooves B against the swingarm stop space C with the stop pro jection D e Fit the projection on the cap to the groove on the collar e Install the collars A on the left and right side of the hub OThe collars are identical e Install the drive chain Install the master link clip A so that the closed end of the U B points in the direction of chain rotation C 6J04070BS1 6J04008BS1 6K04002BS1 WHEELS TIRES 10 9 Wheels Rims e Check the drive chain slack see Final Drive chapter e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 kg m 80 ft lb e Install the new cotter pin A and spread its end NOTE OWhen
168. ing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Unscrew the clamp bolts A and take off the master cylin der B as an assembly with the reservoir and brake lever Front Master Cylinder Installation e Position the master cylinder so that the vertical parting line A of the front master cylinder clamps align with the punch mark B on the handlebar e The master cylinder clamp must be installed with the ar row mark A upward OTighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 9 kgf m 78 in Ib e Replace the washers that are on each side of hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage 6L07033BS1 6L07034BS1 BRAKES 12 17 Master Cylinder Rear Master Cylinder Removal e Remove the cotter pin A e Pull off the joint pin B with washer NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts C and re move the master cylinder D e Unscrew the brake hose banjo bolt E e When removing the brake hos
169. ing with a friction plate A and alternating them Finishing with a friction plate OThere are painted marks on the tangs B of the first and last friction plates CAUTION If dry steel plates and friction plates are installed apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Apply molybdenum disulfide grease to the rubbing portion A of the push rod holder e Install the steel ball B and push rod holder assy C e If a clutch part was replaced install the standard adjust ing washer 1 5 mm thickness A of the push rod holder assy and check the release lever position as explained later precedure e Tighten the clutch spring bolts holding the clutch housing with the hand Torque Clutch Spring Bolts 9 8 N m 1 0 kgf m 83 in Ib 6 14 ENGINE RIGHT SIDE Clutch e Check the release shaft lever positions A OPushing B the release shaft lever C lightly frontward measure the distance between the lever and cable bracket D Release Shaft Lever Position Standard 36 7 44 5 mm x lf the lever position is not within the standard select the correct thickness of adjusting washer s according to the tables shown Adjusting Washers Thickness Part Number 92200 1548 1 0 mm 92200 0045 Release Shaft Lever Position and Adjusting Washer Selection Washers Thickness 36 7 mm to 44 5 mm Standard 1 5 mm Position Distance Judgment
170. int replace the piston pin e Using a cylinder gauge measure the diameter of both of piston pin holes C in the piston and the inside diameter of the connecting rod small end D If either piston pin hole diameter exceeds the service limit replace the piston If the connecting rod small end inside diameter exceeds the service limit replace the connecting rod Piston Pin Diameter Standard 15 992 15 997 mm 0 6296 0 6298 in Service Limit 15 96 mm 0 628 in Piston Pin Hole Diameter Standard 16 004 16 010 mm 0 6301 0 6303 in Service Limit 16 07 mm 0 633 in Small End Inside Diameter Standard 16 010 16 018 mm 0 6303 0 6306 in Service Limit 16 05 mm 0 632 in 6E16055BS1 GE16067BS2 C 5 34 ENGINE TOP END Carburetor Holder Carburetor Holder Installation e Install the carburetor holder A with the marked B side facing toward the cylinder head outside Olnstall the holder clamp C with its screw head D facing left side 6E17005BS1 Torque Carburetor Holder Clamp Screw 2 0 N m 0 2 kgf m 104 in Ib e Fit the projection A of the holder into the recess B of the cylinder head MEN A 6E17006BS1 ENGINE TOP END 5 35 Muffler WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cools down Muffler Removal e Loosen the muffler clamp bolt A
171. ion Inspection e Visually inspect the coolant If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system If the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Radiator Hoses and Connections Inspection OThe high pressure inside the radiator hose A can cause coolant to leak B or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks C or bulges D are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib A B 6D04016BS1 6S06008BS1 6S06010BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Cylinder Head Cover see Engine Top End chapter Timing Inspection Cap A Flywheel Cap B e Fist bring the piston to the top dead center of its com pression stroke to inspect t
172. is it may have been refaced too much replace it e When the engine is assembled be sure to adjustthe valve clearance see Engine Top End in the Periodic Mainte nance chapter ENGINE TOP END 5 29 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Venire Caliper Purpose check seat O D lt against spec Results Too small Y 45 Grind Tool 45 Cutter Purpose increase O D of seat area to spec Machinist s dye on seat 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seating Width Tool Venire Caliper Purpose check seat width against spec Results Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase width of seat area beyond spec to increase O D 60 Grind Tool 60 Cutter Purpose reduce seat width to specification FINISHED GE15042B F 5 30 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Camshaft Chain Guide A Cylinder Bolt B e Tap lightly up with a plastic mallet to separate the cylinder from the crankcase e Remove the cylinder base gasket Piston Removal e Remove the cylinder see this Cylinder Removal e Pl
173. is the same as Drive Chain Slack Adjust ment Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication in Periodic Mainte nance chapter 11 8 FINAL DRIVE Drive Chain Drive Chain Removal e Remove the clip A from the master link using pliers and free the drive chain from the rear sprocket e Remove the drive chain from the chassis Drive Chain Installation e Fit the drive chain back onto the sprockets with the ends at the rear sprocket e Install the master link A from the frame side e Install the link plate B so that the mark faces out Clip C e Install the clip A so that the closed end of the U B pointed in the direction of chain rotation C e Adjust the drive chain slack see Drive Chain Slack Ad justment e Check the rear brake see the Brakes chapter 6K04002BS1 FINAL DRIVE 11 9 Sprockets Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B Drive Chain Guide C e Remove Drive Chain A free of engine sprocket e Remove the circlip B and pull off the engine sprocket C Special Tools Outside Circlip Pliers 57001 144 Engine Sprocket Installation e Install the engine sprocket so that the flatten side faces A inside e Replace the circlip with a new one e Install the circlip so tha
174. k so that the distance B between the top end A of the outer tube and the upper surface C of the steering stem head is specified dimension B 8 mm 0 59 in PIS e Route the cables and hose according to the Cable Har E TTO ness Hose Routing section in the Appendix chapter Ca e Install the front wheel see Wheels Tires chapter e Tighten the fork clamp bolts Torque Upper Fork Clamp Bolts 20 N m 2 0 kgf m 14 5 ft Ib Lower Fork Clamp Bolts 20 N m 2 0 kgf m 14 5 ft Ib 6M04106BS1 NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Check the front brake operation after installation Front Fork Disassembly each fork leg e Loosen the front fork upper clamp bolts A e Loosen the each fork top plug B e Remove the front fork see Front Fork Removal e Hold the inner tube lower end in a vise e Disassemble the top plug A from the outer tube B Gsiehior F SUSPENSION 13 15 Front Fork e Use wrenches A on the rod nut B and top plug C loosen the push rod nut e Remove the top plug from the push rod e Lift the fork spring D and its top spring seat E out of the outer tube e Take the rebound damping adjuster rod A out of the push rod e Hold the fork tube A upside down over a clean container B and pump it to drain the oil NOTE OPump
175. ks this includes any appliance with a pilot light e Remove Seat see Frame chapter Bolts A Radiator Shrouds B e Turn the fuel tap lever A to the OFF position e Slide out the clamp B and pull the fuel hose C off the fuel tap D e Remove the fuel tank mounting bolt A and band B e Pull out the fuel tank breather hose C e Remove the fuel tank D e Drain the fuel Fuel Tank Installation e Check the rubber dampers A on the frame kif the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Insert the fuel tank breather hose outlet end into the steer ing stem hole see Appendix chapter 3 32 FUEL SYSTEM Fuel Tank Fuel Tap Removal e Remove the fuel tank and drain it e Remove the mounting bolts A and take out the fuel tap B Fuel Tap Installation e Be sure the O ring is in good condition to prevent leaks e Be sure to clamp the fuel hose to the tap to prevent leaks Fuel Tank and Tap Cleaning WARNING Clean the fuel tank in a well ventilated area and take care that there is no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank e Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e
176. l gauge is very sensitive to the motorcycle s position and en gine rpm at time of shut down Because of the semi dry sump lubrication system with separate oil chambers in the crank room and transmission room under certain condi tions oil can accumulate in the crank room and give a false low reading at the oil level gauge which indicates oil vol ume in the transmission room Engine Oil Level Inspection e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower levels B in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf no oil appears in the gauge tip the motorcycle slightly to the right until oil is visible then return to an upright position If no oil appears even when tipped at an ex treme angle remove both drain plugs to empty any oil that may be in the transmission and crankcase reinstall the drain plugs and refill with the specified amount of oil Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil ODO not run the engine at high engine speed Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure If the oil level is too high remove the exce
177. lace the disc Runout Standard Not more than 0 25 mm 0 098 in Service Limit 0 3 mm 0 01 in 6L08012BS1 6L08013BS1 12 20 BRAKES Brake Hose Brake Hose Removal Installation e Refer to the Brake Hose Replacement in Periodic Main tenance chapter Brake Hose Inspection e Refer to the Brake Hose and Connection Check in Peri odic Maintenance chapter SUSPENSION 13 1 Suspension Table of Contents Exploded View 13 2 Spring Replacement 13 24 Specifications 13 6 Rear Shock Absorber Special Tools ist 13 7 Disassembly Oil Change 13 24 Front ROK net se nes 13 9 Rear Shock Absorber Assembly 13 24 Air Pressure ccccccccccononccnoncncncnononos 13 9 Rear Shock Absorber Scrapping 13 25 Rebound Damping Adjustment 13 9 Swingarm 13 26 Compression Damping Swingarm Removal 13 26 AdjUStMment sein 13 9 Swingarm Installation 13 27 Fork Oil Level Adjustment Swingarm Bearing Removal 13 27 SIMPY esses es uses 13 10 Swingarm Bearing Installation 13 27 Oil Change Oil Level Adjustment Drive Chain Guide Guide Roller each fork leg 13 12 Chain Slipper Wear 13 27 Front Fork Removal 13 12 Swingarm Bearing Sleeve Front Fork Installation 13 14 Inspection 13 28 Front Fork Disassembly e
178. lamp Hold the throttle cable C D I Unit Bracket 17 4 APPENDIX Cable Wire and Hose Routing DAN OP OVP GON Clutch Cable C D I Unit Main Harness Clamps Run the clutch cable Clamps Run the clutch cable Run the clutch cable inside of the mag neto lead Hot Start Cable Engine Stop Switch Lead GB09381BW4 C Clamp Hold the hot start cable engine stop switch lead and main harness Clamp Run the hot start cable and main harness Throttle Cables Clamp Hold the hot start cable and throt tle sensor lead Clamp Run the throttle sensor lead of main harness side APPENDIX 17 5 Cable Wire and Hose Routing Y O O1 ND oo Clutch Cable C D I Unit Main Harness Bolt together with ground lead terminal Neutral Switch Lead Connector Magneto Lead Clamp Run the magneto lead outside of the clutch cable Engine Stop Switch Clamp Hold the hot start cable engine stop switch lead and main harness 11 12 13 14 19 16 GB09383BW4 C Clamp Run the hot start cable and main harness Clamp Hold the hot start cable and throt tle sensor lead Clamp Run the throttle sensor lead of main harness side Throttle Sensor Hot Start Cable Ignition Coil 17 6 APPENDIX Cable Wire and Hose Routing GB09384BN4 C 1 Radiator Overflow Hose 10 Right Radiator 2 Clamp 11 Radiator
179. lay Inspection ORefer to the Clutch Lever Free Play Check in Periodic Maintenance chapter Clutch Lever Free Play Adjustment ORefer to the Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Clutch Lever Installation e Set the clutch lever A mating surface B to the punch mark C of the handlebar D Clutch Cable Removal e Turn in the adjuster fully A e Slide the dust cover A out of place e Loosen the knurled locknut B at the clutch lever and screw in the adjuster C e Line up the slots D in the clutch lever locknut and ad juster and then free the cable from the lever ENGINE RIGHT SIDE 6 9 Clutch Lever and Cable e Free the cable from the cable holder A e Free the clutch inner cable tip B from the clutch release lever C CAUTION Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one W e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Appendix chapter e Adjust the clutch cable see Clutch Lever Free Play Ad justment in Periodic Maintenance chapter Clutch Cable Inspection and Lubrication e During a periodic inspection or when the cable has been removed inspect and lubricate the cable see General Lubrication in the Periodic Maintenance chapter 6 10 ENGINE RIGHT SIDE Clutch Cover and
180. le adjusting screw B until the idle speed is correct To increase idle speed C To decrease idle speed D e Open and close the throttle a few times to make sure that the idle speed is with in the specified range Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSince repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in the element material or any other damage to the ele ment replace the element with a new one A WARNING Clean the element in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove Seat see Frame chapter Wing Bolt A Air Cleaner Element B e Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present
181. lee 11 9 Engine Sprocket Installation e ii 11 9 Rear Sprocket Removal cnn cnn 11 9 Rear Sprocket Installation 11 9 Sprocket Wear Inspection 11 9 Rear Sprocket Warp Inspection 11 10 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View Torque N m kgf m ft Ib Rear Sprocket Nuts 34 3 5 25 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Engine Sprocket Output Shaft Chain Slipper Swingarm Chain Guide Locknut Adjusting Bolt 10 Chain Adjuster 11 Drive Chain 12 Rear Sprocket 13 Upper Chain Guide Roller 14 Lower Chain Guide Roller G Apply grease O Apply oil L Apply a non permanent locking agent R Replacement Parts Z o Fastener Remarks cono a N gt 11 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Chain slack Chain 20 link length Standard Chain Make Type Length Sprocket Engine sprocket diameter Rear sprocket diameter Rear sprocket warp 52 62 mm 2 05 2 44 in ste 317 5 318 2 mm 12 50 12 53 in DAIDO D I D 520DMA2 114 Links 55 48 55 68 mm 2 184 2 192 in 13T 54 8 mm 2 157 in 232 62 233 12 mm 9 158 9 178 in 48T 232 1 mm 9 138 in Under 0 4 mm 0 016 in 0 5 mm 0 020 in FINAL DRIVE 11 5 Special Tools Outside Circlip Pliers Jack 57001 144 57001 1238
182. llation 4 uc eto 12 20 Brake Hose Inspection 12 20 12 2 BRAKES Exploded View GLO2083B 5 BRAKES 12 3 Exploded View No Fastener one Remarks N m kgf m ft Ib 1 Front master cylinder clamp bolts 8 8 0 9 78 in lb 2 Brake hose banjo bolts 25 2 5 18 3 Brake pad bolt 18 1 8 13 4 Caliper bleed valve 7 8 0 8 69 in lb 5 Caliper mounting bolts 25 25 18 6 Brake disc mounting bolts 9 8 1 0 87 in lb L 7 Brake lever pivot bolt locknut 5 9 0 6 52 in lb 8 Brake reservoir cap screws 1 5 0 15 13 in lb Brake lever pivot bolt 0 6 52 imlb 10 Front Brake Reservoir 11 Brake Lever 12 Brake Lever Adjuster 13 Locknut 14 Brake Hose 15 Clamps 16 Front Caliper 17 Brake Pad 18 Piston 19 Front Disc BF Apply brake fluid L Apply a non permanent locking agent Si Apply Silicone grease R Replacement Parts 12 4 BRAKES Exploded View BRAKES 12 5 Exploded View Torque No Fastener Nim koi FCI Remarks 1 Brake hose banjo bolts 25 2 5 18 2 Rear master cylinder mounting bolts 9 8 1 0 87 in lb 3 Rear master cylinder push rod locknut 18 1 8 13 4 Caliper bleed valve 7 8 0 8 69 in Ib 5 Brake pad bolt 18 1 8 13 6 Rear brake pad bolt plug 2 5 0 25 22 in lb 7 Caliper holder shaft 27 20 Brake pedal mounting bolt 18 Brake reservoir cap bolts 0 15 11 Brake Hose 12 Rear Mas
183. lly inspect the bearing for abrasion discoloration or other damage lf the needle bearing and sleeve show any sings of ab normal wear discoloration or damage replace them as a set SUSPENSION 13 29 Tie Rod Rocker Arm Tie Rod Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Unscrew the nut A and remove the guide roller B CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the tie rod rear mounting bolt A e Remove the tie rod front mounting bolt B and then take out the tie rod C Tie Rod Installation e Apply plenty of grease to the inside of the oil seals e Be sure seated the washers e Tighten the tie rod front and rear mounting nuts Torque Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft 1b Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt A e Remove the tie rod rear mounting bolt B e Remove the caps C e Remove the rocker arm pivot shaft A e Remove the rocker arm B 13 30 SUSPENSION Tie Ro
184. m difference in gauge reading is the crankshaft runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0031 in lf the runout at either point exceeds the service limit re place the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit 8 mm 0 354 in A e First correct the horizontal misalignment by striking the projecting crank half A with a plastic soft lead or brass hammer as shown e Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit GS10000BS1 6S10001BS1 6105028BS1 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vice depending on the nature of the misalign ment CAUTION Do not hammer the crank half at the point B If flywheel misalignment cannot be corrected by the above method replace the crankpin or the crankshaft itself Connecting Rod Big End Seizure xin case of serious seizure with damaged flywheels the crankshaft must be replaced xin case of less serious damage disassemble the crank shaft and replace the crankpin needle bearing and con necting rod Wheel Tires Air Pressure Inspection Adjustment e Using tire air pressure gauge A measure th
185. me Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake When handing the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 2 36 PERIODIC MAINTENANCE Periodi
186. ment Parts Replacement Parts must be KAWASAKI genuine or rec AG ommended by KAWASAKI Gaskets O rings Oil seals La NS Grease seals circlips or cotter pins must be replaced with new ones whenever disassembled 68020108 Assembly Order pa In most cases assembly order is the reverse of disassem E A bly however if assembly order is provided in this Service 2 e gt e Manual follow the procedures given lt PX Sos ine A D PA E E NIJ Se AN N TN 020118 Tightening Sequence em Bolts nuts or screws must be tightened according to the A NX specified sequence to prevent case warpage or deformation Ce l which can lead to malfunction If the specified tightening HH ES A r S f E i 9 sequence is not indicated tighten the fasteners alternating or A diagonally fe solos TA 68020128 1 4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is n
187. mm 5 8 mm 0 2283 in 0 2323 0 2362 in Shift drum groove width 6 05 6 20 mm 6 3 mm 0 2480 in 0 2382 0 2441 in TIR Total Indicator Readings CRANKSHAFT TRANSMISSION 9 5 Special Tools Bearing Puller Crankshaft Jig 57001 135 57001 1174 Outside Circlip Pliers Crankcase Splitting Tool Assembly 57001 144 57001 1362 Bearing Driver Set Kawasaki Bond Liquid Gasket Gray 57001 1129 92104 1063 9 6 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e Remove the engine from the frame see Engine Re moval Installation chapter e Set the engine on clean surface while parts are being re moved e Remove Magneto Cover see Electrical System chapter Cylinder Head Cover see Engine Top End chapter Camshaft Chain Tensioner see Engine Top End chap ter Cylinder Head see Engine Top End chapter Cylinder and Piston see Engine Top end chapter Right Engine Cover see Engine Right Side chapter Clutch see Engine Right Side chapter Primary Gear see Engine Right Side chapter Oil Pump Idle Gear see Engine Lubrication System chapter Oil Pumps see Engine Lubrication System chapter Kickstarter Assembly see Engine Right Side chapter Kickstarter Idle Gear see Engine Right Side chapter External Shift Mechanism see Engine Right Side chap ter Flywheel Magneto see Electrical System chapter e Remove the output shaft
188. n Ib Water Pump Cover Bolt with washer A 7 0 N m 0 7 kgf m 60 in Ib Coolant Drain Plug 7 0 N m 0 7 kgf m 60 in Ib Engine Oil Drain Plug 7 0 N m 0 7 kgf m 60 in Ib e Apply grease to the water pipe O ring B e Insert the water pipe C into the hole D of the water pump cover e Tighten Torque Water Pipe Bolt 9 8 N m 1 0 kgf m 87 in lb 4 10 COOLING SYSTEM Water Pump e Fill the cooling system see Coolant Filling e Bleed the air from the cooling system e Check the engine oil level and add the engine oil Impeller Removal e Drain Coolant see Coolant Draining Engine Oil see above Water Pump Cover e Remove the impeller bolt A and take out the impeller B with washer Impeller Installation e Install the washer A and impeller B e Tighten the impeller bolt Torque Impeller Bolt 7 0 N m 0 7 kgf m 61 in Ib e Install the water pump cover Water Pump Inspection e Visually check the impeller A x lf the surface is corroded or if the blades B are dam aged replace the impeller 6D06003BS1 e Check the drainage outlet passage A at the bottom of the right engine cover for coolant leaks If the oil seal is damaged the coolant leaks through the seal and drains through the passage Replace the oil seals COOLING SYSTEM 4 11 Water Pump Water Pump Gear Removal e Remove Water Pump Cover see this chapter Impeller see
189. nd water pipe see Cooling System chapter e Tighten OApply a non permanent locking agent to two cover bolts see Cooling System chapter OTighten two cover bolt with the washer see Cooling Sys tem chapter Torque Water Pump Cover Bolts 9 8 Nm 1 0 kgf m 87 in Ib Water Pump Cover Bolts with washer 7 0 N m 0 7 kgf m 61 in Ib Coolant Drain Plug 7 0 N m 0 7 kgf m 61 in Ib Water Pipe Bolt 9 8 N m 1 0 kgf m 87 in Ib e Pour in the specified type and amount of oil see Engine Oil Change and coolant see Cooling System chapter 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Screen Cleaning e Split the crankcase see Crankshaft Transmission chap ter e Remove the oil screen A e Clean the oil screens with a high flash point solvent and remove any particles stuck to them 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 solvent e Check the screens A carefully for any damage holes broke wires gasket pulling off x lf the screen is damaged replace it e Install Oil Screen see Crankshaft Transmission chapter Crankcase see Crankshaft Transmission chapter Breather Hose Inspection e Be certain that the breather hose are routed without being flattened or kinked and is connected co
190. ned rotted or swollen the piston assembly should be replace to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup e Check the dust covers E for damage lf they are damaged replace them e Check that the relief F and supply G ports are not plugged x lf the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with com pressed air e Check the piston return springs H for any damage lf a spring is damaged replace it K Rear Master Cylinder faa i A ua PT 20 PA GLO7022B BRAKES 12 19 Brake Disk Brake Disc Inspection e Visually inspect the disc A x lf it is scratched or damaged replace the disc e Measure the thickness of each disc at the point B where it has worn the most Replace the disc if it has worn past the service limit Thickness Front Rear Standard 2 85 3 15 mm 3 85 4 15 mm 0 112 0 124 in 0 152 0 163 in Service Limit 2 5 mm 0 10 in 3 5 mm 0 14 in e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Set up a dial gauge against the disc A as illustrated OFor the front disc turn the handlebar fully to one side e Measure the disc runout while rotating the wheel slowly B xlf the runout exceeds the service limit rep
191. ng Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket chain guide worn Gear Shifting Faulty Primary gear worn or damaged Doesn t go into gear shift pedal doesn t Decompressure spring broken return Magneto flywheel loose Clutch not disengaging Shift fork bent worn or seized Shift return spring pin loose Shift return spring weak or broken Shift shaft lever broken Pawl guide plate broken Shift pawl broken Shift pawl spring tension lose Gear seized Gear set lever operation trouble Shift drum broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Pawl guide plate worn Abnormal Engine Noise Knocking Faulty CDI unit Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat value Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Abnormal Drive Train Noise Clutch noise Clutch housing finger and friction plate tang worn Clutch housing gear worn Metal chips jammed in clutch housing gear teeth Transmission
192. no brake drag and no fluid leakage lf necessary bleed the air from the lines see Brakes chapter 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 unidentified Brake Pad Wear Inspection e Remove the brake pad see Brake Pad Removal in Brakes chapter e Check the lining thickness and condition of the pads in each caliper lf either pad is damaged replace both pads in the caliper as a set lf the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Lining Thickness Front Rear Standard 3 8 mm 0 150 in 6 4 mm 0 252 in Service Limit 1 mm 0 04 in 1 mm 0 04 in e Install the brake pad see Brake Pad Installation in Brakes chapter e Tighten Torque Brake Pad Bolt 18 N m 1 8 kgf m 13 ft lb 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Master Cylinder Cup and Dust Seal Replacement e Remove the front master cylinder see Brake chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip B Special Tool Inside Circlip Pliers 57001 143 e Remove the washer C e Pull out the piston D
193. noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient low viscosity Kick ratchet gear not properly disengaging from kick gear Kick shaft idle gear worn or chipped Drive chain noise Drive chain maladjusted Drive chain worn Rear and or engine sprocket worn Drive chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Front fork air pressure high Rear shock absorber noise Shock absorber trouble Spring weak or broken Disc brake noise Pad surface glazed Disc warped Caliper trouble Pad installed incorrectly APPENDIX 17 11 Troubleshooting Guide Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened Abnormal Exhaust Color White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner element clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable hose wire routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering
194. non permanent locking agent 13 6 SUSPENSION Specifications Item Standard Service Limit Front Fork Air pressure Rebound damping adjustment from the seated position adjuster turned fully clockwise Compression damping adjustment from the seated position adjuster turned fully clockwise Oil viscosity Oil capacity Oil level fully compressed spring removed Fork spring free length Atmospheric pressure 11 clicks counterclockwise 12 clicks counterclockwise EU 8 clicks counterclockwise 11 clicks counterclockwise EU KAYABA 01 or SAE 5W CORRESPOND 564 4 mL 19 07 0 14 US oz 95 mm 3 7 in from top of outer tube 460 mm 18 11 in Adjustable Range 16 clicks Adjustable Range 16 clicks Adjustable Range 70 120 mm 2 8 4 7 in 450 mm 17 72 in Rear Suspension Uni Trak Rear Shock Absorber Rebound damping adjustment from the seated position adjuster turned fully clockwise Spring preload adjustment Adjusting nut position from the center of the mounting hole upper Rear shock spring free length Gas Reservoir Compression damping adjustment from the seated position adjuster turned fully clockwise Gas pressure Tie Rod Rocker Arm Sleeve outside diameter Tie rod Rocker Arm Large Small Rocker Arm Mounting Bolt Runout 12 clicks counterclockwise 113 mm 4 41 in 260 mm 10 24 in 11 clicks counterclockwise 980
195. nting Bolt Nuts 33 Engine Bracket Bolt Nuts 22 Swingarm Pivot Shaft Nut 72 Crankshaft Transmission Breather Fitting E 11 Reed Valve Screws 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Ne kaim ftlb Remarks Piston Oil Nozzle 2 5 0 25 22 in lb L Crankcase Bolts 9 8 1 0 87 in lb Engine Oil Drain Plug for crank room oil sump 0 7 61 in lb for transmission room oil sump 1 5 11 Output Shaft Bearing Retaining Screw 0 65 56 in lb L Drive Shaft Bearing Retaining Screw a 0 65 56 in lb L Shift Drum Bearing Retaining Bolts 1 0 87 in lb L Gear Set Lever Nut 0 9 78 in lb Shift Drum Cam Bolt 2 4 17 L Neutral Switch 1 2 104 in 1b Wheels Tires Front Axle 79 8 0 58 Front Axle Clamp Bolts 20 2 0 14 5 Rear Axle Nut 110 11 0 80 Spoke Nipple Not less Not less Not less than 2 2 than 0 22 than 19 in lb Final Drive Rear Sprocket Nuts 34 3 5 25 Engine Sprocket Cover Bolts 9 8 1 0 87 in lb Brakes Brake Lever Pivot Locknut 5 9 0 6 52 in lb Brake Reservoir Cap Screws 1 5 0 15 13 in lb Brake Lever Pivot Bolt 5 9 0 6 52 in lb Caliper Mounting Bolts Front 25 2 5 18 Brake Hose Banjo Bolts 25 2 5 18 Front Master Cylinder Clamp Bolts 8 8 0 9 78 in lb Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb Rear Master Cylinder Push Rod Locknut 17 1 7 12 5 Brake Reservoir Cap Bolts 1 5 0 15 13 in lb Brake Disc Mounting Bolts Front 9 8 1 0 87 in lb Rear 23 2 3 16 6 Caliper Bleed
196. nto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same mamner e Check that the tube is not pinched between the tire and rim e Tighten the bead protector nut and A valve stem nut B and put on the valve cap C e Check and adjust the air pressure after installing 6J05010481 WHEELS TIRES 10 13 Hub Bearings Hub Bearing Removal e Remove the wheel see Wheel Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the oil seals and circlips Special Tool Inside Circlip Pliers 57001 143 e Remove the hub bearing by tapping evenly around the bearing inner race as shown A Bar B Distance Collar C Hub Bearing Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub B with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Lubricate them and install them using the bearing driver set A so that the marked or shielded sides face out OPress in the bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Replace the circlips and oil seals with new ones e Press in
197. o make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts O 2003 Kawasaki Heavy Industries Ltd Second Edition 1 Jan 16 2004 K LIST OF ABBREVIATIONS pound s ABDC AC ATDC BBDC BDC BTDC C DC F ft kg kgf ampere s after bottom dead center m alternating current min after top dead center N before bottom dead center Pa bottom dead center PS before top dead center psi degree s Celsius r direct current r min rpm farad s TDC degree s Fahrenheit TIR foot feet V gram s mass W hour s Q mass force liter s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s 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
198. o wide Replace the piston and or cylinder Piston seizure Inspect the cylinder and piston repair or replace them if necessary Bad condition of piston ring and or piston ring grooves Auto decompressor do not move smoothly Replace the piston and or the piston rings Replace the auto decompressor ENGINE TOP END 5 19 Cylinder Head Cylinder Head Removal e Remove Fuel Tank see Fuel System chapter Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft see Camshaft Removal Nut A Bolt B loosen Exhaust Pipe C Clamp Screw D Radiator Hose E e Remove Engine Bracket Bolts A Engine Brackets B Breather Hose C Clamp Screw D loosen e Move back the carburetor E e Disconnect Ignition Coil Lead A e Remove Ignition Coil Bracket Bolts B Ignition Coil Bracket with Ignition Coil C e Remove the 6 mm cylinder head bolts A and loosen the cylinder bolt B OThis prevents the 6 mm bolts from becoming damaged 5 20 ENGINE TOP END Cylinder Head e Remove the 10 mm cylinder head bolts A gt e Tap lightly up with a plastic mallet A to separate the cylin der head B from the cylinder e Move back the carburetor A and hold it e Pull the cylinder head upward B ODo not damage the radiator core OClear the front chain guide e Remove the cylinder head gasket
199. odic Maintenance chap ter If the coolant level is low add coolant up to the bottom of the filler neck e Install the radiator cap e Check the cooling system for leaks A 6 6D04016BS1 4 8 COOLING SYSTEM Coolant Cooling System Pressure Testing CAUTION During pressure testing do not exceed the pres sure for which the system is designed to work The maximum pressure is 123 kPa 1 25 kgf cm 18 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds If the pressure holds steady the cooling system is all right e Remove the pressure tester replenish the coolant and install the radiator cap x lf the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the effi ciency of the cooling syst
200. of the ratchet gear with the pin B e Before installing the shift shaft apply high temperature grease to the oil seal lips and shift shaft splines e Insert the shift shaft C OBe sure to install the washer D e Install Clutch see this chapter Right Engine Cover see this chapter e Install the shift pedal A as shown 50 5 mm 1 988 in B e Tighten Torque Shift Pedal Bolt 9 8 N m 1 0 kgf m 87 in lb External Shift Mechanism Inspection e Check the shift shaft A for bending or damage to the splines lf the shaft is bent straighten or replace it If the splines are damaged replace the shift mechanism e Check the return spring B for cracks or distortion lf the spring is damaged in any way replace it e Check the shift lever C for distortion xf the shift lever is damaged in any way replace the shift shaft ENGINE RIGHT SIDE 6 19 External Shift Mechanism e Check the ratchet assembly for damage lf ratchet A pawls B pins C or springs D are dam aged in any way replace them e Check the gear set lever A and its spring B for cracks or distortion xlfthe lever or spring is damaged in any way replace them e Visually inspect the shift drum cam A x If it is badly worn or if it shows any damage replace it GRO7O10BS1 GRO7O11BS1 GRO7OOSBS1 6 20 ENGINE RIGHT SIDE Kickstarter Kick Pedal Assy Remo
201. olts Upper 20 N m 2 0 kgf m 14 5 ft lb Lower 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque GNO50415S1 GNO5010481 14 8 STEERING Steering e Install the parts removed see the appropriate chapter A WARNING Do not impede the handlebar turning by routing the cables wires and hoses improperly see the Gen eral Information chapter e Check and Adjust Steering Front Brake Clutch Cable Throttle Cable STEERING 14 9 Steering Maintenance Stem Bearing Lubrication e Refer to the Stem Bearing Lubrication in Periodic Mainte nance chapter Stem Bearing Wear Damage e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer rase and the rollers Replace the bearing assembly if it show damage Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness x lf the steering stem shaft is bent A replace the steering stem GNO401038S1 14 10 STEERING Handlebar Handlebar Removal e Remove Clutch Holder A see Clutch chapter Engine Stop Switch B Clamp C Discard Left Handlebar Grip D e Remo
202. oolant 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 wheels Since coolant is harmful to the human body do not use for drinking Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Lean the motorcycle slightly to the right until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap 6S05027BS1 GCO7023BS1 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the coolant level The coolant level A should be at the bottom of the filler neck B If the coolant level is low add coolant through the filler opening to the bottom of the filler neck Install the cap Recommended coolant Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Water and coolant mixture ratio 1 1 water 50 Coolant 50 Total amount 1 2 L 1 27 US qt Coolant Deteriorat
203. or a suitable tool e Clean the cylinder head using high flash point solvent e Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air e Install the valves see Valve Installation 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold room or ambient temperature e Visually Inspect the inside of the cylinder for scratches and abnormal wear x If the cylinder is damaged or badly worn replace it with a new one e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment shown in the figure If any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed A 10 mm 0 39 in B 25 mm 0 98 in C 60 mm 2 36 in Cylinder Inside Diameter Standard 77 000 77 012 mm 3 0315 3 0320 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 77 06 mm 3 0339 in or more than 0 05 mm 0 020 in difference between any two measurements Piston Cylinder Clearance The piston to cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston to cylinder clearance must be adhered to whenever the cylinde
204. or nut by half a turn and then tighten to specified torque Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent to the threads Lh Left hand Threads S Tighten the fasteners following the specified sequence Torque Fastener Nm kgfm ftlb Remarks Fuel System Throttle Pulley Cover Bolt 3 4 0 3 30 in lb Throttle Cable Locknut 7 0 0 7 61 in lb Plunger Cap Bolt 1 0 0 1 10 in lb Rear Frame Mounting Bolts 34 3 5 25 Air Cleaner Duct Clamp Screw 2 0 0 2 17 in lb Fuel Tap Plate Mounting Screws 0 8 0 08 7 in lb Cooling System Right Engine Cover Bolt 9 8 1 0 87 in lb Water Pipe Bolt 9 8 1 0 87 in lb Water Pump Cover Bolts 9 8 1 0 87 in lb L 1 Water Pump Cover Bolts with washer 7 0 0 7 61 in lb L 1 Water Pump Impeller Bolt 7 0 0 7 61 in lb Radiator Hose Clamp Screws 1 5 0 15 13 in lb Radiator Screen Bolts 9 8 1 0 87 in lb Coolant Drain Plug 7 0 0 7 61 in lb Radiator Mounting Bolts 9 8 1 0 87 in lb Radiator Shroud Bolts 9 8 1 0 87 in lb Engine Top End Auto Decompressor Bolt 12 1 2 104 in lb Cylinder Head Cover Bolts 9 8 1 0 87 in lb Cylinder Head Bolts M10 50 5 0 36 S M6 12 1 2 104 in lb S Camshaft Cap Bolts 12 1 2 104 in lb S Carburetor Holder Clamp Screws 2 0 0 2 17 in lb Plug 20 2 0 14 L Lower Camshaft Chain Guide Bolt 9 8 1 0 87 in lb Rear Camshaft Chain Guide Bolt 15 1 5 11 Exhaust Pipe Stud L Pl
205. orque No Fastener Ne Ronin FCI Remarks 1 Neutral switch 12 1 2 104 in lb 2 Flywheel nut 49 5 0 36 3 Stator bolts 7 0 0 7 61 in lb 4 Spark plug 13 1 3 115 in lb 5 Magneto cover bolts L35 9 8 1 0 87 in lb L 6 Magneto cover bolts L30 9 8 1 0 87 in lb 7 Neutral lead terminal screw 1 3 0 13 12 in lb 8 Timing inspection cap 4 0 0 4 35 in lb Crankshaft sensor bolts 61 in lb C D I unit bolts 87 in lb Ignition coil bolts 61 in lb Flywheel cap Magneto Cover Flywheel Magneto Stator Ignition Coil C D I Unit Spark Plug Cap Main Harness Crankshaft Sensor Throttle Sensor Engine Stop Switch Apply Silicon Sealant Replace Parts Apply a non permanent locking agent 16 4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Crankshaft sensor resistance Magneto output voltage Stator coil resistance 80 120 Q in the text in the text Ignition System Ignition timing Disconnect the throttle sensor lead Ignition coil 3 needle arcing distance Primary winding resistance Secondary winding resistance 8 BTDC 2 000r min rpm 7 mm 0 26 in or more 0 28 0 34 Q at 20 C 7 65 10 35 kQ at 20 C Spark plug Type NGK CR8EB Gap 0 7 0 8 mm 0 026 0 031 in C D I unit in the text Throttle Sensor Input voltage around 5V Output voltage when the throttle valve completely closed 0 58 0 78 V when the throttle fully opened 3
206. ow hoses properly see Ap pendix chapter CAUTION Always keep the hoses free of obstruction and make sure they do not get pinched by the chain or shock absorber e Connect the throttle sensor connector e After installing the carburetor do the following OTurn the fuel tap to the ON position and check for fuel leakage from the carburetor WARNING Fuel spilled from the carburetor is hazardous OAdjust the following items if necessary Throttle Cable Idle Speed see Periodic Maintenance chapter Fuel Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove the carburetor see Carburetor Removal e Place a suitable container beneath the carburetor e Remove the drain plug A from the bottom of the float bowl and check for water or dirt in the fuel xlIf any water or dirt comes out clean the carburetor fuel tap and fuel tank see this chapter e Install the drain plug on the float bowl and tighten it se curely e Install the carburetor Carburetor Disassembly e Remove the carburetor e Remove all vent hoses A 6C06091BS1 3 18 FUEL SYSTEM Carburetor e Unscrew the screw A e Pull out th
207. pokes and tighten others within the standard torque to change the position of different parts of the rim If the rim is badly bent however it must be replaced Rim Runout with tire installed under 1 0 mm 0 039 in 2 mm 0 08 in under 1 0 mm 0 039 in 2 mm 0 08 in Wheel Bearing Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness binding or noise lf roughness binding abnormal noize is found replace the hub bearing e Turn the handlebar until the handlebar doesn t move to either side e The wheel edge is moved to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked lf the play is found replace the bearing 6y040610S1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Final Drive Drive Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links xlf there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry A Bushing D Pin Link B Roller E Roller Link CI Pin e Stretch the chain taut by hanging a 98 N 10 kgf 20 Ib O weight A on the chain e Measure the length of 20 links B on the straight part C of C the chain from the pin center of the 1st pin to the pin center of the 21st pin S
208. pring should also be replaced in or der to keep the rear shock absorbers balanced of motor cycle stability GM040116S1 Shock Absorber Spring Free Length Standard 260 mm 10 24 in Service Limit 255 mm 10 04 in Rear Shock Absorber Removal e Remove Seat Side Covers Silencer see Engine Top End chapter Rear Frame with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt A e Remove the rear shock absorber upper mounting bolt B nut and pull out the rear shock absorber C down and out Rear Shock Absorber Installation e Pack the rocker arm needle bearings with grease e Tighten the following Torque Rear Shock Absorber Upper Mounting Nut 39 N m 4 0 kgf m 29 ft lb Rear Shock Absorber Lower Mounting Nut 34 N m 3 5 kgf m 24 ft lb Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib 13 24 SUSPENSION Rear Suspension Uni Trak Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions e Remove Side Covers Seat Silencer Engine Top End chapte
209. r Rear Frame with Air Cleaner Housing e Remove the rear shock absorber e Clean the threaded portion on the upper of the rear shock absorber e Hold the lower of the rear shock absorber with a vise e Using the hook wrenches C loosen the locknut B and turn the adjusting nut A all way up Special Tool Hook Wrench 57001 1101 GMO5006BS1 e Remove the rear shock absorber from the vise Slide down the rubber bumper A e Remove the spring guides B from the shock absorber and lift off the spring C e Exchange the spring for an optional part Install the spring so that closed coil large diameter end A faces upward e Install the spring guide e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber A N e Install the parts removed LS DD GMO5055BS1 Rear Shock Absorber Disassembly Oil Change ORefer to the Rear Shock Absorber Oil Change in Periodic Maintenance chapter Rear Shock Absorber Assembly ORefer to the Rear Shock Absorber Oil Change in Periodic Maintenance chapter SUSPENSION 13 25 Rear Suspension Uni Trak Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not 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
210. r is less than the service limit replace the camshaft with a new one and measure the clearance again Camshaft Journal Diameter Standard 21 959 21 980 mm 0 8645 0 8654 in Service Limit 21 93 mm 0 8634 in If the clearance still remains out of the service limit re place the cylinder head unit 6E11075BS1 ENGINE TOP END 5 17 Camshaft Camshaft Chain Removal e Remove Camshaft see Camshaft Removal Magneto Flywheel see Electrical System Lower Camshaft Chain Guide Bolt A Lower Chain Guide B e Remove the camshaft chain C from the crankshaft sprocket Camshaft Chain Installation e Use the driver A to bring the lower chain guide B upward e Tighten the chain guide bolt C Torque Lower Camshaft Chain Guide Bolt 9 8 N m 1 0 kgf m 87 in lb e Install Flywheel Magneto see Electrical System chapter Camshaft see Camshaft Installation 5 18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement e Start the engine e Thoroughly warm up the engine so that the engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running e Stop the engine e Remove Fuel Tank see Fuel System chapter e Remove the spark plug A with spark plug wrench B or owner s tool Special Tool Spark Plug Wrench Hex 16 57001 1262 Owner s Tool Spark Plug Wrench 92110 1172 e Attach the compres
211. r is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must not be less than the minimum in order to avoid piston seizure The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference between the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard 0 030 0 057 mm 0 0012 0 0022 in Piston Piston Ring and Piston Pin Replacement e Refer to the Cylinder Section in Engine Top End chapter PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Exhaust System e The exhaust system in particular the silencer is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss If car bon has built up inside the silencer exhaust efficiency is reduced causing engine performance to drop elf the silencer is badly damaged dented cracked or rusted replace it Replace the silencer packing if the exhaust noise becomes too loud or engine performance drops Silencer Packing Change e Remove the silencer see Engine Top End chapter e Remove the inner pipe mounting bolts A GSO7009BS1 e Tap the bracket A of the silencer body with a plastic mal let B to separate from the inner pipe e Pull off th
212. r races e Install the steering stem and adjust the steering see Steering chapter Frame Frame Inspection e Clean the frame with steam cleaner e Visually inspect the frame and rear frame for cracks dents bending or warp x lf there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it Electrical System Spark Plug Cleaning and Inspection e Remove Seat see Frame chapter Fuel Tank see Fuel System chapter Spark Plug Cap e Clean the plug hole A using the compressed air B GNO4009BS1 GNO4004BS1 6S16001BS1 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Remove the spark plug A using the spark plug wrench B Special Tool Spark Plug Wrench 57001 1262 Owner s Tool Spark Plug Wrench 16 mm 92110 0002 e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool x lf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug e Measure the gap A with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap
213. r removed parts CRANKSHAFT TRANSMISSION 9 13 Crankshaft Crankshaft Removal e Disassemble the crankcase see Crankcase Disassem bly e Remove the transmission shaft see this chapter e Using the hand press A remove the crankshaft B from the right crankcase C i LE suf mag A an Giono P x lf the bearing stay on the crankshaft when splitting the crankcase or removing the crankshaft from the right re move the bearings from the crankshaft with a bearing puller Special Tools Bearing Puller A 57001 135 Crankshaft Installation e Apply high temperature grease to the outer side of the crankshaft bearings and use the bearing driver set A and a press to drive the bearing to the bottom of the crankcase B While driving the bearing in make sure to use a holder to support the boss area Special Tool Bearing Driver Set 57001 1129 Insert the crankshaft jig A between the crankshaft fly wheels opposite the connecting rod big end to protect fly wheel alignment as shown and press the crankshaft into the right crankcase e When pressing position the jig in the crankcase opening so the jig does not hit the crankcase Special Tool Crankshaft Jig 57001 1174 e Apply engine oil to the connecting rod big end bearing Crankshaft Disassembly Since assembly of the crankshaft demands exacting tol erances the disassembly and reassembly of the crankshaft can only be done by a s
214. r to the Idle Speed Inspection in Periodic Mainte nance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in Periodic Mainte nance chapter Service Fuel Level Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove the fuel tank e Remove the carburetor and hold it in true vertical position on a stand The fuel hose and carburetor cable do not have to be removed to inspect the fuel level A e Put the fuel tank on a bench and connect the fuel tap to the carburetor using a suitable hose e Remove the drain plug from the bottom of the float bowl and screw a fuel level gauge B into the plug hole Special Tools Fuel Level Gauge 57001 122 6006061652 C FUEL SYSTEM 3 13 Carburetor e Hold the gauge vertically against the side of the carbure tor body so that the zero line C is several millimeters higher than the bottom edge D of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the zero line is even with the bottom edge of the carbu retor body N
215. radiator hose clamp screw e Install Carburetor Fuel Tank see Fuel System chapter Exhaust Pipe see this chapter Cylinder Head Cleaning e Refer to the Cylinder Head Warp Inspection in Periodic Maintenance chapter Cylinder Head Warp e Refer to the Cylinder Head Warp Inspection in Periodic Maintenance chapter 5 22 ENGINE TOP END Valves Valve Clearance Inspection ORefer to the Engine Top End in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and the shim from the valve NOTE OUse the valve spring compressor assembly and the adapter to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 20 57001 1154 B Valve Installation CAUTION Do not lap the valve to the valve seat using the grinding compound It will come off oxide film treated surface of the valve e Visually inspect the valve surface lf the surface is damaged replace it e Replace the oil seal C with a new part e Apply a thin coat of molybdenum disulfide grease to the valve stem A before installing the valve e Check to make sure that the valve moves up and down smoothly e Check to make sure that the valve and the valve seat are making proper contact e Install the valve spring so thatthe closed coil end D faces the spring seat B e Compress the val
216. rbor 4 5 57001 1116 57001 1331 Valve Seat Cutter 60 628 Valve Guide Reamer 4 5 57001 1328 57001 1333 Spark Plug Wrench Hex 16 Valve Guide Driver 4 5 57001 1262 57001 1564 ST5715648T Compression Gauge Adapter M10 x 1 0 Piston Pin Puller 57001 1317 57001 1568 ig ST571568ST Valve Seat Cutter Holder 4 5 57001 1330 ENGINE TOP END 5 11 Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel System chapter Spark Plug Cap A e Remove the cylinder head cover bolts B and remove the cylinder head cover C Cylinder Head Cover Installation e Apply silicon sealant A to the cylinder head as shown Sealant Three Bond TB1211F e Replace the head cover gasket e Install the head cover gasket A on the cylinder head B e Make sure that the upper chain guide A is bottomed CAUTION Unless the upper chain guide is bottomed the camshaft chain could push the cylinder head cover upward leading to an oil leak e Install the head cover from the motorcycle left side e Install the head cover bolt washers A with the metal side upwards e Tighten the cover bolt B Torque Cylinder Head Cover Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the spark plug cap OPull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap 6E09017BS1
217. red or replaced e f the fork is not smooth confirm the cause CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Front Fork Oil Change each fork leg e Loosen the front fork upper clamp bolts A e Loosen the fork top plug B e Remove Front Wheel see Wheels Tires chapter Front Brake Cliper see Brakes chapter Brake Hose Clamps see Brake Hose and Connection Check e Loosen the front fork lower clamp bolts A e Remove the front fork OWith a twisting motion work the fork leg B down and out e Hold the inner tube lower end in a vise e Disassemble the top plug A from the outer tube B e Push the outer tube all the way down away from the top plug and hold it there throughout the following procedure 6S14B101 I PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures e Use wrenches A on the rod nut B and the top plug C to loosen the top plug e Remove the top plug from the push rod e Lift the fork spring D and its top spring seat E out of the outer tube e Take the rebound damping adjuster rod A out of the push rod e Hold the fork tube A upside down over a clean container B and pump it to drain the oil NOTE OPump the push rod up C and down to discharge the fork oil e Hold the fork tube upright press the outer tube and the push rod all the way down e Ins
218. replaced as a set e Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high flash point solvent e Using compressed air blow out the oil passages in the crankcase halves Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or ex plosions could result e Be sure to replace any oil seal removed with a new one e Press in the new oil seals using a press and bearing driver so that the seal surface A is flush B with the surface of the crankcase C e Apply high temperature grease to the oil seal lips D Right Crankcase Oil Seal F Metal Side Face E Left Crankcase Oil Seals output shaft G shift shaft H e Support the crankcase bearing boss with a suitable re tainer A e Using a press and the bearing driver set C install a new bearing B until it bottoms out Special Tool Bearing Driver Set 57001 1129 CAUTION Support the crankcase bearing boss when the bear ing is pressed or the crankcase could be damaged 6104000BS1 CRANKSHAFT TRANSMISSION 9 9 Crankcase e Press the new drive shaft bearing A in the left and right crankcase half so that the sealed side B faces outside of the engine
219. ressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge hand must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge hand flicking downward The relief valve must open within the specified range Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Radiator Hoses Breather Hose Inspection e Refer to the Radiator Hoses and Connections Inspection in Periodic Maintenance chapter Radiator Hoses Breather Hose Installation e Install the radiator hoses or breather hose being careful to follow the performed bends see Appendix chapter Avoid sharp bending kinking flattening or twisting e Tighten the hose clamps securely Torque Radiator Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib 6D07000BS1 6D07001BS1 GD07060281 ENGINE TOP END 5 1 Engine Top End Table of Contents
220. retor holder loose Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Hot start stuck open Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brake dragging Drive train trouble Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted 17 10 APPENDIX Troubleshooting Guide Clutch inner cable sticking Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release function trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever play excessive Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing seized Clutch release function trouble Clutch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing or cam face worn Valve lifter worn Other noise Connecting rod big end small end clear ance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaki
221. riodic Maintenance Procedures 2 11 Final Drive 2 31 Fuel Systems tenir 2 11 Drive Chain Wear Inspection 2 31 Fuel Hose and Connection Drive Chain Lubrication 2 31 Inspection Sprocket Wear Inspection 2 32 Throttle Grip Free Play Inspection 2 11 Rear Sprocket Warp Inspection 2 32 Throttle Grip Free Play O Ponant 2 33 Adjustment 2 11 Brake Lever and Pedal Hot Start Lever Free Play Adjustment 2 33 Inspection 2 12 Brake Fluid Level Inspection 2 34 Idle Speed Inspection 2 12 Brake Fluid Change 2 35 Idle Speed Adjustment 2 13 Brake Pad Wear Inspection 2 37 Air Cleaner Element Cleaning and Brake Master Cylinder Cup and Inspection 13 Dust Seal Replacement 2 38 Cooling System 2 15 Caliper Piston Seal and Dust Seal Coolant Level Inspection 2 15 Replacement 2 39 Coolant Deterioration Inspection 2 16 Brake Hose and Connection Radiator Hoses and Connections CHECK iaa a aeaa lors ut 2 42 Inspection 2 16 Brake Hose Replacement 2 42 Engine Top End ccsceeeee 2 17 SUSPENSION 2 44 Valve Clearance Inspection 2 17 Front Fork Inspection 2 44 Valve Clearance Adjustment 2 17 Front Fork Oil Change each fork Cylinder Head Warp Inspection 2 19 NSO
222. rocedures Brake Fluid Level Inspection e Check the brake fluid level in the front or rear brake reser voir A NOTE OHold the reservoir horizontal when checking brake fluid level e The front or rear reservoir must be kept above the lower level line B Olf the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line In side the reservoir is stopped end showing the upper level line C Torque Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb 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 unidentified After changing the fluid use only the same type and brand of fluid thereafter PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed 3 WARNING When working with the disc brake observe the pre cautions listed below 1 2 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long ti
223. rque Caliper Bleed Valve 7 8 N m 0 8 kgf m 69 in Ib GLO9060582 C BRAKES 12 11 Brake Fluid e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this in not done 12 12 BRAKES Caliper Caliper Removal Front Brake e Loosen the banjo bolt A so as not to spill brake fluid e Remove the caliper mounting bolts B e Remove the banjo bolt and take off the brake hose from the caliper C e f the caliper is to be disassembled after removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper ORemove the pads OPump the brake lever to remove the piston Rear Brake e Unbolt the caliper guard bolts A and remove the caliper guard B e Unbolt the disc guard bolts C and remove the disc guard D e Loosen the banjo bolt A so as not to spill brake fluid e Loosen the brake pad cap bolt B and pad bolt C before the caliper removal if the caliper is to be disassembled NOTE Olf the caliper is to be disassembled after removal and compressed air is not available
224. rrectly xf it is not correct it e Inspect the breather hose A for damage or sings of de terioration OThis hose should not be hard and brittle nor should be soft swollen Replace it if any cracks or swelling is noticed Crankshaft Transmission Crankshaft Inspection Connecting Rod Big End Radial Clearance e Set the crankshaft on V blocks and place a dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between two gauge readings is the radial clearance Connecting Rod Big End Radial Clearance Standard 0 002 mm 0 014 mm 0 00008 0 0006 in Service Limit 0 06 mm 0 0024 in x lf the radial clearance exceeds the service limit crank shaft should be either replaced or disassembled and crankpin needle bearing and connecting rod big end examined for wear 6105018BS1 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Connecting Rod Big End Side Clearance e Measure the connecting rod big end side clearance A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 0138 in Service Limit 0 55 mm 0 0217 in l the clearance exceeds the service limit replace the crankshaft assembly Crankshaft Runout e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge as shown and turn the crankshaft slowly The maximu
225. rts and shorts resulting from insulation breakdown under high voltage e Remove the ignition coil e Measure the primary winding resistance A OComnect an ohmmeter between the coil terminals OSet the meter to the x 1 Q range and read the meter e Measure the secondary winding resistance B OPull the spark plug cap off the lead OComnect an ohmmeter between the spark plug lead and the ground lead terminal OSet the meter to the x 1 kQ range and read the meter lf the meter does not read as specified replace the coil xf the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good Ignition Coil Winding Resistance Primary windings 0 28 0 34 Q at 20 C Secondary windings 7 65 10 35 kQ at 20 C e Check the spark plug lead for visible damage x lf the spark plug lead is damaged replace the coil Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in Peri odic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in Periodic Main tenance chapter C D I Unit Removal e Remove Belt Open A Bolt B Number Plate C 6P10113BS1 16 16 ELECTRICAL SYSTEM Ignition System e Disconnect the main harness connector A e Unscrew the mounting bolt
226. rum 9 16 CRANKSHAFT TRANSMISSION Transmission e Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear e The shift forks can be identified by their shape or mark Install them noting the direction shown OThe drive shaft fork A is the shortest and install it with its mark IN B facing the engine left side Olnstall the right output shaft fork A with its mark R B facing the engine right side Olnstall the left output shaft fork C with its mark L D facing the engine left side e Fit each shift fork guide pin into the corresponding groove in the shift drum e Apply a small amount of engine oil to the shift rods and slide them into the shift forks e Install the oil screens A as shown Longer Outcrop B Right Crankcase C e Assembly the crankcase see this chapter Transmission Shaft Disassembly e Remove the transmission shafts e Remove the circlips washers then gears Special Tool Outside Circlip Pliers 57001 144 e Do not reuse the removed circlips Transmission Shaft Assembly e Apply engine oil liberally to the transmission shaft gears and bearings e Replace any circlips that were removed with new ones OAlways install the circlips A so that the opening B is aligned with a spline groove C and install toothed wash ers To install a circlip without damage first fit the circlip onto the shaft expanding
227. rum cam bolt Kick Pedal Kickshaft Idle Gear Ratchet Gear Kick Gear Shift Pedal Ratchet Plate Ratchet Assembly Gear Set Lever Shift Drum Cam Shift Shaft Apply a non permanent locking agent Apply engine oil Apply molybdenum disulfide grease Apply grease Stake the fasteners Replacement Parts 17 6 6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Friction Plate Thickness 2 72 2 88 mm 2 62 mm 0 1031 in 0 107 0 113 in Steel Plate Thickness 1 5 1 7 mm 1 4 mm 0 055 in 0 059 0 067 in Friction Plate Warp 0 15 mm 0 0079 in or less 0 3 mm 0 0118 in Steel Plate Warp 0 2 mm 0 0079 in or less 0 3 mm 0 0118 in Clutch Spring Free Length 46 8 mm 1 843 in 44 9 mm 1 768 in Friction Plate Clutch Housing 0 04 0 55 mm 0 9 mm 0 035 in Clearance 0 0016 0 0217 in ENGINE RIGHT SIDE 6 7 Special Tool Clutch Holder 57001 1243 Gear Holder 57001 1557 ST571557ST 6 8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accor dance with the Periodic Maintenance Chart A WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment Clutch Lever Free P
228. s Exploded MEW E e A A EE tre 15 2 A A O 15 4 Frame INSPOClON iii A A A AA 15 4 Rear Frame REMOVAL o 15 4 R ar Frame Installation s5 s ac add cobed ete naera enna 15 4 Engine Guard ins t l den ne tit En dd en nee phd acid aeg tint ee 15 4 SEAL ML ER tae Re nn at e E e sehen et 15 5 Seat REMO A NO ide 15 5 Seat Installation ad ta a ia 15 5 AAN A E 15 6 Side Gover Removal 22e Ay eons ee ee As AO eA A he eee 15 6 Side Cover Installation ita ti o tds iia des 15 6 ENE di tad 15 7 Front Fender Removal oooccooccccnoccccnccnnnocononcccnnccnononononanonnnnnnonannnnannnnnnnn nano nonann EAEE A EEE 15 7 Rear Fender Remo ani id ri 15 7 ReariElap Removal issues sh iene ait Giver Aiea es 15 7 15 2 FRAME Exploded View 6002094B 5 FRAME 15 3 Exploded View No Fastener eue Remarks 1 Upper rear frame mounting bolt 34 3 5 25 2 Lower rear frame mounting bolts 34 3 5 25 G Apply grease R Replacement Parts 15 4 FRAME Frame Frame Inspection e Refer to the Frame Inspection in Periodic Maintenance chapter Rear Frame Removal e Remove Seat see Seat Removal Right amp Left Side Cover see Side Cover Removal Silencer see Engine Top End chapter Rear Fender see Fender Removal Rear Flap see Flap Removal e Unscrew the rear frame mounting bolts A e Remove the rear frame B with air cleaner housing C e Remove Bolts A Air Cleaner Housing B Rear
229. s B and remove the C D I Unit C C D I Unit Inspection CAUTION When inspecting the C D I unit observe the follow ing to avoid damage to the C D I unit Do not disconnect the C D I unit while the engine is running This may damage the C D I unit Ignition Coil Primary Peak Voltage Check e Disconnect the spark plug cap from the spark plug e Connect the good spark plug A to the spark plug cap then touch the engine with it NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug install to the cylinder head e Connect the peak voltage adapter B between the termi nal of primary lead orange and ground connection of the unit with the lead of the ignition coil C connected OSet the tester to DC 250V range Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connection Adapter Positive Ground Lead D Adapter Negative Orange Lead E C D I Unit F Needle Adapter G Special Tool Needle Adapter Set 57001 1457 Hand Tester 57001 1394 6P10114BS1 ELECTRICAL SYSTEM 16 17 Ignition System e Shift the gear to the neutral position then free the engine stop switch e Crank the engine by kicking the pedal several times to measure the peak voltage of
230. s the proper pad disc clearance If this seal is not in good condition pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in left and right pad wear d the seal is stuck to the piston If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Cover Damage e Check that the dust seals and covers are not cracked worn swollen or otherwise damaged If they show any damage replace them Piston Cylinder Damage e Visually inspect the piston and cylinder surfaces Replace the cylinder and piston if they are badly scored or rusty 12 14 BRAKES Caliper Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check too see if the caliper holder shafts are not badly worn or stepped or the rubber friction boot is not dam aged lf the shafts or rubber friction boot are damaged replace the shafts rubber friction boot and the caliper holder Brake Pad Removal For Front Brake Pad e Unscrew the pad bolt A e Take t
231. se wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e Afterthe parts are cleaned dry them with compressed air e Blow through the air and fuel passages with compressed air A e Assemble the carburetor and install it on the motorcycle 3 22 FUEL SYSTEM Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor e Before disassembling the carburetor check the fuel level see Fuel Level Inspection xlf the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Turn the throttle pulley to check that the throttle valve A moves smoothly and returns by spring pressure lf the throttle valve does not move smoothly Replace the throttle valve or pulley spring e Disassemble the carburetor e Clean the carburetor e Check the O rings on the float bowl pilot screw and throt tle sensor are in good condition If any of the O rings are not in good condition replace them e Check the tapered portion A of the pilot screw B for wear or damage x lf th
232. sion gauge A and the adapter hose B firmly into the spark plug hole e With the throttle fully open turn the engine over sharply with the kickstarter several times until the compression gauge stops riding the compression is the highest read ing obtainable Special Tool Compression Gauge 57001 221 Compression Gauge Adapter 57001 1317 Cylinder Compression Service Range 431 706 kPa 4 4 7 2 kg cm 62 6 102 psi 5 kicks e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 9 4 ft Ib e Pull the spark plug cap lightly to make sure the installation of the spark plug cap Problem Diagnosis Remedy Action The cylinder compression is higher than the usable range The cylinder compression is lower than the usable range Carbon accumulation on piston and in cylinder head combustion chamber is suspected due to damaged valve stem or piston oil rings Incorrect cylinder head gasket thickness Damaged auto decompressor spring or decompressor do not move smoothly Exhaust gas leakage around cylinder head Remove the carbon deposits and replace damaged parts if necessary Replace the gasket with a standard one Replace the spring or auto decompressor Replace the damaged gasket and check cylinder head warp Incorrect seating surface of valve Repair seating surface if possible Valve clearance is too narrow Adjust the valve clearance Piston cylinder clearance is to
233. sleeve A and the O rings B ODo not reuse the O rings e Remove Neutral Switch A Breather Hose B Breather Hose Fitting C Giosaiso P CRANKSHAFT TRANSMISSION 9 7 Crankcase e Remove the crankcase bolts A e Install the jig A between the crankshaft flywheels B Special Tool Crankshaft Jig 57001 1174 e Attach the crankcase splitting tool A to the left crankcase OAdjust the gap between the splitting tool arm and bolt using the collar or nut B Special Tool Crankcase Splitting Tool Assembly 57001 1362 e Tighten the center bolt of the crankcase splitting tool to split the crankcase halves ORemove the left crankcase half e Remove Oil Screen A see Transmission Shaft Removal Shift rods B see Transmission Shaft Removal 3 shift forks C see Transmission Shaft Removal Shift dram D see Transmission Shaft Removal Transmission E see Transmission Shaft Removal e Remove the crankshaft from the right crankcase half see Crankshaft Removal e Remove the reed valve A from the left crankcase half OUnscrew the screws B and remove the guide C CAUTION Do not remove the bearings and the oil seals unless it is necessary Removal may damage them 9 8 CRANKSHAFT TRANSMISSION Crankcase Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state so if replaced they must be
234. ss oil through the filler opening using a syringe or some other suitable device x If the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level rather than running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change ORefer to the Engine Lubrication System in the Periodic Maintenance chapter 6605010851 ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oil Filter Change ORefer to the Engine Lubrication System in the Periodic Maintenance chapter Oil Screen Removal e Separate the crankcase see Crankshaft Transmission chapter e Remove the oil screens A from the crankcase Oil Screen Installation e Clean the oil screens thoroughly whenever it is removed for any reason e Clean the oil screens with a high flash point solvent and remove any particles stuck to them WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screens check for any metal parti cles that might indicate internal engine damage e Check the screens A
235. ssemMbly ss niet ne trie enfer ne dnines 3 17 Carburetor Clean sas see en ara t 3 21 Garburetor INSPECTION 2 iia a e td E 3 22 Gatb retot Assembly e rene aaa Gs eee Sea ee ne fc nn nent 3 23 All GIANG hci tirant A A A hes eee heed eee ata 3 29 Air Cleaner Housing Removal ta ici 3 29 Air Cleaner Housing Installation ss 3 29 Element Remo Valioso nia ae eean r ea aren laa 3 29 Element Installation see 3 29 Element Cleaning and Inspection sinistre nm nat sha lene 3 30 Fuel EU LR RE cette lanes E E a cubed a e a hanes 3 31 Fuel Tank REMOVAL aay 3 31 Fuel Tank Installation 3 31 Fuel Tap Removal seson A dee 3 32 Fuel Tap Instala D T 3 32 Fuel Tank and Tap Cleaning sas tte ia 3 32 Fuel Tap INSPIRA 3 32 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View No Fastener Remarks Throttle pulley cover bolt 30 in lb Throttle cable locknut 61 in lb Hot start plunger cap bolt 10 in lb Throttle Cables Throttle Grip Carburetor Cap Throttle Valve Plate Throttle Valve Jet Needle 10 Throttle Pulley Shaft 11 Choke Knob 12 Idle Adjusting Screw 13 Pilot Air Screw 14 Slow Jet 15 Main Jet 16 Needle Jet 17 Starter Jet 18 Float 19 Leak Jet 20 Throttle Sensor 21 Hot Start Plunger 22 Acceleration Pump Diaphragm 23 Slow Air Jet O Apply 2 stroke oil G Apply grease L Apply a non permanent locking agent
236. st Gear Ball Bearing One side G113118B 3 26T 24T 20T 30T aan NT AR sealed Output Shaft Collar Oil Seal 9 18 CRANKSHAFT TRANSMISSION Transmission e Check each gear spins or slides freely on the transmission shaft without binding after assembly Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork may cause difficulty in shifting or allow the transmission to jump out of gear when under power 90 A Shift Fork Gear Groove Wear e Measure the thickness A of the shift fork ears and mea sure the width B of the gear grooves with which the fork engages Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 1929 0 1969 in Service Limit 4 8 mm 0 1890 in Gear Groove Width Standard 5 05 5 15 mm 0 1988 0 2028 in Service Limit 5 25 mm 0 2070 in x lf the thickness of a shift fork ear is less than the service limit the shift fork must be replaced lf the gear groove is worn exceeding the service limit the gear must be replaced Shift Fork Guide Pin Shift Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 2323 0 2362 in Service Limit 5 8 mm 0 2283 in Shift Drum Groove Width Standard 6 05 6 20 mm 0 2382 0 2441 in Service Limit 6 3 mm 0 2480 in xlf the guide pin on any shift fork is
237. t Cutter Operation Care 1 This valve seat cutter is developed to grind the vale for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following 610 Bann menu Cutter Angle B CTE o EA EAAS Cutter Outer Diameter C Repair Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will redu
238. t the tooth is aligned with a spline groove Special Tools Outside Circlip Pliers 57001 144 Torque Engine Sprocket Cover Bolts 4 9 N m 0 5 kgf m 43 in lb Rear Sprocket Removal e Remove the rear wheel see Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Unscrew the rear sprocket bolts A and remove the rear sprocket B Rear Sprocket Installation e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and tighten the nuts Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 ft Ib Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in Periodic Main tenance chapter re 6K05004BS1 11 10 FINAL DRIVE Sprockets Rear Sprocket Warp Inspection e Refer to the Rear Sprocket Wrap Inspection in Periodic Maintenance chapter BRAKES 12 1 Brakes Table of Contents Exploded Views AE AA A ee es 12 2 SPECITICAIONS 257285 ue Pons een Tdi Me den Ten Brent a subca casts caus atiansaderst cur E Th Sons aver RS 12 6 Special TOO S 45 NN 12 7 Brake Lever Brake Pedal a 12 8 Brake Lever Play Adiustment sit ne rt 12 8 Brake Pedal Position Pedal Play Adjustment us 12 8 Brake Pedal Removal siii aa 12 8 Brake Pedal Install a a 12 8 Brake Fluid siii
239. tage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder heaa OSet the hand tester to DC 250 V range OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connection Adapter Positive Red White Lead C Adapter Negative Brake Red Lead D OCrank the engine by kicking the pedal several times to measure the peak voltage of the exciter coil Peak Voltage 40 V or Above xf the voltage is less than the specified check the exciter coil Charge Coil Peak Voltage Check e Disconnect the connector of the magneto lead connector from the main harness e To check the peak voltage do the following procedures NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connection Adapter Positive Yellow Lead C Adapter
240. ter Cylinder 13 Brake Pedal 14 Rear Caliper Cover 15 Rear Caliper 16 Piston 17 Brake Pads 18 Rear Disc BF Apply brake fluid G Apply high temperature grease Si Apply Silicone grease R Replacement Parts L Apply a non permanent locking agent 12 6 BRAKES Specifications Item Standard Service Limit Brake adjustment Lever play Adjustable to suit rider Brake Fluid Recommended disc brake fluid Type Front DOT3 or DOT4 Rear DOT4 Brake Pads Lining thickness Front 3 8 mm 0 150 in 1 mm 0 04 in Rear 6 4 mm 0 252 in 1 mm 0 04 in Brake Disc Thickness Front 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 10 in Rear 3 85 4 15 mm 0 152 0 163 in 3 5 mm 0 14 in Runout Not more than 0 25 mm 0 098 in 0 3 mm 0 01 in BRAKES 12 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 PS 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Play Adjustment e Refer to the Brake Lever Play Adjustment in Periodic Maintenance chapter Brake Pedal Position Pedal Play Adjustment e Refer to Brake Pedal Position Pedal Play Adjustment in Periodic Maintenance chapter Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer C e Remove the mounting bolt D and take off the brake pedal E and return spring Brake Pedal Installation e Replace O rings with new one and apply high tempera ture grease to the O rings
241. the fuel hose fitting B e Tighten the screws e Install all hoses A e Install the carburetor see Carburetor Installation 3 28 FUEL SYSTEM Carburetor e If turn the adjusting screw of the acceleration pump follow the procedure below OAdjust the acceleration pump timing OSelect an arbor A of the same diameter as the throttle valve height B and insert it under the throttle valve Throttle Valve Height 1 25 mm 0 0492 in OTurn in the adjusting screw A fully OCheck the push rod holder B play OTurn the adjusting screw counterclockwise gradually to adjust with the push rod holder moving forward or back ward till no free play is available Push Rod C FUEL SYSTEM 3 29 Air Cleaner Air Cleaner Housing Removal e Remove Side Covers see Frame chapter Seat see Frame chapter Silencer see Engine Top End chapter Bolts and Rear Fender A see Frame chapter Screws and Rear Flap B see Frame chapter Rear Frame Bolts C e Loosen the air cleaner duct clamp D e Remove the rear frame e Unscrew the bolt A e Remove the air cleaner housing B Air Cleaner Housing Installation e Installation is the reverse of the removal e Tighten the rear frame mounting bolts A Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Element Removal e Remove the seat e Remove the wing bolt A and pull out the element B e Stuf
242. the primary ignition coil Peak Voltage 176 V or above WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock If the voltage is less than the specified value see the next page 16 18 ELECTRICAL SYSTEM Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition No good system inspection Repair NV Good i No good Spark plug inspection Replace Good No good Replace No good Voltage is less than the specified value Spark plug cap inspection Ignition coil primary peak voltage inspection No good Voltage is none or almost none Voltage is specified but faulty ignition y Defective ignition coil Inspect Inspection 1 Adapter connection is 1 Speed of cranking engine is incorrect or adapter is slow Increase force of kicking directive engine 2 Engine stop switch Lower resistance in the tester 3 Crankshaft sensor peak Use KAWASAKI Hand Tester voltage Lacking of sampling Sampling Exciter coil peak voltage few times Crankshaft sensor peak voltage Exciter coil peak voltage Replace Replace the malfunctioned no good part All good All good C D I Unit is defective No good Replace the malfunctioned part or inspect in proper way k GP10099B F
243. the push rod up C and down to discharge the fork oil e Remove Push Rod Nut A Spring Guide B e Using the wrenches A loosen the nut B from the holder 6S14025BS1 6S14026BS1 6S14027BS1 6M04023BS1 6M04157BS1 13 16 SUSPENSION Front Fork e Remove Circlip A O ring B Nut C Collar D Holder E e Clean the bottom of the inner tube e Remove the cap on the bottom of the inner tube e Hold the front fork horizontally in a vise e Stop the cylinder unit A from turning by using the fork cylinder holder B Unscrew the cylinder valve assembly C and take the cylinder valve assembly and gasket out of the bottom of the inner tube Special Tool Fork Cylinder Holder 57001 1573 A Inner Tube B Cylinder Valve Assembly C O ring D Gasket e Pull the cylinder unit A out the top of the outer tube B e Remove the push rod and piston assembly A from the fork cylinder B NOTE ODo not disassembly the push rod and piston assembly as the push rod and cylinder are consisted of as the single assembly baspa 6M04158BS1 6M04162BS1 6M04150BS1 6M04161BS1 6M04159BS1 SUSPENSION 13 17 Front Fork e Separate the inner tube A from the outer tube B as follows OSlide up the spring band C OSlide up the dust seal D ORemov
244. the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tools Bead Breaker Assembly 57001 1072 GJ05029BS1 GJO5030BS1 6y05031BS1 10 12 WHEELS TIRES Tires e Step on the side of the tire opposite valve stem pry the tire off the rim with the tire iron A of the bead breaker protecting the rim with rim protectors B Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 CAUTION Take care not to inset the tire irons so deeply that the tube gets damaged e Remove the bead protector and tube when one side of the tire is pried off e Pry the tire off the rim Installation e Inspect the rim and tire and replace them if necessary e Install the tube band and tube e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Position the front tire on the rim so that the valve A is at the tire balance mark B the chalk mark made during removal or the white paint mark on a new tire see Re moval e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Pry one side of the tire back onto the rim Fit the bead protector into the tire e Pry the other side of the tire o
245. tion on the first application of the pedal if this is not done CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents Exploded Vie Wisin A aea doves O A EAE a Ea e a a 9 2 Specifica NS a a a da 9 4 Special TOS ics a r iia 9 5 CTANKCAS 1 A aa A 9 6 Grankcase Disassembly tii dana 9 6 Grankcase ASOMO A eae A acres eee 9 8 QE a LES Matte vavecsss OO 9 13 Crankshaft Removal ccccesctevces nains sen dan A did Mees 9 13 Crankshaft Installation ss 9 13 Crankshaft DiSassembly s5 sise int rte Minced bnegeuedie stent yiahea dettes anti alt ee 9 13 CrankshalSSemMbDiV cried Ta tl ad ideada 9 14 Connecting Rod Bend civic e 9 14 Connecting ROM MIS ia A a 9 14 Transmission dad did iaa init 9 15 Transmission Shaft Removal trillado annie 9 15 Transmission Shaft Installation lt x ii adi s 9 15 Transmission Shaft Disassembly cosita it 9 16 Transmission Shaft Assembly use mien dite etsnd ini derraa tete ent 9 16 Shift FORK Beriding sas int A Tartes 9 18 Shift Fork Gear Groove Wear ue odds 9 18 Shift Fork Guide Pin Shift Drum Groove Wear cccccccseeeenceceeeeeeeeseneeeeeeeeeeeeesneeseneeees 9 18 Gear Damage aut a tada 9 18 B arings O1l Seals ir tdo idad ee nia 9 19 Bearing Replacements irestart aoee ler ad fn nn dent de dede nd Genai 9 19 A nee nue Danns ends ne De nn 9 19 OIL SEAMINSPSCUOM caia ir bee tn seen enks 9 20 9 2 CRANKSHAFT TRANSMISSION Exploded View Se 4 Le 3 aS 8 lt pe 4
246. tness Inspection e Check that all the spokes are tightened evenly lf spoke tightness is uneven or loose tighten the spoke nipples evenly Torque Spoke Nipples 2 2 N m 0 22 kgf m 19 in Ib e Check the rim runout A WARNING If any spoke breaks it should be replaced immedi ately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break eae 93 Ne 6J05002BS1 6S11014BS1 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tool Jack 57001 1238 e Inspect the rim for small cracks dents bending or warp ing xlf there is any damage to the rim it must be replaced e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A The difference be tween the highest and lowest dial readings is the amount of runout e Set a dial gauge against the outer circumference of the rim and rotate the rim to measure radial runout B The difference between the highest and lowest dial readings is the amount of runout lf rim runout exceeds the service limit check the wheel bearings first Replace them if they are damaged If the problem is not due to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recentering the rim Loosen some s
247. to Cable Wire and Hose Routing section in the 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 Replace the hose if it has been sharply bent or kinked Throttle Grip Free Play Inspection e Check throttle grip free play B by lightly turning the throt tle grip A back and forth lf the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering positions by the return spring x lf the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x lf the idle speed increase check the throttle cable free play and the cable routing Throttle Grip Free Play Adjustment e Loosen the locknuts A B at the upper end of the throttle cable e Screw both throttle cable adjuster C D to give the throt tle grip plenty of play e Turn out the decelerator adjuster C until there is no play when the throttle grip is completely closed e Tighten the locknut A e Turn the
248. tor B e Disconnect the magneto lead connector with neutral switch lead connector C from the main harness e Remove the shift pedal see Engine Right Side chapter e Open the clamp A then free the magneto lead B e Slide out the dust cover C e Unscrew the screw D and remove the neutral switch lead E e Remove Magneto Cover Mounting Bolts F Magneto Cover G Magneto Cover Installation e Replace the gasket with a new one e Be sure to install the dowel pins A e Apply silicone sealant to the area B to the magneto lead grommet Sealant Three Bond Silicone Sealant TB1211F e Tighten the cover bolts OApply a non permanent locking agent to the L35 cover bolts Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Connect the lead connector Flywheel Magneto Removal e Remove the magneto cover see Magneto Cover Re moval e Hold the flywheel steady with the rotor holder A and remove the nut B Special Tool Rotor Holder 57001 1567 e Remove the flywheel holder 16 10 ELECTRICAL SYSTEM Flywheel Magneto e Screw the rotor puller A into the flywheel e Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tool Rotor Puller 57001 1565 CAUTION Never strike the grab bar or t
249. tor coils have normal resistance but the voltage check showed the magneto to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 ELECTRICAL SYSTEM 16 13 Ignition Timing Ignition Timing Inspection e Remove the timing inspection cap A e Attach the timing light A to the ignition coil lead in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the ignition timing mark B on the flywheel e Run the engine at the speeds specified and note the align ment of the ignition timing marks OCheck the engine speed using the engine revolution tester A for high accuracy Ignition Timing Engine speed r min rpm Hole notch aligns with 2 000 Line mark on magneto rotor x If the ignition timing is incorrect check the crankshaft sen sor see Crankshaft Sensor Inspection If the crankshaft sensor are normal check the C D I unit see C D I Unit Inspection e Install the timing inspection cap Torque Timing Inspection Cap 4 0 N m 0 4 kgf m 35 in Ib 16 14 ELECTRICAL SYSTEM Ignition System Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you could receive a severe electrical shock Ignition Coil Remo
250. uretor float bowl too high Float valve worn or jammed with foreign matter Starting technique faulty When flooded crank the engine with the hot start opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Ignition coil trouble Engine stop switch shorted Neutral switch trouble Wiring shorted or open Flywheel magneto damage Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent de formed worn or carbon accumulation on the seating surface Decompression trouble Poor Running at Low Speed Spark weak Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Flywheel magneto d
251. ut voltage check in the C D I Unit in spection OWhen inspecting the throttle sensor the throttle valve of the carburetor shall be completely closed and remain the throttle cable connected e Remove the carburetor see Fuel System chapter e Connect the throttle sensor lead connector A with the battery B variable rheostat C and hand testers D as shown Variable Rheostat Blue Lead Terminal E Hand Tester Yellow Lead terminal F Hand Tester Black Lead terminal G e Check the sensor input voltage Throttle Sensor Input Voltage Standard around 5 V e Check the sensor output voltage with the throttle valve is completely closed Throttle Sensor Output Voltage Standard 0 68 0 1 V when the engine speed is idle kif it is not within the specified voltage adjust the throt tle sensor position see Throttle Sensor Position Adjust ment x If it is within specified voltage go to next test e Check the sensor output voltage with the throttle fully opened Throttle sensor Output Voltage Standard 3 5 3 7 V When throttle fully opened If it is not within the specified voltage replace the sensor Throttle Sensor Position Adjustment e Start the engine and warm it up thoroughly e Check the idle speed x lf the idle speed is out of the specified range adjust it see Periodic Maintenance chapter e Loosen the throttle sensor mounting bolt B e Adjust the position of the sensor unt
252. val e Remove Fuel Tank see Fuel System chapter e Disconnect the ignition coil primary lead A e Pull the plug cap B off the spark plug e Unscrew the mounting bolts C and remove the ignition coil D Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle method e Remove the ignition coil e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead A to the tester B and measure the arcing distance A WARNING To avoid extremely high voltage shocks do not touch the coil or lead x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7 mm 0 26 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead xf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap Lf 6P10112BS1 ELECTRICAL SYSTEM 16 15 Ignition System Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer sho
253. val X e Remove Mounting Bolt A Kick Pedal Assy B Kick Pedal Assy Installation e Install the kick pedal assy A at the angle shown 14 24 mm B e Apply a non permanent locking agent to the mounting bolt e Tighten the mounting bolt Torque Kick Pedal Mounting bolt 25 N m 2 5 kgf m 18 ft Ib GROSO13BS1 Kick Pedal Assy Disassembly e Remove the kick pedal assy e Remove Plug Screw A Spring B Steel Ball C Detente Screw D Oil Seal E GROSO12BS1 Kick Pedal Assy Assembly e Apply high temperature grease to the steel ball oil seal lip spring and the sliding portion of the lever e After tightening the screws stake it with a punch Idle Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal e Pull off the idle gear A ENGINE RIGHT SIDE 6 21 Kickstarter Idle Gear Installation e Apply engine oil to the inside of the idle gear e Install the washer A e Fit the idle gear B with the boss C facing toward the engine side Kickshaft Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal Idle Gear A see above e Pull the end B of the kick spring C out of the hole in the crankcase e Turn the kickshaft counterclockwise D and pull out the kickstarter assembly E e Remove the bolts A take off the ratchet guide B
254. ve Throttle Grip Assy A see Fuel System chapter Master Cylinder B see Brakes chapter e Remove Handlebar Clamp Bolts A Handlebar Clamp B Handlebar C Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Install the left handlebar grip so that the arrow A on the grip point to the punch mark B on the handlebar e Install the clutch holder A so that the parting line B of the holder with punch mark C on the handlebar D 6R11003BS1 STEERING 14 11 Handlebar e Apply grease to the throttle cable upper end and clutch cable upper end e Apply a 2 stroke oil to the throttle grip inner wall A e Install the throttle grip assy so that the grip A is in as far as it will go OPosition the throttle grip assy so that the horizontal parting line B of the throttle case with punch mark C on the handlebar Olnstall the master cylinder so that the vertical parting line D of the front master cylinder clamps with punch mark E on the handlebar e Install the handlebar clamp see Steering Adjustment in Periodic Maintenance chapter OFirst tighten the rear clamp bolts A then tighten the front clamp bolts B After tightening the bolts a clearance C will be created behind the clamp Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib GNOGO13BS1 GNOGO14BS1 FRAME 15 1 Frame Table of Content
255. ve spring to install the split keepers F E in order to secure the spring retainer E in place Special Tool Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 20 57001 1154 e The shim G must be installed with its thickness indication facing up towards the retainer OApply high temperature grease to the shim or to the retainer to prevent the shim from falling off when the camshaft is being installed e Apply engine oil to the valve lifter H surface then install the lifter GE15010682 C ENGINE TOP END 5 23 Valves Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide up to 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Hammer lightly on the valve guide arbor A to remove the guide Special Tools Valve Guide Arbor 64 5 57001 1331 Valve Guide Installation e Apply a thin coat of oil to the outer surface of the valve guide e Heat the area around the valve guide up to 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Using the valve guide arbor A press and insert the valve guide in until the valve guide arbor surface B touches the head surface C 13
256. 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 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 Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles 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 preparing this manual we divided the prod uct into its major systems Thes
257. y around the area Eng No KX250NE014233 e Make sure that the crankshaft driveshaft and the output shaft rotate smoothy in the neutral position lf the crankshaft will not turn probably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet A to reposition it 9 12 CRANKSHAFT TRANSMISSION Crankcase e Install the gear set lever A OFit each end of the spring B or original positions ODo not forget to install the colar and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 9 kgf m 78 in Ib e To install the shift drum cam A use the driver B to bring the gear set lever C to the bottom of the crankcase e Mate the shift drum pin D into the shift drum hole OFit the groove E of the shift drum cam on the shift drum pin e Apply non permanent locking agent to the shift drum cam bolts and tighten them Torque Shift Drum Cam Bolt 24 N m 2 4 kgf m 17 ft lb e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st while spinning the output shaft e Set the shift drum in the neutral position e Replace the O rings A on the output shaft with new ones e Install two O rings on the grinding faces of the output shaft while expanding the O ring by the hand e Apply grease to the inside of the output shaft collar B e Insert the collar with the oil groove end facing C in e Install the othe
258. y note the following Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly GENERAL INFORMATION 1 3 Before Servicing Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly 68020088 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol K Ce oration or other damage Refer to the appropriate sections f f of this manual for service limits on individual parts Replace Y the parts if any damage has been found or if the part is be AN yond its service limit amp 680200 8 Replace

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