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Kawasaki ZX400-H2 User's Manual

1. 8 9 Crankshaft Removal denken nnne 8 9 Crankshaft Installation mc 8 9 Connecting Rod 0 8 10 Connecting Rod 8 10 Connecting Rod Big End Bearing Insert Crankpin Wear 8 10 Crankshaft Main Bearing Journal 8 12 Crankshaft Side Clearance 8 13 Transmission 8 14 Shift Pedal Removal 8 14 Shift Pedal Installation 8 14 External Shift Mechanism Removal NOR 8 14 External Shift Mechanism Installation 8 14 Transmission Shaft Removal 8 14 Transmission Shaft Installation 8 15 Transmission Disassembly EEEE M 8 15 Transmission Assembly 8 15 Shift Drum and Fork Remowval eee 8 17 Shift Drum and Fork Installation C 8 17 Shift Drum Disassembly R 8 17 Shift Drum Assembly ndn 8 17 8 2 CRANKSHAFT TRANSMISSION Exploded View Upper Case
2. NC de Ru k M A gt Stir 1 Pr 4 8 m 0 9 ply gre 78 in Ib 15 8 ELECTRICAL SYSTEM Specifications Battery Type Specific gravity 12V 10 Ah 1 280 20 C 68 F Alternator Charging voltage Output voltage Stator coil resistance 14 5 V Night 4 000 r min rpm No less than 43 V 4 000 r min rpm 0 2 0 9 Q Ignition System Pickup coil resistance Ignition coil 3 needle arcing distance Primary winding resistance Secondary winding resistance Spark plug gap Starter Motor Carbon brush length Commutator groove depth Commutator diameter 355 535 Q 7 mm or more 2 3 3 5 Q 12 18 kQ 0 7 0 8 mm 7 mm 0 45 0 75 mm 24 mm Fuel Pump Fuel pump pressure 11 16 kPa 0 11 0 16 kg cm 1 6 2 3 psi Switches and Sensors Rear brake light switch Fan Switch OFF gt ON ON OFF Water temperature sensor resistance ON after about 10 mm pedal travel 93 103 C 199 217 F 91 95 196 203 F 80 C 175 F 47 570 100 C 212 F 25 300 ELECTRICAL SYSTEM 15 9 Special Tools Hand Tester 57001 983 Flywheel Holder 57001 1313 57001 1216 Sealant Kawasaki Bond Silicone Sealant 56019 120 ack 57001 1238 I 1 S
3. 7 SO innere kes EELEE 9 2 WHEELS TIRES Exploded View T1 11 N m 11 0 kg m 80 ft Ib G Apply grease WHEELS TIRES 9 3 Specifications Wheels Rim runout with tire installed Axial Radial Axle runout 100 mm Under 0 05 mm Tires Air pressure when cold Front 225 kPa 2 25 kg cm 32 psi Rear 250 kPa 2 50 kg cm 36 psi Tread Depth Front 4 0 mm 1 mm 2 mm Up to 130 km h 3 mm Over 130 km h Rear 6 0 mm 120 60 VR17 TUBELESS DUNLOP K510F BRIDGESTONE CYROX 17 160 60 VR17 TUBELESS DUNLOP K510 BRIDGESTONE CYROX 16 Standard tire Front Size Type Make Rear Size Type Make 9 4 WHEELS TIRES Special Tools Bearing Driver Set 57001 1129 Bearing Remover Head 015 x 17 57001 1267 lt Jack 57001 1238 Bearing Remover Head 20 x 22 57001 1293 Inside Circlip Pliers 57001 143 Rim Protector 57001 1063 Bearing Remover Shaft 57001 1265 Wheels Rims Front Wheel Removal Remove the following Lower Fairings see Frame chapter Speedometer Cable Lower End Right and Left Brake Calipers A Caliper Mounting Bolts B Speedometer Cable Lower End Right Side Axle Clamp Bolts Loosen Axle Loosen A Axle Using the jack special tool and a stand raise the front wheel off the ground
4. 8 n 6 10 Oil Cooler 6 10 6 10 Installation 6 10 Oil Pressure Measurement Oil Pressure Measurement 202020000000 eee 6 11 6 2 ENGINE LUBRICATION SYSTEM Exploded View N 3 QD lt T1 1 5 N m 0 15 kg m 13 in b T2 4 4 N m 0 45 kg m 39 in Ib T3 9 8 N m 1 0 kg m 7 0 ft Ib T4 12 N m 1 2 kg m 8 5 ft Ib T5 15 N m 1 5 kg m 11 0 ft lb T6 17 N m 1 75 kg m 12 5 ft Ib 17 20 N m 2 0 kg m 14 5 ft Ib T8 29 3 0 kg m 22 ft lb L Apply a non permanent locking agent to the threads SS Apply silicone sealant to the threads UBRICAT ON Y TM 6 3 6 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart pe Q gt GQ N Oil Pump Filter Oil Pump Oil Filter Oil Passage Oil Pressure Switch Releif Valve Oil Hose Camshaft Bracket Camshaft Rocker Arm Oil Return Passage Oil Pipe to Mission Pipe to Output Shaft Output Shaft Drive Shaft Crankshaft Water Pump Oil Pan Oil Drain Plug Oil Return Hose Breather Plate Breather Hose Oil Cooler Oil Cooler Hose Bypass Hole ENGINE LUBRICATION SYSTEM 6 5 6 6 ENGINE LUBRICATION SYSTEM Specifications Engine Oil Grade SE or SF class Vis
5. Units of Force Units of Length A Units of Torque Units of Speed Units of Power Units of Temperature APPENDIX 16 1 16 2 16 2 16 2 16 3 16 4 16 5 16 7 16 7 16 8 16 8 16 8 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 9 16 2 APPENDIX Additional Considerations for Racing This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only However some may wish to subject this motorcycle to abnormal operation such as would be experienced under racing conditions KAWASAKI STRONGLY RECOMMENDS THAT ALL RIDERS RIDE SAFELY AND OBEY ALL LAWS AND REGULATIONS CONCERNING THEIR MOTORCYCLE AND ITS OPERATION Racing should be done under supervised conditions and recognized sanctioning bodies should be contacted for further details For those who desire to participate in competitive racing or related use the following technical information may prove useful However please note the following important notes You are entirely responsible for the use of your motorcycle under abnormal conditions such as racing and Kawasaki shall not be liable for any damages which might arise from such use Kawasaki s Limited Motorcycle Warranty and Limited Emission Control Systems Warranty specifically exclude motorc
6. Disassembiy Assembly Rear Shock Absorber Rebound Damping Force Adjustment Spring Preload Adjustment REMOVAL HR Disassembly Scrapping SUVITIG ATINI Lu uu Removal Swing Arm Sleeve Inspection Tie Rod Rocker Tie Rod Needle Bearing Inspection Tie Rod Rocker Arm Sleeve Inspection SUSPENSION 12 1 12 2 12 4 12 5 12 6 12 6 12 6 12 6 12 8 12 8 12 8 12 10 12 11 12 11 12 11 12 11 12 12 12 12 12 12 12 13 12 13 12 13 12 13 12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 2 SUSPENSION Exploded View 9 y L A hos ww 00000 E a s a 1 ii M e t m JAM arta iret w Ww 1 8 T1 15 N m 1 5 kg m T2 20 N m 2 0 kg m T3 23 N m 2 3 kg m T4 39 N m 4 0 kg m T5 49 N m 5 0 kg m T6 88 N m 9 0 kg m 11 0 ft Ib 14 5 ft lb 16 5 ft Ib 29 ft Ib 36 ft Ib 65 ft Ib
7. E w Pa gy IU Fc E j ill i 2 i L A Radiator B Filler Neck OFill the reservoir tank up to the upper level line with coolant NOTE O Pour in the coolant slowly so that it can expel the air from the engine and radiator Soft or distilled vvater must be used with the antifreeze see Specifications in this chapter in the cooling system If hard water is used in the system it causes scales accumulation in the water passages and considerably reduces the efficiency of the cooling system Water and Coolant Mixture Ratio Recommended Soft Water i 50 Coolant 50 Freezing Point 35 31 F Total Amount 2 3 L NOTE OChoose a suitable mixture ratio by referring to the coolant manufacturer s directions O Start the engine with the radiator cap removed and run it until no more air bubbles can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside O Stop the engine and add coolant up to the radiator filler neck e Install the radiator cap e Fill the reservoir tank up to the upper level line with coolant and install the cap Do not add more coolant above the upper level line Pressure Testing e Remove the radiator cap and install a cooling system pressure tester on the radiator filler neck NOTE O Wet the cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system ca
8. 8 8 N m 0 9 kg m 78 in Ib 9 8 N m 1 0 kg m 7 0 ft ib 12 N m 1 2 kg m 8 5 ft lb 15 N m 1 5 kg m 11 0 ft Ib 20 2 0 kg m 14 5 ft lb 25 N m 2 6 kg m 19 ft Ib 27 N m 2 8 kg m 20 ft Ib Apply grease Apply high temperature grease Apply liquid gasket black Kawasaki Bond 92104 1003 to the mating surface of the right and left crankcase halves Apply a non permanent locking agent to the threads Apply silicone sealant Kawasaki Bond 56019 120 to the gaskets and the threads Apply a thin coat of a molybdenum disulfide grease CRANK HAFT TRANSM SS 8 3 8 4 CRANKSHAFT TRANSMISSION Specifications sunan _ Crankshaft Connecting Rods Connecting rod big end side clearance Connecting rod big end bearing insert crankpin clearance Crankpin diameter 0 13 038mm 71 0 60 mm 0 031 0 059 mm 29 984 30 000 mm 0 10mm 29 97 mm Marking None 29 984 29 994 mm O 29 995 30 000 mm Connecting rod big end bore diameter 33 000 33 016 mm Marking None 33 000 33 008 mm O 33 009 33 016 mm Connecting rod big end bearing insert thickness Blue 1 480 1 485 mm Black 1 485 1 490 mm Brown 1 490 1 494 mm Connecting rod big end bearing insert selection Con Rod Big End Crankpin Diameter Bore Diameter 92028 1492 92028 1494 Cranksha
9. 4 16 Cylinder Head Cover 4 8 Valve Guide Installation 4 16 GAO VAL e aces 4 8 Valve Seat Outside Diameter 4 17 Installation 2 4 8 Valve Seat Width Inspection 4 17 Camshaft Chain Tensioner 4 9 Valve Seat Repair Valve Lapping 4 17 Removai E 4 9 Measure Valve to Guide Clearance Installation 4 9 Wobble Method 4 19 Camshalt ERNEUT 4 10 Cylinder Pistons usi 4 20 Camshaft Removal 4 10 Cylinder Removal 4 20 Camshaft Installation 4 14 Cylinder Installation 4 20 Camshaft Camshaft Cap Wear 4 12 Piston Removal P 4 21 Camshaft Chain 4 12 Piston installation 4 21 Rocker Arm Rocker Shaft 4 13 Cylinder Wear m 4 21 Rocker Arm and Rocker Shaft Removal 4 13 Piston Wear 4 22 Rocker Arm and Rocker Shaft Piston Ring Piston Ring Groove W
10. gums 6 E N VN N N N N LF 7 IN rate a F t m 1 ff gd E N N Coolant x Im N Reservoir Tank y lt T Tar y n p N P 11 ten _ 3 a A 4 Pe HM w f I x Sf I gt X E m ET LM np To Carburetor lt M Pull the hoses down out of the lower fairing 5 Coolant Reservoir Hose 6 Oil Cooler Pipe 7 Fuel Hose from Fuel Pump to Carburetor 1 14 GENERAL INFORMATION View Looking at Front wen j EC Left Turn Siganl Light Right Turn Signal Light f f 3 S EZ Ciamp Clamp 2 Des Ie 3 1 Main Harness 6 Battery Lead 2 To Right Grip Switch 7 Ground Lead 3 To Left Grip Switch 8 To Ignition Coil 1 4 4 To Water Temperature Sensor 9 To Ignition Coil 2 3 5 Starter Motor lead Run the alternator lead D under the main harness 10 To Oil Pressure Switch Neutral Switch and Side Stand Switch 11 Alternator Lead 12 Battery Lead 13 Rear Harness GENERAL INFORMATION 1 15 Run the lead over the fairing stay _ Steering Stem lt Under Bracket Clamp 2 gt gt my Clamp os BR Run the harness through between the fairing inner cover and
11. tm E tch Cable A Release Lever C Clu B 80 90 X If the clutch cannot be adjusted by this method inspect the clutch parts Tighten the knurled locknut at the clutch lever NOTE O sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement After the adjustment is made start the engine and check that the clutch does not slip and that it releases properly Clutch Release Lever Removal CAUTION ne Do not remove the clutch release shaft unless it is absolutely necessary If removed you must replace the oil seal with a new one Place a suitable container under the clutch cover Remove the clutch cover see this chapter Turn the release lever counter clockwise and then pull out the release lever with its shaft Clutch Release Lever Installation Notes Visually inspect the oil seal and replace it if necessary e Install the release lever and turn it clockwise until it stops CLUTCH 5 5 Clutch Cover Removal Drain the engine oil see Engine Oil Change in Engine Lubrication System chapter Remove the lower fairing see Lower Fairing Removal in Frame chapter Remove the inner cover e Remove the clutch cable lower and from the clutch cover Remove the clutch cover bolts and take off
12. AWARNING The ignition system produces extremely high voltage Do not touch the spark plugs ignition coils or spark plug leads while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent IC igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and IC igniter Pickup Coil Removal e Remove the pickup coil cover see Engine Top End chapter e Remove the Allen boit A Allen Bolt Installation Tighten the Allen bolt to the specified torque see Exploded View e nstal the pickup coil cover see Engine Top End chapter Pickup Coil Inspection Disconnect the pickup coil connector Zero an ohmmeter and connect it to the pickup coil leads there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Pickup Coil Resistance x 100 Q 355 535 BK Y Lead Using the highest resistance range of the ohmmeter measure the resistance between the pickup coil leads and chassis ground Any meter reading less than infinity 00 indicates short necessitating replacement of the pickup coll assembly Ignition Coil Removal Remove surg
13. 1 Gear 2 Shaft Do not apply grease to the steel balls to hold them in place This will cause the positive neutral finder mechanism to malfunction Replace any circlip that were removed with new ones e Install the circlips so that the opening is aligned with a spline groove e install the toothed washers so that the teeth are not aligned with the circlip opening L 3 Groov 1 Circlip 2 Toothed Washer 8 16 CRANKSHAFT TRANSMISSION 2nd 6th 4th 3rd Sth Tst 9 ie FS pA ek 10 T T 2 aar oO at Sea aaa Kota Er n CRANKSHAFT TRANSMISSION 8 17 Shift Drum and Fork Removal Shift Drum Disassembly Remove the following Remove the shift drum see this chapter Lower Crankcase Half see Crankcase Splitting e While holding the shift drum with a vise remove the External Shift Mechanism see this chapter shift drum cam bolt Shift Drum Bearing Retainer Bolt Shift Drum Assembly Align the hole of the shift drum cam with the dowel pin A Shift Drum Bearing Retainer Bolt e Pull out the shift rods and take off the shift forks e Pull out the shift drum 1 Shift Drum 3 Dowel Pin 2 Shift Drum Cam 4 Cam Mounting Bolt Shift Drum and Fork Installation e There are three types of the shift forks The smaller shift fork is for the drive shaft gear Other two are for output shaft gears
14. A Alternator Cover Bolt Remove the alternator cover Alternator Cover Installation e Replace the gasket with a new one Run the stator lead as shown Apply silicone sealant to the stator lead grommet 1 Apply silicone sealant Apply silicone to the crankcase halves mating surface on the front and rear sides of the cover mount 15 12 ELECTRICAL SYSTEM 1 x mom dd A Silicone Sealant Applied Area Apply silicone sealant to the left inner cover bolt 1 Left Inner Cover 2 Apply a non permanent locking agent Alternator Rotor Removal e Place the jack special tool under the frame to steady the motorcycle Place a suitable container under the alternator cover Remove the alternator cover Wipe oil off the outer circumference of the rotor Hold the alternator rotor steady with the flywheel holder special tool and remove the rotor bolt A Flywheel Holder 57001 1313 Rotor Bolt B Rotor Threads the rotor puller special tool and the rotor puller special tool onto the alternator rotor e Holding the rotor puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft A Rotor Puller 57001 1216 B Rotor Puller 57001 1277 If the rotor is difficult to remove turn the puller while tapping the end of the puller covered with the cap Do not attempt to strike the alternator rotor itself Striking the rotor can cause
15. If any crankpin has worn past the service limit replace the crankshaft with a new one If the measured crankpin diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankpin Diameter Marks None 29 984 29 994 mm Or 29 995 30 000 mm A Crankpin Diameter Marks O mark or no mark e Measure the connecting rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter NOTE O Tighten the nuts to the specified torque see Exploded View O The mark already on the big end should almost coincide with the measurement Connecting Rod Big End Inside Diameter Marks None 33 000 33 008 mm O 33 009 33 016 mm CRANKSHAFT TRANSMISSION 8 11 J 2 P d a 5 w 1 QS VLL IL _ Q 1 Big End Cap 2 Connecting Rod 3 Diameter Mark O mark or no mark Select the proper bearing insert in accordance with the combination of the connecting rod and crankshaft coding Big End Bearing Insert Selection Con Rod Big End Bore Dia meter Marking 1 Bearing Insert 2 Color Size Mark Install the new inserts the connecting rod and check insert crankpin clearance with the plastigage e Apply molybdenum disulfide grease to the upper inner surface of the connecting rod big end between the connecti
16. L Lic a E E E Td u er ut C 2 1 5 ee IT RN m 2 Pa US 10 Pin B Pin Connector Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc any wiring is poor replace the damaged wiring e Pull each connector apart and inspect it for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem O Connect an ohmmeter between the ends of the leads O Set the meter to the 1 Q range and read the meter kif the meter does not read the lead is defective Replace the lead or the wiring loom if necessary Appendix Table of Contents Additional Considerations for Racing Carburetor Spark Plug Spark Plug Inspection Troubleshooting Guide 99284a49 99 925 9 9 amp Lubrication Nut Bolt and Fastener Tightness Tightness Inspection Standard Torque Table Unit Conversion Table Units Of Mass Units of Volume
17. Measuring Valves 1 Exhaust Valves 3 Cylinder Numbers 2 Inlet Valves Valve Clearance between Cam and Rocker Arm Standard Inlet 0 12 0 17 mm Exhaust 0 16 0 21 mm 4 16 ENGINE TOP END Apply engine oil to the O ring install the spark plug retainer the valve clearance is not within the specified range first record the clearance and then adjust it To change the valve clearance replace the shim with one of a different thickness NOTE OMark and record shim locations so they can be reinstalled in their original positions To select a new shim which brings the valve clearance within the specified range O Remeasure any valve clearance that was adjusted Readjust if necessary Valve Removal Perform the following O Using the valve spring compressor assembly special tool remove the valve A Valve Spring Compressor Assembly 57001 241 B Adapter 57001 1272 C Valve Spring Compressor Joint 57001 1271 Valve Installation e Replace the oi seal with a new one Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation e install the springs so that the closed coil end faces downwards 1 Split Keeper 2 Retainer 3 Valve Spring 4 Closed Coil End 5 Spring Seat 6 Oil Seal 7 Valve Stem Valve Guide Removal e Using the valve guide arbor special tool tap out the valve guide 1 Valve Guide Arbor 57001 1273
18. Standard Service Limit 4 22 ENGINE TOP END Piston Wear Measure the piston outside diameter 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin Piston Outside Diameter 56 942 56 957 mm 56 79 mm Standard Service Limit Piston Diameter Measurement 1 Piston Outside Diameter 2 5mm up from bottom Piston Ring Piston Ring Groove Wear Check for uneven groove wear by inspecting the ring seats The rings should fit perfectly parallel to the groove surfaces If not the piston must be replaced With the piston rings in their grooves make several measurements with a thickness gauge to determine piston ring groove clearance Piston Ring Groove Clearance 0 03 0 07 mm 0 17 mm Standard Service Limit 1 Thickness Gauge Piston Ring End Gap Place the piston ring inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Service Limit Top 0 20 0 40 mm 0 7 mm Second 0 35 0 50 mm 0 8 mm 1 Gap 2 Piston Ring Carburetor Holders Removal Remove the following Clamps Allen Bolts Remove the inlet pipes RE ET A Carburetor Holders B Inlet Pipes e Take off the holders from the inlet pipes Installation Install the carbu
19. Too short Correct reach Carbon builds up there APPENDIX 16 3 Normal Operation Overheating Standard Spark Plug Threads Diameter 10 mm Pitch 1 0 mm Reach 19 mm NOTE OThe heat range of the spark plug functions like a thermostat for the engine Using the wrong type of spark plug can make the engine run too hot resulting in engine damage or too cold with poor performance misfiring and stalling 16 4 APPENDIX Troubleshooting Guide NOTE O This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter lockout or neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn Over Starter motor clutch trouble Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure No fuel flow Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level in carburetor float bowl too high Float va
20. e Push down the front part of the seat until the lock clicks Rear Seat Removal Insert the ignition switch key into the seat lock e Turn the key to the right and pull up on the front of the seat and pull it forward 14 6 FRAME Side Covers Side Cover Removal Remove the following Front Seat Rear Seat Seat Pad Left and Right Cover Clamp Screws Side Cover Mounting Screws A Mounting Screws B Seat Pad C Left and Right Cover Clamp Screws Spread the front part of side covers of the both sides and move the side covers backward Fairings Upper Fairing Removal e Remove the following in the order listed Rear View Mirror Nuts Upper Fairing Mounting Bolts and Screws Air Duct Clamps Loosen Turn Signal Connectors k A Rear View Mirror Nuts C Fairing Mounting Screws B Fairing Mounting Bolts D Air Duct Clamps Be careful not to scratch the painted surface during removal or installation Lower Fairing Removal Remove the following Lower Fairing Mounting Bolts Upper Fairing Mounting Screws A Mounting Bolts B Mounting Screws C Clamp Bolts Do not remove FRAME 14 7 NOTE O Remove the lower fairings as assembly ELECTRICAL SYSTEM 15 1 Electrical System Precautions Wiring Diagram ZX400 H2 m Parts Location Exploded View DIST SU
21. spring Preload Adjustment Remove the shock absorber from the frame see this chapter Loosen the locknut and turn out the adjusting nut to free the spring using stem nut wrenches special tools 57001 1100 Measure the spring free length e Turn in the adjusting nut to the desired position and tighten the locknut Spring Preload Setting Standard Usable Range Spring free length minus 12 mm Spring free length minus 12 to 24 mm weaker to stronger SUSPENSION 12 11 3 Adjusting Nut 4 Spring 1 Spring Length 2 Locknut if the spring action feels too soft or too stiff adjust it as in the front spring preload adjustment section of this chapter Removal e Remove the following Seats Side Cover Assembly Rear Brake Reservoir Bracket Shock Absorber Reservoir Clamps loosen Rear Fender Upper Mounting Bolts Nuts e Remove the shock absorber reservoir from the bracket then pull it forward between the rear frame and the rear fender e Remove the following Lower Fairings see Frame chapter Tie Rod Bolts Nut lower Rear Shock Absorber Mounting Nut upper and lower do not remove the as yet 12 12 SUSPENSION F 1 Banjo Bolt A Rear Shock Absorber Mounting Bolt Nut upper Scrapping AWARNING Since the rear shock absorber contains nitrogen gas do not incinerate the rear shock absorber without first releasing the gas or it may explode Before a rear
22. 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 Refer to the sectional table of contents for the exact pages to locate the specific topic required Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation x Crankshaft Transmission EB Electrical System Appendix GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing 1 Model Identification 1 General Specifications 1 Periodic Maintenance Chart 1 Torque and Locking Agent Cable Wire and Hose Routing 1 1 1 2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine or other parts will work as an a
23. with 45 cutter Ground volume x by 32 cutter AN A i h N i 4 Ground volume o by 60 cutter A 60 x Y OAfter making the 32 grind return to the seat O D measurement step above To measure the seat width use a vernier caliper to measure the width of the 45 angle portion of the seat at several places around the seat xk if the seat width is too narrow repeat the 45 grind until the seat O D measurement step above kif the seat width is too wide make the 60 grind described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width measurement step above the valve to the seat once the seat width and O D are within the ranges specified above O Put a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding compound produces a smooth matched surface on both the seat and the valve O Repeat the process with a fine grinding compound e The seating area should be marked about the middle of the valve face If the seat area is not in the right place the valve check to be sure the valve is the corre
24. 4 Supply Port 10 Dust Cover 5 Cylinder 11 Brake Lever 6 Return Spring Brake Discs Installation e Install the brake disc on the wheel so that the rotation mark aligns with the tire rotation 1 Rotation Mark 2 Rotation Direction e Tighten the disc mounting bolts to the specified torque see Exploded View Wear Replace the disc if the sliding surfaces have worn past the service limit Front Disc Thickness 4 3 4 6 mm 4 0 mm Standard Service Limit Rear Disc Thickness 5 8 6 1 mm 5 0 mm Standard Service Limit Warp e Jack up the motorcycle so that the wheel is off the ground see Wheels Tires chapter and Final Drive chapter For front disc inspection turn the handlebar fully to one side e Set up dial gauge against the disc as shown and measure disc runout runout exceeds the service limit replace the disc 1 Brake Disc 2 Turn the wheel by hand Disc Runout Standard Under 0 2 mm Service Limit 0 3 mm BRAKES 11 15 Suspension Table of Contents Exploded View Specifications Special Tools FIOnEFOIK u uu lQ Rebound Damping Force Adjustment Spring Preload Adjustment Fork Oil Change Removal Installation
25. A Clutch Housing Finger Friction Plate Tang Clutch Hub Spline Inspection e Visually inspect where the teeth on the steel plates wear against the splines of the clutch hub there are notches worn into the splines replace the clutch hub Also replace the steel piates if their teeth are damage ENGINE LUBRICATION SYSTEM 6 1 Engine Lubrication System Table of Contents Exploded View 0 6 2 Engine Oil Flow Chart 6 4 Specifications seeiememeemeees 6 6 Special Tools 6 6 6 6 Engine Oil and Oil Filter ens 6 7 Oil Level Inspection fff 6 7 Engine Oil Change 6 7 Oil Filter Change teen 6 7 Oil Pan E 6 8 Removal 4 eee 6 8 Installation eee 6 8 Relief Valve Oil Pump Filter ws 6 9 Removal 6 9 Installation ene LLL 6 9 Oil Pump 6 9 Removal cccccccoseccececdecceessseees 6 9 installation I RR 6 9 Oil Hose 6 10 Removal enne 8 10 Installation
26. N X 0 1020 kg N X 0 2248 Ib kg X 9 807 N kg x 2 205 Ib Units of Temperature 9 C 40 g 5 F 4 32 68 104 40 20 0 APPENDIX 16 9 Units of Length km X 0 6214 mile m x 3 281 ft mm x 0 03937 in Units of Torque N m x 0 1020 kg m N m X 0 7376 ft lb N m x 8 851 in Ib kg m X 9 807 N m kg m X 7 233 ft lb kg m x 86 80 in Ib Units of Pressure kPa X 0 01020 kg cm kPa x 0 1450 psi kPa X 0 7501 cm Hg kg cm x 98 07 _ kPa kg cm x 14 22 psi cm Hg x 1 933 kPa Units of Speed km h X 0 6214 mph Units of Power kW X 1 360 PS kW X 1 341 HP PS X 0 7355 kW PS X 0 9863 HP 5 F 40 x SC F 40 _ 40 C 9 F 176 212 248 284 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
27. NOTE O Heat the area around the valve guide to 120 150 C 248 302 F Valve Guide Installation e Using the valve guide arbor special tool drive the valve guide until its flange touches the cylinder head NOTE O Heat the area around the valve guide hole to 120 150 C 248 302 F OApply to the valve guide outer surface before valve guide installation e Using the valve guide reamer special tool ream the valve guide A d _ 1 Valve Guide Reamer 57001 1274 Valve Seat Outside Diameter lf the outside diameter of the seating pattern on the valve seat is too large or too small repair the valve seat Valve Seat Outside Diameter 21 5 21 7 mm 18 5 18 7 mm Standard Inlet Exhaust Valve Seat Width Inspection Check the valve seat width O Measure the seat width of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper 1 Valve 2 Valve Seat 3 Seating Surface Outside Diameter 4 Valve Seat Width Valve Seat Width IN and EX Standard 0 5 1 0 mm If the valve seat width is not within the specified range repair the valve seat ENGINE TOP END 4 17 2 Too wide 4 Uneven 3 Too narrow Valve Seat Repair Valve Lapping e Using the valve seat cutters special tools repair the valve seat Valve Seat Cutters Inlet Valves 45 024 5 57001 1113 32 025 57001 1118
28. Starter Motor Removal Starter Motor Installation Starter Motor Disassembly Starter Motor Assembly Note 15 2 15 3 15 4 15 5 15 8 15 9 15 9 15 10 15 10 15 10 15 10 15 10 15 11 15 11 15 11 15 12 15 12 15 13 15 13 15 13 15 14 15 15 15 16 15 16 15 16 15 16 15 16 15 17 15 17 15 17 15 19 15 19 15 19 15 19 15 19 15 20 15 20 15 20 15 20 15 21 Table of Contents Brush Inspection i Commutator Cleaning and Inspection Armature Inspection Brush Lead Inspection Brush Plate and Terminal Bolt Inspection Starter Relay Inspection Lighting System Headlight Beam Horizontal Adjustment Headlight Beam Vertical Adjustment ei Headlight Bulb Replacement Notes Headlight Unit Removal Installation Note Tail Brake Light Bulb Replacement Notes Turn Signal Light Bulb Replacement Note Turn Signal Relay Inspection Radiator Fan System Fan System Circuit Inspection Fan Inspection LR Fan Installation NE Fuel Pump CHAR Removal Installation Fuel Pump Relay I
29. Top Mark B Up Tail Brake Light Bulb Replacement Notes the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base is to the upper right A Pin Closest to Base Insert the socket by aligning the tangs with the catches in the housing so that the triangular mark points left and turn it clockwise A Triangular Mark Turn Signal Light Bulb Replacement Note Be careful not to overtighten the lens mounting screws Turn Signal Relay Inspection Remove the seat Take the turn signal relay out of the bracket A Turn Signal Relay Check the condition or the relay for the following troubles 1 Neither right nor left turn signals come on at all Check that battery voltage is normal e Unplug the relay leads and use an ohmmeter to check that there is continuity close to zero ohms between the relay terminals kif there is no ohmmeter reading or if there is several ohms resistance replace the relay with a new one e Turn the meter to the 25 V DC range connect the meter lead to the brown lead that was disconnected from the relay and connect the meter lead to the orange lead e With the ignition switch on first switch the turn signal switch to the R and then to the L position The meter should register battery voltage at either position kif it does not the fuse ignition switch or wiring is at fault 2 Both right or
30. cylinder Remove the following Carburetor see Fuel System chapter Hose Thermostat Housing Mounting Bolts Water Temperature Sensor Connector e Remove the thermostat housing on the cylinder e Remove the thermostat from the housing B Mounting Bolt A Housing Installation install the thermostat noting the following Install the thermostat so that the stay faces outside Be sure to install the O ring on the housing Add coolant see Coolant Filling Inspection e Remove the thermostat and inspect the thermostat valve at room temperature If the valve is open replace the valve with a new one To check valve opening temperature suspend the thermostat in a container of water and raise the temperature of the water 1 Thermostat 2 Thermometer kif the measurement is out of the specified range replace the thermostat Thermostat Valve Opening Temperature 80 84 C 176 183 F ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded View 4 2 Valve Clearance Adjustment 4 15 Specifications unde 4 4 Valve 4 16 Special TOONS 4 6 Valve Installation cer de 4 16 4 7 Valve Guide Removal a
31. e Install the shift forks as shown noting the rib position Tighten the following to the specified torque see Exploded View Shift Drum Bearing Retainer Bolt Shift Drum Cam Mounting Bolt Apply a non permanent locking agent A Shift Fork clutch side B Shift Fork for drive shaft gear C Shift Fork engine sprocket side W Exploded View Specifications Special Tools Wheels Rims Front Wheel Removal Front Wheel Installation Rear Wheel Removal Rear Wheel Installation Wheel inspection Balance Weight Installation Balance Weight Removal sasssaensadocnusccettusecene sc6 espeneneesqquteteesens w Tire Air Pressure Inspection Tire Inspection Removal Installation Hub Bearings Removal Installation Lubrication Speedometer Gear Housing Disassembly and Assembly Lubrication ezaotcsataaameeanabeereesrneanes b WHEELS TIRES 9 1 heels Tires Table of Contents 100665 7777 74 Fm 402022
32. e Remove the following Lower Fairings see Frame chapter Rocker Arm see Rear Shock Removal Lower and Upper Tie Rod Bolts Hocker Arm B Lower Tie Rad Bolt C Upper Tie Rod Bolt e Remove the tie rods Tie Rod Installation Pack the following bearings with molybdenum disulfide grease Rocker Arm Needle Bearings Tie Rod Needle Bearings eTighten the tie rod upper and lower nuts to the specified torque see Exploded View Rocker Arm Pivot Lubrication Oe Lubricate the rocker arm pivots with mab onun disulfide grease through the grease fitting using a grease gun according to the Periodic Maintenance Chart see General Information chapter and General Lubrication in the Appendix chapter et is normal for a small amount of grease to seep out around the grease seals kif the rocker arm pivots arm pivots are disassembled Lubricate the pivots as follows Wipe all the old grease off the bearings sleeves and grease seals and grease them A Rocker Arm Grease Nipples Rocker Arm Removal The rocker arm is removed during the rear shock removal Refer to Rear Shock Removal in this chapter A Rocker Arm B Bolts Rocker Arm Installation e Installation is the reverse of removal Note the follow ing Apply molybdenum disulfide grease to the inside of the needle bearings Tighten the following nuts to the specified torque see Exploded View Rocker Arm Nuts Shock Absorber Mounting Nut Tie Rod N
33. ing e install a shim thickness 0 5 mm between the lower part of the crankcase and the frame bracket see Exploded View e Supporting the engine first insert the upper bolts and then the lower bolts Tighten the following fasteners to the specified torque see Exploded View Engine Mounting Bolts Engine Bracket Bolts eRun the wires cables and hoses as shown in the Wiring Cables and Hose Routing section of the General Information chapter 9 Adjust the following Throttle Cables see Fuel System chapter Choke Cable see Fuel System chapter Clutch Cable see Clutch chapter Drive Chain see Final Drive chapter e Fill the engine with engine oil see Engine Lubrication System chapter e Fill the engine with coolant and bleed the air from the cooling system see Cooling System chapter Adjust the carburetor synchronization and idling CRANKSHAFT TRANSMISSION 8 1 Crankshaft Transmission Table of Contents Exploded View m 0 2 Specifications buen uarie UD E Vc 8 4 Special Tools nennen nennen nennen 8 6 Sealant O O 8 6 Crankcase CINE 8 7 Crankcase Splitting INN m 8 7 Crankcase Assembly nm Crankshaft Connecting Rods
34. or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfactorily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up immediately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE 1 Hold the brake applied 2 Quickly open and close the valve 3 Release the brake B Bleed Valve A Caliper When air bleeding is finished install the rubber caps on the bleed valve and check that the brake fluid is filled to the upper level line marked in the reservoir handlebar turned so that the reservoir is level BRAKES 11 7 Brake Pedal Brake Pedal Position Adjustment Check that the brake pedal is in the correct position Pedal Position Standard About 43 mm below from center of brake pedal shaft A Footpeg B Brake Pedal NOTE O Usually it is not necessary to adjust the pedal position but always adjust it when the master
35. the yellow paint mark on a new tire e install the tire on the rim using a suitable commercially available tire changer Lubricate the tire beads and rim flanges with a soap and water solution or rubber lubricant to help seat the tire beads in the sealing surfaces of the rim while inflating the tire Center the rim in the tire beads and inflate the tire with compressed air until the tire beads seat in the sealing surfaces AWARNING Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than 400 kPa 4 0 kg cm 57 psi Overinflation can explode the tire with possibility of injury and loss of life Check to see that the rim lines on both sides of the tire sidewalls are parallel with the rim flanges Rim Line if the rim flanges and tire sidewall rim lines are not parallel remove the valve core Lubricate the rim flanges and tire beads Install the valve core and inflate the tire again After the tire beads seat in the rim flanges check for air leaks Inflate the tire slightly above standard inflation Use a soap and water solution or submerge the tire and check for bubbles that would indicate leakage Adjust the air pressure to the specified pressure see Tire Inspection e Install the brake disc s so that the disc rotation mark aligns with the tire rotation see Brake System chapter e Adjust the wheel balance Hub Bearings Removal Rem
36. 035 mm 1 2 050 mm 705 mm 1 125mm 1 395 mm 120 mm 765 mm 163 kg 95 kg 94 kg 16 0 L 13 5 m from 50 km h 3 2 m 4 stroke DOHC 4 cylinder Liquid cooled 57 0 x 39 0 mm 398 mL 12 1 45 6 kW 62 PS 12 500 r min rpm F 44 2 kW PS 12 500 r min rpm UTAC s norm 39 2 N m 4 0 kg m 29 0 ft Ib 10 000 r min rpm Carburetors Keihin CVK D32 x 4 Electric starter Battery and coil transistorized Electronically advanced From 12 5 BTDC 1 200 r min rpm to 45 BTDC 6 000 r min rpm CR9EK or ND U27ETR Left to right 1 2 3 4 1 2 4 3 23 BTDC 65 ABDC 268 57 5 BBDC 27 5 ATDC 265 Forced lubrication wet sump with cooler SE or SF class SAE10W 40 3 0L Gear 2 195 90 41 1 6 GENERAL INFORMATION Items Clutch type Transmission Final drive system Frame Type Caster rake angle Trail Front tire Rear tire Front suspension Rear suspension Brake type Type Gear ratios 1st 2nd 3rd 4th 5th 6th Type Reduction ratio Overall drive ratio Size type Mark Size type Mark Type Wheel travel Type Wheel travel Front Rear Electrical Equipment Battery Headlight Tail brake light Alternator Type Bulb Type Rated output ZX400 H2 Wet multi disc 6 speed constant mesh return shift 2 846 37 13 2 055 37 18 1 631 31 19 1 380 29 21 1 240 31 25 1 111 30 27 Chain drive 3 000
37. 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits if the measurement shows excessive wear or deteriorated performance replace the damaged parts 1 4 GENERAL INFORMATION Model Identification ZX400 H2 Left Side View ZX400 H2 Right Side View GENERAL INFORMATION 1 5 General Specifications Items ZX400 H2 Dimensions Drive Train Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight Front Rear Fuel tank capacity Performance Braking distance Minimum turning radius Engine Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Cylinder numbering method Firing order Valve timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil Grade Viscosity Capacity Primary reduction system Type Reduction ratio 2
38. 20 by unremovable obstructions or irreparably deformed fins replace the radiator with a new one When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun away more than 0 5 m from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun following the core fin direction COOLING SYSTEM 3 9 4 E E m ke 1 Steam Gun Running Direction 1 Pressure Tester 2 Radiator Cap Watching the pressure gauge pump the pressure tester to build up the pressure The cap must open at the relief Radiator Cap Inspection pressure the gauge pointer flicks down Also the cap Check the condition of the top and bottom vaive seals must hold any pressure less than the relief pressure for of the radiator cap at least 6 seconds If any one of them shows visible damage replace the Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kg cm 14 18 psi the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one 1 Bottom Vaive Seal 3 Valve Spring 2 Top Valve Seal e Install the cap on a cooling system pressure tester NOTE O Wet the cap sealing surfaces with water or coolant to prevent pressure leakage 3 10 COOLING SYSTEM Thermostat Removal Remove the fairing and the side cover assembly Drain coolant cylinder head
39. 21 mm Camshaft journal diameter A 23 950 23 972 mm 23 92 mm B 23 900 23 922 mm 23 87 mm Camshaft bearing inside diameter 24 000 24 021 mm 24 08 mm Camshaft runout 0 1 mm TIR Camshaft chain 20 link length 127 0 127 4 mm 128 9 mm Cylinder Head Cylinder compression Usable range 686 1 079 kPa 7 0 11 0 kg cm 99 156 psi 3330 r min rpm Cylinder head warp Valves Valve clearance Inlet Exhaust 0 12 0 17 mm 0 16 0 21 mm Valve spring free length 38 2 mm 36 4 mm Valve head thickness Inlet 0 5 mm 0 25 mm Exhaust 0 7 mm 0 35 mm Valve stem bend 0 02 TIR or under 0 05 mm TIR 45 32 60 Valve seat cutting angle Valve seat surface Width Inlet 0 5 1 0mm Exhaust 0 5 1 0mm Outside diameter Inlet 21 5 21 7 mm Exhaust 18 5 18 7 mm Camshaft Height Measurement ENGINE TOP END 4 5 Seem Valve valve guide clearance wobble method Inlet 0 031 0 140 mm Exhaust 0 085 0 180 mm Valve stem diameter Inlet 3 975 3 990 mm Exhaust 3 955 3 970 mm Valve guide inside diameter 4 000 4 012 mm Cylinder Piston Cylinder inside diameter Piston diameter Piston cylinder clearance Oversize piston and rings Piston ring groove clearance Piston ring end gap 57 000 57 012 mm 56 942 56 957 mm 0 043 0 070 mm 0 5 mm 0 030
40. 60 30 57001 1123 Exhaust Valves 45 22 57001 1205 32 22 57001 1206 60 30 57001 1123 Holder and Bar Holder 57001 1275 Bar 57001 1128 kif the manufacture s instructions are not available use the following procedure Seat Cutter Operating Care 1 This valve seat cutter is developed to grind the valve for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil 4 18 ENGINE TOP END NOTE O Do not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing 1 Cutter 3 Bar 2 Cutter Holder Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following a masi shipas Cutter angle 20 D Outer diameter of cutter 1 Outer Diameter of Cutter 2 Angl
41. Be careful of the direction of the shift drum set lever bolt collar 1 Collar eTighten the shift drum set lever bolt to the specified torque see Exploded View e Install the shift drum set lever spring Transmission Shaft Removal Remove the clutch see Clutch chapter e Remove the engine see Engine Removai Installation chapter e Split the crankcase see this chapter e Remove the drive shaft and output shaft Transmission Shaft Installation Be careful of the following O Apply engine oil to the sliding portion of the gears and bearings O Check to see that the set pins and set rings are in place O Install the drive shaft and output shaft into the upper crankcase half Transmission Disassembly e Remove the transmission shafts e Using the circlip pliers special tool 57001 144 to remove the circlips disassemble the transmission shafts The 5th gear on the output shaft has three steel balls assembled into it for the positive neutral finder mechanism Remove the 5th gear as follows O Set the output shaft in a vertical position holding the 3rd gear OSpin the 5th gear quickly and pull it off upward 1 5th Gear 3 Spin quickly 2 ard Gear Transmission Assembly Install the gear bushings on the shafts with their oil holes aligned with the shaft oil holes 1 Oil Hole 2 Bushing Fit the steel balls into the 5th gear holes as shown CRANKSHAFT TRANSMISSION 8 15 View AA
42. Head TOA Fuse Ignition Switch J Main Fuse 30 High Beam Indicator Light i SON Switch Battery Fan Inspection Fan Installation Remove the following Tighten the fan mounting bolt to the specified toruge Surge Tank see Exploded View in the Cooling System chapter Baffle Plate Disconnect the 2 pin connector in the fan leads A Fan Connector e Using two auxiliary wires supply battery power to the fan lf the fan does not rotate at this time the fan is defective and must be replaced Cooling Fan Circuit 1 Radiator Fan 6 Fan Switch 2 2 pin Connector 7 Radiator 3 Starter Relay 8 Main Fuse 30A 4 Fan Fuse 10A 9 Battery 5 Junction Box x gt 46 a a ELECTRICAL SYSTEM 15 29 Fuel Pump The pump operates when the starter button is pushed on or the engine is running Refer to the Starter Motor section for the Fuel Pump Wiring Diagram When fuel level in the float bowl is low the fuel pump operates to supply fuel into the float bowl When the fuel reaches a certain level the fuel pressure rises and the fuel pump stops A Pump Relay B Fuel Pump Removal Installation Refer to the fuel system chapter Fuel Purnp Relay Inspection e Remove the side cover assembly see Frame chapter and take out the fuel pump relay Set the hand tester special tool 57001 983 to the x 1 kQ range and make the measurements shown in the table
43. Inspection Visually inspect the fuel filter according to the Periodic Maintenance Chart see General Information chapter the filter is clear with no signs of dirt or other contamination it is OK and need not be replaced X if the filter is dark or looks dirty replace it Also check the rest of the fuel system for contamination A Arrow Mark B Blow Fuel Tank Removal Turn the fuel tap to the OFF position to stop the fuel flow A WARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light ee CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capacity is greatly reduced If the canister does become contam inated replace it with a new one e Remove the following Front Seat see Frame chapter Side Cover Assembly Fuel Tank Mounting Bolts Fuel Tap with Fuel Hoses left installed and Fuel Hose to the carburetor removed Air Duct Clamp A Mounting Bolts B Fuel Tap NOTE O take the air ducts out remove the duct pawls from the inside of the fuel tank e Remove the fuel tank FUEL SYSTEM 2 11 Installation e Install the fuel tank hoses COOLING SYSTEM 3 1 Cooling System Table of Contents
44. Oil Plug 2 Right Cil Plug 3 Neutral Switch 4 Return Spring Bolt e Install the set pins and rings 8 8 CRANKSHAFT TRANSMISSION Aa A Set Pin C Passage B Set Rings Apply engine to the transmission gears ball bearings shift drum and crankshaft main bearing inserts e Apply liquid gasket black and silicone sealant as shown in the figure below Liquid Gasket Silver Kawasaki Bond 92014 002 Z Silicone Sealant Kawasaki Bond 56019 120 Apply silicone sealant upon liquid gasket If liquid gasket and silicone sealant adheres to any areas not indicated the engine oil passages may be obstructed causing engine seizure Install the crankshaft shift drum and transmission Set the grip of clamp backward at the crankcase hi A Oil Return Hose Clamp Tighten the crankcase mounting bolts following the tightening sequence to the specified torque see Exploded View O Following the tightening sequence tighten the 8 mm bolts first to about one half of the specified torque and finally to the specified torque OTighten the 6 mm bolts to the specified torque Lower Crankcase 8 x L95 mm C 6 x LAO mm B x 190 mm Upper Crankcase Cl D p 8 x L72 mm E x L95 mm F Q6 x L85 mm G 06 x L65 mm H x L50 mm Apply high temperature grease to the output shaft oil seal lips and press the oil seal in the c
45. Remove the oil pump shaft and pump rotor A Pump Rotor B Pump Shaft Installation Installation is the reverse of removal Note the follow ing When installing the oil pump note the position of the water pump shaft slot and turn the oil pump shaft so that the projection fits into the slot e Tighten the oil pump cover screw to the specified torque see the Exploded view e Replace the pump gear circlip with a new one 6 10 ENGINE LUBRICATION SYSTEM Oil Hose Removal Drain the engine oil Remove the lower fairing see Frame chapter Remove the Allen bolts from the cylinder head and the crankcase e Take out the oil hose A Oil Hose B Allen Bolt Installation e Installation is the reverse of removal e Replace the O rings with new ones if they are damaged eTighten the Allen boits to the specified torque see Exploded View Oil Cooler Removal Remove the following Engine Oil Drain see this chapter Lower Fairings see Frame chapter Muffler see Engine Top chapter Oil Cooler Pipe Fitting Bolts Oil Cooler Mounting Bolts A Fitting Bolts B Mounting Bolts Remove the oil cooler Installation e installation is the reverse of removal Note the follow ing e Replace the O rings with new ones Tighten the oil cooler pipe fitting bolts to the specified torque see Exploded View Oil Pressure Measurement Oil Pressure Measurement NOTE O Mea
46. Specifications Special TOOLS uu a asas m Electrolyte Specific Gravity Inspection Initial Charging Ordinary Charging T Charging System Alternator Cover Removal Alternator Cover Installation Alternator Rotor Removal Alternator Rotor Installation Notes Stator Coil Removal Stator Installation Notes Alternator Inspection Rectifier Inspection Regulator Inspection Regulator Rectifier Output Voltage Inspection Ignition System Pickup Coil Removal LE Installation Pickup Coil Inspection Ignition Coil Removal Ignition Coil Installation Ignition Coil Inspection Spark Plug Remowval m Spark Plug Installation Note Spark Plug Cleaning and Inspection Spark Plug Gap Inspection IC Igniter Inspection oes Electric Starter System
47. Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running O Because of the large amount of current never keep the starter switch pushed when the starter motor will not turn over or the current may burn out the starter motor windings O Do not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly connected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation O Measure coil and winding resistance when the part is cold at room temperature O Electrical Connectors Female Connectors Male Connectors O Color Codes BK BL BR CH Black Blue Brown Chocolate Dark green Green Gray Light blue Light green Orang
48. Switch Horn ienaam a aa a nasser tu z b 1 gt boi GY OK Y Y pt sx Y OF Front Right Turn Signa Light 12 21 front Left Turn Signal Light 42 V 21 15 4 ELECTRICAL SYSTEM Parts Location Ocmon Ooh Wh gt Headlight Unit Meter Unit Starter Motor Tail Brake Light Licence Light Fan Switch Alternator Oil Pressure Switch Neutral Switch Side Stand Switch Turn Signal Light Fuel Pump Water Temperature Sensor Radiator Fan Rear Brake Light Switch Pickup Coil Indicator Light Ignition Switch Front Brake Light Switch Right Grip Switch Starter Lockout Switch Left Grip Switch Ignition Coil 2 3 Ignition Coil 1 4 Spark Plug Battery Junction Box Fuel Pump Relay IC Igniter Regulator Rectifier Starter Relay Turn Signal Relay ELECTRICAL SYSTEM 15 5 Exploded View T1 6 4 N m 0 65 kg m 56 T2 8 3 N m 0 85 kg m 74 in Ib 7 8 8 N m 0 90 kg m 78 in Ib H T4 13 N m 1 3 kg m 113 in Ib T5 25 N m 2 5 kg m 18 ft lb 3 T6 34 N m 3 5 kg m 25 ft ib T7 78 8 0 kg m 58 ft lb see 15 11 L Apply a non permanent locking agent to the threads Apply molybdenum disulfide grease SS Apply silicone sealant 6 CTR CA YTM
49. Switch 7 Ignition Coil 14 Junction Box 1 4 Cylinder 15 Main 30A Fuse De BK TL FBK Y 16 Diodes 17 Battery 18 Side Stand Switch 19 9 pin Connector 20 4 pin Connector 21 Starter Lockout Switch 22 10 pin Connector 23 Neutral Switch Spark Plug Removal e Remove the following Surge Tank see Fuel System chapter Spark Plug Caps Remove the spark plugs with the box wrench in the tool kit P N 92110 1146 or the spark plug wrench special tool 57001 1262 A Spark Plug Wrench 92110 1146 Spark Plug Installation Note Tighten the spark plugs to the specified torque see Exploded View the spark plug leads correctly see Cable Routing section in the General Information chapter Spark Plug Cleaning and Inspection Remove the spark plug and visually inspect Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool If the spark plug electrodes are corrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Inspection Measure the gap with a wire type thickness gauge if the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm ELECTRICAL SYSTEM 15 19 1 Insul
50. T7 110 N m 11 0 kg m 80 ft Ib L Apply molybdenum disulfide grease M Apply a non permanent locking agent to the threads 12 4 SUSPENSION Specifications hm Senar Front Fork Rebound damping setting 6th click from fully counterclockwise position 1 4 turn out position from fully counterclockwise position Spring preload setting Fork oil Viscosity Amount perside when changing oil After disassembly and completely dry Oil level fully compressed without spring Fork spring free length Rear Shock Absorber Rebound damping setting Spring preload setting SAE 5W 355 mL 421 4 mL 94 2 mm below from top of inner tube 311 6 mm No 1 of 4 position Spring free length minus 12 mm Spring free length minus 12 mm to 24 mm Gas pressure 980 kPa 10 kg cm 142 psi Non adjustable SUSPENSION 12 5 Special Tools Steering Stem Nut Wrench 57001 1100 Oil Syringe 57001 1290 Fork Cylinder Holder 57001 1297 Fork Piston Rod Puller M10 x 1 0 57001 1298 Jack 57001 1238 Fork Spring Stopper 57001 1318 Oil Seal amp Bearing Remover 57001 1058 12 6 SUSPENSION Front Fork Rebound Damping Force Adjustment eTo adjust the rebound damping turn the rebound damping adjuster until you feel a click A Rebound Damping Adjuster OThe standard adjuster setting is
51. Tensioner Removal Remove the pickup coil cover e Remove the mounting bolts and take off the camshaft chain tensioner A Camshaft Chain Tensioner C Lock Bolt B Mounting Bolts Pull out the rod from the cam chain guide rear side This is a non return type cam chain tensioner The push rod does not return to its original position once it moves out to take up cam chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Chain Tensioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the cam chain timing and damage the valves Installation Compressing the push rod into the tensioner body and lock it O Remove the lock bolt on the side of the tensioner body O While pushing the taper part of the stopper push the rod ENGINE TOP END 4 9 lt A Taper Part Stopper B Push Rod Compressing the spring against the push rod head insert a thin wire through the hole in the push rod to keep the spring in place A Wire B O ring Apply grease to the O ring Install the top end of a extension rod into a hole of the chain guide A Extension Rod B Chain Guid
52. both left turn signals come on and stay on or flash too slowly Check that battery voltage is normal Check that all wiring connections are good Check that the turn signal bulbs and indicator bulbs are of the correct wattage If all of the above check good replace the relay 3 A single light on one side comes on and stays on Either the light that does not come one is burned out of the incorrect wattage or the wiring is broken or improperly connected 4 Neither light on one side comes Unless both lights for that side are burned out the trouble is with the turn signal switch 5 Flashing rate is too fast If this occurs on both the right and left sides check that the battery is not being overcharged kif the magneto and the battery voltage are normal replace the turn signal relay this occurs on only one side one or both of the turn signal bulbs are of too high a wattage ELECTRICAL SYSTEM 15 27 Radiator Fan System Fan System Circuit Inspection Remove the left lower fairing and disconnect the leads from the radiator fan switch A Fan Switch Terminals Using an auxiliary wire connect the radiator fan switch leads If the fan rotates inspect the fan switch if the fan does not rotate inspect the following Fan Fuse Junction Box Headlight Circuit Leads and Connectors Main Fuse Fan 15 28 ELECTRICAL SYSTEM Headlight Circuit Headlight Switch Junction Box
53. chapter Muffler see Engine Top End Engine Oil Drain see this chapter Oil Pressure Switch Lead Oil Pressure Switch as necessary Oil Pipes A Front C Oil Pressure Switch B Switch Lead Remove the oil pan bolts and take off the oil pan Installation e Installation is the reverse of removal Note the follow ing Apply silicone sealant to the threads of the oil pressure switch and tighten it to the specified torque see Exploded View e Replace the gasket with a new one e Replace the O rings with new ones if they are damaged Tighten the oil pan bolts to the specified torque see Exploded View Relief Valve Oil Pump Filter Removal e Remove the oil pan e Unscrew the oil pressure relief valve from the engine e Pull out the oil pump filter and the oil pipe P d k P C Unround Portion A Relief Valve B Oil Pump Filter Installation Installation is the reverse of removal Note the follow ing O Apply a non permanent locking agent to the thread of the releif valve and tighten it to the specified torque see Exploded View O Replace the oil pipe O ring if it is damaged OWhen installing the oil pump filter note the position of its unround portion ENGINE LUBRICATION SYSTEM 6 9 Oil Pump Removal e Remove the following Clutch see Clutch chapter Circlip Oil Pump Gear Oil Pump Cover B Pump Cover Screw A Pump Cover
54. cylinder is disassembled O f the pedal position cannot be adjusted by turning the clevis the brake pedal may be deformed or incorrectly installed e When the brake pedal is in its rest position measure the length A indicated in the figure if the length A is not within the specified length adjust a nut 3 Clevis 1 Master Cylinder 2 Locknut 11 8 BRAKES Rear Brake Light Switch Adjustment Check the operation of the rear brake light switch by Calipers depressing the brake pedal The brake light should go on after about 10 mm of pedal travel Front Caliper Removal Remove the following Banjo Bolt at the caliper Caliper Mounting Bolts Do not loosen the caliper bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper bolts will cause brake fluid leakage A Brake Pedal If it does not adjust the brake light switch Turn the adjusting nut to adjust the switch A Banjo Bolt C Caliper Mounting Bolts B Caliper Assembly Bolts A Switch Body C Light sooner B Adjusting Nut D Light later Rear Caliper Removal Remove the rear caliper in the same way as the front caliper To avoid damaging the electrical connections inside the switch be sure that the switch body does not turn during adjustment Do not loosen the caliper bolts Take out only the caliper mounting bolts for caliper removal Loosening the caliper bolts will cause brake fluid leak
55. into the notch of cover securely Route the stator coil leads in accordance with the Wire Routing in the General Information chapter Alternator Inspection There are three types of alternator failures short open wire burned out or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging Will result in low output check the alternator output voltage do the following procedures Refer to the appropriate chapters and charging system Wiring Diagram Turn off the ignition switch Disconnect connector 1 Connect the hand tester special tool 57001 983 as shown in table Start the engine Run it at the rpm given in table Note the voltage readings total 3 measurements Alternator NJ CC CENE Voltage Meter werte meet pen pu V One yellow oe lead yellow lead Connector 1 Connector 1 kif the output voltage shows the value in table the alternator operators properly and the regulator rectifier is damaged A much lower reading than that given in the table indicates that the alternator is defective Check the stator coil resistance as follows Stop the engine 15 14 ELECTRICAL SYSTEM Connect the hand tester special tool 57001 983 as shown in table Note the readings total 3 measurement Me
56. linkage resulting in an unsafe riding condition Carburetor Disassembly Assembly AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm Do not force the needle jet holder air bleed pipe and main jet or overtighten them They could be damaged requiring replacement 1 Main Jet 2 Needle Jet Holder If the needle jet is damaged replace the carburetor Carburetor Inspection AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Slide the starter plunger lever right to left to check that the starter plungers move smoothly and return with spring tension If the starter plungers do not work properly replace the carburetors 2 10 FUEL SYSTEM Turn the throttle cable lever to check that the throttle butterfly valves move smoothly and return by spring tension if the throttle valves do not move smoothly Replace the carburetors Check that the O ring
57. piston base special tools install the cylinder block 1 New Valve 3 Move the Valve 2 Valve Guide A Piston Base 57001 147 e Install the cylinder and the chain guide exhaust side as shown 1 Chain Guide Piston Removal Remove the cylinder see this chapter Place a clean cloth under the pistons and remove the piston pin snap rings from the outside of each piston Using the piston pin puller assembly special tool remove the piston pins 1 Piston Pin Puller Assembly 57001 910 2 Adapter Piston Installation The top and second rings must be installed with the R marks on the rings facing up R Mark R Mark 1 Top Ring 2 Second Ring The arrow on the piston head must point toward the front of the engine The piston ring openings must be positioned as shown below The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top rina ENGINE TOP END 4 21 1 Top Ring 2 Second Ring 3 Oil Ring Steel Rails 4 Oil Ring Expander 5 Arrow Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall Cylinder Wear Measure the cylinder inside diameter taking a side to side and a front to back measurement at each of the two positions total of four measurements shown below SK WV Ws Wa Cylinder Inside Diameter 57 000 57 012 mm 57 10 mm
58. specified replace the junction box Fuse Circuit Inspection Ven Rain O 15 36 ELECTRICAL SYSTEM Starter Circuit Remove the junction box see Fuse Removal Check conductivity of the following numbered terminal by connecting the hand tester special tool and one 12 V battery to the junction box as shown the relay does not work as specified replace the junction box Relay Circuit Inspection with the battery disconnected Meter Connection Meter Reading OO OO Relay Circuit Inspection with the battery connected Meter Connection Connection Q Battery Diode Circuit Inspection Remove the junction box from the motorcycle Pull off the connectors from the junction box Check conductivity of the following pair of terminals Terminals for Diode Circuit Inspection 14 12 14 15 14 16 The resistance should be low in one direction and more than ten times as much in the other direction if any diode shows low or high in both directions the diode is defective and the junction box must be replaced NOTE O The actual meter reading varies with the meter used and the individual diodes but generally speaking the lower reading should be from zero to one half the scale ELECTRICAL SYSTEM 15 37 Junction Box Internal Circuit lt lt xT L t3 Eu amp LT af Fi ad S aj z i Jam 1 r mi D
59. the cover CAUTION p gt Do not remove the clutch release shaft for clutch cover removal Clutch release shaft removal damages the oil seal in the clutch cover necessitating the oil seal replacement Clutch Cover Installation Note e Replace the clutch cover gasket with a new one Apply silicone sealant to the mating surface as shown A Silicone Sealant Kawasaki Bond 56019 120 e Clamp the pick up coil wire as shown A Pick up Lead B Clamp Apply a non permanent locking agent tot he following bolts and screw 5 6 CLUTCH Apply a locking agent 1 Clutch Cover 2 Right Inner Cover e Tighten the clutch cover bolts to the specified torque see Exploded View Clutch Removal e Remove the clutch cover Remove the clutch spring bolts retainers and springs then take off then clutch spring plate with the bearing and pusher A Clutch Spring Bolt B Retainer C Bearing E Clutch Spring Plate Remove the friction plates and steel plates as a set Remove the clutch hub nut When loosening the hub nut use the clutch holder special tool to keep the clutch hub from turning as shown B Holder 57001 1243 A Wrench e Remove the thrust washer clutch hub clutch cam washer clutch housing needle bearing collar and spacer Clutch Installation Notes e Clutch installation is the reverse of removal attent
60. the magnets to lose their magnetism Alternator Rotor Installation Notes Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone AWARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Alternator Rotor Cleaning Area 1 The tapered portion of the crankshaft 2 The alternator rotor boit and the threads in the crankshaft 3 The tapered portion of the alternator rotor 4 Chamfer e Install the washer so that the chamfer side faces out e Tighten the alternator rotor bolt to the specified torque see Exploded View while holding the alternator rotor steady with the flywheel holder special tool 57001 1313 A Silicone Sealant Applied Areas Install a new gasket and the alternator cover Tighten the cover bolts to the specified torque see Exploded View Fill the engine with engine oil see Engine Lubrication System chapter Stator Coil Removal Remove the alternator cover see this chapter e Remove the holding plate e Unit the pickup coil lead and stator coil lead grommets out of the notch of cover Unscrew the mounting bolt and take off the stator ELECTRICAL SYSTEM 15 13 A Holding Plate B Grommets Mounting Bolts Stator Stator Installation Notes Fit the stator coil lead grommet first and the pickup coil lead grommet
61. whether or not a spark plug of the correct heat range is used should be determined by removing and inspecting the plug When a plug of the correct heat range is being used the electrodes will stay hot enough to keep all the carbon burned off but cool enough to keep from damaging the engine and the plug itself This temperature is about 400 800 C 750 1 450 F and can be judged by noting the condition and color of the ceramic insulator around the center electrode If the ceramic is clean and of a light brown color the plug is operating at the right temperature A spark plug for higher operating temperatures is used for racing Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a colder plug If a spark plug with too cool a heat range is used that is a cold plug that cools itself too well the plug will stay too cool to burn off the carbon and the carbon will collect on the electrodes and the ceramic insulator The carbon on the electrodes conducts electricity and can short the center electrode to ground by either coating the ceramic insulator or bridging across the gap Such a short will prevent an effective spark Carbon build up on the plug can also cause other troubles It can heat up red hot and cause preignition and knocking which may eventually burn a hole in the top of the piston Spark Plug 4 2 J 3 i A
62. with its grease seal which is pressed onto the steering stem with the steering stem bearing puller and adapters special tools STEERING 13 5 1 Bearing Puller 57001 158 2 Adapter 57001 317 3 Bearing Puller Stud 57001 1190 4 Tapered Roller Bearing 5 Stem Base Installation e Installation is the reverse of removal Note the follow ing O Apply grease to the outer races and then drive them into the head pipe using the drivers and the press shaft special tools 1 Press Shaft 57001 1075 2 Driver 57001 1106 Install the grease seal noting the direction shown 13 6 STEERING 1 Grease Seal O Apply grease to the lower tapered roller bearing and drive it onto the steering stem using the stem bearing driver and adapter special tools 57001 137 and 57001 1092 1 Stem Bearing Driver 57001 137 2 Adapter 57001 1092 Install the steering stem base on the head pipe and install the following parts 4 Stem Locknut 5 Pawl Washer 6 Washer 1 Upper Bearing 2 O ring 3 Grease Seal eThe following four steps should be performed after steering bearing installation This procedure settles the bearings in place OUsing the stem nut wrench tighten the stem locknut to 39 N m 4 0 kg m 29 ft Ib of torque To tighten the steering stem locknut to the specified torque hook the wrench on the stem locknut and pull the wrench at the hole by 22 2 kg force in
63. 0 070 0 20 0 40 mm 0 35 0 50 mm Top Second Valve Head Valve Stem Bend Valve stem s r i diameter Valve head thickness 4 6 ENGINE TOP END Special Tools Compression Gauge 57001 221 Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Joint 57001 1271 Valve Guide Arbor o4 57001 1273 1 Valve Guide Reamer 04 57001 1274 Valve Seat Cutter Holder 4 57001 1275 Valve Seat Cutter 45 24 5 57001 1113 ENGINE TOP END 4 7 Valve Seat Cutter 32 25 57001 1118 Piston Base 57001 147 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 60 30 57001 1123 Sealant C Kawasaki Bond Silicone Sealant 56019 120 Valve Seat Cutter 45 022 57001 1205 4 8 ENGINE TOP END Cylinder Head Cover Removal Remove the following Fuel Tank see Fuel System chapter Air Cleaner Housing see Fuel System chapter Ignition Coils Throttle Cable Choke Cable Baffle Plate A Baffle Plate Bolt Remove the cylinder head cover bolts and take off the cover A Bolts B Cylinder Head Cover Installation e Replace the head cover gasket with new one if it is damaged Apply silicone sealant to the cylinder head as shown Tighten the cover bolts to the specified torque see Exploded View Silicone Sealant Applied Areas Camshaft Chain
64. 1 Ignition Switch 12 Headlight 10A Fuse Junction Box 13 Taillight 10 Fuse Junction Box 14 Battery 15 Load 1 W Lead Terminal 2 BR Lead Terminal 3 BK Y Lead Terminal 4 Y1 Lead Terminal 5 Y2 Lead Terminal 6 Y3 Lead Terminal NOTE O The actual meter reading varies with the meter used and the individual diode but generally speaking the lower reading should be from zero to one half the scale Regulator Inspection To test the regulator out of circuit use three 12 V batteries and a test light made from 12 V 3 6 W bulb in a socket with leads e Remove the regulator rectifier unit from the frame e Using auxiliary leads connect one of the yellow lead terminal at the unit to the battery terminal and connect the test light between the black yellow lead terminal at the unit and the battery terminal At this time the bulb should not be lit ELECTRICAL SYSTEM 15 15 Connect the brown lead terminal to the other battery terminal and connect the black yellow lead terminal to the battery terminal momentarily At this time the bulb should not be lit 1 Reguiator Rectifier 6 BR Lead Terminal 2 Test Light 7 BK Y Lead Terminal 3 12 V Battery 8 Y Lead Terminal 4 12 V Battery 9 Y2 Lead Terminal 5 W Lead Terminal 10 Y3 Lead Terminal To apply 24 V to the regulator rectifier connect two 12 V batteries in series and connect the brown lead terminal to the battery termi
65. 45 15 7 317 Top gear Tubular diamond 24 85 mm 120 60 VR17 TUBELESS DUNLOP K510F BRIDGESTONE CYROX 17 160 60 VR17 TUBELESS DUNLOP K510 BRIDGESTONE CYROX 16 Telescopic fork 120 mm Swing arm uni trak 140 mm Dual discs Single disc 12 V 10 Ah Semi sealed beam Quartz halogen 12 V 60 55 W x 2 12V 5 21 2 Three phase AC 23 A 10 000 r min rpm 14 V Specifications are subject to change without notice and may not apply to every country F France Model 1 Italy Model GENERAL INFORMATION 1 9 _ The table below relating tightening torque to thread Torque and Locking Agent diameter lists the basic torque for the bolts and nuts Use l m this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with The following tables list the tightening torque for the dry solvent cleaned threads major fasteners requiring use of a non permanent locking agent or liquid gasket Basic Torque for General Fasteners Letters used in the Remarks column mean Threads dia L Apply a non permanent locking agent to the threads LG Apply liquid gasket to the threads 3 4 49 0 35 0 50 30 43 in lb M Apply molybdenum disulfide grease 5 9 78 0 60 0 80 52 69 in Ib Apply an oi to the threads and seating surface 14 19 14 1 9 10 0 135 Tighten t
66. A Jack or Stand B Jack 57001 1238 e Pull out the axle to the right and drop the front wheel out of the forks Do not lay the wheel down on one of the discs This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Front Wheel Installation Installation is the reverse of removal Note the follow Ing NOTE OPut the speedometer gear drive onto the wheel hub notches then install the housings that it fits in the drive notches OFit the speedometer gear housing stop in the fork leg stop 1 Notches 2 Projections 9 6 WHEELS TIRES 1 Housing Stop 3 Front 2 Fork Leg Stop OFit the collar in the right side of the hub Apply grease to the speedometer gear and hub grease seal Tighten the following fasteners to the specified torque see Exploded View Axle Nut Axle Clamp Bolts Caliper Mounting Bolts Check the front brake AWARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done Rear Wheel Removal Remove the following Chain Case Rear Caliper Cotter Pin and Axle Nut Remove the drive chain from the rear sprocket toward the left see Final Drive chapter Pull out the axle Move the rear wheel back and remove the caliper bracket installed Do not lay the whe
67. CTRICAL SYSTEM 1 Commutator 2 Emery Cloth Measure the diameter of the commutator Replace the starter motor with a new one if the commutator diameter is less than the service limit 1 Commutator Segment 2 Diameter Commutator Diameter Standard Service Limit 24 mm 23 mm Armature Inspection Using the x 1 ohmmeter range measure the resist ance between any two commutator segments kif there is a high resistance or no reading between any two segments a winding is open and the starter motor must be replaced e Using the highest ohmmeter range measure the resist ance between the segments and the shaft there is any reading at all the armature has a short and the starter motor must be replaced 1 Segment 2 Shaft NOTE O ven 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 Lead Inspection e Using the x 1 ohmmeter range measure the resist ance as shown Brush and Terminal Brush and End Cover 0 Terminal A Brush B Brush there is not close to zero ohms the brush lead has open Replace the terminal bolt assembly and or the brush holder a
68. Chain Slack Adjustment 10 4 Wheel Alignment Adjustment 10 4 Drive Chain Wear Inspection 10 4 Lubrication 10 5 Drive Chain Removal 10 5 Drive Chain Installation 10 6 Sprocket Coupling 10 6 Engine Sprocket Removal 10 6 Engine Sprocket 1 lt 1 10 6 Rear Sprocket Removal 10 7 Rear Sprocket Installation 10 7 Rear Sprocket Wear 10 7 Coupling Installation 10 7 10 2 FINAL DRIVE Exploded View one bolt only T1 9 8 N m 1 0 kg m 7 0 ft Ib T2 74 N m 7 5 kg m 54 ft lb L Apply a non permanent locking agent to the threads FINAL DRIVE 10 3 Specifications Standard Service Limit Drive Chain Make and type ENUMA EK520 SX 0 Endless 108 links Chain slack 20 35 mm 35mm is best Less than 20 mm or more than 40 mm 20 link length 317 5 318 2 mm 323 mm Special Tools Jack 57001 1238 Bearing Driver Set 57001 1129 10 4 FINAL DRIVE Drive Chain Drive Chain Slack Adjustment Set the motorcycle up on its side stand and check that the chain slack is within the standard value Drive Chain Slack Standard Service Limit 20 35 mm 35mm is best 20 40 mm 1 Chain Slack O Check to see that the notches on the alignment indica tors on both sides are in the same position C Swing Arm Marks D Cotter Pin A No
69. D Cylinder Head Cylinder Compression Measurement NOTE O Use the battery which is fully charged e Warm up the engine thoroughly Remove the following Fuel Tank see Fuel System chapter Surge Tank see Fuel System chapter Spark Plugs Ge Attach the compression gauge and adapter special tools firmly into the spark plug hole A Compression Gauge 57001 221 B Adapter 57001 1317 Hold the throttle wide open and crank the engine with the starter e When the gauge stops rising stop cranking and read the gauge Cylinder Compression Usable Range 686 1 079 kPa 2330 r min rpm 7 0 11 0 kg cm 99 156 psi cylinder compression is higher than the specified range check the following OCarbon build up on the cylinder head combustion chamber O Carbon build up on the piston head cylinder compression is lower than the specified range check the following O Valve not seating properly O Piston cylinder clearance excessive O Gas leakage around the cylinder head gasket O Valve clearance too small O Piston ring piston ring groove clearance Removal Drain coolant see Cooling System chapter e Remove the following Radiator see Cooling System chapter Muffler Camshafts see this chapter Oil Hose Cylinder Head Engine Mounting Bracket Bolts Nuts Cylinder Head Remove the cylinder head bolts and take off the cylinder head Installation Installation is the reverse of re
70. Exploded View 3 2 Specifications 3 3 Special Tool 3 3 Sealant 3 3 Coolant Flow Chart 3 4 Coolant 3 5 Coolant Level Inspection 3 5 Coolant Draining 3 5 Coolant Filling 3 5 Pressure Testing 3 6 Water Pump 3 7 Removal us sss 3 7 Installation 3 7 Water Pump Inspection 3 7 Radiator and Radiator Fan 3 8 Removal 3 8 Radiator Inspection 43 8 Radiator Cap inspection 3 9 Thermostat 3 10 Removal 3 10 Installation 3 10 Inspection 3 10 3 2 COOLING SYSTEM Exploded View T1 T3 T4 T5 SS 2 0 N m 0 2 kg m 17 in Ib 3 4 N m 0 35 kg m 30 in Ib 7 8 N m 0 8 kg m 69 in Ib 8 8 0 9 kg m 78 in Ib 18 N m 1 8 kg m 13 ft lb Apply a non permanent locking agent to the threads Apply silicone sealant to the threads COOLING SYSTEM 3 3 Specifications Coolant Type Permanent type of antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50 coolant 50 Freezing point 35 C 31 F Total amount 2 3 L reservoir tank full level Radiator Cap r
71. If the tester readings are not as specified replace the fuel pump relay the tester readings are normal check the fuel pump operation Use only Hand Tester 57001 983 for this test An ohmmeter other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the pump relay will be damaged 15 30 ELECTRICAL SYSTEM Fuel Pump Relay Internal Resistance o Q Pump Operational Inspection Remove the fuel pump with the fuel filter see Fuel System chapter Prepare a container filled with kerosene Prepare the rubber hoses and connect them to the pump fittings Connect the suitable pressure gauge to the outlet hose as shown 1 Fuel Pump 6 Kerosene 2 Pressure Gauge 7 2 Pin Connector 3 Outlet Hose 8 Battery 4 Inlet Hose 9 Auxiliary Leads 5 Fuel Filter Connect the pump leads to the battery using auxiliary wires as shown if the pump operates check the pump relay If the pump does not operate the pump is defective xkif the pump operates and the pump relay is normal close the outlet hose while operating the fuel pump When the pump stops read the pressure gauge If the pressure gauge reading is out of the specified pressure the pump is defective Fuel Pump Pressure Standard 11 16 kPa 0 11 0 16 kg cm 1 6 2 3 psi Meters Gauges Removal R
72. NERAL INFORMATION Oil Pressure Switch Terminal Oil Pressure Switch Oil Pump Cover Screws Oil Plug Right M18 Oil Plug Left PT Oil Cooler Pipe Fitting Bolt Oil Pan Bolts Engine Removal Installation Engine Mounting Bracket Bolt Engine Mounting Bolts Crankshaft Transmission Shift Drum Cam Mounting Bolts Shift Drum Set Lever Bolt Shift Drum Bearing Retainer Bolt Shift Return Spring Bolt Neutral Switch Breather Plate Mating Surfaces Breather Plate Bolt Crankcase Bolts p6 p8 Crankcase Mating Surfaces S LG SS only Connecting Rod Big End Cap Nuts Shift Pedal Mounting Bolt Wheels Tires Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Final Drive Engine Sprocket Cover Bolts L Engine Sprocket Plate Bolt Rear Sprocket Nuts Rear Sprocket Studs Brakes Bleed Valves Caliper Mounting Bolts Front Caliper Assembly Bolts Front Rear Pad Spring Screws Disk Mounting Bolt Front Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Locknut Front Brake Light Switch Mounting Screw Brake Pedal Mounting Bolt Rear Master Cylinder Rod Locknut Caliper Mounting Bolts Rear Rear Master Cylinder Mounting Bolts Torque Link Nut Front Rear Suspensions Front Fork Clamp Bolts Upper Lower Front Fork Top Bolt Piston Rod Nut Front Fork Bottom Allen Bolts Rear Shock Absorber Spring Adjuster Locknut Rear Shock Absorber Mounting Nuts Swing Arm Pivot Shaft Nut R
73. Passage O Lightly apply compressed air to the oil passage until the pistons hit the rubber gasket Block the hose joint opening during this operation A Push down B Apply compressed air C Hose Joint Opening 11 10 BRAKES AWARNING To avoid serious injury never place your fingers or palm inside the caliper opening compressed air into the caliper the piston may crush your hand or fingers O Pull out the pistons by hand If you apply e Remove the following Dust Seals Fluid Seals Repeat the previous step to remove the pistons from the other side of the caliper body Rear Caliper Disassembly Disassemble the rear caliper in the same manner as the front caliper see Front Caliper Disassembly Note the additional information below O Remove the piston dust seal before piston removal A Rear Caliper B Dust Seal I A i 2 TE 2 LI E Lx kamili E A Rear Caliper B Apply compressed air Assembly Notes brake fluid to the cylinders pistons and fluid seals and push the pistons into the cylinders by hand Take care that neither the cylinder nor the piston skirt get scratched OFor the rear caliper install the dust seal around the piston and push them into the cylinder Check that the dust seal is properly fitted into the grooves in the piston and caliper body Front Caliper Rear Caliper 1 Piston 3 Dust Seal 2 Flu
74. Reach 3 LB Plug gap 1 Terminal 4 Gasket 2 Insulator b Center Electrode 3 Cement 6 Side Electrode Spark Plug Condition Carbon Fouling Oil Fouling Spark Plug Inspection Remove the spark plug and inspect the ceramic insulator Whether or not the right temperature plug is being used can be ascertained by noting the condition of the ceramic insulator around the electrode A light brown color indicates the correct plug is being used If the ceramic is black it indicates that the plug is firing at too low a temperature so the next hotter type should be used instead If the ceramic is white the plug is operating at too high a temperature and it should be replaced with the next colder type CAUTION If the spark plug is replaced with a type other than the standard plug make certain the replacement plug has the same thread pitch and reach length of threaded portion and the same type electrode regular type or projected type as the standard plug If the plug reach is too short carbon will build up on the plug hole threads in the cylinder head causing overheating and making it very difficult to insert the correct spark plug later If the reach is too long carbon will build up on the exposed spark plug threads causing overheating preigniton and possibly burning a hole in the piston top In addition it may be impossible to remove the plug without damaging the cylinder head Plug Reach
75. age t i 4 7 A Banjo Boit C Caliper Mounting Bolts B Caliper Assembly Bolts Caliper Installation Tighten the caliper mounting bolts to the specified torque see Exploded View Connect the brake hose to the caliper putting a new flat washer on each side of the brake hose fitting eTighten the banjo bolt to the specified torque see Exploded View Check the fluid level in the master cylinder reservoir and bleed the brake line see Bleeding the Brake Check the brake for good braking power no brake drag and no fluid leakage AWARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first application of the lever or pedal if this is not done Front Caliper Disassembly Remove the following Front Brake Pads see this chapter Front Caliper see this chapter Remove the caliper assembly bolts and split the front caliper BRAKES 11 9 A Caliper Assembly Bolts Remove the piston insulator and the O rings Using compressed air remove the pistons One way to remove the pistons is as follows O Install a wooden board more than 10 mm thick and a rubber gasket on the caliper half as shown Leave one of the oi passages open 1 Bolt and Nut 2 Rubber Gasket 3 Wooden Board 4 Oil Passage sealed by Rubber Gasket 5 Oil
76. aner Housing Removal Carburetors Idle Speed Adjustment Service Fuel Level Adjustment Carburetor Removal Carburetor Installation Carburetor Disassembly Assembly Carburetor Inspection Fuel Pump and Filter Removal Installation Fuel Pump Inspection Fuel Filter inspection Fuel Tank Removal Installation FUEL SYSTEM 2 1 o o bbb l io iis O O O O O cO 0 WOUOWMWAONINNNADAMOOOATHL AN N N N N So N 2 2 FUEL SYSTEM Exploded View Jet Needle Pilot Screw Pilot Jet Needle Jet Holder Main Jet Main Air Jet Pilot Air Jet D 2 4 FUEL SYSTEM Specifications Choke Cable Free Play 2 3mm Idle Speed 1 200 50 r min rpm Carburetor Specifications Make type Synchronization vacuum Keihin CVK D32 2 7 kPa 2 cm Hg or less difference between two cylinders Main jet Standard 98 Option 92 95 100 102 Main air jet 100 Need
77. ard Front fork oil excessive Front fork oil viscosity too high Front fork adjustment too hard Rear shock adjustment too soft Tire air pressure too high Front fork anti dive mechanism trouble Front fork bent Too soft Front fork oil insufficient and or leaking Front fork oil viscosity too low Front fork air pressure too low Front fork rear shock absorber spring weaken Rear shock absorber oil leaking Front fork anti dive mechanism trouble Brake Doesn t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged Master cylinder scratched inside Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation electrolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator Rectifier trouble Battery Overcharged Regulator Rectifier trouble APPENDIX 16 7 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 O Whenever the vehicle has been operated under wet or rainy conditions or especially after using high pressure spray water perform the general lubrication Pivots Lubricate with Motor Oil Side Sta
78. ator 2 Center Electrode 3 Plug Gap 4 Side Electrode IC Igniter Inspection e Remove the side cover assembly see Frame chapter e Remove the ignitor connector Zero an ohmmeter and connect it to terminals of the IC igniter to check the internal resistance of the igniter Use only Hand Tester 57001 983 for this test A tester other than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the IC igniter will be damaged Replace the IC igniter if the reading is not the specified value 15 20 ELECTRICAL SYSTEM IC Igniter Internal Resistance Range Electric Starter System Starter Motor Removal Remove the fuel tank see Fuel System chapter Remove the terminal nut of starter motor wiring and take out the mounting bolts O Using the socket wrench special tool 57001 1268 makes work easy Pull the starter motor upwards with twisting motion Tester Positive Lead Connection Ter minal A 17 9 2 22 22 27 DANADANA N 5 6 7 0 7 0 13 TENERE 5 8 5 8 15 15 19 T2 feel Pea teal 5 6 7 0 13 A Starter Motor IC Igniter Terminal Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter motor legs and crankcase where the start
79. awl spring broken Abnormal Engine Noise Knocking IC igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Abnormal Drive Train Noise Clutch noise Weak or damaged rubber damper Clutch housing friction plate clearance excessive Clutch housing gear worn Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive chain noise Drive chain adjusted improperly Chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Ca
80. brasive and shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings 2 Battery Ground Remove the ground lead from the battery before performing any disassembly operations on the motorcycle This prevents a the possibility of accidentally turning the engine over while partially disassembled b sparks at electrical connections which will occur when they are disconnected c damage to electrical parts 3 Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them evenly in a cross pattern This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 4 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench b Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wo
81. carburetor body e adjust the fuel level remove the float bowl and bend the tang on the float arm to change the float height A Float B Tang Measure the float height tilting the carburetor so that the tang on the float just touches the needle rod in the float valve Olncreasing the float height lowers the fuel level and decreasing the float height raises the fuel level 4 1 Bottom Edge of Carburetor Body 2 Needle Rod 3 Float 4 Float Height 5 Float Valve Float Height Standard 11 2 mm NOTE ODo not push the needle rod in during the float height measurement Carburetor Removal AWARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the following Fuel Tank see Fuel Tank Removal Surge Tank see Surge Tank Removal Air Cleaner Housing see Air Cleaner Housing Removal idie Adjuster Fuel Hoses Loosen the carburetor clamps and remove the carburetors Carburetor Installation e Install the holder clamps as shown being careful of the screw position and the screw head direction see Engine Top End chapter FUEL SYSTEM 2 9 A WARNING Be sure to install the holder clamp screws in the direction shown Or the screws could come in contact with the throttle
82. ck the operation of the gauge Gauge Operation Test ignition Switch Position ON Wire Location Water temperature sensor female connector disconnected Results Gauge should read C when sensor wire is opened Gauge should read H when sensor wire is grounded to engine Do not ground the wiring longer than necessary After the pointer swings to the H position stop the test Otherwise the gauge could be damaged these readings are not correct the trouble is with the gauge and or wiring A Sensor Connector B Water Temperature Gauge Check the water temperature gauge circuit wiring see Wiring Inspection elf all wiring and components other than the water temperature gauge unit check out good the gauge is defective ELECTRICAL SYSTEM 15 33 Tachometer Circuit BK Y 4 gt 2 gt BK Y 1 Ignition Switch 6 Ignition Coil 1 4 2 6 Pin Connector 7 Spark Plug 3 Tachometer 8 30A Main Fuse in Starter Relay 4 4 Pin Connector 9 Battery 5 IC Igniter Water Temperature Gauge Circuit Ok BK Y 4C23 BK Y 1 Ignition Switch 5 Water Temperature Sensor 2 6 Pin Connector 6 Starter Relay 3 Water Temperature Gauge 7 30A Main Fuse 4 6 Pin Connector 8 Battery 15 34 ELECTRICAL SYSTEM Water Temperature Sensor nspection Suspend the sensor in a container of coolant so that the temperature sensing projection and threaded portion are submerged e U
83. cosity SAE 10W 40 Capacity 2 8 L when filter is not removed 3 0 L when filter is removed Oil Pressure Measurement Oil Pressure 4 000 r min rpm oil temp 90 C 194 F 216 275 kPa 2 2 2 8 kg cm 31 40 psi Special Tools Sealant Oil Pressure Gauge 10 kg cm 57001 164 Kawasaki Bond Silicone Sealant 56019 120 Engine Oil and Oil Filter AWARNING Motorcycle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Oil Level Inspection e Support the motorcycle perpendicular to the ground Check that the engine oil level is between the upper and lower levels in the gauge 1 Upper Level 2 Lower Level 3 Oil Filler Opening Plug NOTE O Situate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several minutes for all the oil to drain down O f the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles Racing the engine before the oil reaches every part can cause engine seizure If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly the oil pressure warning light will light If this light stays on when the engine
84. ct part If it is it may have been refaced too much replace it Be sure to remove all grinding compound before assembly When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment ENGINE TOP END 4 19 Valve Lapping 3 Valve 1 Lapper 2 Valve Seat Measure Valve to Guide Clearance Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below Insert a new valve into the guide and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth to measure valve valve guide clearance Repeat the measurement in a direction at a right angle to the first the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Service Limit Inlet 0 031 0 140 mm 0 34 mm Exhaust 0 085 0 180 mm 0 41 mm 4 20 ENGINE TOP END Cylinder Pistons Cylinder Removal e Remove the following Cylinder Head see Cylinder Head Removal Camshaft Chain Guide exhaust side Water Pipe Remove the cylinder Cylinder Installation e Install the new cylinder gasket Apply engine oil to the cylinder bore Using the
85. d Adjustment after Installation Disassembly ITO oS Assembly rrr rr FEE AREE RE Sa EUN RES Inspection Visually Brake DISCS a n Installation es BRAKES 11 1 11 2 11 4 11 4 11 5 11 5 11 5 11 5 11 5 11 6 11 7 11 7 11 8 11 8 11 8 11 8 11 9 11 9 11 10 11 10 11 11 11 11 11 11 11 12 11 12 11 13 11 13 11 13 11 13 11 13 11 13 11 14 11 14 11 14 11 14 11 14 11 14 11 2 BRAKES Exploded View T1 2 T3 T4 T5 T6 T7 T8 T9 1 0 N m 0 10 kg m 9 in Ib 1 2 N m 0 12 kg m 10 in Ib 2 9 N m 0 30 kg m 26 in Ib 5 9 N m 0 6 kg m 52 in Ib 7 8 N m 0 8 kg m 69 in Ib 18 N m 1 8 kg m 13 0 ft Ib 21 N m 2 1 kg m 15 0 ft Ib 23 N m 2 3 kg m 16 5 ft Ib 25 N m 2 5 kg m 18 0 ft Ib T10 27 N m 2 8 kg m 20 ft lb T11 32 N m 3 3 kg m 24 ft Ib T12 34 N m 3 5 ka m 25 ft Ib BRAKES 11 3 G Apply grease Ge Apply molybdenum disulfide grease nd 11 4 BRAKES Specifications Rem smo a Service Li Brake Fluid Grade Brand recommended D O T 3 Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty Castrol Girling Universal Castrol GT LMA Castrol Disc Brake Fluid Non adjustable Brake Lev
86. d Pipe Outer Race Driver 57001 1106 Steering Stem Nut Wrench 57001 1100 Bearing Puller Adapter 57001 317 Head Pipe Outer Race Press Shaft 57001 1075 Bearing Puller Stud 57001 1190 13 4 STEERING Steering Adjustment e Check the steering OLift the front wheel off the ground using the jack special tool 57001 1238 see Wheels Tires chapter OWith the front wheel pointing straight ahead alternately tap each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the lower bracket hits the stop If the wheel binds or catches before the stop the steering Is too tight O Feel for steering looseness by pushing and pulling the forks kif you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the motion of the fork which must be taken into account Be sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Adjust the steering if necessary Remove the following parts Upper Fairing see Frame chapter Fuel Tank see Fuel System chapter Fork Lower Clamp Bolts both sides loosen Stem Head Nut Loosen Adjust the steering with the stem nut wrench special tool a 1 m CN ee N a y N fj xa i me
87. djustment The headlight beam is adjustable vertically If adjusted too low neither low nor high beam will illuminate the road far enough ahead If adjusted too high the high beam will fail to illuminate the road close ahead and the low beam will bind oncoming drivers Loosen the adjusting bolt and adjust the beam until the beam points straight ahead Tighten the bolt after adjusting the beam NOTE O On high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlights to the proper angle according to local regulations ELECTRICAL SYSTEM 15 25 A Adjusting Bolt Headlight Bulb Replacement Notes When handling the quartz halogen bulbs never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode e Install the dust cover so that the TOP mark point up and the cover fits onto the bulb firmly as shown A Top Mark B Up 15 26 ELECTRICAL SYSTEM 1 Dust Cover 2 Headlight Bulb Check the headlight aim after instailation Headlight Unit Removal Installation Note e Install the headlight unit so that the TOP mark on the lens points up EZ Mm m k yi M 4 Pub 4 1 H l 4 ann i i E x I i 1 ET HEU T is d iMd r A
88. e e Install the tensioner body on the engine Apply a non permanent locking agent to the mounting bolts and tighten them to the specified torque see Exploded View Pull the wire out and tighten the lock bolt e Install the pickup coil cover 4 10 ENGINE TOP END OApply silicone sealant to the crankcase parting line and grommet see 4 12 O Apply a non permanent locking agent to only one bolt see 4 12 Camshaft Camshaft Removal e Remove the following Lower Fairings see Frame chapter Pickup Coil Cover Damper Rubber from Rear Cam Chain Guide e Remove the following Carburetor see Fuel System chapter Cylinder Head Cover this chapter Spark Plug Retainer Camshaft Chain Tensioner this chapter NOTE OBefore removing the chain tensioner position the crankshaft at 1 4 piston TDC 1 TDC Mark 2 Timing Mark Crankcase Parting Line 3 Front e Remove the camshaft cap bolts and take off the camshaft caps camshafts and upper chain guide k gt L 1 i gt t Lii Lia le l P HPF T an a ta a y 1 1 d d 7 NE Wr ai 8 s IAS 1 A Camshaft Caps C Upper Chain Guide B Camshafts Stuff a clean cloth into the chain tunnel to keep any parts from falling into the crankcase CAUTION The crankshaft may be turned while the camshafts are removed Always puli the chain
89. e Pink Purple Red White Yellow Right Handleber Switches Wiring Diagram ZX400 H2 1 de 6 av Pje ov v 07 esna ue3 5 55 wa OT egna 1U6 1PV H Y Ov Bens PTT Junction Box Pump Fue Reley pump Switch Ignition Coils Head lohnt Switch Front Brake Light Switch Engine Stop Switch Starter Button H EL o a o a x m 5 m gt 2 2 8 Ir c w c lt amp 2 lt 069 2 gt gt o lt o o P1 gt p Q gt 8 we N a lt Ug wx 29 C A c 5 5 02 Ses pas gt 9 oe m me um gt gt o e gt gt C gt C gt 5 on Sn n te 2 5 u gt Head iont 12 v 80 55 w city Light 12 aw o v 2 o D 4 cx on aw 2m m lt gt gt o 4 n zw s 22 A 2s eo ELECTRICAL SYSTEM 15 3 I i i Regulator Rectifier Neutral Pressure Switch Switch Side Stand Switch Switch Dimer Stater Passing Left Handlebar Switches utton signal Switch Lockout Butt ns Turn
90. e manner and measure a 20 link length Since the chain may wear unevenly take measurement at several places x If any measurement exceeds the service limit replace the chain Camshaft Chain 20 Link Length Standard 127 0 127 4 mm Service Limit 128 9 mm Chain Length Measurement 20 link Length Rocker Arm Rocker Shaft Rocker Arm and Rocker Shaft Removal Remove the camshafts this chapter NOTE O Mark the rocker arms so they may be put back in the same position Remove the rocker shaft plug and rocker shaft and take off the rocker arms E 1 A d 3 L j 4 A Plug C Rocker Shaft B Rocker Arms Rocker Arm and Rocker Shaft Installation Notes e Blow the rocker arm oil passage clean with compressed air and apply oil to the rocker arm bore before installa tion 1 Rocker Arm 2 Oil Pressure e Apply engine oil to the rocker shaft and insert the shaft running it through the cylinder head the rocker arms and springs e install the retainer spring on each rocker arm as shown ENGINE TOP END 4 13 1 Springs conical 2 Springs eTighten the following to the specified torque see Exploded View Upper Chain Guide Bolts Camshaft Cap Bolts Rocker Shaft Plug Rocker Arm and Rocker Shaft Inspection Note inspect the rocker arms and rocker shafts If they are badly worn replace them 4 14 ENGINE TOP EN
91. e Fuel System chapter Carburetors see Fuel System chapter Baffle Plate Oil Cooler and Oil Pipes see Engine Lubrication System chapter Radiator see Cooling System chapter Muffler see Engine Top End chapter Engine Sprocket see Final Drive chapter Disconnect wiring from the engine and free them from the clamps Clutch Cable Spark Plug Caps Pickup Coil Lead Connector Battery Ground Lead Terminal Starter Motor Lead Terminal Water Temperature Sensor Lead Connector Oil Pressure Switch Connector Side Stand Switch Connector Alternator Leads Connector Neutral Switch Connector A Battery Ground Lead Terminal B Side Stand Switch Connector C Neutral Switch Connector the crankshaft is to be removed after engine removal you may remove the following parts at this time Cylinder Alternator O In case of the transmission you may remove the clutch e Remove the engine mounting nuts and the bracket nuts but do not remove the bolt as yet 7 4 ENGINE REMOVAL INSTALLATION A Bracket B Bracket Bolts and Nuts C Engine Mounting Bolts and Nuts Place the jack special tool under the swing arm to steady the motorcycle e Place the suitable stand or the jack under the engine Remove the engine mounting bolts Support the engine before sliding out the engine mounting bolts k Jack 57001 1238 3 Suitable Stand A B Installation e Installation is the reverse of removal Note the follow
92. e adjuster stops Remove the fork top bolt from the outer tube To loose the piston rod nut inside the top spring press the top spring down with suitable thin plates and insert the fork spring stopper special tool between the piston rod nut and the top spring O Loosen the piston rod nut holding the spring preload adjuster A Suitable Thin Plates C Piston Rod Nut B Fork Spring Stopper 57001 1316 e Remove the following Fork Top Bolt Collar Top Spring with Fork Spring Guide Main Spring Push Rod Piston Rod Nut A Push Rod B Piston Rod C Piston Rod Nut Pour the fork oil into a container Remove the following from the outer tube Dust Seal Circlip A Dust Seal B Circlip Use the fork outer tube weight special tool to separate the inner tube from the outer tube O Holding the inner tube by hand in a vertical position pull down the outer tube several times to pull out the inner tube SUSPENSION 12 9 3 Outer Tube 4 Pull down 1 inner Tube 2 Weight 57001 1218 OThe oil seal washer and guide bushes come off with the inner tube Hold the axle holder in a vise Stop the cylinder from turning by using the front fork cylinder holder special tool Unscrew the Allen bolt then take the bolt and gasket out of the bottom of the axle holder J ig 1 1 Cylinder Holder 57001 1297 4 Allen Wrench 2 Piston Cylinder Unit 5 Vise 3 Allen Bo
93. e chain may wear unevenly take measurement at several places 1 Weight 2 Straight Part 3 Ruler 4 Measure this length Drive Chain 20 Link Length Standard 317 5 318 2 mm Service Limit 323 mm If any measurement exceeds the service limit replace the chain Also replace the engine and rear sprockets when the drive chain is replaced A WARNING For safety use only the standard chain It is an endless type and should not be cut for installation Lubrication The O rings between the side plates seal in the lubricant between the pin and the bushing To avoid damaging the O rings and resultant loss of lubricant observe the following rules Use only kerosene or diesel oil for cleaning an O ring drive chain Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O rings Immediately blow the chain dry with compressed air after cleaning Complete cleaning and drying the chain within 10 minutes special lubricant is not available a heavy oil such as SEA 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication FINAL DRIVE 10 5 i Oil Applied Areas Drive Chain Removal e Remove the following Lower Fairings see Frame chapter Chain Cover Engine Sprocket Cover see this chapter Rear Shock Absorber Mounting Nut lower Tie Rod Nuts upper Swing Arm Shaft Nut Rear Caliper s
94. e of Cutter 3 Cutter Operating Procedures Clean the seat area carefully Coat the seat with machinist s dye Fit a 45 cutter into the holder and slide it into the valve guide Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylinder head must be replaced e Measure the outside diameter of the seating surface with a vernier caliper If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the specified range xk If the outside diameter of the seating surface is too large make the 32 grind described below if the outside diameter of the seating surface is within the specified range measure the seat width as described below e Grind the seat at a 32 angle until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide Turn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to prevent overgrinding Valve Seat Repair Widened width of engagement by machining
95. e service limit replace the crankshaft with a new one If the measured journal diameters are not less than the service limit but do not coincide with the original diameter markings on the crankshaft make new marks on it Crankshaft Main Journal Diameter Marks None 29 984 29 992 mm 1 29 993 30 000 mm Crankshaft Main Journal Diameter Marks 1 mark or no mark Measure the main bearing bore diameter and mark the upper crankcase half in accordance with the bore diameter NOTE O Tighten the crankcase bolts to the specified torque see Exploded View OThe mark already on the upper crankcase half should almost coincide with the measurement Crankcase Main Bearing Bore Diameter Marks O 33 000 33 008 mm None 33 009 33 016 mm 1 Crankcase Main Bearing Bore Diameter Marks O mark or no mark CRANKSHAFT TRANSMISSION 8 13 Select the proper bearing insert in accordance with the combination of the crankcase and crankshaft coding Bearing Insert 2 Size Color Mark 1 Crankcase 3 No 2 Journal e Install the new inserts in the crankcase halves and check 2 Measure here insert journal clearance with plastigage Crankshaft Side Clearance Insert a thickness gauge between the crankcase and the crankweb at the No 2 journal to determine clearance kif the clearance exceeds the service limit replace the crankcase halves as a set Crankshaft Side Cl
96. e tank cover see Fuel System chapter Remove the ignition coil from the bracket Ignition Coil Installation Connect the primary leads to the ignition coil terminals Black Lead to 1 4 Coil Green Lead to 2 3 Coil Red Lead to both Coils Ignition Coil Inspection Remove the ignition coils Measure the arcing distance with Kawasaki coil tester special tool 57001 1242 to check the condition of the ignition coil NOTE OSince a tester other than the Kawasaki coil tester may produce a different arcing distance the Kawasaki coil tester is recommended for reliable results 1 Ignition Coil Tester 57001 1242 2 lgnition Coil ELECTRICAL SYSTEM 15 17 AWARNING To avoid extremely high voltage shocks do not touch the coil or lead lf the distance reading is less than the specified value the ignition coil or spark plug caps are defective Ignition Coil Arcing Distance 7 mm or more e determine which part is defective measure the arcing distance again with the spark plug caps removed from the ignition coil if the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug caps Measuring coil resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and short
97. e the tire bead with engine oil or petroleum distillates because they will deteriorate the tire e Install the balance weight on the rim O Slip the weight on the rim flange by pushing or lightly hammering the weight in the direction shown in the figure WHEELS TIRES 9 7 O Check that the blade and weight seat fully on the rim flange and that the clip is hooked over the rim ridge and reaches rim flat portion AWARNING If the balance weight has any play on the rim flange the blade and or clip have been stretched Replace the loose balance weight Do not reuse used balance weight Balance Weight 41075 1014 41075 1015 41075 1016 Weight grams 10 20 30 Installing Balance Weight a Press or lightly hammer the weight in Rim Flange Blade 9 8 WHEELS TIRES Balance Weight Removal a When the tire is not on the rim Push the blade portion toward the outside with a regular tip screw driver and slip the weight off the rim flange Discard the used balance weight Removing Balance Weight without tire on rim b When the tire is on the rim Pry the balance weight off the rim flange using a regular tip screw driver as shown in the figure O Insert a tip of the screw driver between the tire bead and weight blade until the end of the tip reaches the end of the weight blade Push the driver grip toward the tire so that the balance weight slips off the ri
98. ear 4 22 Installation Notes 4 13 Piston Ring End Gap 4 22 Rocker Arm and Rocker Shaft Inspection Note 4 13 Carburetor Holders 4 23 Cylinder Head manaa 4 14 Removal 4 23 Cylinder Compression Measurement 4 14 Installation 4 23 4 14 Mutffler mm 4 23 Installation una 4 14 Removal ull u S Sa cela nna ai 4 23 Valves cesses m 4 15 Installation 4 23 NGN TOP ND 4 Exploded View ENGINE TOP END 4 3 T 2 Y d T1 8 8 0 9 kg m 78 in ib T2 9 8 N m 1 0 kg m 7 0 ft Ib 12 N m 1 2 kg m 8 5 ft lb T4 25 N m 2 5 kg m 18 0 ft Ib L Apply a non permanent locking agent to the threads M Apply molybdenum disulfide grease SS Apply silicone sealant to the threads 4 4 ENGINE TOP END Specifications x hmm sma Camshaft Cam height Inlet 31 778 31 918 mm 4 31 68 mm Exhaust 31 469 31 609 mm 31 37 mm Camshaft camshaft cap clearance A 0 028 0 071 mm 0 16 mm B 0 078 0 121 mm 0
99. earance Standard 0 05 0 20 mm Service Limit 0 40 mm Main Bearing Insert Selection Crankshaft Main Journal Diameter Crankcase Main Bearing Bore Diameter Mark Crankshaft Bearing Insert EZE 92028 1419 1 2 3 4 The bearing inserts for No 5 has oil groove 8 14 CRANKSHAFT TRANSMISSION Transmission Shift Pedal Removal Remove the left lower fairing see Frame chapter Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position Remove the shift lever and shift pedal Shift Pedal Installation Apply grease to the shift pedal pivot Tighten the shift pedal mounting bolt to the specified torque If necessary adjust the pedal position from the standard position to suit you as follows Loosen the front and rear rod locknuts NOTE O The locknut next to the knurled portion of the rod has left hand threads Turn the rod to adjust the pedal position e Tighten the locknuts securely B Locknut External Shift Mechanism Removal Remove the following Engine Oil see Engine Lubrication System chapter Clutch Shift Pedal Pull out the shift mechanism arm with the shift shaft Remove the shift drum set lever spring and them remove set lever gt s A Shift Mechanism Arm C Set Lever Spring B Shift Drum Set Lever External Shift Mechanism Installation
100. ee Brakes chapter Loosen the drive chain Remove the side stand A Side Stand Bracket Bolts Place the jack under the frame to steady the motorcycle Disengage the chain from the rear sprocket and the engine sprocket Remove the swing arm shaft and pull it backward Remove the chain 10 6 FINAL DRIVE Drive Chain Installation e Installation is the reverse of removal Note the follow ing e Tighten the following fasteners to the specified torque Rear Shock Absorber Mounting Nuts Tie Rod Nuts Swing Arm Shaft Nut Rear Wheel Axle Nut Apply a non permanent locking agent to the side stand bracket bolts and tighten the specified torque see Frame chapter Adjust the drive chain see this chapter Sprocket Coupling Engine Sprocket Removal Loosen the drive chain see Drive Chain Slack Adjust ment e Remove the following Left Lower Fairing see Frame chapter Shift Pedal Engine Sprocket Cover A Bolts C Engine Sprocket Cover B Bolt locking agent Remove the engine sprocket plate Pull the engine sprocket off the output shaft along with the chain A Engine Sprocket Remove the engine sprocket Engine Sprocket Installation e Installation is the reverse of removal Note the follow ing Engage the sprocket with the drive chain so that hollow side faces inward e Tighten the sprocket plate bolt to the specified torque see Exploded View Apply a non per
101. el on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Rear Wheel Installation e Installation is the reverse of removal Note the follow ing Apply grease to the following Coupling Grease Seal Wheel Hub Grease Seal Caliper Holder Pivot e Adjust the drive chain after installation see Final Drive chapter e Tighten the following fasteners to the specified torque see Exploded View Axle Nut Caliper Mounting Bolts Check the rear brake Wheel Inspection Remove the tire from the wheel see Tire Removal Measure the rim runout by using the dial gauge Rim Runout 1 Radial Runout 2 Axial Runout rim runout exceeds the service limit check the wheel bearings see this chapter f the problem is not due to the bearings the wheel must be replaced Axial Runout Service Limit 0 5 mm Radial Runout Service Limit 0 8 mm AWARNING Never attempt to repair a damaged wheel If there is any damage besides wheel bearings the wheel must be replaced to insure safe operational condition Balance Weight Installation Check if the weight portion has any play on the blade and clip plate X if it does discard it Lubricate the balance weight blade tire bead and rim flange with a soap and water solution or rubber lubricant This helps the balance weight slip onto the rim flange Do not lubricat
102. elief pressure 93 123 kPa 0 95 1 25 kg cm 14 18 psi Thermostat Valve opening temperature Valve full opening lift 80 0 84 0 C 176 183 F Not less than 6 mm 95 C 203 F Special Tool Sealant Socket Wrench Hex 8 57001 1268 Kawasaki Bond Silicone Sealant 56019 120 3 4 COOLING SYSTEM Coolant Flow Chart When the engine is cold the thermostat is closed so that the coolant flow is restricted through the small hole air hole on the thermostat causing the engine to warm up more quickly Water Jacket 8 Cylinder Head 9 Hadistor Cap 10 Radiator Fan 11 Thermostatic Fan Switch AU 12 Radiator 13 Coolant Reservoir Tank Water Pump Water Pipe Hadiator Hose Radiator Hose Fitting Water Temperature Sensor Thermostat Coolant Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambient temperature Check the coolant level in the reservoir tank with the motorcycle held perpendicularly Check the coolant level from between the fuel tank and the flame at the left side If the coolant level is lower than the lower level line add coolant to the upper level line A Reservoir Tank B Upper Level a C Lower Level D Mounting Bolt For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion pro
103. emove the following Upper Fairing see Frame chapter Headlight Unit Speedometer Cable Upper End Wiring Connectors Remove the meter unit by taking off the mounting nuts Place the meter or gauge so that the face is up If a meter or gauge is left upside down or sideways for any length of time it will malfunction Bulb Replacement To remove the wedge base type bulb pull the bulb out of the socket Do not use bulb rated for greater wattage than the specified value Do not turn the bulb to prevent damage to the bulb ELECTRICAL SYSTEM 15 31 b A Puil the bulb Meter Gauge Assembly Note e Install each lead on the original position shown a r C BR Lead D BK Lead A W Y Lead B BK Y Lead Tachometer Inspection Check the tachometer circuit wiring see Tachometer Circuit and Wiring Inspection If all wiring and components other than the tachometer unit check out good the unit is suspect Check the unit as shown Remove the surge tank see Fuel System chapter e Remove the BK lead of the ignition coil e Turn the ignition switch ON e Open or connect the BK lead to the battery positive terminal using an auxiliary lead Then the pointer should flick e Turn the ignition switch OFF If the pointer does not flick replace the tachometer unit 15 32 ELECTRICAL SYSTEM A Tachometer B Pointer flicks Water Temperature Gauge Operation Inspection Prepare an auxiliary wire and che
104. ension Front Fork Clamp Bolts Front Fender Mounting Bolts Rear Shock Absorber Mounting Nuts Swing Arm Pivot Shaft Nut Uni Trak Link Nuts Steering Stem Head Nut Handlebar Mounting Bolts Engine Engine Mounting Bolts Cylinder Head Boits Muffler Connecting Pipe Clamp Bolts Muffler Mounting Bolt and Nut Muffler Connecting Clamp Bolts Clutch Lever Pivot Nut Others Side Stand Bolt Front Footpeg Mounting Bolts Footpeg Bracket Mounting Bolts Down Tube Mounting Bolts Standard Torque Table This table relating tightening torque to thread diameter lists the basic torque for bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value Refer to each chapter for reference to these features All of the values are for use with dry solvent cleaned threads General Fasteners Threads dis 100 13 5 190 25 45 62 33 45 74 10 0 54 72 11 5 160 83 115 17 0 23 125 165 23 33 165 240 Unit Conversion Table Prefixes for Units Prefix Symbol mega M x 1 000 000 kilo k x 1000 centi C x0 01 milli m x x 0 001 micro x 0 00001 Units of Mass kg X 2 205 Ib g X 0 03527 2 Units of Volume L X 0 2642 gal US L X 0 2200 gal imp L X 1 057 qt US L X 0 8799 qt imp L x 2 113 pint US L X 1 816 pint imp mL x 0 03381 oz US mL X 0 02816 oz imp mL x 0 06102 cu in Units of Force
105. er Free Play Brake Pedal Brake pedal free play Brake pedal position Non adjustable 43 mm below from center of brake pedal shaft Brake Light Switch Front Non adjustable Rear ON after about 10 mm pedal travel Brake Pad Lining Thickness Front 4 mm f Rear 4 mm Brake Discs Disc thickness Front 4 3 4 6 mm Rear 5 8 6 1 mm Disc runout 0 2 mm or under Special Tools Jack 57001 1238 Inside Circlip Pliers 57001 143 Brake Fluid Fluid Level Inspection In accordance with the Periodic Maintenance Chart inspect the brake fluid level in the front and rear brake fluid reservoir Check the brake fluid level in the reservoir NOTE O Hold the reservoir horizontal when checking brake fluid level The fluid level must be kept above the lower level lines If the fluid level is lower than the lower level line fill the reservoir to the upper level line of the reservoir AWARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that already is in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Mixing different types and brands of brake fluid lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate gt A Lower L
106. er motor is grounded e Apply small amount of engine oil to the O ring e Tighten the following fasteners to the specified torque see Exploded View NOTE Starter Motor Mounting Bolt No measurement is needed on H terminal Terminal Nut Starter Motor Disassembly Remove both end covers and pull the armature out of voke A Bolts B End Covers Be careful not to lose the brush springs e Remove the screw and take out the brushes e Unsolder the terminal and take out the brushes A Brushes B Brushes A Soldered Terminal ELECTRICAL SYSTEM 15 21 Starter Motor Assembly Note e inspect the O rings if it is not damaged e install the brushes and springs into the end cover holder O Clamp the brush leads with clips on the end cover and fix the springs NOTE OBe careful not to damage the leads and O rings e Pulli the armature out from the yoke and install it on the end cover brush side Fit the alignment projection on the yoke into the notches of the end cover Brush Inspection Measure the length of each brush any is worn down to the service limit replace the carbon brush holder assembly and the terminal bolt assembly Starter Motor Brush Length Standard Service Limit 7 0 mm 3 5 mm Commutator Cleaning and Inspection e Smooth the commutator surface if necessary with fine emery cloth and clean out the grooves as illustrated 15 22 ELE
107. ert and check clearance with a plastigage before assembling engine to be sure the correct bearing inserts are installed e Apply engine oil to the big end bearing inserts eTighten the big end cap nuts to the specified torque see Exploded View 1 Main Bearing Inserts 3 Big End Cap 2 Connecting Rod 4 Crankshaft Connecting Rod Big End Bearing Insert Crankpin Wear e Measure the bearing insert crankpin clearance with a lastigage Connecting Rod Installation p astigage To minimize vibration a pair of connecting rods left two rods or right two should have the same weight mark A Crankpin B Plastigage NOTE O Tighten the big end cap nuts to the specified torque see Exploded View O Do not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance 0 031 0 059 mm 0 10 mm Standard Service Limit If clearance is within the standard no bearing replace ment is required If clearance is between 0 059 mm and the service limit 0 10 mm replace the bearing inserts with inserts painted blue Check insert crankpin clearance with the plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure clearance exceeds the service limit measure the diameter of the crankpins Crankpin Diameter Standard Service Limit 29 984 30 000 mm 29 97 mm
108. es Friction Plate Wear Damage Inspection Friction or Steel Plate Warp Inspection Clutch Spring Free Length Measurement Clutch Housing Finger Inspection Clutch Hub Spline Inspection E CLUTCH 5 1 n 01 01 P P N 01 O YJ O O 5 2 CLUTCH Exploded View wi uu s am oe 2 T3 oe et L bt ERa Ay OX 2 C ey s ZZ 5 gt d Sas 2 P T1 12 N m 1 2 kg m 8 5 ft Ib T2 9 8 N m 1 0 kg m 7 0 ft lb 130 N m 13 5 kg m 98 16 L Apply a non permanent locking agent to the threads M Apply a thin coat of a molybdenum disulfide grease SS Apply silicone sealant to the threads Specifications Clutch Clutch lever free play Friction plate thickness Friction and steel plate warp Clutch spring fee length Special Tools Clutch Holder 57001 1243 ss CLUTCH 5 3 Standard Service Limit 2 3mm 2 7 2 9mm 0 2 mm or under 33 6 mm Sealant Kawasaki Bond Silicone Sealant 56079 120 5 4 CLUTCH Clutch Due to the fiction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accordance with the Periodic Maintenance Chart AWARNING To avoid a serious burn never touch the en
109. es show signs of damage replace the friction plates and steel plates as a set Measure the thickness of the friction plates at several points see Specifications if any of the measurements is less than the service limit replace the friction plate A Friction Plate Friction Plate Thickness Standard 2 7 2 9 mm Service Limit 2 5 mm 5 8 CLUTCH Friction or Steel Plate Warp Inspection Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate and each friction plate or steel plate The gap is the amount of friction or steel plate warp any plate is warped over the service limit replace it with a new one oe 1 Friction or Stee Plate 2 Thickness Gauge Friction and Steel Plate Warp Standard less than 0 2 mm Service Limit 0 3mm Clutch Spring Free Length Measurement Since the spring becomes shorter as it weakens check its free length to determine its condition any of the springs is shorter than the service limit it must be replaced A Clutch Spring Clutch Spring Free Length Standard 33 6 mm Service Limit 32 6 mm Clutch Housing Finger Inspection Visuaily inspect the fingers of the clutch housing where the tang of the friction plates hit them they are badly worn or if there are grooves cut where the tang hit replace the housing X Also replace the friction plates if their tangs are damaged A
110. evel Line B Upper Level Line Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water BRAKES 11 5 Brake Fluid Requirement Recommended fluids are given in the table below If none of the recommended brake fluids are available use extra heavy duty brake fluid only from a container marked D O T 3 Recommended Disc Brake Fluid D 0 T 3 Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty Castrol Girling Universal Castrol GT LMA Castrol Disc Brake Fluid Changing Brake Fluid Remove the rubber cap on the bleed valve OG Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container Open the bleed valve counterclockwise to open and pump the brake lever or pedal until all the fluid is drained from the line Close the bleed valve e Remove the reservoir cap Fill the reservoir with fresh brake fluid Install the reservoir cap Open the bleed valve apply the brake by the brake lever or pedal close the valve with the brake held applied and then quickly release the lever or pedal Repeat this operation until the brake line is filled and fluid starts coming out of the plastic hose NOTE O Replenish the fluid in the reservoir as often as necessary to keep it from running complete
111. f ON A S Z d l ities 37 YN i 4 mW V v7 4 gt 7 A 1 Stem Head Nut 2 Stem Nut Wrench 57001 1100 If the steering is too tight loosen the stem locknut a fraction of a turn If the steering is too loose tighten the locknut a fraction of turn NOTE O Turn the locknut 1 8 turn at a time maximum eTighten the following bolts and nut to the Ee torque see Exploded View Steering Stem Head Nut Front Fork Lower Clamp Bolts Check the steering again If the steering is still too tight or too loose repeat the adjustment Steering Stem Removal Remove the following parts Surge Tank see Fuel System chapter Upper and Lower Fairings see Frame chapter Front Fork Legs see Suspension chapter Brake Hose Joint Steering Stem Head Nut Stem Head Handlebar Handie Holder Push up on the stem base and remove the steering stem locknut using the stem nut wrench special tool 57001 1100 then remove the steering stem base e Remove the upper tapered roller bearing inner race e To remove the outer races pressed into the head pipe install the outer race remover special tool as shown below NOTE O f either steering stem bearing is damaged it is recommended that both the upper and lower bearings including outer races should be replaced with new ones 1 Outer Race Remover 57001 1107 e Remove the lower tapered roller bearing
112. ft side clearance 0 05 0 20 mm Crankshaft runout 0 02 mm or less Crankshaft main bearing insert journal clearance Crankshaft main journal diameter 0 40 mm 0 05 mm TIR 0 014 0 038 mm 29 984 30 000 mm 0 08 mm 29 96 mm Marking None 29 984 29 992 mm 1 29 993 30 000 mm Crankcase main bearing bore diameter 33 000 33 016 mm Marking O 33 000 33 008 mm None 33 009 33 016 mm Crankshaft main bearing insert thickness Brown 1 491 1 495 mm Black 1 495 1 499 mm Blue 1 499 1 503 mm CRANKSHAFT TRANSMISSION 8 5 Item Standard Service Limit Crankshaft main bearing insert selection Bearing Bore Journal Diameter 92028 1418 92028 1421 92028 1420 1 2 3 4 92028 1419 1 2 3 4 8 o Ne 01 2 The bearing inserts for No 5 has no oil groove Transmission Shift fork ear thickness 4 9 5 0 mm Gear shift fork groove width 5 05 5 15 mm Shift fork guide pin diameter 5 9 6 0 mm Shift drum groove width 6 05 6 20 mm 8 6 CRANKSHAFT TRANSMISSION Special Tools Sealant Socket Wrench Hex 8 57001 1268 Kawasaki Bond Silicone Sealant 56019 120 Crankcase Crankcase Splitting e Remove the engine see Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while parts are being removed e Remove the following Cylinder Head if the crankshaft is to be rem
113. ghtened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter trouble Miscellaneous Throttle valve won t fully open Vacuum piston doesn t slide smoothly Brake dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect IC igniter trouble Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bow too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct poorly sealed Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high APPENDIX 16 5 Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect Water temperature gauge broken Water temperature sensor broken Coolant incorrect Coolant level too low Coolant deteriorated Cooling s
114. gine or exhaust pipe during clutch adjustment Clutch Adjustment Check Pull the clutch lever just enough to take up the free play e Measure the gap between the lever and the lever bracket A Adjuster B Locknut C Clutch Lever Free Play 2 3mm If the gap is too wide the clutch may not release fully If the gap is too narrow the clutch may not engage fully In either case adjust the clutch Clutch Adjustment Loosen the knurled locknut at the clutch lever e Turn the adjuster so that the clutch lever will have 2 3 mm of play e Tighten the locknut if it cannot be done use the adjusting nuts at the lower end of the cable e Remove the fairings pa eremo A Fairing Mounting Screws B Fairing Mounting Bolts Loosen the lower cable adjusting nuts at the clutch cover as far as they will go A Adjusting Nuts C Pull Outer Cable B Bracket Loosen the knurled locknut at the clutch lever eTurn the adjuster so that 5 6 mm of threads are visible i AX d a rm eme ii et A x A Adjuster B Locknut 6mm e Pull the clutch cable tight and tighten the lower cable adjusting nuts against the bracket e Turn the adjuster at the clutch lever until the free play is Correct At this time check that the clutch release lever to clutch cable angle is 80 90
115. he idie adjusting screw with the throttle grip released and stops against the carburetor stopper with the throttle grip opened 2 6 FUEL SYSTEM Choke Cable Surge Tank Choke Cable Adjustment Surge Tank Removal Remove surge tank see this chapter e Remove the fuel tank this chapter Check choke cable free play Remove the surge tank O Remove the fuel tank see Fuel Tank Removal O Determine the amount of choke cable play at the choke lever Pull the choke lever until the starter plunger lever at the carburetor contacts with the starter plunger the amount of choke lever lower end travel is the amount of choke cable play Ag us o A Surge Tank Mounting Bolt Install the air cleaner element so that the mesh side faces the carburetor A Starter Plunger Lever C Play B Starter Plunger Choke Cable Play Standard 2 3mm If the play is incorrect loosen the locknut and turn the adjuster at the middie of the cable until the proper amount of choke cable play is obtained A Air Cleaner Element B Mesh Side A Adjuster B Locknut e Tighten the locknut against the adjuster securely Air Cleaner Element Cleaning AWARNING Clean the element in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gas
116. he adjuster bottom and the spring prelaod adjuster end is 25 mm Pee F i Furs cf E A 25 mm Olnstall the main spring onto the push rod so that the closed side is upward O Install the top spring and collar onto the push rod O Press the top spring down with drivers and insert the fork spring stopper special tool between the piston rod and the top spring O Tighten the top bolt finger tight OWhile holding the fork top boit tighten the rod nut to the specified torque see Exploded View NOTE O Do not remove the fork spring stopper special tool while pressing the top spring down so that the spring cause the force against the rod nut O Install the top bolt in the outer tube Rear Shock Absorber Rebound Damping Force Adjustment The rebound damping force adjuster at the lower end of the rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions The numbers on the adjuster show the setting position A Rebound Damping Force Adjuster B Number If the damping feels too soft or too stiff adjust it in accordance with the following table Position Damping Force OThe standard setting position of the adjuster for an average build rider of 68 kg 150 Ib with no passenger and no accessories is No 1 e Turn the rebound damping force adjuster to the desired number until you feel a click
117. he fasteners following the specified 25 34 26 35 190 25 sequence 44 61 45 62 33 45 73 98 74 100 54 72 115 155 11 5 160 83 115 165 225 17 0 230 125 165 225 325 23 33 165 240 SS Apply silicone sealant St Stake the fasteners to prevent loosening Fastener Nm kgm fti Cooling System Coolant Drain Plugs Cylinder Thermostatic Housing Bolt cylinder head Thermostatic Fan Switch Water Temperature Sensor Water Pump Mounting Bolt Water Pump Pipe Mounting Bolt Radiator Hose Clamp Bolts Radiator Horse Fitting Mounting Bolt cylinder Radiator Fan Mounting Bolt Engine Top End Cylinder Head Cover Bolts I 1 0 Cylinder Head Cover Woodruff Plug Mounting _ Camshaft Chain Guide Bolt Rear 2 5 Chain Tensioner Mounting Bolt Rocker Shaft Plug 1 0 Upper Chain Guide Bolt 1 2 Inlet Pipe Mounting Bolt carburetor holder p Outlet Pipe Mounting Bolt cylinder head 78 in i Camshaft Cap Bolts 1 2 8 5 Cylinder Head Bolts 8 mm 2 5 18 0 6 mm 1 2 8 5 Clutch Clutch Cover Mating Surfaces _ 55 Clutch Cover Bolts 0 90 78 L two bolts Clutch Cover Damper Bolts 1 0 7 0 L Clutch Hub Nut 13 5 98 R Clutch Spring Bolts 2 8 5 Engine Lubrication System Engine Drain Plug 2 0 Oil Hose Mounting Bolt cylinder head crankcase 0 90 Oil Filter 1 0 or hand tight Oil Filter Mounting Bolt 3 0 Oil Pressure Relief Valve 1 5 1 10 GE
118. id Seal Be sure to install the following A Piston Insulators B O Rings Tighten the caliper assembly bolts to the specified torque see Exploded View BRAKES 11 11 Brake Pads Front Brake Pad Removal Remove the following Pad Spring Clip Pad Pin 1 hs P amp Clip Remove the brake pads Rear Brake Pad Removal Remove the following Rear Caliper see this chapter Plastic Pad Cover Clips Pad Pins Springs 11 12 BRAKES Lining Wear For front caliper pad inspection remove the pad spring see Front Caliper Removal For rear caliper pad inspection remove the rear caliper see this chapter Remove the pad cover the lining thickness of either pad is less than the service limit replace both pads in the caliper as a set Pad Lining Thickness front and rear Standard 4 mm Service Limit 1 mm 1 Springs 3 Pad Pins 2 Clips 4 Outside Remove the brake pads Installation Notes e Push the caliper pistons by hand as far as they will go e Install the pad pin s and clip s as shown The clip s must be outside of the pads Ta e T 1 A Spring For the rear caliper install the springs pad pins and clips on the original position shown see Rear Brake Pad Removal A Service Limit A WARNING Do not attempt to drive the motorcycle until a f
119. inder head So if a cap is installed in a wrong location the camshaft may seize because of improper oil clearance in the bearings e Tighten the camshaft cap bolts to the specified torque see Exploded View e Install the camshaft chain tensioner e install the pickup coil cover noting the following O Apply silicone sealant to the following Crankcase Parting Line Grommet 4 12 ENGINE TOP END A Apply silicone sealant Apply a non permanent locking agent to the following boit only Camshaft Camshaft Cap Wear Measure each clearance between the camshaft and the camshaft cap using plastigage press gauge NOTE O Tighten the camshaft cap bolts to the specified torque see Exploded View A Plastigage Width NOTE ODo not turn the camshaft when the plastigage is between the journal and camshaft cap any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Camshaft Cap Clearance 1 44 Journals Standard 0 028 0 071 mm Service Limit 0 16 mm 2 3 Journals Standard 0 078 0 121 mm Service Limit 0 21 mm If the camshaft journal diameter is less than the service limit see Specifications replace the camshaft with a new one and measure the clearance again If the clearance still remains out of the limit replace the cylinder head unit Camshaft Chain Wear Hold the chain taut with a force of about 5 kg in som
120. ine Air Bleed Brake Drag Braking Power Brake Fluid Leakage Disassembly e Remove the following parts Dust Cover Retainer Piston with Secondary Cup Primary Cup Spring CAUTION Do not remove the secondary cup from the piston since removal will damage them 5 Brake Lever Pivot Bolt Nut 2 Piston 6 Front Brake Light Switch 3 Secondary Cup 7 Boot 4 Retainer 11 14 BRAKES Assembly assembly clean all parts including the master cylinder with brake fluid or alcohol Apply brake fluid to the removed parts and to the inner wall of the cylinder Except for the disc pads and disc use only disc brake fluid isopropy alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake e Take not to scratch the piston or the inner wall of the cylinder Inspection Visually Check that there are no scratches wear rust or pitting on the following parts Inside of the Master Cylinder Outside of the Piston Primary Cups Secondary Cups Dust Covers Return Springs Relief and Supply Port Plugged If they are damaged replace them 1 Reservoir 7 Primary Cup 2 Diaphragm 8 Piston 3 Relief Port 9 Secondary Cup
121. ion to the following items 1 Spacer 9 Stee Plate 2 Needle Bearing 10 Washer 3 Collar 11 Hub Nut 4 Clutch Housing 12 Pusher 5 Washer 13 Bearing 6 Clutch Hub 14 Spring Plate 7 Clutch Cam 15 Ciutch Spring 8 Friction Plate 16 Retainer Olnstall the spacer with the chamfered side facing inwards O instali the clutch cam on the clutch hub O Discard the used hub nut and install a new nut O Install the clutch holder special tool 57001 1243 to keep the clutch hub from turning and tighten the clutch hub nut to the specified torque see Exploded View O Install the friction plates and steel plates starting with a friction plate and alternating them Olnstall the last friction plate fitting the tangs the groove on the housing as shown 1 Last Friction Plate OApply molybdenum disulfide grease to the pusher end and ball bearing CLUTCH 5 7 If new dry steel plates and friction plates are install ed apply engine oil to the surfaces of each plate to avoid clutch plate seizure OWhen install the spring plate align the marks on the hub and the plate A Marks OTighten the clutch spring bolts to the specified torque see Exploded View Friction Plate Wear Damage Inspection e Visually inspect the friction plates to see if they show any signs of seizure overheating or uneven wear x if any plat
122. is running above idle speed stop the engine immediately and find the cause ENGINE LUBRICATION SYSTEM 6 7 Engine Oil Change e Support the motorcycle perpendicular to the ground after warming up the engine e Remove the engine drain plug to drain the oil A Drain Plug B Front The oil in the filter can be drained by removing the filter see Oil Filter Change xk Replace the drain plug gasket with a new one if it is damaged eTighten the drain plug to the specified torque see Exploded View Pour in the specified type and amount of oil Engine Oil Grade SE or SF class Viscosity SAE 10W 40 Amount 3 0 L filter is removed 2 8 L filter is not removed Oil Filter Change Remove the lower fairing Drain the engine oil see this chapter Remove the oil filter with the oil filter wrench T i 4 2 A Oil Filter Replace the filter with a new one When installing the oil filter be careful of the following O Apply oil to the gasket before installation 6 8 ENGINE LUBRICATION SYSTEM OTighten the filter with the oil filter wrench to the specified torque see Exploded View or tighten it with hands about turns after gasket contacts the mounting surface of engine Pour in the specified type and amount of oil Oil Pan Removal Set the motorcycle its side stand e Remove the following Lower Fairings see Frame
123. itable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants 17 Electrical Wires All the electrical wires are either single color or two color and with only a few exceptions must be connected to wires of the same color On any of the two color wires there is a greater amount of one color and a lesser amount of a second color so a two color wire is identified by first the primary color and then the secondary color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed to make red the main color Wire cross section Name of Wire Color Hed Wire Strands Yellow Red Yellow Red 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed These replacement parts will be damaged or lose their original function once removed
124. le jet 6 N77C 35 Jet needle mark Pilot jet slow jet Pilot air jet 120 Pilot screw 2 turns out Starter jet 45 Service fuel level 8 1 mm below the mark Float height 11 x2mm Air Cleaner Air cleaner element oil Grade Viscosity SE or SF class SAE 30 Special Tools Vacuum Gauge amp Tachometer 57001 1291 Pilot Screw Adjuster A 57001 1239 I Fuel Level Gauge 57001 1017 Throttle Grip and Cables Throttle Cable Adjustment Check throttle grip free play A Throttle Grip Free Play Throttle Grip Free Play Standard 2 3mm the free play is incorrect loosen the locknut and turn the adjuster of the accelerator cable until the proper amount of throttle grip piay is obtained B Adjuster A Locknut Tighten the locknut against the adjuster securely If the play can not be adjusted by using the adjuster at the throttle grip use the adjusters at the carburetors Remove the fuel tank see Fuel Tank Removal e Remove the surge tank see Surge Tank Removal Screw in the adjuster fully at the throttle grip and tighten the locknut FUEL SYSTEM 2 5 i 7 A Accelerator Cable B Adjuster C Locknut D Decelerator Cable Loosen all the adjuster and slide both throttle cables at the carburetor to obtain the specified free play Tighten the locknuts e Check that the throttle linkage lever stops against t
125. liper trouble Other noise Bracket nut bolt etc not properly mounted or tightened Oil Pressure Warning Light Goes On Engine oil pump damaged Engine oil screen clogged Engine oil level too low Engine oil viscosity too low Camshaft bearings worn Crankshaft bearings worn Oil pressure switch damaged Wiring damaged Relief valve stuck open O ring at the oil passage in the crankcase damaged Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level to high Black smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner O ring damaged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Steering stem locknut too tight Bearing damaged Steering bearing lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swing arm pivot bearings worn Rim warped or not balanced Wheel bearing worn Handlebar mounting bolt loose Steering stem head nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swing arm bent or twisted Steering maladjusted Front fork bent Right left fork legs unbalanced oil level air pressure anti dive setting Shock absorption unsatisfactory Too h
126. llation Grease the following Ball Bearing Coupling Grease Seal Coupling Internal Surface A Grease here Brakes Table of Contents Exploded View Specifications Special Tools Brake Fluid b Fluid Level Inspection Brake Fluid Change Brake Fluid Requirement Brake Pedal Position Adiustment Rear Brake Light Switch Adjustment Calibers ou lu Front Caliper Removal Rear Caliper Removal Caliper Installation Front Caliper Disassembly Rear Caliper Disassembly Assembly Notes Brake Pads T Front Brake Pad Removal Rear Brake Pad Removal Installation Notes Lining Master Cylinders eee Front Master Cylinder Installation Rear Master Cylinder Removal Notes Rear Master Cylinder Installation Notes Inspection an
127. llows O Connect a clear plastic hose to the bleed valve at the caliper running the other end of the hose into a container O Pump the brake lever or pedal a few times until it comes hard O Holding the brake applied quickly open turn counter clockwise and close the valve O Repeat this operation until no more air can be seen coming out into the plastic hose OCheck the fluid level in the reservoir every so often replenishing it as necessary 1 Open the bleed valve 2 Apply the brake and hold it 3 Close the bleed valve 4 Then quickly release the brake Bleeding the Brake Line When working with the disc brake observe the precautions listed below Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be in effective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil
128. lt 6 Axle Holder CAUTION Be sure to hold the outer tube at disassembling Or the piston cylinder unit could loosen and the bottom Allen bolt cannot be removed 12 10 SUSPENSION Assembly Replace the bottom Allen bolt gasket with new one e Replace the following with new ones whenever they have removed from inner tube Oil Seal Dust Seal e Visually inspect the following and replace them if necessary Guide Bush O ring of the Top Bolt e Remove the guide bush from the inner tube and cover the groove with vinyl for installing new dust seal and oil seal Install the following onto the inner tube Dust Seal Oil Seal spring force upward Guide Bush outer tube side e Install the following into the outer tube using the seal driver special tool Guide Bush outer tube side Washer Oil Seal 1 Fork Oil Seal Driver 57001 1288 2 Oil Seal e Apply a non permanent locking agent to the Allen bolt and tighten it to the specified torque see Exploded View Insert the push rod in the piston rod Pour in the specified type and amount of oil see Fork Oil Change e Tighten the fork top bolt O Tighten the rod nut finger tight O Check that the visible thread length is at least 12 mm A 12 mm or more C Piston Rod B Rod Nut OTurn the spring preload adjuster fully counterclockwise until the adjuster stops O Screw in the rebound damping adjuster on the top bolt so that the distance between t
129. lve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully open to allow more air to reach the engine No spark spark weak Battery voltage low Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap not in good contact Spark plug incorrect C igniter trouble Neutral starter lockout or side stand switch trouble Pickup coil trouble Ignition coil trouble Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Battery voltage low Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble Ignition coil trouble Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged poorly sealed or missing Starter plunger stuck open Fuel level in carburetor float b
130. ly out Bleed the air from the lines continue with Bleeding the Brake Filling up the Brake Line 11 6 BRAKES Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongly and there will be a loss in braking power e Bleed the air from the brake whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed or whenever a brake line fitting has been loosened for any reason Check that there is plenty of fluid in the reservoir O The fluid level must be checked several times during the bleeding operation and replenished as necessary see Brake Fluid Change X If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line With the reservoir cap off slowly pump the brake lever or pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the master cylinder end of the line brake lever or pedal action still feels soft or spongy bleed the remaining air as fo
131. m flange Discard the used balance weight Removing Balance Weight with tire on rim Tires Tire Air Pressure Inspection NOTE O Measure the tire pressure when the tires are cold that is when the motorcycle has not been ridden more than a mile during the past 3 hours Front Up to 181 kg 225 kPa 401 Ib 2 25 kg cm 32 psi Rear Up to 181 kg 250 kPa 401 Ib 2 50 kg cm 36 psi Tire Inspection e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Measure the tread depth at the center of the tread with a depth gauge 1 Depth Gauge If any measurement is less than the service limit replace the tire Tire Tread Depth Front Standard 4 0 mm Service Limit 1 mm Rear Standard 6 0 mm Service Limit 2 mm Up to 130 km h 3 mm Over 130 km h Removal e Remove the following Wheel see this chapter Disc s Valve Core let out the air e To maintain wheel balance mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position 1 Chalk Mark or Yellow Mark 2 Valve Stem Ge Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire Remove the tire from the rim using a suitable c
132. manent locking agent to the engine sprocket cover boit one bolt only see Exploded View Rear Sprocket Removal Remove the rear wheel see Wheels Tires chapter Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Pull out the rear wheel coupling from the rear wheel Remove the rear sprocket nuts Remove the rear sprocket Rear Sprocket Installation e Installation is the reverse of removal Note the follow ing O Install the sprocket facing the tooth number marking outward A Tooth Number Marking Tighten the rear sprocket nuts to the specified torque see Exploded View ef the stud bolt is to be replaced apply a non permanent locking agent to the lower half of the stud bolt Install the rear wheel see Wheels Tires chapter Rear Sprocket Wear e Visually inspect the rear sprocket teeth If the teeth are worn as illustrated replace the sprocket and inspect the drive chain and engine sprocket see Drive Chain Wear Inspection CAUTION If a sprocket requires replacement the drive chain is probably worn also Upon replacing the rear sprocket inspect the chain and engine sprocket FINAL DRIVE 10 7 NOTE O Sprocket wear is exaggerated for illustration Sprocket Teeth Worn Tooth Rear Sprocket Worn Tooth Engine Sprocket Direction of rotation Coupling Insta
133. may be poorly routed or they may be damaged Correct any problem before operating the motorcycle A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition Check idle speed idie Speed Standard 1200 50 r min rpm OG Turn the idle adjusting screw until idle speed is correct A Idle Adjusting Screw Service Fuel Level Adjustment A WARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the fuel tank and air cleaner housing see this chapter Connect a fuel tank to the carburetors with a suitable hose Prepare a fuel hose 6 mm in diameter and 300 mm in length Connect the fuel level gauge special tool to the carburetor float bow with the fuel hose Situate the motorcycle so that it is perpendicular to the ground Check the fuel level as shown OTurm out the carburetor drain plug a few turns Wait until the fuel level in the gauge settles NOTE O Keeping the gauge vertical align the top line with the mark on the carburetor body right side Then turn out the drain plug to feed fuel to the gauge A Fuel Level Mark B Fuel Level Gauge 57001 1017 Service Fuel Level 8 1 mm below the mark on the
134. moval Note the follow ing e Install the new cylinder head gasket with new one e When the engine is mounted on the frame install the chain guide rear side into the cylinder head and tighten the mounting bolt to the specified torque see Exploded View e Beforehand install the chain guide into the cylinder head e Tighten the following bolts to the specified torque see Exploded View Camshaft Chain Guide Bolt rear side Cylinder Head Bolts Camshaft Cap Bolts Upper Chain Guide Bolts Oil Hose Mounting Bolts Engine Mounting Bolts Tighten the cylinder head bolts following the tightening sequence Install the chain guide front side 1 Chain Guide front side ENGINE TOP END 4 15 Valves Valve Clearance Adjustment NOTE OValve clearance must be checked and adjusted when the engine is cold at room temperature e Remove the following Cylinder Head Cover Spark Plug Retainer Using a thickness gauge measure the valve clearance between the rocker arm and the cam OWhen positioning 4 piston TDC at the end of the compression stroke inlet valve clearance of 2 and 4 cylinders exhaust valve clearance of 3 and 4 cylinders see Camshaft Removal Measuring Valves 1 Exhaust Valves 3 Cylinder Numbers 2 inlet Valves OWhen positioning 1 piston TDC at the end of the compression stroke inlet valve clearance of 1 and 3 cylinders exhaust valve clearance of 1 and 2 cylinders
135. nal and the black yellow lead terminal to the battery terminal momentarily The bulb should now light and stay on until the bulb circuit is opened 5 Y Lead Terminal 6 Y2 Lead Terminal 7 Lead Terminal 1 Regulator Rectifier 2 Test Light 3 12 V Battery 4 BK Y Lead Terminal CAUTION The test light works as an indicator and also as a current limiter to protect the regulator rectifier from excessive current Do not use an ammeter instead of a test light 1 Regulator Rectifier 6 BR Lead Terminal 2 Test Light 7 BK Y Lead Terminal 3 12 V Battery 8 Y Lead Terminal 4 12 V Battery 9 Y2 Lead Terminal 5 12 V Battery 10 Y3 Lead Terminal Do not apply more than 24 volts If more than 24 volts is applied the regulator rectifier may be damaged Do not apply 24 V more than a few seconds If 24 volts IS applied for more than a few seconds the regulator rectifier may be damaged 15 16 ELECTRICAL SYSTEM Repeat the above three steps for other two yellow leads in connector 2 which leads to the regulator rectifier Replace the regulator rectifier if the bulb does not light as described above NOTE OThe above test is not foolproof If the above checks show the regulator rectifier is not damaged but there is still trouble in the charging system first carefully inspect the alternator battery wiring and all connections Replace the regulator rectifier if all these other components turn ou
136. nd Ciutch Lever Brake Lever Brake Pedal Points Lubricate with Grease Throttle Inner Cable Lower End Speedometer Inner Cable Grease the lower part of the inner cable sparingly Cables Lubricate with Cable Lubricant Choke Cable Throttle Cables Clutch Cabie Cable Lubrication 2 C Me 1 Cable 2 Pressure Cable Luber K5601 9 021 16 8 APPENDIX Nut Bolt and Fastener Tightness Tightness Inspection e Check the tightness of the bolts and nuts listed Here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature kif there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications 1f torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by1 2 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 Clamp Bolts Rear Axle Nut Chain Adjusting Bolt Locknut Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts Torque Link Nuts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin Susp
137. nd adjust the steering Bearing Wear Damage Replace the bearing assemblies if they show damage Stem Cap Deterioration Damage Replace the grease seal if necessary Steering Stem Warp the steering stem shaft is bent replace the steering stem Frame Table of Contents Front Seat Installation Rear Seat Removal Rear Seat Installation Side Covers Side Cover Removal Fairings Upper Fairing Removal Lower Fairing Removal FRAME 14 1 14 2 14 5 14 5 14 5 14 5 14 5 14 6 14 6 14 6 14 6 14 6 14 2 FRAME Exploded View To take the ducts oul remove the duct pawls from the inside of the 2 8 e fuel tank L Apply a non permanent locking agent to the threads FRAME 4 4 RAM 5 kg m Ib T1 25 T2 31 ft kq m Apply qrease he ing Apply non permanen threads FRAME 14 5 Seats Front Seat Removal Remove the front seat mounting bolt move it upward and slide it forward A Seat Lock B Seat Mounting Belt Rear Seat Installation e install the seat mounting belt e Slip the hooks of the rear seat under the brace on the A Mounting Bolt frame and put the stoppers of the seat into the holes in the frames Front Seat Installation e Slip the hooks of the front seat under the brace on the frame A Hook C Stoppers B Brace D Holes
138. ng rod big end and the bearing insert Do not apply molybdenum disulfide grease to the inner surface of the big end cap between the big end cap and the bearing insert 8 12 CRANKSHAFT TRANSMISSION 1 Apply molybdenum disulfide grease 3 Oil 2 Do not apply grease 4 Big End Cap Crankshaft Main Bearing Journal Wear e Measure the bearing insert crankshaft main journal clearance with a plastigage A Crankshaft Main Journal B Plastigage NOTE Tighten the crankcase bolts to the specified torque see Exploded View ODo not turn the crankshaft during clearance measure ment OJournal clearance less than 0 025 mm can not be measured by plastigage however using genuine parts maintains the minimum standard clearance Crankshaft Main Bearing Insert Journal Clearance Standard 0 014 0 038 mm Service Limit 0 08 mm clearance is within the standard no bearing replace ment is required If clearance is between 0 038 mm and the service limit 0 08 mm replace the bearing inserts with inserts painted blue Check insert journal clearance with the plastigage The clearance may exceed the standard slightly but it must not be Jess than the minimum in order to avoid bearing seizure clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft Main Journal Diameter 29 984 30 000 mm 29 96 mm Standard Service Limit any journal has worn past th
139. nspection e p Pump Operational Inspection Meters Gauges BOmnoUala Bulb Replacement on Meter Gauge Assembly Note or Tachometer Inspection Water Temperature Gauge Operation Inspection Water Temperature Sensor Inspection Fan Switch Inspection Junction Box TUR Fuse Removal Fuse Installation Fuse Inspection Junction Box Fuse Circuit Inspection Starter Circuit Diode Circuit Inspection Electrical Wiring ninm Wiring Inspection MN cO 15 2 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems Learn and observe all the rules below O Do not reverse the battery lead connections This will burn out the diodes in the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface
140. ocker Arm Nuts one portion one bolt only GENERAL INFORMATION 1 11 em fe Tie Rod Nuts Steering Steering Stem Head Nut Handlebar Mounting Bolts Handlebar Holder Allen Bolts Handle Holder Clamp Bolt Frame Fairing Inner Cover Mounting Screws L engine side Side Stand Bracket Bolts 23 L Electrical System Spark Plugs 113 in lb Pickup Coil Cover Bolts 78in lb bolt only Pickup Coil Bolt 56 in Ib Timing Rotor Allen Bolts 18 0 Alternator Alternator Cover Bolts Alternator Rotor Bolt Alternator Stator Allen Bolt Alternator Stator Lead Clamp Bolt Alternator Cover Mating Surfaces Starter Motor Mounting Bolts Starter Motor Clutch Allen Bolt Battery Ground Lead Bolt Crankcase 1 12 GENERAL INFORMATION Cable Wire and Hose Routing Run the cable into the clamp 1 Clutch Cable 2 Choke Cabie 3 Throttle Cable 4 Speedometer Cable NN e A gt Clamp JN Install the cable elbow YN in parallel with the frame gt Vd center line GENERAL INFORMATION 1 13 1 Battery Vent Hose Transparent 2 Battery Vent Hose Black Battery Fuel Tank 3 Fuel Tank Breather Hose 4 Coolant Reservoir Tank Breather Hose Coolant Reservoir Tank Run the horse under the cross pipe Run the horses through backside of the swing arm pivot Battery Case View Looking at Top
141. oden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads 6 Edges Watch for sharp edges especially during major engine disassembly and assembly Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 7 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent commonly available in North America is Standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 8 Gasket O Ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 9 Liquid Gasket Non Permanent Locking Agent Follow manufacturer s directions for cleaning and preparing surfaces where these compounds will be used Apply sparingly Excessive amounts may block engine oil passages and cause serious damage An example of a non permanent locking agent commonly available in North America is Locktite Lock n Seal Blue 10 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 11 Ball Bearing When installing a ball bearing the bearing race which is affected by fric
142. odes can not be removed Fuse Removal Remove the seats see Frame chapter e Unlock the hook to lift up the locking arm e Pull the fuses straight out of the junction box with needle nose pliers Pull out the main fuse from the starter relay C Main Fuse Fuse Installation If a fuse fails during operation inspect the electrical system to determine the cause and then replace it with a new fuse of proper amperage ELECTRICAL SYSTEM 15 35 Fuse Inspection Remove the fuse see Fuse Removal inspect the fuse element If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit installation of a fuse with a higher rating may cause damage to wiring and components Fuse Housing Fuse Element Blown Element Terminals Junction Box Fuse Circuit Inspection Remove the junction box see Fuse Removal 9 Pull off the connectors from the junction box Make sure all connector terminals are clean and tight and none of them have been bent Clean the dirty terminals and straighten slightly bent terminals Check conductivity of the numbered terminals with the hand tester special tool if the tester dose not read as
143. oline or low flash point solvents to clean the element A fire or explosion could result Remove the surge tank see this chapter Take out the air cleaner element B Element Mesh A Air Cleaner Element AWARNING If dirt or dust is allowed to pass through into the carburetors the throttle may become stuck possibly causing accident Wash the element a bath of high flash point solvent and then dry it with compressed air or by shaking it After cleaning saturate a clean lint free towel with SE or SF class SAE30 oil and apply the oil to the element by tapping the foam side of the element with the towel enstall the element so that the mesh side faces the carburetor Oil Draining A drain hose is connected to the bottom of the air cleaner housing to drain oil accumulated at the bottom of the housing Drain oil by taking off the plug at the lower end of the drain hose FUEL SYSTEM 2 7 A Plug B Drain Hose Air Cleaner Housing Removal Remove the following Fuel Tank see Fuel Tank Removal Serge Tank Air Cleaner Element see Element Cleaning Crankcase Breather Hose e Remove the air cleaner housing A Plugs and Bolts C Bolts B Crankcase Breather Hose 2 8 FUEL SYSTEM Carburetors Idle Speed Adjustment Start the engine and warm it up thoroughly Turn the handlebar from side to side while idling the engine If idle speed varies the throttle cables
144. ommer cially available tire changer NOTE OThe tires cannot be removed with hand tools because they fit the rims too tightly Installation e inspect the rim and tire and replace them if necessary Ciean the sealing surfaces of the rim and tire and smooth the sealing surfaces of the rim with a fine emery cloth if necessary e Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve WHEELS TIRES 9 9 1 Plastic Cap 4 Valve Stem 2 Valve Core 5 Valve Seat 3 Stem Seal 6 Valve Opened e instal a new valve in the rim O Remove the valve cap lubricate the stem with a soap and water solution and pull the stem through the rim from the inside out until it snaps into place 1 Apply soap and water solution 2 Pull the stem out Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber a soap and water solution or rubber lubricant to the rim flange and tire beads Check the tire rotation mark on the front and rear tires and install them on the rim accordingly NOTE O The direction of the tire rotation is shown by an arrow on the tire sidewall 9 10 WHEELS TIRES l N 1 sx 1 Rotation Direction 2 Rotation Mark Arrow Position the tire on the rim so that the valve is at the tire balance mark the chalk mark made during removal or
145. ove the following Wheel see this chapter Oil Seals and Circlips Use the bearing remover special tool to remove the hub bearings 1 Bearing Remover Shaft 57001 1265 2 Bearing Remover Head CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Installation the bearings by using the bearing driver set special tools 57001 1129 NOTE O Install the bearings so that the marked or sealed side faces out Lubrication NOTE O Since the front and rear hub bearings are packed with grease and sealed they are not required to be removed for lubrication Clean and grease the rear hub bearings WHEELS TIRES 9 11 Speedometer Gear Housing Disassembly and Assembly NOTE Olt is recommended that the assembly be replaced rather than attempting to repair the components Install the speedometer gear housing so that it fits in the speedometer gear drive notches see Front Wheel Installation Lubrication Clean and grease the speedometer gear housing 1 Speedometer Gear Housing 2 Grease FINAL DRIVE 10 1 Final Drive Table of Contents Exploded View cous 10 2 Specifications 10 3 Special Tools 10 3 Drive 10 4 Drive
146. oved see Engine Top End chapter Cylinder Piston if the crankshaft is to be removed see Engine Top End chapter Starter Motor see Electrical System chapter Crankcase Bolt upper and lower if necessary remove the following Clutch see Clutch chapter External Shift Mechanism see this chapter Timing Rotor see this chapter Oil Pump see Engine Lubrication System chapter Alternator Rotor see Electrical System chapter Water Pump see Cooling System chapter Oil Filter Mounting Bolt Oil Pan Oil Pump Filter Oil Pipe e Gently tap the crankcase half with a plastic mallet and separate the crankcase halves Crankcase Assembly CAUTION The upper and lower crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set e With a high flash point solvent clean off the mating surfaces of the crankcase halves and wipe dry Using compressed air blow out the oil passages in the crankcase haives Install the oil pipe e Apply silicone sealant to the breather plate mating surface on the upper crankcase and then install the breather plate CRANKSHAFT TRANSMISSION 8 7 Apply non permanent locking agent to the plate mounting bolt see Exploded View SS Apply silicone sealant L Apply a non permanent locking agent 1 Breather Plate 2 Oil Return Hose 3 Oil Pipe SS Apply silicone sealant L Apply a non permanent locking agent 1 Left
147. ow too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other IC igniter trouble Carburetors not synchronizing Vacuum piston doesn t slide smoothly Engine oil viscosity too high Drive train trouble Brake dragging Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble ignition coil trouble Fuel air mixture incorrect Starter plunger stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Bleed holes of needle jet holder or needle jet clogged Air cleaner clogged poorly sealed or missing Air cleaner duct poorly sealed Water or foreign matter in fuel Carburetor holder loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Fuel filter clogged Compression low Spark plug loose Cylinder head not sufficiently ti
148. pen flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases Always remove the battery from the motorcycle for charging If the battery is charged while still installed battery electrolyte may spill and corrode the frame or other parts of the motorcycle Do not use a high rate battery charger as is typically employed at automotive service stations unless the charger rate can be reduced to the level required Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 115 F during charging reduce the charging rate to lower the temperature and increase charging time proportionately Check the electrolyte level after charging ELECTRICAL SYSTEM 15 11 Charging System Alternator Cover Removal Remove the lower fairing Set a suitable container under the engine Remove the alternator cover bolts using the socket wrench special tool 57001 1268 1 29 ni
149. perties The diluted coolant can attack the aluminum engine parts In an emergency soft water can be added But the diluted coolant must be returned to the correct mixture ratio within a few days If coolant must be added often or the reservoir tank has run completely dry there is probably leakage in the cooling system Check the system for leaks To remove the reservoir tank remove the fuel tank Coolant Draining AWARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury immediately wipe up or wash away any coolant that spills on the frame engine or wheels Since coolant is harmful to the human body do not use for drinking COOLING SYSTEM 3 5 Remove the fairings Place a container under the engine Remove the drain plug A Water Pump B Drain Plug Remove the following Radiator Cap Cylinder Drain Plugs A Cylinder Drain Plugs The coolant will drain from the radiator and engine Coolant Filling Tighten the drain plugs to the specified torque see Exploded View Fill the radiator up to the thermostat housing filler neck with coolant 3 6 COOLING SYSTEM d j Ph 1 Fa il Tug L V h a i md emm 1 1 3 X 1 pA af j i
150. r If the oil is above or below the specified level remove or add oil and recheck the oil level Tighten the fork top plug to the specified torque see Exploded View Change the oil of the other fork leg in the same manner e Adjust the rebound damping force and the spring preload see this chapter 12 8 SUSPENSION Removal Remove the following Lower Fairing Front Wheel Front Fender Mounting Bolts and Screws Fork Clamp Bolts upper and lower loosen Handle Holder Clamp Bolts loosen B Handle Holder Clamp Bolt i A Fork Clamp Bolts if the fork leg is to be disassembled loosen the fork top bolt A Fork Top Bolt e With a twisting motion work the fork leg down and out Installation e If the fork leg was disassembled adjust the fork oil level e Align the bottom of chamfer on the outer tube upper end with the upper surface of the steering stem head 2 Ce Le Hm A Tube B Steering Stem Head Tighten the following fasteners to the specified torque see Exploded View Fork Clamp Bolts upper and lower Front Fork Top Bolt if necessary Handle Holder Clamp Bolt Adjust the spring preload adjuster and the rebound damping adjuster see this chapter Check the front brake after installation Disassembly Remove the front fork see this chapter Drain the fork oil Turn the spring preload adjuster fully counterclockwise until th
151. rankcase until the seal is even with the end of the hole e install the collar 1 Oil seal is even with end of hole 2 Collar Check the following O Shift drum is in the neutral position OThe 1 and 4 pistons are at TDC Drive shaft and output shaft turn freely ONeutral finder operates properly while spinning the output shaft gears can be shifted from 1st to 2nd CRANKSHAFT TRANSMISSION 8 9 Crankshaft Connecting Rods Crankshaft Removal Remove the engine Remove the cylinder head cylinder and pistons Split the crankcase see Crankcase Splitting Take the crankshaft out of the upper crankcase Crankshaft Installation CAUTION If the crankshaft bearing inserts or crankcase halves are replaced with new ones select the bearing inserts and check clearance with a plastigage before assembl ing engine to be sure the correct bearing inserts are installed O Apply engine oil e Apply engine oil to the crankshaft main bearing inserts 8 10 CRANKSHAFT TRANSMISSION Connecting Rod Removal Remove the crankshaft Remove the connecting rods from the crankshaft NOTE O Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions 1 Big End 3 Weight Mark Alphabet 2 Connecting Rod If the connecting rods big end bearing inserts or crankshaft are replaced with new ones select the bearing ins
152. refully until the pressure reaches 123 kPa 1 25 kg cm 18 psi During pressure testing do not exceed the pressure for which the system is designed The maximum pressure is 123 kPa 1 25 kg cm 18 psi Watch the gauge for at least 6 seconds If the pressure holds steady the system is all right 3 Radiator Filler Neck 1 Pressure Tester 2 Adapter kif the pressure drops soon check for leaks Water Pump Removal Remove the fairings e Drain the coolant by removing the water pump drain plug e Remove the following Shift Lever Engine Sprocket Cover Radiator Hose Clamp on Water Pump Water Pipe Water Pump Mounting Bolts 2 E am A Water Pump B Mounting Bolts Pull the water pump out of the crankcase and the radiator hose Installation nstall the water pump with the water pump cover removed e Turn the water pump impeller so that the water pump shaft slot fits the oil pump shaft projection LI 1 k J A Water Pump Shaft B Pump Shaft e Install the water pipe e Tighten the following bolts to the specified torque see Exploded View Water Pump Mounting Bolts COOLING SYSTEM 3 7 Water Pump Pipe Mounting Bolt Radiator Hose Clamp Bolt Apply a non permanent locking agent to the engine sprocket cover bolt one bolt only see Final Drive chapter e Install the water pump cover e Fill the coolant see Coolant Filling Water P
153. retor holder so that the pipe is upward e Install the holder clamps as shown being careful of the screw position and the screw head direction 3 Screw Head 4 Stopper 1 Holder Clamp 2 Screw A WARNING Be sure to install the holder clamp screws in the direction shown Or the screws could come in contact with the throttle linkage resulting in an unsafe riding condition ENGINE TOP END 4 23 Muffler Removal Remove the following Lower Fairing Radiator Do not remove the hoses and not drain coolant Remove the nuts and take off the exhaust pipe holders v L 1 i Holder A Nuts Remove the muffler mounting bolt and nut rear step bracket Remove the muffler Installation Installation is the reverse of removal Replace the exhaust gaskets Clutch Table of Contents Exploded View Specifications Special Tools nennen Sealant Clutch Adjustment Check Clutch Adjustment Clutch Release Lever Removal Clutch Release Lever Installation Notes Clutch Cover Remowval Clutch Cover Installation Note Clutch Removal Em Clutch Installation Not
154. rk position rod puller special tool bleed the air in the fork oil by pumping the push rod A Fork Piston Rod Puller 57001 1298 B Piston Rod e Pull up the piston rod with the fork piston rod puller special tool NOTE OPull up the piston rod slowly so as not to spill the fork oil out of the fork tube e Measure the fork oil level Fork oil level may be measured using the oil syringe specia tool SUSPENSION 12 7 NOTE O Measure the fork oil level compressing the outer tube and piston rod down with the push rod installed O Set the oil syringe stopper so that its lower side shows the oil level distance specified NOTE The gauge tube is graduated in 1 cm division OThe syringe body is graduated in 10 mL division excluding the gauge tube of about 5 mL capacity Oil Level fully compressed without spring 94 2 mm from the top of the inner tube O With the fork fully compressed insert the gauge the into the inner tube and position the stopper across the inner tube top end NOTE O Position the stopper so that the gauge tube is the center of inner tube diameter or the specified oil level can not get correctly OPull the handle slowly to pump out the excess oil until the oil comes out no longer no oil is pumped out there is insufficient oil in the inner tube Pour in enough oil then pump out the excess oil as shown above A Oil Syringe 57001 1290C Oil Level Distance B Stoppe
155. s on the float bowl and pilot screws and the diaphragm on the vacuum piston are in good condition If of the O rings or diaphragms are not in good condition replace them Check the plastic tip of the float valve needle It should be smooth without any grooves scratches or tears Push and release 1 Plastic Tip 3 Rod 2 Valve Needle 4 Valve Needle Wear X if the plastic tip is damaged replace the needle e Check the tapered portion of the pilot screw for wear or damage 2 Tapered Portion 1 Pilot Screw kif the pilot screw is worn or damaged on the tapered portion it will prevent the engine from idling smoothly Replace it Fuel Pump and Filter A WARNING Gasoline is extremely flammable and can be explosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light br Be prepared for fuel spillage Removal Remove the following Right Side Cover see Frame chapter Fuel Hoses Disconnect the pump lead connector Remove the fuel pump and filter Installation Connect the fuel hoses O Install the fuel filter so that the arrow on it shows the fuel flow from the fuel tank to the fuel pump O Be sure to route the hoses so that they will not be kinked or stretched Fuel Pump Inspection Refer to the Electrical System chapter Fuel Filter
156. s resulting from insulation breakdown under high voltage Disconnect the primary leads from the coil terminals Measure the primary winding resistance Connect an ohmmeter between the coil terminals O Set the meter to the x 1 Q range and read the meter Measure the secondary winding resistance O Pull the spark plug cap off the lead O Connect an ohmmeter between the spark plug leads Set the meter to the x 1 and read the meter If the meter does not read as specified replace the coil Ignition Coil Winding Resistance 2 3 3 50 12 18 Primary Windings Secondary Windings Ignition Coil Winding Resistance 1 Measure primary winding resistance 2 Measure secondary winding resistance 3 Ignition Coil If the meter reads as specified the ignition coil windings are probably good Howewver if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be qood 15 18 ELECTRICAL SYSTEM Check the spark plug leads for visible damage If any spark plug lead is damaged replace the coil ignition System Wiring Diagram 1 IC Igniter 8 Ignition Coi 2 6 pin Connector 2 3 Cylinder 3 4 pin Connector 9 Spark Plug 4 2 pin Connector 10 4 pin Connector 5 Pickup Coil 11 6 pin Connector 1 4 Cylinder 12 Engine Stop Switch 6 Timing Rotor 13 ignition
157. shock absorber is scrapped drill a hole at a point shown to release the nitrogen gas completely Wear safety glasses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens A Rear Shock Absorber Mounting Bolt Nut lower B Tie Rod Bolt Nut lower O Using the jack special tool raise the rear wheel off the ground see Frame chapter Remove the shock absorber mounting bolt lower Remove the shock absorber mounting boit upper Remove the shock absorber towards the ground 1 42 44mm 2 Hole Installation e Tighten the following nuts to the specified torque see Exploded View Tie Rod Nut Shock Absorber Mounting Nuts Disassembly Since the rear shock absorber contains high pressure nitrogen gas do not remove or loosen the oil hose banjo bolt or disassemble the rear shock absorber SUSPENSION 12 13 Swing Arm Sleeve Inspection there is visible damage replace the sleeve the ball bearing and all the needle bearings as a set Swing Arm Removal Remove the following Rear Wheel see Wheels Tires chapter Shock Absorber Mounting Bolt lower Tie Rod Bolts upper Swing Arm Shaft Installation e Tighten the following fasteners to the specified torque see Exploded View Swing Arm Nut Shock Absorber Mounting Nut Tie Rod Nut Install the rear wheel see Wheels Tires chapter 12 14 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal
158. sing an ohmmeter measure the internal resistance of the sensor across the terminal and the body at the temperatures shown in the table Water Temperature Sensor 80 C 175 F 47 570 100 C 212 F 25 30 Q NOTE OThe sensor and thermometer must not touch the container sides or bottom 2 Thermometer 1 Water Temperature Sensor kif the ohmmeter does not show the specified values replace the sensor Fan Switch Inspection Using ohmmeter check to see that only the connections shown in the table have continuity about zero ohms the switch has an open or short repair or replace it with new one Fan Switch Resistance ORising temperature From OFF to ON at 93 103 C 199 217 F OFalling temperature From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 O OFF More than 1 M Q SN I f AU 1 Y _ k _ 1 Fan Switch Suspend the switch in a container of coolant so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer in the coolant NOTE OThe switch and thermometer must not touch the container sides or bottom Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently Junction Box The junction box has fuses relays and diodes The relays and di
159. ssembly Brush Plate and Terminal Bolt Inspection Using the x 1 Q ohmmeter range measure the resist ance as shown between terminal bolt and brush plate between terminal bolt and brush between terminal bolt and end cover kif there is any reading the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly Starter Relay Inspection Remove the left side cover see Frame chapter e Remove the starter relay e Connect the hand tester and 12 V battery to the starter relay as shown kif the relay does not work as specified the relay is defective Replace the relay Testing Relay Hand Tester Range 1 range Criteria When battery is connected gt 0 Q When battery is disconnected oo Q 1 Tester 2 12 V Battery ELECTRICAL SYSTEM 15 23 ELECTRICAL SYSTEM Electric Starter and Fuel Pump Circuit Lighting System The headlight beam is adjustable both horizontally and vertically Headlight aiming must be correctly adjusted both for your safety as well as that of oncoming drivers In most areas it is illegal to ride with an improperly adjusted headlight Headlight Beam Horizontal Adjustment e Turn the adjusting screw on the headlight rim in or out until the beam points straight ahead Turning the adjusting screw clockwise makes the headlight beam point to the left A Adjusting Screw Headlight Beam Vertical A
160. stand for about 30 minutes before charging NOTE Of the electrolyte level drops add electrolyte to the upper level line before charging Set the charging rate at 1 10 the battery capacity and charge it for 10 hours For example if the battery is rated at 14 Ah the charging rate would be 1 4 A CAUTION If the battery is not given a full initial charging it will discharge in a few weeks After that it can not be charged by supplement charging Do not use a high rate battery charger as is typically employed at automotive service stations unless the charger rate can be reduced to the level required Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 C 115 F during charging reduce the charging rate to lower the temperature and increase charging time proportionately Ordinary Charging Remove the rear and front seats see Frame chapter and take out the battery Set the charging rate and time according to the battery condition previously determined see Electrolyte Specific Gravity Inspection using the Battery Charging Rate Time Table AWARNING Keep the battery away from sparks and o
161. sure the oil pressure after the engine is warmed up Remove the foliowing Right Lower Fairing see Frame chapter Oil Passage Plug Attach the oil pressure gauge and adapter special tools to the plug hole Oil Pressure Gauge 57001 164 B Adapter 57001 1278 Oil Pressure Standard 216 275 kPa 2 2 2 8 kg cm 31 40 psi 4000 r min rpm 90 194 F of oil temp the oil pressure is much lower than the standard check the oil pump relief valve and or crankshaft bearing insert wear immediately ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded View HP Special Tool pmo 7 3 Engine Removal Installation eese nee 23957 3 RSV 7 3 7 2 ENGINE REMOVAL INSTALLATION Exploded View T1 30 N m 3 1 kg m 22 ft Ib Install a shim thickness 0 5 mm between the lower part T2 36 N m 3 7 kg m 27 ft lb of the crankcase and the frame bracket ENGINE REMOVAL INSTALLATION 7 3 Special Tool Engine Removal Installation Jack 57001 1238 Removal e Remove the following Fairings see Frame chapter Engine Oil Drain see Engine Lubrication System chapter Coolant Drain see Cooling System chapter Fuel Tank see Fuel System chapter Air Cleaner Housing se
162. t good Regulator Rectifier Output Voltage Inspection Check the battery condition see Battery section Warm up the engine to obtain actual alternator operat ing conditions e Remove the seat Check that the ignition switch is turned off and connect the hand tester as shown in table Black Yellow Voltage Connector 5 Regulator Rectifier Output Voltage Meter Range Meter to Meter 25V Battery e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then turned off The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage e Turn off the ignition switch to stop the engine and disconnect the hand tester the regulator rectifier output voltage is kept between the values given in table the charging system is considered to be working normally if the output voltage is much higher than the values specified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open the battery voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective Ignition System
163. taut while turning the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Camshaft Installation e Installation is the reverse of removal Note the follow ing Apply engine oil to all cam parts if the camshaft s and or cylinder head are replaced with new ones apply a thin coat of molybdenum disulfide grease to the new cam part surfaces NOTE OThe exhaust camshaft has an EX mark and the inlet camshaft has an IN mark Be careful not to mix up these shafts 1 EX Mark 2 IN Mark e Position the crankshaft at TDC for the 1 and 4 pistons engage the cam chain with the camshaft sprockets as shown 1 Timing Mark Crankcase Parting Line 2 TDC Mark for 1 and 4 Pistons Near to F Mark 3 Front ENGINE TOP END 4 11 e Pull the tension side exhaust side of the chain taut to install the chain OThe timing marks must be aligned with the cylinder head upper surface and positioned respectively as shown after the camshaft chain slack is taken up by the tensioner Camshaft Chain Timing right side view 1 Front 6 1st 2 Timing Mark 7 2nd 3 Cylinder Head Upper Surface 8 Exhaust Camshaft 4 29th 9 Inlet Camshaft 5 30th e The camshaft cap locations are numbered Install the caps in the positions as shown 1 Camshaft Cap 2 Upper Chain Guide 3 Location Number The camshaft caps are machined with the cyl
164. tch B Alignment Indicator Adjust the chain slack as follows Loosen the following nuts Axie Nut Both Chain Adjuster Locknuts NOTE O Do nat loosen the torque link nut C Axle D Torque Link Nut A Locknut B Adjuster O Turn the chain adjusters forward or rearward until the drive chain has the correct amount of chain slack O The right and left notches on the alignment indicators should point to the same marks or positions on the swing arm see above A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition OTighten the adjuster iocknuts securely OTighten the axle nut to the specified torque see Exploded View O Insert a new cotter pin through the axle and nut and spread its ends Wheel Alignment Adjustment Check to see if wheel alignment is properly adjusted The right and left notches on the alignment indicators should point to the same marks or positions on the swing arm If they are not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Drive Chain Wear Inspection e Stretch the chain taut hanging 98 N 10 kg 20 Ib weight on the chain Measure the length of 20 links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin Since th
165. ter Reading Range Meter to One yellow 02 x1Q lead 0 9 Q Connector 1 if there is more resistance than shown in the Table or no meter reading infinity for any two leads the stator has an open lead and must be replace Much less than this resistance means the stator is shorted and must be replaced Using the highest resistance range of the hand tester measure the resistance between each of the yellow leads and chassis ground Any meter reading less than infinity indicates a short necessitating stator replacement If the stator coils have normal resistance but the voltage check showed the aiternator to be defective then the rotor magnetism have probably weakened and the rotor must be replaced Stator Coil Resistance Another yellow lead Connector 1 Charging System Wiring Diagram 7 rr h Connector 1 Alternator 2 Connector 1 3 Regulator Rectifier 4 Connector 2 5 Diode Rectifier 6 Control Circuit IC 7 Connector 5 8 Main Fuse 30A 9 Connector 3 10 Connector 4 Rectifier Inspection Check the rectifier resistance as follows Remove the regulator rectifier and disconnect the connector 2 see Charging System Wiring Diagram Connect an ohmmeter to the regulator rectifier as shown in the Table and check the resistance in both directions of each diode following the table Rectifier Circuit WE c Connections Meter 1
166. the 6th click from the fully clockwise position Harder Softer Clockwise Counterclockwise n a 2 1 2 3 4 5 6 7 8 9 10 11 P m position adjuster turned fully clockwise AWARNING lf both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Spring Preload Adjustment Turn the adjuster in to increase spring preload and out to decrease spring preload A Preload Adjuster OThe standard adjuster setting for the average build rider of 68 kg 150 16 with no passenger and no accessories is 14 mm as shown A 14 mm B 5 Marks Adjuster Protrusion Standard 14 mm 5 Marks Usable Range 5 20 mm 1 8 Marks CAUTION When setting the standard position do not turn adjuster beyond the fully counterclockwise position Fork top bolt may be loosen A WARNING If both adjusters are not adjusted equally handling may be impaired and a hazardous condition may result Fork Oil Change e Remove the following Front Fork see Front Fork Removal Top Bolt Top Spring Main Spring Pour out the fork oil with the fork upside down Using the piston rod puller special tool move the piston rod up and down several times in order to expel all the oil from inside the fork cylinder gt i m Inner Tube B Rod Puller 57001 1298 C Piston Rod the specified type of oil in the fork cylinder Using the fo
167. the direction shown Stem Nut Wrench 57001 1100 O Check that there is no play and the steering stem turns smoothly without the rattle If not the steering stem bearing may be damaged O Again back out the stem lockout a fraction of a turn until it turns lightly OTurn the stem locknut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight eTighten the following fasteners to the specified torque Front Fork Clamp Bolts Upper and Lower see Suspension chapter Steering Stem Head Nut see this chapter Front Axle Nut see Wheel Tires chapter Front Clamp Bolts see Suspension chapter Caliper Mounting Bolts see Brake chapter Check and adjust the following items after installation Steering Throttle Cables Choke Cables Clutch Front Brake STEERING 13 7 Steering Stem Bearing Bearing Lubrication Perform the following O Remove the steering stem O Using a high flash point solvent wash the upper and lower tapered roller bearings in the cages OWipe the upper and lower outer races which are press fitted into the frame head pipe clean of grease and dirt O Visually check the outer races and the rollers Replace the bearing assemblies if they show wear or damage O Pack the upper and lower tapered roller bearings in the cages with grease and apply light coat of grease to the upper and lower outer races Ol Install the steering stem a
168. the engine the water hose Round A to the 2 backward and covering s Clamp the connectors put p Bend the clamp inside the cover to Clamp Run the lead 2 under the fuel filter a 1 To Horn 6 Ground Lead 11 Fuel Pump Lead 2 Ignition Switch Lead 7 To Left Turn Signal Light 12 Pickup Coil Lead 3 To Ignition Coil 8 Radiator Fan Switch Lead 13 Rear Brake Light Switch Lead 4 To Radiator Fan 9 Main Harness 5 Water Temperature Sensor 10 To Oil Pressure Switch Neutral Switch and Side Stand Switch 1 16 GENERAL INFORMATION To Main Harness Run the lead inside of the water pump 1 Alternator Lead 2 To Oi Pressure Switch 3 To Neutral Switch 4 Side Stand Switch Lead 5 Battery Lead Crankcase Upper Surface rearward Breather Hose Fuel System Table of Contents Exploded View Specifications Special 5 Throttle Grip and Cables Throttle Cable Adjustment Choke Cable Choke Cable Adjustment Surge Tank Surge Tank Removal Air Cleaner NERONE Element Cleaning Oil Draining Air Cle
169. tion should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft GENERAL INFORMATION 1 3 12 Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press it in with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole 13 Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips Before a shaft passes through a seal apply a little high temperature grease on the lips to reduce rubber to metal friction 14 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 15 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them 16 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more su
170. ull brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first application of the lever or pedal if this is not done Master Cylinders Front Master Cylinder Installation The master cylinder clamp must be installed with the arrow mark upward Tighten the upper clamp boit first and then the lower clamp bolts to the specified torque see Exploded View There will be a gap at the lower part of the clamp after tightening 1 Tighten upper clamp bolts first 2 Lower Clamp Bolt 3 Arrow Mark Use a new flat washer on each side of the brake hose fitting eTighten the banjo bolts to the specified torque see Exploded View Rear Master Cylinder Removal Notes Remove the cotter pin and then pull the joint pin out of the push rod clevis and brake pedal A Clevis B Cotter Pin C Joint Pin e Remove the master cylinder by taking off the mounting bolts 1 Primary Cup BRAKES 11 13 Rear Master Cylinder Installation Notes Use a new flat washer on each side of the brake hose fitting Tighten the banjo bolts to the specified torque see Exploded View Tighten the rear master cylinder mounting bolts 2 to the specified torque see Exploded View Inspection and Adjustment after Installation Check and adjust the following items after installation Brake Pedal Position Rear Brake Light Switch Position Brake L
171. ump Inspection Check the drainage outlet passage at the bottom of the water pump body for coolant leaks kif the mechanical seal is damaged the coolant leaks through the seal and drains through the passage Replace the water pump unit A Drainage Outlet Passage at the bottom of the pump body 3 8 COOLING SYSTEM Radiator and Radiator Fan Removal AWARNING The radiator fan is connected directly to the battery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR 15 DISCONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES e Remove the following Fairings Fuel Tank see Fuel System chapter Coolant drain see Water Pump Removal Baffle Plate Radiator Fan Connector I Y C E 1 i i m k is Tx c m C A Radiator Fan Connector Li Radiator Fan Switch Connector Radiator Hoses A Radiator Fan Switch Connector Radiator Hose A Radiator Hose Radiator Lower Mounting Bolts Radiator Side Mounting Bolts A Lower Mounting Bolts B Side Mounting Bolts Remove the radiator Radiator Inspection Check the radiator core f there are obstructions to air flow remove them If the corrugated fins are deformed carefully straighten them If the air passages of the radiator core are blocked more than
172. ut Needle Bearing Inspection f there is any doubt as to the condition of either needle bearing replace the bearing s and sleeve as a set remove the needle bearings use the oil seal and bearing remover special tool 57001 1058 SUSPENSION 12 15 Tie Rod Rocker Arm Sleeve Inspection there is visible damage replace the sleeve and needle bearing s as a set Steering Table of Contents Exploded View M Special Tools Steering M Steering Stem Removal Installation Steering Stem Bearing Bearing Lubrication Bearing Wear Damage Stem Cap Deterioration Damage Steering Stem Warp STEERING 13 1 13 2 13 3 13 4 1 3 4 13 5 13 5 13 5 13 7 13 7 13 7 13 7 13 7 13 2 STEERING Exploded View 4 CW V w X i J it M lm T1 9 8 1 0 kg m 7 0 ft Ib T2 23 N m 2 3 kg m 16 5 ft Ib T3 39 N m 4 0 kg m 29 ft Ib sit T4 25 N m 2 6 kg m 19 0 ft Ib A y G Apply grease Special Tools Stem Bearing Driver 57001 137 x x Stem Bearing Driver Adapter 57001 1092 Bearing Puller 57001 158 STEERING 13 3 Hea
173. y i t 15 10 ELECTRICAL SYSTEM Battery Electrolyte Level Inspection e The electrolyte level should be between the upper and the lower level lines kif the level of electrolyte any cell is below the lower level line add only distilled water to cell until the level is at the upper level line CAUTION Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery 1 Upper Level Line 2 Lower Level Line Electrolyte Specific Gravity Inspection Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer O Read the level of the electrolyte on the floating scale Hydrometer em e 1 Read here kif the specific gravity is below 1 20 charge 60 the battery needs to be charged Initial Charging Remove the rear and front seats see Frame chapter and take out the battery AWARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases Fill each cell to the upper level line on the battery case with fresh electrolyte specific gravity 1 280 at a temperature of 30 C 86 F or less Let the battery
174. ycles which are used in competition or related uses Please read the warranty carefully Motorcycle racing is a very sophisticated sport subject to many variables The following information is theoretical only and Kawasaki shall not be liable for any damages which might arise from alterations utilizing this information e When the motorcycle is operated on public roads it must be in its original state in order to ensure safety and compliance with applicable regulations Carburetor Sometimes an alteration may be desirable for improved performance under special conditions when proper mixture is not obtained after the carburetor has been properly adjusted and all parts cleaned and found to be functioning properly If the engine still exhibits symptoms of overly rich or lean carburetion after all maintenance and adjustments are correctly performed the main jet can be replaced with a smaller or larger one smaller numbered jet gives a leaner mixture and larger numbered jet a richer mixture Spark Plug The spark plug ignites the fuel and air mixture in the combustion chamber To do this effectively and at the proper time the correct spark plug must be used and the spark plug must be kept clean and the gap adjusted Tests have shown the plug listed in the General Information chapter to be the best plug for general use Since spark plug requirements change with the ignition and carburetion adjustments and with riding conditions
175. ystem component incorrect Radiator clogged Thermostat trouble Radiator cap trouble Thermostatic fan switch trouble Fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Gauge incorrect Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect Thermostatic fan switch trouble Thermostat trouble Clutch Operation Faulty Clutch slipping Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch slave cylinder trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Clutch hub locknut loose Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift return spring weak or broken Shift return spring pin loose 16 6 APPENDIX Pawl spring broken Shift mechanism arm broken Jumps out of gear Shift fork worn Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Neutral positioning pin spring weak or broken Shift fork pin worn Drive shaft output shaft and or gear splines worn Overshifts Neutral positioning lever spring weak or broken P

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