Home

Kawasaki KLR500,650 87-04 Supplementary Service Manual ENG

1. SUPPLEMENT 2002 MODEL 17 1 Supplement 2002 Model Table of Contents Foreword re How to Use this Manual General Information General Specifications Torque and Locking Agent Engine Right Side Left Side Specifications Engine Oil and Oil Filter Engine Oil Change 172 17 2 17 3 17 3 17 5 17 6 17 8 17 6 17 6 17 2 SUPPLEMENT 2002 MODEL Foreword How to Use this Manual This Supplement 2002 Model designed to be used in conjunction with the front part of this manual up to 16 15 and or Base Manual KLR600 Service Manual Part No 99924 1050 01 The specifications and maintenance procedures described in this chapter are only those that are unique to the KL650 A16 model Complete and proper servicing of the KL650 A16 model therefore requires mechanics to read both this chapter and the front of this manual SUPPLEMENT 2002 MODEL 17 3 General Information General Specifications Tems KL650 A16 Dimensions Overall length 2205 mm Overall width 940 mm Overall height 1 345mm Wheelbase 1 495 mm Road clearance 240 mm Seat height 890 mm Dry weight 153 kg 153 5 kg Curb weight Front 81 kg CA 81 5 kg Rear 97kg
2. ME Kawasaki Pari 99824 108068 Pret apan
3. Refer to Base Manual 3 2 ENGINE TOP END Non permanent Locking Agent Liquid Gasket Silicone Sealant Molybdenum Disulfide Grease Engine Oil Follow the specific tightening sequence 7 8 0 80 kam 69 9 8 N m 1 0 kg m 87 indb 12 Ncm 1 2 kg m 104 inb 15 Nem 1 5 11 0 18 N m 1 8 kg m 13 0 ft lb 20 N m 2 0 kg m 14 5 ft lb vozgr 25 Nam 2 5 kg m 18 0 feb 49 N m 5 0 kg m 36 feb T9 65 N m 6 6 kg m 48 ft lb EEEEEEKE ENGINE TOP END 3 3 3 4 ENGINE TOP END Standard Service Limit Camshafts Chi Cam height Camshaft bearing oil clearance Camshaft journal diameter Camshaft bearing inside diameter Camshaft chain 20 link length Balancer chain 20 link length Valves Valve clearance Valve head thickness Valve stem bend Valve stem diameter Valve guide inside diameter Valve guide valve clearance wobble method Valve seating area width Valve spring free length Cylinder Head Cylinder compression Cylinder head warp Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust Valve seating area outside diameter Inlet Exhaust Inner Outer 36 75 36 85 mm 36 25 36 35 mm 0 030 0 064 mm 22 949 22 970 mm 23 000 23 013 mm 127 0 127 4 mm 190 5 190 9 mm 0 10 0 20 mm 0 15 0 25 mm 1 0 mm 1 0 mm Less than 0 01 mm TIR 6
4. 2 Magneto Magneto Magneto Rectifier Circuit Inspection Meter Regulator Circuit Test Remove the regulator rectifier Prepare the test tools shown Tools for Regulator Circuit Test Test light Bulb rated 12 V and 3 6 W Batteries 12 V battery and 6 V battery Test wires gt 5 auxiliary wires Connect the test light and the 12 V battery to the regulator rectifier as shown eCheck M2 and terminals respectively Regulator Circuit Test 1st Step Regulator Rectifier 12 V Battery The test light limits the current flow through the regulator rectifier Do not use an ammeter or multimeter in its place lf the test light turns on the regulator rectifier is defective Replace it Alf the test light does not turn on continue the test eMomentarily apply 12 V to the voltage monitoring terminal Check M1 M2 and M3 terminals respectively Regulator Circuit Test 2nd Step Regulator Rectifier 12 V Battery If the test light turns on the regulator rectifier is defective Replace it Alf the test light does not turn on continue the test eMomentarily apply 18 V to the voltage monitoring terminal by adding a 6 V battery Check M1 M2 and M3 terminals respectively Do not apply more than 18 V to the regulator rectifier and do not the 18 V applied for more than a few seconds or the unit will be damaged
5. Set the motorcycle up on a stand or jacks so that it is stable during the removal and installation operations Loosen drive chain Harness Rear brake connectors caliper Throttle cables Choke cable a Rear shock absorber e Front fender L Front fork ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents Exploded View 142 Lighting System A E Service Data 144 Headlight Horizontal Adjustment E Special Tools Headlight Vertical Adjustment 2 14 15 Precautions 145 Headlight Bulb Installation ome Battery P 145 Headlight Dimmer or Passing Charging System 145 Switch Inspection Measuring Regulator Rectifier Front Brake Light Switch Inspection Output Voltage Loaded Rear Brake Light Switch Adjustment Measuring Stator Coil Resistance 14 5 Rear Brake Light Switch Inspection Testing Stator Coil Insulation Turn Signal Inspection B Regulator Rectifier Inspection 14 5 Tachometer and Water Temperature Gauge 14 16 Ignition System Disassembly Adjustment 147 Maintenance E Spark Plug Cleaning and Gapping 147 Meter Mounting Inspection Removal Installation ees 147 Meter Power Supply Test Magneto Removal or Installation 147 Tachometer Inspection Magneto Installation 147
6. Starter Button Connections A RH Switch Housing 6 pin Connector Red Starter Clutch Inspection Remove the alternator cover and starter idle gear and turn the starter clutch gear by hand The starter clutch gear should turn clockwise freely but should not turn counterclockwise the clutch does not operate as it should or if it makes noise disassemble the starter clutch examine each part visually and replace any worn or damaged parts C Locked A Starter Clutch Gear B Turns freely ELECTRICAL SYSTEM 14 15 Electric Starter System Wiring Diagram ml E BR BR J L o w w BL R ic r 16 1 Ignition Switch 5 Fuse 20A 9 Starter Relay 2 Engine Stop Switch 6 Starter Lockout Switch 10 Battery 3 Starter Button 7 Neutral Switch 4 Starter Circuit Relay 8 Starter Motor NOTE OStarter clutch inspection can be done by removing the starter motor Lighting System Headlight Vertical Adjustment Refer to the Base Manual noting the following Loosen the headlight lower mounting bolt A Starter Idle Gear C Locked B Turns Freely A Headlight Lower Mounting Bolt 14 16 ELECTRICAL SYSTEM Headlight Dimmer or Passing Switch In
7. Drive Train Primary reduction system Type Gear Reduction ratio 2 272 75 33 Clutch type Wet multi disc el Transmission Type 5 speed constant mesh return shift 5 Gear ratios 1st 2 266 34 15 E 2nd 1 529 26 17 3rd 1 181 26 22 4th 0 954 21 22 5th 0 791 19 24 Final drive system Type Chain drive y Reduction ratio 2 866 43 15 3 133 47 15 Overall drive ratio 5 157 Top gear 5 637 Top gear Frame Type Caster rake angle Trail Front Tire Type Size Rear Tire Type Size Front suspension Type Wheel travel Tubular semi double cradle 28 112 mm Tube type 90 90 21 54S Tube type 130 80 17 65S Telescopic fork pneumatic 230 mm Items GENERAL INFORMATION 1 5 KL 650 A1 A2 A3 A4 A5 A6 A7 A8 A9 KL500 A1 A2 Rear suspension Type Swing arm uni trak Wheel travel 230 mm Brake type Front Single disc S Rear Single disc Electrical Equipment Battery 12 14 Ah Headlight Type Semi Sealed beam w Bulb 12 V 60 55 W quartz halogen Tail brake light 12V 5 21 w ODO 12 V 8 27 W Alternator Type Three phase AC Rated output Voltage regulator Type 14 A 8 000 r min rpm 14 V Shortcircuit Specifications subject to change without notice and may not apply to every country Same as KL650 A1 Abbreviation Australian Model Austrian Model U K Model Canadian Model Californian Model French Model W
8. KLR650 Kawasaki KLR500 Motorcycle Service Manual Supplement Quick Reference Guide General Information Fuel System Engine Top End Engine Right Side Left Side Cooling System Engine Removal Installation Engine Bottom End Transmission Wheels Tires Final Drive Brakes Suspension Steering 11 l Controls Instruments 12 E Frame Electrical System Appendix This quick reference guide will assist you in locating a desired topic or procedure Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page lt Refer to the sectional table of contents for the exact pages to locate the specific topic required Supplement 2000 2001 Models Supplement 2002 Model EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with applicable reg ulations of the United States Environmental Protection Agency and California Air Re sources Board Additionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates
9. Others Side Stand Nut Rear Frame Mounting Bolts Clutch Lever Holder Clamp Screws Clutch Lever Pivot Nut Footpeg Bracket Mounting Bolts Footpeg Pivot Cotter Pins Rear Carrier Mounting Bolts APPENDIX 15 3 SUPPLEMENT 2000 2001 MODELS 16 1 Supplement 2000 2001 Models Table of Contents Foreword General Information Model Identification General Specifications Torque and Locking Agent Fuel System Specifications Engine Top End Exploded View Engine Right Side Lett Side Exploded View Specifications Engine Bottom End Transmission Exploded View Final Drive Exploded View Specifications Electrical System Specifications Wiring Diagram 16 2 16 3 16 3 16 4 16 6 16 6 16 6 16 7 16 7 16 8 16 8 16 10 16 11 16 11 16 12 16 12 16 12 16 13 16 13 16 14 16 2 SUPPLEMENT 2000 2001 MODELS Foreword How to Use this Manual This Supplement 2000 2001 Models designed to be used in conjunction with the front part of this manual up to 15 3 and or Base Manual KLR600 Service Manual Part No 99924 1050 01 The specifications and maintenance procedures described in this chapter are only those that are unique to the KL650 A14 A15 model Complete and proper servicing of the KL650 A14 A15 model therefore requires mechanics to read both this chapter and the front of this manual SUPPLEMENT 2000 2001 MODELS 16 3 General Information Model Identification KL650 A14 Left Sid
10. Coolant Changing Coolant Filling Air Bleeding Visual Leak Inspection a Cooling System Pressure Testing Flushing Precaution of Disassembly Assembly Radiator Radiator Fan Removal Points Radiator Cleaning Points Radiator Inspection Radiator Cap Inspection Radiator Hose Reserve Tank Hose Inspection Thermostatic Fan Switch Water Temperature Sender Removal Point Installation Point Inspection Thermostat Installation Point Thermostat Inspection Water Pump Mechanical Seal Disassembly Inspection x Assembly Points Refer to Base Manual 5 2 COOLING SYSTEM Exploded View Mark white Mark white LS Liquid Gasket Silicone Sealant T1 7 4 N m 0 75 kg m 65 inb 2 9 8 N m 1 0 kg m 87 indb T3 15 N m 1 5 11 0 feb Service Data Item F D R h T H T COOLING SYSTEM 5 3 Standard Coolant Type recommended Mixed ratio provided coolant when shipping Freezing point provided coolant when shipping Total amount Radiator Cap Relief pressure Valve opening temperature Valve full opening lift Thermostat Coolant Flow Chart lt Cold m Radiator Cap To Reservoir Tank Radiator Water Pump To Cylinder Jacket From Cylinder Head Thermostat Through Thermostat Air Bl eder Hole Through Thermostat Valve fogecip nh m Perma
11. Fork Oil Changing 116 Fork Disassembly 116 Fork Assembly 116 Inner Tube Inspection Guide Bush Inspection Guide Bush Replacement 116 Uni trak 116 Spring Preload Adjustment 116 Damper Adjustment 117 Rear Shock Removal 11 7 Rear Shock Scrapping Rear Shock Installation Point Uni trak Sleeve Inspection Uni trak Needle Bearing Inspection Uni trak Lubrication Refer to Base Manual 11 2 SUSPENSION STEERING Grease Non permanent Locking Agent quid Gasket Molybdenum Disulfide Grease Foro 212 N m 1 2 kg m 104 in Ib 25 2 5 kg m 18 0 ft lb 29 N m 3 0 kg m 22 feb 39 N m 4 0 kg m 29 ft lb 59 N m 6 0 kg m 43 ft lb 98 N m 10 0 kg m 72 ft lb SUSPENSION STEERING 11 3 NOTE The marked end of the needle bearing must be faced out 114 SUSPENSION STEERING Service Data Item Standard Service Limit Front Fork Air pressure 0 atmospheric pressure Oil viscosity SAE 10W20 Oil amount par side 420 4 mL Oil level fully compressed 190 2 mm from top of inner tube Rear Shock Absorber Spring preload adjuster No 1 of 5 positions Damper adjuster No 1 of 4 positions Uni trak Sleeves Sleeve outside diameter Swing arm pivot 19 979 20 000 mm 19 95 mm Rocker arm pivot 27 979 28 000 mm 27 95 mm Tie rod ends 19 979 20 000 mm 19 95 mm Rear Shock lower end 19 9
12. Specifications Standard Service Limit Clutch Clutch lever play 2 3 mm 10 15 mm at lever end Friction plate thickness 283 1 mm 26mm Friction steel plate warp Less than 0 2 mm 0 3 mm Clutch spring free length 387 mm 364 mm Engine Lubrication System Engine Grade Viscosity Amount Level Relief valve opening pressure Oil pressure 4000 rpm r min 90 C 194 F SE SF or SG class On and After KL650 A15 API SF or SG SH or SJ with JASO MA SAE 10W40 10W50 20W40 or 20W50 22 L filter is not removed 25 L filter is removed Between upper and lower level lines 430 590 kPa 4 4 6 0 63 85 psi 78 147 kPa 0 8 1 5 11 21 psi SUPPLEMENT 2000 2001 MODELS 16 11 Engine Bottom End Transmission Exploded View LX I i n D 6X3 i QA 2 32 e do 29 5 do at gt o n 19 2 Jo 3 25 5 29 EE G Grease O Engine Oil 9 8 Nem 10kg m 72 feb 16 12 SUPPLEMENT 2000 2001 MODELS Final Drive Exploded View Shield Side L Non permanent Locking Agent T1 98 N m 10kg m 72ft Ib T2 32 Nem 3 3kg m 24 ft lb 93 N m 9 5kg m G9ft lb Specifications Item Standard Service Limit Drive Chain Standard
13. T1 12 N m 1 2 kg m 104 in Ib 2 15 N m 1 5 kg m 11 0 ft lb G Grease ENGINE BOTTOM END TRANSMISSION 7 3 Output Shaft p E e 9 25 5 30 3 Align the oil holes xO e 8 7 4 ENGINE BOTTOM END TRANSMISSION Service Data Item Standard Service Limit Transmission Shift fork finger thickness 44 45mm 43mm Gear shift fork groove width 4 55 4 65 mm 4 8 mm Shift fork guide pin diameter 59 6 0 mm 5 8 mm Shift drum groove width 6 05 6 20 mm 6 3 mm Crankshaft Connecting rod big end radial clearance 0 008 0 020 mm 0 07 mm Connecting rod side clearance 0 25 0 35 mm 0 60 mm Crankshaft runout Left half 0 03 mm TIR 0 10 mm TIR Right half 0 04 mm TIR 0 10 mm TIR Cold fitting tolerance between crankpin and flywheel 0 093 0 122 mm WHEELS TIRES 8 1 Wheels Tires Table of Contents Exploded Viera pecus wu AAS Was ww d Ei ZS w 82 Service Data 8 3 Special Tools 84 Installation Point of Tires Adjustment after Tire Installation 84 Tire Wear Inspection 84 Rear Wheel Removal 84 Rear Sprocket Installation Rear Wheel Installation Points 84 Disc Installation 84 Front Wheel Balance 84 Spokes and Rims Spoke Tightness Inspection Rim Runout Inspection Wheel Bearings Bearing Removal Installation Poi
14. the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or 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 follows Indicates a conditional sub step or what action to take based upon the results of the condi tional step it follows In most chapters an exploded view illustration of the system components follows the Table of Contents n these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing Model Identification 1 2 Specifications 1 3 Periodic Maintenance Chart 16 Torque and Locking Agent 17 Cable Wire and Hose Routing 110 Refer to Base Manual 1 2 GENERAL INFORMATION KL500 A1 Specifications GENERAL INFORMATION 1 3 Items KL 650 A1 A2 A3 A4 A5 A6 A7 AB A9 KL500 A1 A2 Dimensions Overall length 2 290 mm ODO 2 205 mm DO 2250 mm Overall width 940mm Overall height 1345 mm id Wheelbase 1495 mm q Road clearance 240 mm n Seat height 890 mm z Dry weight 153 kg Ca 153 5 kg id Curb weight Front 81 kg 81 5 kg Rear 97kg Fuel tank capacity 23L Performance Climbing ability 32 3 Braking distance 12 5 m from
15. 6 Jet needle N31R Pilot jet 40 Pilot air jet 70 Pilot screw 1 3 8 tums out Starter jet 452 Service fuel level 0 5mm above 1 5mm below the float bowl mating surface Float height 17 5mm High altitude adjustment US model Main jet 145 Pilot jet 38 Air Cleaner Element oil Grade Viscosity SE class SAE30 SUPPLEMENT 2000 2001 MODELS 16 7 Engine Top End Exploded View L Non permanent Locking Agent T1 7 8 N m 0 80 kg m 69 in Ib LS Liquid Gasket Silicone Sealant T2 9 8N m 1 0 kg m 87 in Ib M Molybdenum Disulfide Grease T3 12N m 1 2 kg m 104 in Ib O Engine Oil TA 15N m 1 5 kg m 11 0 ft lb S Follow the specific tightening sequence T5 18N m 1 8 kg m 13 0 ft lb T6 20N m 2 0 kg m 14 5 ft lb T7 25N m 2 5 kg m 18 0 ft lb T8 49N m 5 0 kg m 36 ft lb T9 65N m 6 6 kg m 48 ft lb 16 8 SUPPLEMENT 2000 2001 MODELS Enginr Right Side Left Side Exploded View G Grease T3 15N m 1 5kg m 11 0ft b L Non permanent Locking Agent T4 20N m 2 0kg m 14 5ft lb M Molybdenum Disulfide Grease T5 23N m 2 3kg m 16 5ft Ib T1 9 8N m 1 0kg m 87in Ib T amp 25N m 2 5kg m 18 0ft Ib T2 12N m 1 2kg m 104in Ib T7 44N m 4 5kg m 33ft 1b T8 120N m 12 0kg m 871t lb T9 130N m 13 5kg m 98ft Ib T10 8 8N m 0 9kg m 78in Ib T11 S8N m 10kg m 72ft Ib SUPPLEMENT 2000 2001 MODELS 16 9 16 10 SUPPLEMENT 2000 2001 MODELS
16. 60 kg m 52 indb T2 7 8 N m 0 80 kg m 69 inb T3 8 8 N m 0 90 kg m 78 in Ib T4 23 N m 2 3 kg m 16 5 ft lb T5 25 N m 2 5 kg m 18 0 feb 10 4 BRAKES Service Limit Item Standard Brake Fluid Grade 0 0 T 3 4 Sai Brake Pads Pad lining thickness 4 5mm 1mm Brake Discs Disc thickness Front 3 8 4 1 mm 3 5 mm Rear 4 8 5 1 mm 4 5 mm Disc runout Less than 0 2 mm 0 3 mm Brake Pedal Pedal position Brake Light Switch Rear brake light switch operation Level with footpeg top ON after about 15 mm pedal travel BRAKES 10 5 4 Front Brake Adjustment Inspection T Brake Fluid Level Inspection Refer to the Base Manual noting the following Holding the reservoir horizontally check that the brake fluid level in the reservoir is higher than the lower level q A Safety Clip Retaining Pin Caliper Assembly Points Apply brake fluid to the outside of the piston and the fluid seal and push the piston into the cylinder by A Lower Level B Upper Level hand Take care that neither the cylinder nor the piston skirt scratched Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts and holder holes PBC is a special high temperature water resistant grease install the anti rattle spring in the caliper as shown Front Brake Disassembly Assembly Pad Removal Points Remove the caliper mounting bolts and lift the
17. 965 6 980 mm 6 955 6 970 mm 7 000 7 015 mm 0 04 0 11 mm 0 05 0 12 mm 36 9 37 1 mm 31 9 32 1 mm 0 8 1 2 mm 37 6 mm 40 5 mm 530 855 kPa 5 4 8 7 kg cm 77 124 psi 36 65 mm 36 15 mm 0 15 mm 22 92 mm 23 07 mm 128 9 mm 193 4 mm 0 5 mm 0 7 mm 0 05 mm TIR 6 95 mm 6 94 mm 7 08 mm 0 24 mm 0 24 mm 0 05 mm ENGINE TOP END 35 Item Standard Service Limit Cylinder Piston Cylinder inside diameter KL650 100 000 100 012 mm 100 10 mm KL500 89 000 89 012 mm 89 10 mm Piston diameter KL650 99 942 99 957 mm 99 80 mm KL500 88 942 88 957 mm 88 80 mm Piston cylinder clearance 0 043 0 070 mm Piston ring groove clearance Top amp 2nd 0 02 0 05 mm 0 16 mm Piston ring groove width Top amp 2nd 1 21 1 22 mm 1 31 mm Oil 2 81 2 83 mm 2 91 mm Piston ring thickness Top amp 2nd 1 17 1 19 mm 1 10 mm Piston ring end gap L Top amp 2nd 0 2 0 4 mm 0 7 mm 3 6 ENGINE TOP END Camshaft Chain Tensioner Installation Remove the cap bolt and take off the spring Unlock the ratchet stopper and push the rod into the tensioner body A Ratchet Stopper B Push Rod install the chain tensioner with the gasket so that the arrow on it points downwards Head Oil Pipe 2 L9 1 Camshaft Cap 2 O ring 3 Oil Pipe 4 Apply engine oil Installation Points of Cylinder Head Refer t
18. Brake light switch check 2 10 11 Steering check elelele 116 Steering stem bearing lubricate 2 years 11 7 Front fork oil change 11 6 Tire wear check gt 8 5 Spoke and rim runout a IPFO ea 8 6 Swing arm pivot uni trak Tinka z E e 00 14 Battery electrolyte level check month e elelele 14 4 General lubrication perform 15 2 Nut bolt and fastener tightness check t For higher odometer readings repeat at the frequency interval established here 15 2 Replace add adjust clean or torque if necessary Californian Model 0 US Model Canadian Model Page See Base Manual GENERAL INFORMATION 1 7 Torque and Loc The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean Apply non permanent locking agent to the threads LG Apply liquid gasket to the threads LS Apply liquid gasket silicone sealant to the threads Apply a molybdenum disulfide lubricant grease or oil to the threads and seated surface or washer S Tighten the fasteners following the specified sequence Torque Fastener s Remarks Engine Top End Cylinder head cover bolts 78 0 80 69 in Ib Camshaft
19. Table of Contents Exploded View Service Data Special Tools Camshaft Chain Tensioner Removal Installation Cylinder Head Cover Adjustment before Head Cover Installation Installation Camshaft Chain Guides Camshaft Chain Camshafts Camshaft Removal Point Chain Guide Installation Point Camshaft Installation Points Assembly Points of Camshafts and Sprockets Disassembly Point of Camshaft Sprocket Bolt Camshaft Oil Clearance Inspection Camshaft Chain Balancer Chain Wear KAWASAKI Automatic Compression Ri Oil Pipes Oil Pipe Installation Points Valve Clesrance Adjustment Inspection Adjustment Measuring Valve Installed Height Valve Maintenance Valve Seat Inspect Valve Seat Repair Measuring Valve to Guide Clearance Wobble Method Cylinder Head Compression Measurement Removal Point of Cylinder Head Installation Points of Cylinder Head Adjustment and Operation after Installation Disassembly Points of Cylinder Head K Cylinder Head Warp Cylinder Piston Removal Point of Piston Installation Points of Piston Rings Installation Points of Cylinder Block Piston Ring End Gap Cylinder Inside Piston Diameter Boring Honing Muffler Installation Spark Arrestar Cleaning U S model
20. Tightening Torque Rear Caliper Mounting Bolts 25 N m 2 5 kg m 18 0 ft Ib eCheck the rear brake effectiveness Disc Installation Points Clean the disc and wheel hub mating surfaces of any dirt and foreign particles Mount the brake disc on the wheel so that the marked side faces out eTighten the disc mounting bolts to the specified torque Tightening Torque Disc Mounting Bolts 23 N m 2 3 kg m 16 5 ft lb After installing the disc check the disc runout see chapter 10 Rg a 4 V gt gt D A A Mark Front Wheel Balance To improve stability and decrease vibration at high speed the front wheel must be kept balanced Check and balance the front wheel when required or when a tire and or rim is replaced with a new one Raise the front wheel so that it can be spun freely eCheck that all the spokes are tightened evenly and the rim runout is within the service limit the wheel lightly and mark the wheel at the top when the wheel stops A Mark at the top Repeat this procedure several times Xf the wheel stops of its own accord in various positions it is well balanced If the wheel always stops in one position balance the wheel Temporarily attach a balance weight on the wheel Attach a balance weight loosely to the spoke under the marking A Balance Weight eRotate the wheel turn and see whether or not the wheel stays in this position If it does the correc
21. Water Temperature Gauge Ignition Coil Installation 147 Circuit Check E Ignition System Maintenance 148 Water Temperature Sender Check Switch Inspection 148 Radiator Diode Inspection Initial Ignition Coil Inspection 14 9 Fan Motor Inspection CDI Unit Inspection lt 14 10 Fan Relay Inspection Exciter or Pickup Coil Inspection 14 10 Fan Switch Inspection Electric Starter 14 11 Wiring Diagram Starter Motor Removal 14 11 Installation Points PORE RTI Refer to Base Manual Starter Motor Disassembly 14 11 Starter Motor Assembly Points 14 11 Starter Clutch Removal 1412 Installation Point 14 12 Starter Motor Brush Length Brush Spring Inspection Commutator Cleaning and Inspection Armature Inspection Brush Plate Inspection Positive Brush Assembly inspection 5 Starter Relay Inspection Starter Circuit Relay Inspection Starter Button Inspection Starter Clutch Inspection 14 2 ELECTRICAL SYSTEM MA KL650 A4 Se REO L Non permanent L locking Agent y Q 2 L M Molybdenum Disulfide Grease is SG Silicone Grease N gt ur 0 T1 9 8 N m 1 0 kg m 87 14 4 ELECTRICAL SYSTEM Regulator rectif
22. arm pivot bolt to the specified torque Tightening Torque Engine Mounting Bolts 10 mm 44 N m 4 5 kgm 33 feb Engine Mounting Bolts 8 mm 23 N m 2 3 kem 16 5 feb Engine Mounting Bracket Bolts 8 mm 23 Nem 2 3 kg m 16 5 feb Swing Arm Pivot Bolt 98 N m 10 0 kg m 72 ft lb Rocker Arm Pivot Bolt 98 N m 10 0 kg m 72 ft lb Tightening Sequence Fill the engine with engine oil Fill the cooling system with coolant Adjust the following Throttle Cables Choke Cable Clutch Cable Drive Chain ENGINE BOTTOM END TRANSMISSION 7 1 Engine Bottom End Transmission Table of Contents Exploded N les wma EE wicca 72 Disassembly Flow Chart Service Data 74 Special Tools Crankcase Splitting Crankcase Disassembly Point Crankcase Assembly Points Rear Balancer Installation Transmission Disassembly Point Transmission Assembly Points Crankshaft Installation Points Transmission Maintenance Shift Drum Shift Fork Shift Rod Gear Groove Inspection Crankshaft Disassembly Disassembly Point Assembly Points Crankshaft Maintenance Connecting Rod Big End Radial Clearance Big End Seizure Connecting Rod Side Clearance Crankshaft Runout Crankshaft Alignment Roller Bearing Wear Damage Refer to Base Manual 7 2 ENGINE BOTTOM END TRANSMISSION L Non permanent Locking Agent LG Liquid Gasket
23. arrester Since the engine must be run during this pro cedure the muffler will become hot Remove the drain plugs on the muffler ENGINE TOP END 3 7 A Drain Plugs ln an open area away from combustible materials start the engine with the transmission in neutral Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged form the muffler Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odorless poison ous gas Breathing exhaust gas leads to carbon mon oxide poi eStop the engine Install the drain plugs ENGINE RIGHT SIDE LEFT SIDE 4 1 Engine Right Side Left Side Table of Contents Exploded View 42 OilPressure Flow Chart Right Side Parts Removal 44 Relief Valve Opening Pressure Flow Chart Left Side Parts Removal 45 Oil Pressure Measurement E Engine Lubrication System Oil Pump Service Data 46 Removal Point n Special Tools Tc 2 3 Installation Points v ave vie ov de s ces 47 Engine Sprocket 47 Play 47 oe cor cr TX UT Play Adjustment Installation Points Clutch Release Removal 47 Magneto E Clutch Release Installation 47 Removal Clutch Removal Installation Clutch Installation Balancer Mech
24. cap bolts 12 12 104 in Ib Camshaft sprocket bolts 49 5 0 36 L Oil pipe banjo bolts 20 2 0 14 5 Cylinder head bolts 10 mm 65 66 48 MS 8mm 18 18 130 s 6mm 98 1 0 87 in Ib s Cylinder head nuts 25 25 18 0 s Cylinder bolt 9 8 10 87 in Ib 5 Cylinder nuts 25 25 18 0 s Engine Right Side Left Side Cover damper mounting bolts 9 8 1 0 87 in lb L Clutch spring bolts 98 10 87intb Clutch hub nut 130 13 5 98 Primary gear nut 120 120 8 Oil pressure relief valve 15 15 11 0 L Balancer shaft front right end nut 44 45 33 Balancer chain guide inner bolts 8mm 25 25 18 0 6 mm 12 12 104 in lb Shift return spring pin L Engine drain plug 23 23 16 5 Oil pipe banjo bolts 20 20 145 Cooling System Radiator fan switch 7 4 0 75 65 in Ib Water temperature sender 15 1 5 11 0 LS Impeller nut 1 0 87 inb 1 8 GENERAL INFORMATION Fastener im a Tdi Remarks Engine Removal Installation Engine mounting bolts and nuts 10mm 44 45 33 s 8mm 25 25 18 0 5 Engine mounting bracket bolts and nuts 8 mm 25 25 18 0 Swing arm pivot bolt and nut 14 mm 98 10 0 72 s Engine Bottom End Transt Crankshaft bearing retainer screws L Shift drum pin plate bolt 12 12 104 in Ib L Wheels Tires Front axle nut 78 8 0 58 Rear axle nut 93 9 5 69 Spoke nipples 2 0 3 9 0 2 0 4 17 35 inb Final Drive Engine sprocket bolts 98 1 0 87 inib Rear sprocket studs L Rear sprocket nuts 32 33 24 Brake
25. the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the intake side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the carburetion system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmos phere Instead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to r
26. the throttle valve may not open fully at full throttle On the other hand if the grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary Inspection Check that there is 2 3 mm throttle grip free play when lightly turning the throttle grip back and forth A Throttle Grip B 2 3 mm With the throttle grip closed check that the decelerator inner cable is tight by touching it at the lower end A Decelerator Inner Cable If the throttle grip free play is incorrect or the decel erator inner cable is loose with the throttle closed adjust the throttle grip CONTROLS INSTRUMENTS 12 5 Adjustment eLoosen the locknuts and screw both throttle cable adjusting nuts in fully at the upper ends of the throttle cables to give the throttle grip plenty of play With the throttle grip completely closed turn out the decelerator cable adjusting nut until the inner cable just becomes tight Tighten the locknut A Accelerator Cable Adjusting Nut B Decelerator Cable Adjusting Nut C Locknuts Turn the accelerator cable adjusting nut until the correct throttle grip free play is obtained Tighten the locknut NOTE lf the throttle cables cannot be adjusted by using the cable adjuster nuts at the upper ends of of the throttle cables use the cable adjuster
27. 0 PER VIOLATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in com pliance with Federal regulations Removal of the muffler s or any internal portion of the muffler s Removal of the air box or air box cover Modifications to the muffler s or air intake system by cutting drilling or other means if such modifications result in increased noise levels WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety This warning may apply to any of the following components or any assembly containing one or more of these components Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS Operate if possible out of doors or in a well ventilated place Preferably use hand tools or lo
28. 3 in Ib 6 59 78 060 080 52 69 8 14 19 14 19 10 0 13 5 10 25 34 26 35 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 74 100 16 115 155 115 160 83 115 18 165 225 170 23 125 165 20 225 325 23 33 165 240 1 10 GENERAL INFORMATION 1 Choke Cable 9 Ground Lead 16 To Magneto 2 Throttle Cable 10 To Diode Assembiy 17 To Neutral Switch 3 Main Harness 11 To Turn Signal Relay and Pickup Coil 4 Clutch Cable 12 To Horn 18 To Radiator Fan 5 To Meter Bracket 13 To CDI Unit Relay 6 To Headlight 14 To Water Tempera 19 To Radiator Fan 7 To Turn Signal Light ture Sender 20 To Radiator Fan 8 To City Light 15 To Ignition Coil Switch 21 Harness Position Mark Electrical Wires 22 To Starter Relay 23 To Starter Circuit Relay 24 To Side Stand Switch 25 To Rear Brake Light a Switch zo 26 To Fuses 27 To Battery 28 To Regulator Rectifier To Rear Harness GENERAL INFORMATION 1 11 Electrical Wires Viewed from A 9 Viewed from B 1 LH Switch Leads 13 To Headlight 2 RH Switch Leads 14 Headlight Bracket 3 Starter Lockout 15 Ground Lead Switch Leads 16 Frame Top Tube 4 RH Switch 6P 17 To Neutral Switch Connector Red and Pickup Coil 5 Meter 9P Connector 18 Main Harness 6 Ignition Switch 6P 19 To Water Tempera ture Sender Connector Black 20 Ignition 7 LH Switch 9P 21 Spark Plug Cap Connecto
29. 50 km h Minimum turning radius 24m E Engine Type 4 stroke DOHC 4 valve 1 cylinder Cooling system Liquid cooled Bore and stroke 100 0 x 83 0 mm 89 0 x 80 0 mm Displacement 651 mL 497 mL Compression ratio 95 1 id Maximum horsepower 35 3 kW 48 PS 25500 r min rpm 29 4 kW 40 PS Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark Plug 34 2 kW 46 5 PS 6500 r min rpm UTAC s norms 19 9 kW 27 PS 5800 r min rpm DIN A3 19 9 kW 27 PS 5500 r min rpm DIN A3 32 4 kW 44 PS 6500 r min rpm 54 9 N m 5 6 kg m 40 5 146 65500 r min rpm 45 1 Nm 4 6 kg m 33 3 ft Ib 82500 r min rpm e a 48 N m 4 9 kg m 35 ft4b 2300 r min rpm M 49 N m 5 0 kg m 36 ft Ib 25000 r min rpm Carburetor Keihin CVK40 Electric col Electronically advanced From 10 BTDC 1 300 r min rpm to 30 BTDC 3 300 r min rpm NGK DPR8EA 9 or ND X24EPR U9 NGK DPBEA 9 or ND X24EP U9 7 500 r min rpm 38 2 N m 3 9 kem 28 2 ft lb 66 000 r min rpm 1 4 GENERAL INFORMATION Items KL 650 A1 A2 A3 A4 A5 A6 A7 A8 A9 KL500 A1 A2 Valve timing Inlet Open 19 BTDC Close 69 ABDC Duration 268 dj Exhaust Open 57 BBDC yl Close 31 ATDC Duration 268 i Lubrication system Forced lubrication wet sump Engine oil Grade SE or SF class Viscosity SAE10W40 10W50 20W40 or 20W50 Capacity 25L
30. 79 20 000 mm 19 95 mm Stem Bearing Driver 57001 137 Adapter 57001 1074 Handle 57001 183 Adapter 57001 1057 ER Driver Press Shaft 57001 1075 Drivers 57001 1076 1106 lt E Y Sy Stem Nut Wrench 57001 1100 a 1 1 I 1 I 1 I SUSPENSION STEERING 11 5 Oil Seal Driver 57001 1104 lt NOTE Following tools can be used for front fork servicing instead of using the oil seal driver P N 57001 1104 Fork Outer Tube Weight 57001 1218 gt No Fork Oil Seal Driver 57001 1219 Stem Bearing Remover 57001 1107 11 6 SUSPENSION STEERING Front Fork Fork Oil Level Refer to the Base Manual noting the following Front Fork Oil Level 190 2 mm below the top end of the inner tube Fork Oil Changing Refer to the Base Manual noting the following Front Fork Oil Kayaba 6 10 Viscosity SAE 10W20 Amount per sid When changing oil 355 mL After disassembly and completely dry 420 4 mL Fork Disassembly Refer to the Base Manual noting the following When separating the inner tube from the outer tube the fork outer tube weight special tool P N 57001 1218 can be used to separate them instead of using the driver special tool P N 57001 1104 Perform the following Mount the weight special tool on the top o
31. A Engine Stop Switch 6 pin Connector Red B Ignition Switch 6 pin Connector Black C Starter Lockout Switch 3 pin Connector Ignition Coil Inspection Refer to the Base Manual noting the following Ignition Coil Test Arcing Distance 1 Electro Tester 57001 980 2 Ignition Coil ELECTRICAL SYSTEM 14 9 A Magneto 6 pin Connector B Neutral Switch and Pickup Coil 3 pin Connector C Diodes D CDI Unit A Neutral Switch B Side Stand Switch C Side Stand Switch 2 pin Connector Ignition Coil Winding Resistance 1 Measure primary winding resistance 2 Measure secondary winding resistance 3 Ignition Coil Ignition Coil Resistance Primary 015 0210 Secondary 38 5840 14 10 ELECTRICAL SYSTEM CDI Unit Inspection Refer to the Base Manual noting the following CDI Unit Internal Resistance KL500 KL650 A1 A2 A3 Unit kQ Meter Positive Lead Connection BL R BK W BK R BK 10 45 4 20 3 15 4 20 0 1 6 1 6 CDI Unit Internal Resistance KL650 A4 Unit kQ Meter Positive Lead Connection lead w R RG BUR w 5 R 10 55 5 25 5 38 5 25 20 90 amp RG 2 10 2 10 1 6 LJ 10 50 F ES BK E BK 2 Exciter or Pickup Coil inspection Refer to the Base Manual noting the following Resist
32. Fuel tank capacity 23L Performance Minimum turning radius 24m Engine Type 4 stroke DOHC 4 valve 1 cylinder Cooling system Liquid cooled Bore and stroke 100 0 x 83 0 mm Displacement 651 mL Compression ratio 95 1 Maximum horsepower 35 3 KW 48 ps 6500 r min rpm Maximum torque 55 5 6 kgf m 40 5 ft lb 5500 r min rpm Carburetion system Carburetor Keihin CVK40 Starting system Electric Ignition system Timing advance Electronically advanced Ignition timing from 10 1300 r min rpm to 30 BTDC 3300 r min rpm Spark plugs NGK DPRBEA 9 or ND X 24 EPR U9 Valve timing Inlet Open 19 Close 69 ABDC Duration 268 Exhaust Open 57 BBDC Close 31 Duration 268 Lubrication system Forced lubrication wet sump Engine Type SE SF or SG API SH or SJ with JASO MA Viscosity SAE10W40 Capacity 25L 17 4 SUPPLEMENT 2002 MODEL General Information Items KL650 A16 Drive Train Primary reduction system Type Gear Reduction ratio 2 272 75 33 Clutch type Wet multi disc Transmission Type 5 speed constant mesh return shift Gear ratios 1st 2 266 34 15 2nd 1 444 26 18 3rd 1 136 25 22 0 954 21 22 0 791 19 24 Final drive system Type Chain drive Reduction ratio 2 866 43 15 Overall drive ratio 5 157 Top gear Frame Type Tubular semi double cradle Caster rake angle 28 Trail 112 mm Front tire Type Tube type Size 90 90 21 54S Rear t
33. Motor Inspection Refer to the Base Manual noting the following A Radiator Fan Connector Fan Relay Inspection Refer to the Base Manual noting the following A Fan Relay cee or 5v Soto aL 99 st aw HH 1 J 1 TGNITION SWITCH CONNECTIONS LOCK Ester sie aroan aov 8 ec OFF rank aw Tam na tight VW DG van VW SEDO nvew aw Lett Turn Sanal Lane 2V 1w DONO 12923 w 14 19 APPENDIX 15 1 Appendix Table of Contents Additional Considerations for Carburetor gt Spark Plug Spark Plug Inspection 2 Tic QURE os sega ae s Qe on Tr a A 15 2 General Lubrication 15 2 Lubrication 15 2 Nut Bolt and Fastener Tightness 15 2 A O UQ U u beng Ara e 15 2 Unt Comscin TRADI uas xa Refer to Base Manual 15 2 APPENDIX Troubleshooting Guide Refer to the Base Manual adding the fol
34. Regulator Circuit Test 3rd Step 6 V Battery Regulator Rectifier 12 V Battery Alf the test light did not light when the 18 V was applied momentarily to the voltage monitoring terminal the regulator rectifier is defective Replace it If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit Ignition System Adjustment Spark Plug Cleaning and Gapping Refer to the Base Manual noting the following ELECTRICAL SYSTEM 14 7 Standard Spark Plug Plug DPR8EA 9 or ND X24EPR U9 ADOD NGK DPBEA 9 or ND X24EP U9 Plug 0 8 0 9 mm Tightening Torque 14 N m 1 4 kg m 10 0 Australian Model Italian Model South African Model US Model cece Removal Installation Magneto Removal or Installation Refer to the Base Manual noting the following Replace the magneto flywheel bolt with a new one This bolt is required to replace if it has been tightened once to the specified torque Tightening procedure of the magneto flywheel bolt is the following Tighten the magneto flywheel bolt to 120 Nem 12 0 87 ft lb of torque Do not overtighten it now Loosen the bolt and then tighten it again to the same torque above Finally tighten the bolt to the specified torque Tight
35. The Quick Reference Guide shows you all of the product s systems 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 General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example 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 Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This warning symbol identifies special instruc tions or procedures which if not correctly followed could result in personal injury or loss of life cThis caution symbol identifies special instruc tions or procedures which if not strictly ob served could result in damage to or destruc tion of equipment This manual contains five more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE oThis note symbol indicates points of particular interest for more efficient and convenient operation indicates a procedural step or work to be done olndicates a procedural sub step or how to do
36. The engine drain plug is installed at the bottom of the crankcase wv A Drain Plug Engine Oil Grade SE or SF class Viscosity SAE 10W40 10W50 20W40 or 20W50 Amount 2 2 L oil filter is not removed 2 5 L oil filter is removed Engine Sprocket Removal Refer to the Base Manual noting the following Loosen the drive chain to remove it from the rear sprocket Remove the cotter pin and loosen the rear axle nut 48 ENGINE RIGHT SIDE LEFT SIDE C Locknut D Chain Adjusting Nut Cotter Pin B Rear Axle Nut OLoosen the locknuts and back out both left and right chain adjusting nuts evenly Push the rear wheel forward to loose the chain Balancer Mechanism Removal Point Refer to the Base Manual noting the following Using the magneto holder special tool P N 57001 1184 to keep the crankshaft and balancer shafts from turning loosen or tighten the nut of the front right balancer weight C Nut D Toothed Lockwasher A Water Pump Shaft B Right Weight Assembly Points Refer to the Base Manual noting the following eTighten the front right balancer weight nut to the specified torque and bend the toothed lockwasher over the nut Tightening Torque Balancer Weight Nut 44 N m 4 5 kg m 33 ft Ib COOLING SYSTEM 5 1 Cooling System Table of Contents Exploded View Service Data Cooling System Special Tool Coolant Coolant Deterioration Coolant Level Inspection
37. Unit 6 3 Removal MT 6 3 Installation 2 2 0 eee teen eee eens 6 4 Engine Disassembly Precaution Flow Chart Refer to Base Manual 6 2 ENGINE REMOVAL INSTALLATION M Molybdenum Disulfide Grease Follow the specific tightening sequence 1 25 Nam 2 5 kg m 18 0 ft4b T2 44 Nem 4 5 kg m 33 feb T3 98 N m 10 0 72 feb ENGINE REMOVAL INSTALLATION 6 3 Engine Unit Removal For later installation convenience note and record how and where cables wires and hoses are routed They should not be bent sharply kinked or twisted Drain the engine oil chapter 4 and coolant chapter 5 Remove the parts and free the cables and wiring shown in the chart Place a stand or block under the engine and remove the engine mounting bolts nuts and brackets OThis chart is designed to aid in determining proper removal sequence Select the component you wish to remove and follow the arrows to that point on the chart Y itch le Fuel tank Rear brake pedal and master cylinder assembly Magneto connector neutral switch and pickup coil connector 22 AA Engine mounting bolts nuts brackets and swing arm pivot shaft 6 4 ENGINE REMOVAL INSTALLATION Installation Engine unit installation is the reverse of removal Note the following Tighten the engine mounting bolts bracket bolts and swing
38. ance of Exciter and Pickup Coil Meter x109 Connections female connectors disconnected 100 200 Exciter Coil BK Y 100 150 22 Pickup Coil Electrical Starter System Starter Motor Removal Remove the muffler and exhaust pipe Disconnect lead from starter motor terminal Unscrew starter motor mounting bolts and pull the starter motor out of its guide A Mounting Bolts C Ground Lead B Starter Motor Terminal ODo not tap the starter motor shaft or body Tapping on the shaft or body could damage the motor Installation Points When installing the starter motor clean the starter motor legs and crankcase where the starter motor is grounded Apply small amount of engine oil to the O ring B Clean here Starter Motor Disassembly Unscrew the retaining screws and pull off both end Covers ELECTRICAL SYSTEM 14 11 Take the armature out of the yoke housing Remove the brush plate assembly from the housing oo ES Remove the nut and remove the terminal bolt and then remove the positive brush assembly with the plastic holder Starter Motor Assembly Points Push the brush plate into place with its tab fitting in the yoke housing notch A Tab B Notch install the brush end cover so that the long vertical tab on the brush plate aligns with the key slot in the cover A Long Tab B Key Slot 14 12 ELECTRICAL SYSTEM As a further check these marks
39. ange measure the re sistance between the commutator and the shaft If there is any reading at all the armature has a short and the starter motor must be replaced Even if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with an ohmmeter If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one Brush Plate Inspection Using the x 1 Q ohmmeter range measure the resist ance between the negative brushes and the plate If there is not close to zero ohms the brush plate must be replaced ELECTRICAL SYSTEM 14 13 Using the highest ohmmeter range measure the re sistance between the metal plate and the positive brush holders xIf there is any reading at all the brush holder has a short and the brush plate must be replaced Positive Brush Assembly Inspection Using the x 1 ohmmeter range measure the re sistance between the positive brush and the terminal bolt If there is a high resistance or no reading a lead is open and the brush assembly must be replaced Using the highest ohmmeter range measure the resistance between the terminal bolt and the pole housing If there is any reading at all the insulation is faulty and the positive brush assembly must be replaced Starter Relay Inspection Disconnect the starter m
40. anism 48 Friction Plate Wear Chain Tension Adjustment Damage Inspection Removal Point ca MES Friction or Steel Plate Assembly Points ar Warp Inspection lt Balancer Chain Guide Install Clutch Spring Free Length Camshaft Chain Guide Installation Measurement sopes asap Idler Shaft Circlip Installation 8 Clutch Housing Finger Inspection Balancer Chain Timing Procedure Clutch Hub Spline Inspection BEINEN GERD sone ik NR Refer to Base Manual Removal or Installation Kick Starter Optional Installation Assembly Points Engine Lubrication System Engine Oil and Filter KL te canet Oil Level Inspection Installation Points of Oil Filter 4 2 ENGINE RIGHT SIDE LEFT SIDE Exploded View G Grease L Non permanent Locking Agent M Molybdenum Disulfide Grease T1 9 8 N m 1 0 kg m 87 in Ib T2 12 N m 1 2 kg m 104 indb T3 15 Nem 1 5 kg m 11 0 46 20 N m 2 0 kg m 14 5 feb 5 23 Nm 2 3 kg m 16 5 46 T6 25 N m 2 5 kg m 18 0 ft lb T7 44 Nam 4 5 kg m 33 feb T8 120 N m 12 0 kg m 87 130 N m 13 5 kg m 98 ft lb ENGINE RIGHT SIDE LEFT SIDE 4 3 4 4 ENGINE RIGHT SIDE LEFT SIDE Flow Chart Right Side Parts Removals The following chart is intended to be an aid to proper removal Select the c
41. caliper off the disc A Anti rattle Spring A Caliper Mounting Bolts Master Cylinder Installation Refer to the Base Manual noting the following Remove the safety clip and pull out the pad retaining The master cylinder clamp must be installed with the pin UP mark pointing up 10 6 BRAKES UP Mark Master Cylinder Disassembly Points Using the circlip pliers special tool P N 57001 143 remove the circlip and pull the piston and spring out of the cylinder Front Master Cylinder Spring Piston Circlip Primary Cup Secondary Cup not remove the primary and secondary cups from the piston since removal will damaged them Rear Brake Adjustment Inspection Pedal Position Adjustment When the brake pedal is in its rest position it should be at the position specified Brake Pedal Position Level with footpeg top Standard B Brake Pedal elf it is not adjust the brake pedal position as follows Remove the master cylinder bracket bolts A Master Cylinder Bracket Bolts B Locknut C Clevis D Adjusting Nut E Cotter Pin F Clevis Pin Pull out the cotter pin and the clevis pin eLoosen the locknut of the rod with the clevis held 0 or down the adjusting nut by turning the clevis to adjust the brake pedal position NOTE olf the pedal position cannot be adjusted by turning the clevis the brake pedal may be deformed or incorrectly installed Off th
42. chain On and After KL650 A14 EKS20SR O 1061 Chain slack 50 55 mm 50 60 mm Chain 20 link length 317 5 318 1mm 323mm SUPPLEMENT 2000 2001 MODELS 16 13 Electrical System Specifications Item Service Limit Battery Electrolyte level Between upper and lower levels Specific gravity 1 280 20 68 F Charging System Regulator rectifier output voltage Magneto stator coil resistance Ignition System Spark plug Type Gap Ignition coil Arcing distance Primary winding resistance Secondary winding resistance Exciter coil resistance Pickup coil resistance Electric Starter System Starter motor Carbon brush length Commutatoy diameter Meter Unit Water temperature sender resistance Radiator fan switch OFF Battery 15 V 0 3 10 DPR8EA 9 or ND X24EPR U9 0 8 0 9 mm 7mm or more 3 needle method 0 15 0210 3 8 5 8k0 100 2000 100 1500 12 0 12 5 mm 28 mm 47 570 80 176 26 300 100 212 F Above 94 100 C 201 212 Below 91 C 196 F SUPPLEMENT 2000 2001 MODELS 16 15
43. cm 63 85 psi 78 147 kPa 0 8 1 5 kg cm 11 21 psi tem Standard Service Limit Clutch Clutch lever play 2 3mm M 10 15 mm at lever end Friction plate thickness 2 9 3 1 2 75 mm Friction steel plate warp Less than 0 2 mm 0 3 mm Clutch spring free length 34 2 mm 33 1 mm Engine Lubrication System Engine oil Grade SE or SF class Viscosity SAE 10W40 10W50 20W40 or 20W50 Amount 2 2 L filter is not removed 2 5 L filter is removed Level Between upper and lower level lines E Clutch Play Inspection Refer to the Base Manual noting the following When checking the clutch lever play without the hand cover removal check the lever play at the lever end A Clutch Lever Play at lever end 10 15 mm Clutch Release Removal Refer to the Base Manual noting the following Before pulling out the clutch release lever and shaft assembly take out the shaft positioning bolt A Positioning Bolt not remove the clutch release lever and shaft assembly unless it is absolutely necessary If removed the oil seal replacement may be required ENGINE RIGHT SIDE LEFT SIDE 47 Clutch Release Installation Refer to the Base Manual noting the following Before installing the lever and shaft assembly check the oil seal and replace it if necessary Engine Lubrication System Engine Oil and Filter Oil Change Refer to the Base Manual noting the following
44. ction system Type Gear Reduction ratio 2 272 75 33 Clutch type Wet multi disc Transmission Type 5 speed constant mesh return shift Gear ratios 1st 2 266 34 15 2nd 1 444 26 18 3rd 1 136 25 22 4th 0 954 21 22 sth 0 791 19 24 Final drive system Type Chain drive Reduction ratio 2 866 43 15 Overall drive ratio 5 157 Top gear Fram Type Tubular semi double cradle Caster rake angle 28 Trail 112 mm Front lire Type Tube type Size 90 90 21 545 Rear tire Type Tube type Size 130 80 17 65S Front suspension Type Telescopic fork pneumatic Wheel travel 230 mm Rear suspension Type Swingarm uni trak Wheel travel 230 mm Brake Type Front Single disc Rear Single disc Electrical Equipment Battery 12 V 14 Ah Headlight Type Semi Sealed beam Bulb 12 V 60 55 W quartz halogen Tail brake light 12V 8 27 W 12 521 W Alternator Type Three phase AC Rated output 17 A 7 000 r min 14 V Voltage requlator Type Short Circuit Specification subject to change without notice and may not apply to every country CA California Model 16 6 SUPPLEMENT 2000 2001 MODELS Torque and Locking Agent Fastener Engine Right Side Left Side Clutch spring bolts Final Drive Engine sprocket Nut Fuel System specifications KL650 A14 A15 Carburetor Idle speed 1300 50r min rpm Standard specifications Make type Keihin CVK40 Main jet 148 Main air jet 450 Needle jet
45. e View KL650 A14 Right Side View 16 4 SUPPLEMENT 2000 2001 MODELS General Specifications Items KL650 A14 KL650 A15 Dimensions Overall length 2 205 mm Overall width 940 mm Overall height 1345 mm Wheelbase 1495 mm Road clearance 240 mm Seat height 890 mm Dry weight 183 kg CA 153 5 kg Curb weight Front 81 kg CA 81 5 kg Rear 97 kg Fuel tank capacity 23L Performance Minimum turning radius 24m Engine Type 4 stroke DOHC 4 valve 1 cylinder Cooling system Liquid cooled Bore and stroke 100 0 x 83 0 mm Displacement 651 mL Compression ratio 95 1 Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plugs Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil Grade Viscosity Capacity 35 3 48PS 6500 r min rpm 55 N m 5 6 kg m 40 5 16 5500r min rpm Carburetor Keihin CVK40 Electric CDI Electronically advanced From 10 BTDC 1 300 r min rpm to 30 BTDC 3 300r min rpm NGK DPRBEA 9 or ND X 24 EPR US 19 BTDC 69 ABDC 268 57 BBDC 31 268 Forced lubrication wet sump SE SF or SG class API SE SF or SG API SH or SJ with JASO MA SAE10W40 10W50 20W40 20W50 25L SUPPLEMENT 2000 2001 MODELS 16 5 Items KL650 A14 KL650 A15 Drive Train Primary redu
46. e brake rod protrusion is 3 0 3 5 mm below the nut the pedal will be at the position specified Brake Rod Protrusion 2 1 Master Cylinder 2 Adjusting Nut 3 Rod Protrusion eCheck the brake pedal position and readjust it if necessary Install the removed parts and tighten the locknut eCheck the brake light switch and adjust if necessary Brake Lining Wear Inspection Refer to the Front Brake Adjustment Inspection section in the Base Manual Brake Fluid Level Inspection Refer to the Front Brake Adjustment Inspection section in the Base Manual noting the following Holding the reservoir horizontally check that the brake fluid level in the reservoir is between the upper and lower lines C Lower Level A Reservoir B Upper Level Brake Fluid Change Refer to the Front Brake Adjustment Inspection section in the Base Manual noting the following BRAKES 10 7 Press down the brake pedal instand of squeezing the brake lever to apply the rear brake Brake Line Air Bleeding Refer to the Front Brake Adjustment Inspection section in the Base Manual noting the following Press down the brake pedal instead of squeezing the brake lever to apply the brake Brake Fluid Recommendation Refer to the Front Brake Adjustment Inspection section in the Base Manual Rear Brake Disassembly Assembly Observe the WARNING and CAUTION in the Brake Fluid Recommendation Inspection and Adjustment after Installat
47. e notch on the left chain adjuster should align the same swing arm mark that the right chain adjuster notch aligns with NOTE Wheel alignment can also be checked using the straight edge or string method Misalignment of the wheel and may result in an unsafe result in abnormal wea ing condition Tighten the axle nut loosely and tighten both chain adjusting nuts but not enough to change the adjust ment and then tighten both locknuts securely Tighten the axle nut to the specified torque Tightening Torque Rear Axle Nut 93 N m 9 5 kg m 69 ft lb Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary insert the new cotter pin through the axle nut and axle and spread its ends Olf the axle nut is not securely tightened and the cotte pin is not installed an unshaft riding condition may result eCheck the rear brake effectiveness Drive Chain Removal Place a stand or block under the motorcycle to raise the rear wheel off the ground eAfter removing the engine sprocket and drive chain from the rear sprocket remove the swing arm pivot shaft and tie rod bolt upper or lower A Swing Arm Pivot Shaft B Tie rod Bolts Pulling back the swing arm remove the drive chain from the motorcycle BRAKES 10 1 Brakes Table of Contents Exploded View 102 Rear Brake Disassembly Assembly 10 7 Service Data 104 Inspectio
48. efore starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation For the duration of your warranty period especially we recommend that all repairs and scheduled maintenance be performed in accord ance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your Motor cycle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance Use proper tools and genuine Kawasaki Motor cycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts 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 product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter
49. emove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser Continued on next page NOTE The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are exceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the standards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT 57 EXCEEDING 10 00
50. ening Torque Magneto Flywheel Bolt 175 N m 18 0 kg m 130 ft lb OUse a 6 point socket instead of 12 point one to tighten the flywheel bolt to the specified torque Ignition Coil Installation Connect the primary leads to the ignition coil terminals as shown in the figure Ignition Coil Terminals e QV 1 Terminal BK 2 Terminal BK Y 14 8 ELECTRICAL SYSTEM Ignition System Maintenance Ignition System Wiring 1 10 11 12 o EN 10 KL650 A4 BK F3 BK Y BK Y G W Ignition Switch Engine Stop Switch Diodes Ignition Coil Spark Plug CDI Unit Exciter Coil Magneto Pickup Coil Neutral Switch Starter Lockout Switch Side Stand Switch Starter Circuit Relay Switch Inspection Refer to the Base Manual noting the following Starter Lockout Switch Connections Color BK Y BL R BR G W Lu When the clutch lever is pulled on When the clutch lever is released _ om Engine Stop Switch and Starter Button Connections Engine Stop Switch Starter Button BK W BK Y BR YIR OFF C O RUN OO OO Pushed A Starter Lockout Switch C Engine Stop Switch 8 lgnition Switch
51. ese specified adjustments are not considered to be emission contro system tampering and vehicle performance is generally unchanged as a result High altitude adjustments require replacement of certain carburetor jets High Altitude Carburetor Specifications Main J 145 Pilot Je 38 After high altitude adjustments are performed provide the customer with the Vehicle Emission Control In formation Update Label and label installation in structions P N 99969 0614 Advise the customer that by law the Vehicle Emission Control Information Update Label must be affixed to any vehicle modified with the high altitude adjust ments NOTE Olf a vehicle with the high altitude adjustments is used below 4 000 feet 1 219 meters the update label must be removed and the original carburetor parts must be reinstalled FUEL SYSTEM 25 Carburetor Disassembly Carburetor Installation Refer to the Base Manual noting the following Refer to Cable Wire and Hose Routing in the chapter 1 for the carburetor overflow tube and air vent tube routing Adjustment after Installation Adjust the following Throttle Grip Choke Lever Idle Speed Element Removal Remove the right side cover Remove the screws and take off the air cleaner element cap A Element Cap B Element C Wing Head Bolt Remove the wing head bolt and take off the air cleaner element Push a clean lint free towel into the air cleaner housi
52. est German Model eoQoeQo Italian Model South African Model Spanish Model U S Model Greek Model 16 GENERAL INFORMATION Periodic Maintenance Chart OPERATION Whichever comes first gt Spark plug clean Spark plug check Valve clearance check Air cleaner element clean Air cleaner element replace Throttle grip play check Idle speed check Fuel system check Coolant change 2 years park arrestor clean for model Evaporative emission control system check for model ilter replace Rad jator hoses connections check year Fuel hoses connections check il Balancer chain tension adjust Clutch adjust rive chain wear check ele Drive chain lubricate 300 km Drive chain slack check 800 km Brake lining wear check ele Brake fluid level check month e Brake fluid change 2 years Brake hoses connections check CHEO Brake hose replace 4 years E Master cylinder cup and dust seal replace 2 years Caliper piston seal and dust seal 2 replace en SE
53. f the outer tube by fitting the step of the weight to the top corner of the outer tube Holding the inner tube by hand in a vertical position stroke the outer tube several times and pull it down ur a A Fork Outer Tube Weight 57001 1218 Fork Assembly Refer to the Base Manual noting the following When installing the guide bush and oil seal at the outer tube top the fork oil seal driver special tool P N 57001 1219 can be used to install them instead of using the driver special tool P N 57001 1104 See Guide Bush Replacement Guide Bush Replacement Refer to the Base Manual noting the following When installing the guide bush and oil seal at the outer tube top the fork oil seal driver special tool P N 57001 1219 can be used to install them instead of using the driver special tool 57001 1104 Perform the following Olnstall the guide bush with a used guide bush or washer on it by tapping the used guide bush or washer with the driver until it stops The slit of the bush must be faced toward the left or right Guide Bush Installation 1 Driver 57001 1219 2 Used Guide Bush 3 Slit toward the left or right 4 New Guide Bush 5 Tap Uni trak Spring Preload Adjustment The spring preload adjuster on the rear shock ab sorber has 5 positions so that the spring force can be adjusted for different riding conditions Using a socket wrench turn the spring preload adjuster as requ
54. fications Tem Standard Service Limit Engine Lubrication System Engine oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE10W40 Capacity 2 2 L filter is not removed 559 2 5 L filter is removed Level Between upper and lower level lines Relief valve opening pressure 430 590 kPa a 4 4 6 0 kgl cm 63 85 psi Oil pressure 78 147 kPa 94000 rpm r min 90 C 194 F 0 8 1 5 kgl cm 11 21 psi Engine Oil and Oil Engine Oil Change Type API SE SF or SG sae 208 50 API SH or SJ with JASO MA SAE10W 40 2 2 L Oil fitler is not removed SEIEN gt 255 L filter is removed NOTE SAE 108 40 Depending on the atmospheric temperature of your riding area the No 9 9 39 3 engine oil viscosity should be changed accordingly to the chart soe MODEL APPLICATION Vem Begining Frame ser asson or kiasa 000001 LECT E 2 XARLERTELARSTUT or wee Kus DECEM SUE we nene gt 36 RARER DUTT 1001 ALEA TOMADO _ _ _ 1963 Reso SPARE 3684 estas 195 eso 49 BRAREATDSADSIDI IA ERA O 2001 L68015 a EAN OOO ng Wissb A16_ KARLEATIR20075007 DTN inte ruber change to one machen omo
55. hin CVK40 lt Main jet 148 150 148 145 155 DO 148 Main air jet 50 lt Needle jet 6 lt 7 6 Jet needle N31W N31T N31R N74C N31R N60B N60N Pilot jet 40 lt Pilot air jet 80 70 lt Pilot screw 1 4 turns out 13 turns out 174 turns out 0 00 1 1 Starter jet 52 lt lt Service fuel level 0 5 1 mm q Wie Float height 17 5 mm lt Height altitude adjustment US model Main jet 145 Pilot jet 38 e Air Cleaner Element oil Grade SE class lt gt Viscosity SAE30 gt lt West German Model o Model Swiss Model Fuel Tank Removal Point Before removing the fuel tank or disconnecting the fuel hose from the fuel tap turn the fuel tap lever to the OFF position to prevent fuel leaking out while the tank is removed or the hose is disconnected Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Carburetor Adjustment High Altitude Performance Adjustment US model To improve the Emission Control Performance of vehicle operated above 4 000 feet 1 219 meters Kawasaki recommends the following Environmental protection Agency EPA approved modification NOTE When properly performed th
56. ier output voltage Magneto stator coil resistance Ignition System Spark plug Type Gap Ignition coil Arcing distance Primary winding resistance Secondary winding resistance Exciter coil resistance Pickup coil resistance Electric Starter System Starter motor Carbon brush length Commutator diamater Meter Unit Water temperature sender resistance Radiator Fan Radiator fan switch ON OFF Battery 15 V 03 100 NGK DPR8EA 9 or ND X24EPR U9 amp D O NGK DPSEA 9 or ND X24EP U9 0 8 0 9 mm 7 mm or more 3 needle method 0 15 0 219 3 8 5 8 100 200 2 100 1502 12 0 12 5 mm 28 mm 47 57 2 80 176 F 26 30 2 100 C 212 F Above 94 100 C 201 212 F Below 91 C 196 F Item Standard Battery Electrolyte level Between upper and lower levels Specific gravity 1 280 20 C 68 F Charging System Australian Model Italian Model 9 O South African Model US Model Precautions ELECTRICAL SYSTEM 14 5 Refer to the Base Manual noting the following CBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor windings Charging System Charging System Wiring Diagram Refer to the Base Manual noting the following Refer to Cable Wire and Hose Routing in the chapter 1 for
57. ion Refer to the Front Brake Disassembly Assembly section in the Base Manual noting the following eCheck the rear brake for good braking power no brake drag and no fluid leakage 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 Pad Removal Refer to the Front Brake Disassembly Assembly section in the Base Manual noting the following A Rear Caliper Mounting Bolts 10 8 BRAKES Caliper Removal Refer to the Front Brake Disassembly Assembly section in the Base Manual noting the following else the brake pedal instead of using the brake lever to remove the caliper piston Caliper Installation Refer to the Front Brake Disassembly Assembly section in the Base Manual Caliper Disassembly Refer to the Front Brake Disassembly Assembly section in the Base Manual Caliper Assembly Refer to the Front Brake Disassembly Assembly section in the Base Manual Disc Installation Refer to the Front Brake Disassembly Assembly section in the Base Manual Master Cylinder Installation Points Discard the used flat washers and install new washer each side of the brake hose fittings eCheck and adjust the brake pedal position Master Cylinder Disassembly Points Using the circlip pliers special tool P N 57001 143 remove the circlip and
58. ire Type Tube type Size 130 80 17 65S Front suspension Type Telescopic fork pneumatic Wheel travel 230 mm Rear suspension Type Swingarm uni trak Wheel travel 230 mm Brake type Front Single disc Rear Single disc Electrical Equipment Battery 12 V 14 Ah Headlight Type Semi Sealed beam Bulb 12 V 60 55 W quartz halogen Tail brake light 12V 5 21 W Alternator Type Three phase AC Rated output 17 A 97000 r min rpm 14 V Voltage regulator Type Short Circuit Specification subject to change without notice and may not apply to every country CA California Model SUPPLEMENT 2002 MODEL 17 5 General Information Torque and Locking Agent Torque Fastener Nm kgfm fib Remarks Fuel System Fuel tap bolts 25 0 25 22 inb Engine Removal Installation Engine mounting bolts and nuts 10 mm 44 45 33 8mm 27 28 20 Wheels Tires Front axle nut 88 9 0 65 Rear axle nut 98 10 72 Spoke nipples 51 0 52 45 inb Brakes Brake pedal mounting bolt 88 09 78 inb Master cylinder mounting bolts 25 25 18 Suspension Steering Steering stem nut 49 05 43 indb Swing arm pivot nut 9 0 6s Front fork clamp bolts upper 20 20 14 Controls Instruments Handlebar clamp bolts 25 25 18 Frame Rear frame mounting bolts 27 28 20 Step holder mounting bolts 32 33 24 Electrical System Fan switch 78 08 69 inb 17 6 SUPPLEMENT 2002 MODEL Engine Right Side Left Side Speci
59. ired OFor californian vehicles remove the liquid vapor separator from its bracket A Spring Preload Adjuster Setting Table for Spring Preload and Damper Adjusters Riding An average ondition build rider A rider and rider a passenger lAdjuster with load Spring preload Qo2 Dor3 Damper Don O Standard setting number is identified with a circle marking Damper Adjustment Refer to the Base Manual noting the following See Setting Table in the Spring Preload Adjustment paragraph to adjust the damper adjuster Rear Shock Removal Remove the following Side Covers Seat Fuel Tank Battery Muffler Remove the mounting bolt of the rear brake master cylinder reservoir Remove the rear right footpeg bracket bolts Loosen the clamp of the carburetor air duct Disconnect the main harness connectors and remove the clamps to free rear frame from the harness eLoosen the rear frame lower bolts and remove the upper bolts Tilt the rear frame backwards SUSPENSION STEERING 11 7 A Carburetor Air Duct Clamp B Reservoir Mounting Bolt C Footpeg Bracket Bolts D Rear Frame Upper Bolt remove E Rear Frame Lower Bolt loosen A Rear Frame B Rear Shock Absorber Loosen the upper and lower shock absorber mounting nuts Do not remove them yet Place a stand or block under the motorcycle so that the rear wheel off the ground Remove the rear shock absorber
60. lowing Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter motor damaged Battery voltage low Relay not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch damaged Engine stop switch damaged Engine stop switch off Fuse blown Starter lockout or neutral switch damaged Starter motor rotating but engine doesn t turn over Starter motor clutch damaged Alternator rotor bolt loosened General Lubrication Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Lubricate the points listed below with indicated lubricant NOTE Whenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubrication Pivots Lubricate with Motor Oil Side Stand Clutch Lever Brake Lever Brake Pedal Rear Brake Rod Joint Points Lubricate with Grease Throttle Inner Cable Lower Ends Clutch Inner Cable Upper End Side Stand Switch Inner Cable Lower End Speedometer Inner Cable Grease the lower part of the inner cable sparingly Cables Lubricate with Rust Inhibitor Choke Cable Throttle Cables Clutch Cable Side Stand Switch Cable Cable Lubrication Nut Bolt and Fastener Tightness Tightness Inspection eCheck the tightness of the bolts and nuts listed here Also check to see
61. mounting bolts and nuts take out the rear shock absorber Rear Shock Installation Point Tighten the following bolts to the specified torque Tightening Torque Rear Shock Mounting Upper 59 N m 6 0 kg m 43 ft lb Lower 98 N m 10 0 kg m 72 ft lb Rear Frame Mounting Bolts 25 N m 2 5 kg m 18 0 ft lb CONTROLS INSTRUMENTS 12 1 Controls Instruments Table of Contents POD VES cs uo kie ie oz awas AAA 122 Serie Lo qi ocior at nC hon a Vines lue cnr NDA ERE CE let t 124 Special Tool 12 4 Choke Lever Adjustment pipette Eee ar POC k een RRA pan WPS Adjustment Clutch T lt Meter Unit 126 Removal 12 6 Disassembly y Speedometer Speedometer Disassembly EUBRICBEION ad da ao as waw HEVDE ARS VIS E RR vi Instaliationiss acies sie aires n UE xia SU X UN lin P a a Refer to Base Manual CONTROLS INSTRUMENTS 12 3 12 4 CONTROLS INSTRUMENTS Standard Choke Lever Choke cable free play 2 3mm Throttle Grip Throttle grip free play 2 3mm Clutch Clutch lever free play 2 3mm 10 15 mm at lever end Throttle Grip There are two throttle cables an accelerator cable for opening the throttle valve and a decelerator cable for closing it If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle response Also
62. n and Adjustment after Special Tool a 10 4 Installation 107 Front Brake Adjustment Inspection 105 Pad Removal 10 7 Brake Lining Wear Inspection Caliper Removal a 10 8 Brake Fluid Level Inspection 105 Caliper Installation 108 Brake Fluid Change y Caliper Disassembly 10 8 Brake Line Air Bleeding P Caliper 10 8 Brake Fluid Recommendation gt Disc Installation 108 Front Brake Disassembly Assembly 105 Master Cylinder Installation Points 108 Inspection and Adjustment after Master Cylinder Disassembly Points 108 Installation um eee eee T Master Cylinder Assembly 10 8 Pad Removal 105 Brake Maintenance 108 Caliper Removal Points gt Brake Disc Runout Inspection 10 8 Caliper Installation Points Brake Light Switch Caliper Disassembly Points Inspection Caliper Assembly Points 105 Adjustment D Disc Installation Points E Removal Master Cylinder Installation 105 Master Cylinder Disassembly Points 10 6 Refer to Base Manual Master Cylinder Assembly Points Rear Brake Adjustment Inspection Pedal Position Adjustment Brake Li Brake Fluid Level Inspection Brake Fluid Brake Line Air Bleeding Wear Inspection Brake Fluid Recommendation 10 2 BRAKES Exploded View T1 5 9 N m 0
63. nent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Soft water 50 coolant 50 35 31 F 13L 93 123 kPa 0 95 1 25 kg cm 14 18 psi 69 5 72 5 C 157 162 F Not less than 3 mm 85 C 185 F 5 4 COOLING SYSTEM Coolant Level Inspection Refer to the Base Manual noting the following The reserve tank is mounted to the right lower side of the frame head pipe A FULL Mark C Tank Cap B LOW Mark Set the motorcycle on its side stand during the coolant level inspection Radiator Radiator Fan Removal Points Refer to the Base Manual noting the following The radiator is one piece type and is mounted to the left lower side of the frame head pipe A Radiator C Radiator Fan B Radiator Cap D Radiator Fan Switch Water Pump Mechanical Seal Assembly Points Refer to the Base Manual noting the following elmpeller shim selection is not necessary Install only the shim which is 0 8 mm thickness Water Pump Installation Balancer Shaft 2 Right Weight 3 Nut Impeller Washer Shim 0 8 mm thickness Impeller Shaft Lockwasher 5 6 7 8 Tightening Torque Impeller Nut 9 8 N m 1 0 87 in Ib ENGINE REMOVAL INSTALLATION 6 1 Engine Removal Installation Table of Contents Exploded View 6 2 Engine
64. ng to keep dirt or other foreign material from entering dirt gets through into the engine excessive engine wear and possibly engine damage will occur Element Installation Points Coat the element lip with a layer of all purpose grease to assure a complete seal against the cleaner case Be sure the foam gasket is in place in the groove in the element cap 2 6 FUEL SYSTEM A Foam Gasket Body Installation Point elf the air cleaner body drain tubes were removed install them in place on the bottom of the housing The longer drain tube including the air filter must be installed the rear side fitting dirty side fitting E 29 A Long Drain Tube B Short Drain Tubes Fuel System Cleanliness Fuel Tank and Cap Inspection Visually inspect the gasket on the tank cap for any damage Replace the gasket if it is damaged Remove the hose s from the fuel tank and open the tank cap eCheck to see if the breather and water drain pipes also the fuel return pipe for the US California vehicle in the tank are not clogged Check the tank cap breather too If the tank pipes are clogged remove the tank and drain it and then blow the pipes free with compressed air If the tank cap breather is clogged replace it not apply compressed air to the air vent holes on the tank cap This could cause damage and clogging of the labyrinth in the cap A Air Vent Holes ENGINE TOP END 3 1 Engine Top End
65. ng Agent T1 9 8 Nm 1 0 87 in Ib T2 32 Nem 3 3 kg m 24 feb E T3 93 Nm 9 5 kg m 69 feb i Shielded Side Service Data Standard Drive Chain Standard chain KL650 A1 A2 A3 EK520LD O 106 L KL650 A4 DID JAPAN 520V2 106 L gt KL500 EK520LD O 108 L ena Chain slack 50 55 mm 50 60 mm Chain 20 link length 317 5 318 4 mm 323 mm Drive Chain Chain Slack Inspection Stand the motorcycle on its side stand elf the drive chain appears dry lubricate it Rotate the rear wheel to find the place where the chain is tightest because the chain wears unevenly Measure the vertical movement midway between the sprockets If the drive chain is too tight or too loose adjust it so that the chain slack is within the standard value Drive Chain Slack Drive Chain Slack Standard 50 55 Too tight less than 50 mm Too loose than 60 mm Chain Slack Adjustment Remove the cotter pin and loosen the rear axle nut A Axle Nut D Locknut B Cotter Pin E Notch C Chain Adjusting Nut F Marks Loosen the left and right chain adjusting nut locknuts If the chain is too tight back out the left and right chain adjusting nuts evenly and kick the wheel forward until the chain is too loose Turn both chain adjusting nuts evenly until the chain has the correct amount of slack To keep the chain and FINAL DRIVE 9 3 wheel properly aligned th
66. nts Wheel Bearing Inspection Bearing Lubrication Refer to Base Manual WHEELS TIRES 8 3 Item Standard Service Limit Tires Standard tire Front 90 90 21 54S DUNLOP K750 A3 DUNLOP TRAIL MAX Rear 130 80 17 65S DUNLOP K750 A3 DUNLOP TRAIL MAX Tire tread depth Front 6 4mm 2mm Rear 8 8mm 2mm Tire air pressure 150 kPa 1 5 kg cm 21 psi Up to 97 5 kg 215 Ib load 150 kPa 97 5 182 kg 215 401 Ib load 200 kPa 2 Wheels Wheel balance Less than 10 g gt Balance weights 10 g 20 g 30 g Spokes and Rims Rim runout Radial amp Axial 2 Australian Model 8 4 WHEELS TIRES Adjustment after Tire Installation eCheck and adjust the following Tire Air Pressure Wheel Balance front wheel only Wheels Rear Wheel Removal Remove the rear caliper from the caliper holder with the brake hose connected A Caliper Mounting Bolts Caliper Holder Remove the cotter pin and take off the rear axle nut B Cotter Pin A Rear Axle Nut Place a stand or block under the motorcycle so that the rear wheel is raised off the ground Pull the rear axle off the wheel and free the drive chain from the rear sprocket Rear Wheel Installation Points eAdjust the drive chain slack after installing the rear wheel Tighten the rear caliper mounting bolts to the specified torque
67. o the Base Manual noting the following Cylinder Head Bolts and Nuts Tightening Torque and Sequence A Arrow install the spring and tighten the cap bolt with the gasket Oil Pipe Installation Points Refer to the Base Manual noting the following Apply engine oil to both ends of the head oil pipe to Prevent damage to the O rings in the camshaft caps Cylinder Head Bolts 10 mm Torque them first to 20 N m 2 0 kg m 14 5 46 and then to 65 N m 6 6 kgm 48 ft lb following the tightening sequence Cylinder Head Nuts 25 Nm 2 5 18 0 ft lb Cylinder Nuts Retighten 25 Nam 2 5 18 0 ft lb Cylinder Head Bolt 8 mm 18 N m 1 8 kg m 13 0 ft lb Cylinder Head Bolts 6 mm 9 8 1 0 87 in Ib Cylinder Piston Installation Points of Piston Rings Refer to the Base Manual noting the following Cross Section of Piston Rings Top and Second N Mark Top Ring Second N Mark Ring not mix up the top and second rings The top and second rings are not symmetrical and must be installed with the marked side facing up Spark Arrester Cleaning U S model This motorcycle is equipped with a spark arrester approved for off road use by the U S Forest Service It must be properly maintained to ensure its efficiency In accordance with the Periodic Maintenance Chart clean the spark arrester OTo avoid burns wear gloves while cleaning the spark
68. omponent you wish to remove and follow the arrows to that point on the chart Engine in motorcycle Clutch cable lower Exhaust pipe Clutch release Shift pedal assembly Rear brake pedal and master cylinder assembly _ Right engine cover k Optional Balancer weight front need for special tool Shift drum holder ENGINE RIGHT SIDE LEFT SIDE 4 5 Flow Chart Left Side Parts Removals OThe following chart is intended to be an aid to proper removal Select the component you wish to remove and follow the arrows to that point on the chart Engine in motorcycle Drive chain cover Engine sprocket cover Neutral switch Magneto connector neutral switch and pickup coil connector Engine sprocket Magneto cover I Balancer chain tensioner bolt Pickup coil Magneto stator Balancer chain idler shaft Balancer chain guides cam chain guides Left engine cover Balancer weight front Camshaft chain balancer chain idler Balancer chai sprocket front Balancer chai sprocket rear need for special tool Balancer chain 4 6 ENGINE RIGHT SIDE LEFT SIDE Relief valve opening pressure Oil pressure 64 000 rpm r min 90 C 194 F 430 590 kPa 4 4 6 0 kg
69. otor lead and battery positive lead from the starter relay 14 14 ELECTRICAL SYSTEM OThe battery positive lead with the rubber cap is connected directly to the battery positive terminal even when the ignition switch is off so take care not to short the removed lead to chassis ground Using the x 1 2 ohmmeter range measure the re sistance across the relay terminals If the relay clicks but the meter does not read zero the relay is defective and must be replaced If the relay does not click at all the relay is defective and must be replaced If the relay makes a single clicking sound and the meter reads zero the relay is good The trouble is in the starter motor or the motor power supply wires Switch Position Ignition switch ON Engine stop switch RUN Starter button ON Neutral switch ON Transmission is in Neutral Meter Connectie Location Starter relay terminals leads disconnected Meter Range x 12 Meter Reading 0 and relay clicks when starter button is pushed B Starter Circuit Relay A Starter Relay Starter Circuit Relay Inspection Starter circuit relay inspection is the same as the radiator fan relay inspection Refer to the Fan Relay Inspection is the Base Manual Starter Button Inspection Using an ohmmeter check to see that only the con nections shown in the table have continuity about zero ohms the switch has an open or short repair it or replace it with a new one
70. pull the piston and spring out of the cylinder Rear Master Cylinder 1 Spring 2 Piston 3 Circlip 4 Primary Cup 5 Secondary Cup not remove the primary and secondary cups from the piston since removal will damage them Master Cylinder Assembly Refer to the Front Brake Disassembly Assembly section in the Base Manual Brake Maintenance Brake Disc Runout Inspection A warped disc will cause the brake pads to drag on the disc and will wear down both the pads and disc quickly Dragging will also cause overheating and poor braking efficiency Raise the wheel off the ground oTurn the handlebar fully to one side if it is the front wheel Set up a dial gauge against the brake disc and rotate the wheel to measure the runout The difference between the highest and lowest dial reading is the amount of runout If runout is beyond the service limit replace the brake disc SUSPENSION STEERING 11 1 Suspension Steering Table of Contents Exploded View 11 2 Service Data 11 4 Special Tools 115 Steering Steering Inspection E Steering Adjustment Stem Bearing Lubrication Grease Seal Deterioration Damage Stem Bearing Removal n Stem Bearing Grease Seal installation 8 Steering Stem Installation Adjustment after Installation BOK 2 116 Air Pressure Adjustment Fork Oil Level 116
71. r Red 22 8 Starter Lockout 23 Radiator Fan Switch Connector Connector 24 Turn Signal Relay 9 Meter Bracket 25 Radiator Fan Relay 10 Main Harness 26 CDI Unit 2P 11 To Turn Signal Light Connector 12 To City Light 27 Neutral Switch and Pickup Coil 3P Connector 28 Magneto 6P Connector 29 CDI Unit 6P Connector 30 CDI Unit 31 Diode Assembly Viewed from C 1 12 GENERAL INFORMATION Electrical Wires 2 Main Harness RI SSS Rear Brake Light Z Switch Leads S Rear Brake Light Switch Magneto Leads N Neutral Switch and Pickup Coil Leads To Fuses To Battery Battery Lead To Regulator peuo ma Rectifier 10 To Rear Harness 1 Side Stand Switch 11 Starter Relay x 16 Battery Lead 12 Ground Lead 17 Turn Signal Light 13 Starter Motor Lead Leads 14 Starter Circuit Relay 18 Tail Brake Light Leads 19 Rear Harness 20 License Plate Light Leads 21 Ground Lead 22 Radiator Fan Leads 23 Radiator Fan Switch Lead GENERAL INFORMATION 1 13 Fuel Hoses and Battery Vent Hose Fuel Tank Breather Hose Crankcase Breather Hose Carburetor Air Vent jose l Carburetor Overflow Hose Ground Lead Battery Vent Hose Breather Hose Blue To Fuel Tank Vacuum Hoses and Breather Hoses Fuel Return Hose Californian Model Red Pesan p Purge Hose Green To Carburetor To F
72. s Front master cylinder clamp bolts 88 0 90 78 inb Rear master cylinder mounting bolts 23 23 16 5 Caliper mounting bolts 25 25 180 Disc mounting bolts 23 23 16 5 Brake hose banjo bolts 25 25 18 0 Air bleed valves 78 080 69inb Brake lever pivot nut 5 9 0 60 52 in Ib Suspension Steering Front fork clamp bolts and nuts 25 25 18 0 Air valves 12 12 104 L Fork top bolts 29 3 0 22 Fork bottom Allen bolts 39 4 0 29 L Fork drain screws LG Rear shock absorber mounting bolts and nuts Upper 12 mm 59 6 0 43 Lower 14 mm 98 10 0 72 Swing arm pivot bolt and nut 14 mm 98 10 0 72 Rocker arm pivot bolt and nut 14 mm 98 100 72 Tie rod bolts and nuts 14 mm 98 10 0 72 Steering stem head nut 39 4 0 29 GENERAL INFORMATION 1 9 Torque R Fastener Nm mes fb Controls Instruments Handlebar clamp bolts 24 24 17 5 Frame Rear frame mounting bolts 25 25 18 0 Electrical System Spark plug 14 1 4 10 0 Magneto flywheel bolt 175 18 0 130 Starter motor mounting bolts 9 8 1 0 87 in Ib Starter clutch bolts 34 35 25 L The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads General Fasteners Threads dia mm N m kgm 5 34 49 0 35 0 50 30 4
73. s at the lower ends of the throttle cables Do not forget to securely tighten the adjuster locknuts after adjustment B Locknuts A Cable Adjusters OBe sure the upper ends of the outer cables are fully seated in their adjusting nuts or they could slip into place later creating enough grip play to prevent 12 6 CONTROLS INSTRUMENTS throttle operation resulting in a hazardous riding Disconnect the 9 pin meter connector conditions Remove the meter mounting nuts and the speedometer cable nut and take off the meter unit Start the engine Turn the handlebar from side to side while idling the engine If idle speed varies the throttle cables may be poorly routed or they may be damaged Correct any problem before operating the motorcycle with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition A Meter Mounting Nuts C Meter 9 pin Connector B Speedometer Cable Nut White Removal Remove the headlight cover and connector cover A Connector Cover B Screws FRAME 13 1 Frame Table of Contents a Bir ah e NIE eats 132 Disassembly Flow Chart Chassis 13 4 FRAME 13 3 13 4 FRAME GThis chart is designed to aid in determining proper removal sequence Select the component you wish to remove and follow the arrows to that point on the chart
74. should align on the outside of the starter A Align marks Starter Clutch Removal Pull off the magneto flywheel from the crankshaft Holding the magneto flywheel in a vise remove the Allen bolts A Magneto Flywheel Starter Clutch Allen Bolts Separate the starter clutch assembly Installation Point Apply a non permanent locking agent to the threads of the Allen bolts and tighten them to the specified torque Tightening Torque Starter Clutch Bolts 34 N m 3 5 kg m 25 ft lb Starter Motor Brush Length Measure the length of each brush lf any is worn down to the service limit replace all brushes Measure brush length B Brush Spring Brush Spring Inspection eCheck that the brush springs are in place and snap the brushes firmly into place If not reinstall or replace the spring Commutator Cleaning and Inspection Smooth the commutator surface if necessary with fine emery cloth and clean out the grooves A Commutator Measure the diameter of the commutator Replace the starter motor with a new one if the com mutator diameter is less than the service limit Armature Inspection Using the x 1 Q ohmmeter range measure the re sistance between any two commutator segments there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced A Segment B Shaft Using the highest ohmmeter r
75. spection Refer to the Base Manual noting the following Headlight Dimmer or Passing Switch Connections Other than US and Canada Headlight Switch Dimmer Switch Passing Button Color BR RW Color R BK RIY Color R BK ON HI OFF Push Om EE R Y for Italian Model A LH Switch Housing 9 pin Connector Red Screws B RH Switch Housing 6 pin Connector Red Remove the tachometer or water temperature gauge Tachometer and Water Temperature Gauge Disassembly Remove the meter cover A Tachometer Mounting Screws B Water Temperature Gauge Mounting Screws A Meter Cover C Screw B Knob Maintenance Refer to the Base Manual noting the following A Meter 9 pin Connector White Tachometer Inspection NOTE OThe tachometer inspection is explained on the assump tion that the ignition system operates normally Turn the ignition switch ON With the BK Y and the BR lead connected open or connect the BK lead to the BR lead repeatedly using an auxiliary wire Then the tachometer hand should flick If the hand does not flick replace the tachometer unit Radiator Fan Initial Check Refer to the Base Manual noting the following The radiator and radiator fan assembly is mounted to left lower side of the frame head pipe A Radiator Fan Switch ELECTRICAL SYSTEM 14 17 Fan
76. t balance weight is being used WHEELS TIRES 8 5 If the wheel rotates and the weight goes up replace the weight with the next heavier size If the wheel rotates and the weight goes down replace the weight with the next lighter size Repeat these step until the wheel remains at rest after being rotated turn Rotate the wheel another turn and then another Y turn to see if the wheel is correctly balanced Repeat the entire procedure as many times as neces sary to achieve correct wheel balance install the balance weight firmly on the wheel Clamp on the balance weight firmly using pliers NOTE Balance weights are available from Kawasaki Dealers in 10 20 and 30 gram sizes An imbalance of less than 10 grams will not usually after running stability not use four or more balance weight more than 90 9 If the wheel requires an excess balance weight remove and disassemble the wheel to find the cause FINAL DRIVE 9 1 Final Drive Table of Contents Exploded a san sya 92 Service Data 92 Drive Chain 93 Chain Slack Inspection 93 Chain Slack Adjustment a ee 93 Wear Inspoction s sav on severe essi weiss Chain Guide Wear Lubrication Drive Chain Removal 93 Engine Sprocket sur e meras cle enis muelle ep Refer to Base Manual 9 2 FINAL DRIVE Exploded View L Non permanent Locki
77. that each cotter pin is in place and in good condition NOTE For the engine fasteners check the tightness of them when the engine is cold at room temperature If there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the basic torque table see Torque and Locking Agent in the General Information chapter For each fastener first loosen it by turn then tighten it If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Front Axle Nut Front Axle Nut Cotter Pin Rear Axle Nut Rear Axle Nut Cotter Pin Brakes Front Master Cylinder Clamp Bolts Front Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Bracket Bolts Rear Caliper Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Suspension Front Fork Clamp Bolts and Nuts Rear Shock Absorber Mounting Bolts and Nuts Swing Arm Pivot Shaft Nut Uni trak Rocker Arm Pivot Nut Uni trak Tie rod Bolts and Nuts Steering Stem Head Nut Handlebar Clamp Bolts Engi Engine Mounting Bolts and Nuts Cylinder Head Bolts Cylinder Head Nuts Exhaust Pipe Holder Nuts Exhaust Pipe Mounting Bolt Muffler Mounting Bolts and Nuts Exhaust Pipe and Muffler Connecting Clamp Bolt Radiator Mounting Bolts Shift Pedal Bolt
78. the battery vent hose routing BR W w 4 W two gt 1 4 EN el gt E el pL m EM SES h o Hu gt H 3 z T Y E 1 n 1 Charging Coils Magneto 4 Fuse 20A 2 Regulator Rectifier 5 Battery 3 Ignition Switch 6 Loads Measuring Stator Coil Resistance Refer to the Base Manual noting the following Meter Connections Lead location Female magneto connector disconnected Meter range x12 One meter load One yellow lead Another meter lead Other yellow lead Meter Reading 03 102 Regulator Rectifier Inspection R el lectifier Circuit Test Remove the regulator rectifier A Regulator Rectifier 14 6 ELECTRICAL SYSTEM Zero the ohmmeter and connect it to the regulator rectifier terminals Check the resistance between the terminals following the table XThe resistance should be low in one direction and more than ten times as much in the other direction If any two leads are low or high in both directions the rectifier is defective and must be replaced NOTE OThe actual meter reading varies with the meter used and the individual rectifier but generally speaking the lower reading should be from zero to the first of the scale Regulator Rectifier Terminal B Battery Terminal Monitor Terminal G Ground Terminal
79. uel Tap Vacuum Hose White Liquid Vapor Separator Breather Hose Blue lose Canister To Canister Air Cleaner Drain Hose A3 y 10 Air Cleaner 9 29 I FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded View 22 Service Data 24 Special Tool T Fuel Tank 2 5 Removal Point 25 Carburetor 25 Adjustment 25 Idle Inspection Idle Adjustment High Altitude Performance Adjustment U S model 25 Maintenance Service Fuel Level Inspection Service Fuel Level Adjustment zj Carburetor Disassembly 25 Disassembly Points Assembly Points Carburetor Installation 25 Adjustment After Installation 25 Air Cleaner 25 Element Removal y Inspection and Cleaning Element Installation Points 25 Body Removal Body Installation Point 26 Fuel System Cleanliness 26 Inspection amp Cleaning k Fuel Tank and Cap Inspection 5 26 Evaporative Emission Control System Californian Model Periodic Inspection Canister Inspection s Liquid Vapor Separator Inspection 2 Separator Test Fuel Tank Inspection Refer to Base Manual FUEL SYSTEM 2 3 24 FUEL SYSTEM Specifications Iz Item KL500 A1 A2 KLE50 A1 A2 KL650 A3 Carburetor Idle speed 1300 100 r min rpm lt Standard specifications Make type Kei
80. w speed tools equipped if necessary with an appropriate dust extraction facility If high speed tools are used they should always be so equipped elf possible dampen before cutting or drilling eDampen dust and place it in properly closed receptacle and dispose of it safely Foreword This KLR650 500 Service Manual Supple ment is designed to be used in conjunction with the KLR600 Service Manual P N 99924 1050 01 The maintenance and repair procedures described in this Supplement are only those that are unique to the KLR650 500 Most service operations are identical to those for the KLR600 Complete and proper servicing of the KLR650 500 therefore requires both this Supplement and the base Service Manual This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechan ics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily Whenever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thoroughly familiarize yourself with the pro cedures b

Kawasaki KLR500,650 87-04 Supplementary Service Manual ENG

Contents

Download Pdf Manuals

Related Search

Related Contents