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Kawasaki Brute Force 750 4x4i Offroad Vehicle User Manual

Contents

1. 16 13 Middle Cover Installation 16 13 Left Side Cover Removal 16 14 Left Side Cover Installation 16 14 Right Side Cover Removal 16 14 Right Side Cover Installation 16 15 Electrical Parts Case Removal 16 15 Electrical Parts Case Installation 16 16 Radiator Cover Removal 16 16 Radiator Cover Installation 16 16 Guards 16 17 Front Guard Removal
2. 15 12 Steering Inspection 15 12 Steering Stem Straightness 15 12 Steering Bearing Sleeve Lubrication 15 12 Steering Stem Clamp Inspection 15 12 Steering Stem Bearing Inspection 15 12 Steering Knuckle Bearing Inspection 15 13 Tie rod End Inspection 15 13 Steering Knuckle Joint Inspection 15 13 Handlebar 15 14 Handlebar Removal 15 14 Handlebar Installation
3. 1 2 Model Identification 1 7 General Specifications 1 8 Unit Conversion Table 1 11 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly oper ation on a vehicle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the vehicle disconnect the battery wires from the battery to prevent the engine from accidentally turning over Disconnect the ground wire first and then the positive When completed with the service first connect the positive wire to the positive terminal of the battery then the negative wire to the negative terminal Edges of Parts Lift large or
4. 8 7 Oil Level Inspection 8 7 Engine Oil Change 8 7 Oil Filter Change 8 7 Oil Screen Removal 8 7 Oil Screen Cleaning 8 8 Oil Pressure Measurement 8 8 Oil Pressure Relief Valve 8 9 Oil Pressure Relief Valve Removal 8 9 Oil Pressure Relief Valve Installation 8 9 Oil Pressure Relief Valve Inspection 8 9 Oil Pump
5. 11 12 Front Hub 11 13 Front Hub Removal 11 13 Front Hub Installation 11 13 Front Hub Disassembly Assembly 11 14 Rear Hub 11 15 Rear Hub Removal 11 15 Rear Hub Installation 11 15 Rear Hub Disassembly Assembly 11 16 11 2 WHEELS TIRES Exploded View WHEELS TIRES 11 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Tie rod Locknuts 37 3 8 27 2 Tie rod End Nuts 42 4 3 31 3 Wheel Nuts First Torque 15 1 5 11 S 3 Wheel Nuts Final Torque 76 78 56 S 4 Front Axle Nuts 197 20 14
6. 11 6 Toe in Inspection 11 7 Toe in Adjustment 11 7 Wheels Rims 11 9 Wheel Removal 11 9 Wheel Installation 11 9 Wheel Rim Inspection 11 9 Wheel Rim Replacement 11 10 Tires 11 11 Tire Removal 11 11 Tire Installation 11 11 Tire Inspection
7. 10 14 Connecting Rod Twist 10 14 Connecting Rod Big End Side Clearance 10 15 Connecting Rod Big End Bearing Crankpin Wear 10 15 Crankshaft Runout 10 17 Crankshaft Main Bearing Journal Wear 10 17 Transmission 10 18 Shift Lever Removal 10 18 Shift Lever Installation 10 19 Transmission Removal 10 21 Transmission Installation 10 22 Shift Fork Bending
8. 4 14 Radiator Fan Installation 4 14 Radiator Inspection 4 15 Radiator Cleaning 4 15 Radiator Cap Inspection 4 15 Thermostat 4 16 Thermostat Removal 4 16 Thermostat Installation 4 16 Thermostat Inspection 4 16 Radiator Fan Switch 4 18 Radiator Fan Switch Removal 4 18 Radiator Fan Switch Installation
9. 14 17 Stabilizer Installation 14 18 14 2 SUSPENSION Exploded View SUSPENSION 14 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Front Shock Absorber Mounting Nuts 34 3 5 25 2 Front Suspension Arm Pivot Nuts 42 4 3 31 3 Front Knuckle Joint Nuts 29 3 0 22 G Apply grease R Replacement Parts 14 4 SUSPENSION Exploded View SUSPENSION 14 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Rear Shock Absorber Mounting Nuts 34 3 5 25 2 Stabilizer Holder Bolts 23 2 3 17 3 Stabilizer Joint Nuts 48 4 8 35 4 Rear Suspension Arm Pivot Nuts 48 4 8 35 5 Rear Knuckle Mounting Nuts 48 4 8 35 G Apply grease R Replacement Parts RL Apply rubber lubricant 14 6 SUSPENSION Specifications Item Standard Service Limit Shock Absorbers Usable Range Spring Preload Setting Position Front and Rear No 2 1 5 SUSPENSION 14 7 Special Tools Inside Circlip Pliers 57001 143 Outside Circlip Pliers 57001 144 Spring Compressor 57001 1087 Steering Stem Nut Wrench 57001 1100 Jack 57001 1238 14 8 SUSPENSION Shock Absorbers Front Shock Absorber Preload Adjustment The spring adjusting sleeve A on front shock absorber has 5 positions so that the spring ca
10. 16 17 Front Guard Installation 16 17 Front Bottom Guard Removal 16 17 Front Bottom Guard Installation 16 18 Engine Bottom Guard Removal 16 18 Engine Bottom Guard Installation 16 18 Rear Bottom Guard Removal 16 18 Rear Bottom Guard Installation 16 18 Flaps and Footboards 16 19 Left Footboard Removal 16 19 Left Footboard Installation 16 19 Right Footboard Removal 16 19 Right Footboard I
11. 14 10 Shock Absorber Spring Replacement 14 10 Rear Shock Absorber Scrapping 14 11 Suspension Arms 14 12 Front Suspension Arm Removal 14 12 Front Suspension Arm Installation 14 13 Front Suspension Arm Disassembly 14 13 Front Suspension Arm Assembly 14 14 Rear Suspension Arm Removal 14 15 Rear Suspension Arm Installation 14 15 Rear Suspension Arm Disassembly 14 16 Rear Suspension Arm Assembly 14 16 Stabilizer Removal
12. 6 13 Drive Pulley 6 14 Drive Pulley Removal 6 14 Drive Pulley Disassembly 6 14 Drive Pulley Inspection 6 15 Spider Shoe Side Clearance Adjustment 6 17 Drive Pulley Assembly 6 18 Drive Pulley Installation 6 19 Driven Pulley 6 21 Driven Pulley Removal 6 21 Driven Pulley Disassembly 6 21 Driven Pulley Inspection 6
13. 15 14 15 2 STEERING Exploded View STEERING 15 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Handlebar Holder Bolts 29 3 0 22 S 2 Steering Stem Clamp Bolts 25 2 5 18 3 Tie rod End Nuts 42 4 3 31 4 Tie rod Locknuts 37 3 8 27 5 Steering Stem Bearing Joint Bolts 23 2 3 17 L 6 Steering Stem Bottom End Nut 62 6 3 46 7 Front Knuckle Joint Nuts 29 3 0 22 8 Master Cylinder Clamp Bolts 9 0 0 92 80 in lb S 9 Variable Differential Control Lever Bolt L AD Apply adhesive agent AG Apply grease Amoco rykon premium grease No 2 EP Green G Apply grease L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence 15 4 STEERING Specifications Item Standard Service Limit Tie rods Tie rod Length 393 3 mm 15 48 in STEERING 15 5 Special Tools Inside Circlip Pliers 57001 143 Bearing Driver Set 57001 1129 15 6 STEERING Steering Steering Stem Removal Remove Front Fender see Frame chapter Handlebar see Handlebar Removal Cotter Pins and Tie rod End Nuts A Steering Stem Bearing Joint Bolts B right and left CAUTION Do not loosen the locknuts C at the ends of the tie rod adjusting sleeve or the toe in of the front wheels will be changed Flatten out the bended washer A Remove Steering Clamp B
14. 13 19 Brake Hose Inspection 13 19 Brake Hose Replacement 13 19 Rear Brake Lever Pedal and Cables 13 20 Brake Pedal Position Inspection 13 20 Brake Pedal Position Adjustment 13 20 Rear Brake Lever Free Play Inspection 13 20 Brake Pedal Free Play Inspection 13 20 Rear Brake Lever and Pedal Free Play Adjustment 13 20 Brake Pedal Removal 13 20 Brake Pedal Installation 13 21 Brake Cable Removal 13 21 Brake Cable Installation 13 22 Brake Cable Lubrication 13 22 Internal Wet Brake 13 23 Internal Wet Brake Disassembly 13 23 Internal Wet Brake Assembly 13 23 13 2 BRAKES Exploded View BRAKES 13 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Reservoir Cap Screws 1 5 0 15 13 in lb 2 Brake Lever Pivot Bolt 6 0 0 60 52 in lb 3 Brake Lever Pivot Bolt Locknut 6 0 0 60 52 in lb 4 Master Cylinder Clamp Bolts 9 0 0 92 80 in lb S 5 Brake Hose Banjo Bolts 25 2 5 18 6 Brake Caliper Mounting Bolts 25 2 5 18 7 Bleed Valves 5 4 0 55 48 in lb 8 Brake Disc Mounting Bolts 37 3 8 27 L 9 Caliper Holder Shaft 17 1 7 13 10 Pad Mounting Bolts 17 1 7 13 B Apply brake fluid L Apply a non permanent locking agent
15. 4 18 Radiator Fan Switch Inspection 4 18 Coolant Temperature Warning Light Switch 4 19 Coolant Temperature Warning Light Switch Removal 4 19 Coolant Temperature Warning Light Switch Installation 4 19 Coolant Temperature Warning Light Switch Inspection 4 19 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Radiator Mounting Bolts 8 8 0 90 78 in lb 2 Radiator Fan Switch 18 1 8 13 3 Radiator Fan Assembly Bolts 4 9 0 50 43 in lb 4 Thermostat Housing Cover Bolts 8 8 0 90 78 in lb 5 Coolant Temperature Warning Light Switch 6 9 0 70 61 in lb SS 6 Air Bleeder Bolt 8 8 0 90 78 in lb 7 Water Pump Cover Bolts 8 8 0 90 78 in lb 8 Coolant Drain Plug 8 8 0 90 78 in lb 9 Water Pump Impeller 7 8 0 80 69 in lb 10 Water Pipe Mounting Bolts 8 8 0 90 78 in lb G Apply grease SS Apply silicone sealant Kawasaki Bond 56019 120 4 4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and c
16. 8 10 Oil Pump Removal 8 10 Oil Pump Installation 8 10 Oil Pipe 8 12 Oil Pipe Removal 8 12 Oil Pipe Installation 8 12 8 2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 8 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Oil Filter 18 1 8 13 R 2 Oil Pressure Switch 15 1 5 11 SS 3 Oil Pipe Bolts 8 8 0 90 78 in lb 4 Engine Drain Plug 20 2 0 14 5 Oil Pressure Relief Valve 15 1 5 11 L 6 Oil Pump Bolts 8 8 0 90 78 in lb 7 Chain Guide Bolts 8 8 0 90 78 in lb 8 Oil Pump Drive Chain Tensioner Bolt 25 2 5 18 9 Oil Filter Mounting Bolt 25 2 5 18 L 15 mm 10 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb G Apply grease L Apply a non permanent locking agent O Apply engine oil R Replacement Parts SS Apply silicone sealant Kawasaki Bond 56019 12
17. 5 39 Cylinder Piston Installation 5 39 Cylinder Wear 5 41 Piston Wear 5 41 Piston Cylinder Clearance 5 41 Piston Ring Piston Ring Groove Wear 5 42 Piston Ring Groove Width 5 42 Piston Ring Thickness 5 42 Piston Ring End Gap 5 43 Exhaust System 5 44 Spark Arrester Cleaning 5 44 Muffler and Exhaust Pipe Removal 5 44 Muffler and Exhaust Pipe Installation 5 45 Exhaust System Inspection 5 46 5 2 ENGINE TOP END Exploded View ENGINE TOP END 5 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Rocker Case Bolts 55 mm 2 2 in 8 8 0 90 78 in lb S 2 Rocker Case Bolts 130 mm 5 1 in 9 8 1 0 87 in lb S 3 Rocker Case Bolts 30 mm 1 2 in 9 8 1 0 87 in lb S 4 Rocker Case Bolts 25 mm 1 0 in 9 8 1 0 87 in lb S 5 Cylinder Head Bolts M10 First Torque 25 2 5 18 S MO 5 Cylinder Head Bolts M10 Final Torque 49 5 0 36 S 6 Cylinder Head Bolts M6 9 8 1 0 87 in lb 7 Valve Adjusting Cap Bolts 8 8 0 90 78 in lb 8 Water Pipe Mounting Bolts 8 8 0 80 78 in lb 9 Rocker Shaft Bolts 20 2 0 14 10 Valve Adjusting Screw
18. 17 74 Drive Belt Failure Detection System 17 83 Drive Belt Failure Detection System Inspection 17 83 Carburetor Heater System 17 84 Air Temperature Sensor Inspection 17 84 Carburetor Heater Inspection 17 85 Switches 17 86 Brake Light Switch Adjustment 17 86 Radiator Fan Switch Inspection 17 86 Coolant Temperature Warning Light Switch Inspection 17 87 Switch Inspection 17 87 Drive Belt Failure Detection Switch 17 88 Fuses 17 89 Fuse Removal 17 89 Fuse Installation 17 89 Fuse Inspection 17 89 ELECTRICAL SYSTEM 17 3 Parts Location Light Dimmer Switch A Starter Button B Engine Stop Switch C Reverse Power Assist Switch Override D Rear Brake Light Switch E Power Outlet Connector F 120 W 2WD 4WD Shift Switch A Front Brake Light Switch B Ignition Switch C Battery A Igniter B Actuator Controller C Reset Connectors D Starter Circuit Relay Neutral E Fuse Box F Starter Relay G Radiator Fan Breaker H Vehicle Down Sensor I Starter Circuit Relay Brake J Radiator Fan Switch A Radiator Fan B Frame Ground Lead C Ign
19. 10 24 Shift Fork Gear and Shifter Groove Wear 10 24 Transmission and Shift Mechanism Inspection 10 25 Ball Bearing Needle Bearing and Oil Seal 10 27 Ball and Needle Bearing Replacement 10 27 Ball and Needle Bearing Wear 10 27 Oil Seal Inspection 10 27 10 2 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 10 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Connecting Rod Big End Cap Nuts 34 3 5 25 MO 2 Engine Drain Plug 20 2 0 14 3 Crankcase Bolts M8 75 mm 2 95 in 20 2 0 14 S 4 Crankcase Bolts M8 110 mm 4 33 in 20 2 0 14 S 5 Crankcase Bolt M8 110 mm 4 33 in 20 2 0 14 S L 1 6 Crankcase Bolts M6 40 mm 1 57 in 9 8 1 0 87 in lb 7 Crankcase Bolts M6 65 mm 2 56 in 9 8 1 0 87 in lb L 8 Bearing Position Plate Screws 4 9 0 50 43 in lb 9 Do not apply a non permanent locking agent to this area 2 3 mm 0 08 0 12 in 10 About 12
20. 2 23 Valve Clearance Inspection 2 23 Valve Clearance Adjustment 2 24 Spark Arrester Cleaning 2 24 Converter System 2 25 Drive Belt Inspection 2 25 Drive Belt Deflection Inspection 2 25 Drive Belt Deflection Adjustment 2 26 Actuator Lever Engine Brake Control Lever Assembly Inspection 2 27 Engine Lubrication System 2 27 Engine Oil Change 2 27 Oil Filter Replacement 2 28 Wheels Tires 2 28 Tire Inspection 2 28 Final Drive 2 29 Variable Differential Control Lever Play Inspection 2 29 Variable Differential Control Lever Play Adjustment 2 29 Front Final Gear Case Oil Change 2 30 Rear Final Gear Case Oil Change 2 31 Universal Joint Lubrication 2 32 Brakes 2 32 Front Brake Pad Wear Inspection 2 32 Front Brake Hoses and Connections Inspection 2 32 Front Brake Hose Replacement 2 33 Brake Fluid Level Inspection 2 33 Brake Fluid Change 2 34 Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement 2 34 Front Brak
21. 7 4 Recoil Starter Inspection 7 4 7 2 RECOIL STARTER Exploded View RECOIL STARTER 7 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Recoil Starter Mounting Bolts 5 9 0 60 52 in lb L L Apply a non permanent locking agent 7 4 RECOIL STARTER Recoil Starter Recoil Starter Removal Remove Recoil Starter Mounting Bolts A Recoil Starter B Recoil Starter Installation Apply a non permanent locking agent Recoil Starter Mounting Bolts Tighten Torque Recoil Starter Mounting Bolts 5 9 N m 0 60 kgf m 52 in lb Recoil Starter Inspection Check the starter rope for excessive wear or fraying ENGINE LUBRICATION SYSTEM 8 1 8 Engine Lubrication System Table of Contents Exploded View 8 2 Specifications 8 4 Special Tools amp Sealant 8 5 Engine Oil Flow Chart 8 6 Engine Oil and Oil Filter
22. 3 17 Carburetor Assembly 3 19 Carburetor Separation 3 20 Carburetor Joining 3 20 Carburetor Cleaning 3 21 Carburetor Inspection 3 22 Air Cleaner 3 24 Air Cleaner Element Removal 3 24 Air Cleaner Element Installation 3 24 Air Cleaner Element Cleaning and Inspection 3 24 Air Cleaner Housing Removal 3 24 Air Cleaner Housing Installation 3 26 Fuel Tank 3 28 Fuel Tank Removal 3 28 Fuel Tank Installation 3 29 Fuel Tank Cleaning 3 30 Fuel Tap Removal 3 30 Fuel Tap Installation 3 30 Fuel Tap Inspection 3 31 Fuel Tap Cleaning 3 32 Fuel Pump 3 33 Fuel Pump Removal 3 33 Fuel Pump Removal 3 33 Fuel Pump Installation 3 34 Fuel Pump Inspection 3 34 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Idle Adjusting Screw Bracket Bolt 8 8 0 90 78 in lb 2 Choke Lever 3 Choke Cable 4 Throttle Cable 5 Throttle Lever 6 Jet Needle 7 Pi
23. 3 8 Throttle Lever Free Play Inspection 3 8 Throttle Lever Free Play Adjustment 3 8 Throttle Case Removal Disassembly 3 8 Throttle Case Assembly Installation 3 8 Throttle Cable Installation 3 9 Throttle Case Inspection 3 9 Throttle Cable Lubrication and Inspection 3 9 Choke Lever and Cable 3 10 Choke Lever Free Play Inspection 3 10 Choke Lever Free Play Adjustment 3 10 Choke Lever and Cable Removal 3 10 Choke Lever and Cable Installation 3 11 Choke Cable Lubrication and Inspection 3 11 Carburetor 3 12 Idle Speed Inspection 3 12 Idle Speed Adjustment 3 12 Pilot Screw Adjustment 3 12 Service Fuel Level Inspection 3 12 Service Fuel Level Adjustment 3 14 Carburetor Synchronization Inspection 3 14 Carburetor Synchronization Adjustment 3 15 Fuel System Cleanliness Inspection 3 15 Carburetor Removal 3 15 Carburetor Installation 3 17 Carburetor Disassembly
24. 13 8 Brake Fluid Change 13 8 Brake Line Air Bleeding 13 9 Master Cylinder 13 10 Master Cylinder Removal 13 10 Master Cylinder Installation 13 10 Master Cylinder Disassembly 13 11 Master Cylinder Assembly 13 11 Master Cylinder Inspection Visual Inspection 13 12 Calipers 13 13 Caliper Removal 13 13 Caliper Installation 13 13 Caliper Disassembly 13 14 Caliper Assembly 13 14 Fluid Seal Damage 13 15 Dust Seal and Friction Boot Damage 13 15 Piston and Cylinder Damage 13 16 Caliper Holder Shaft Wear Inspection 13 16 Brake Pads 13 17 Brake Pad Removal 13 17 Brake Pad Installation 13 17 Brake Pad Wear Inspection 13 17 Brake Discs 13 18 Disc Cleaning 13 18 Disc Removal 13 18 Disc Installation 13 18 Disc Wear 13 18 Disc Runout 13 18 Brake Hoses
25. 5 20 Camshaft Removal 5 20 Camshaft Installation 5 20 Camshaft Assembly 5 21 Cam Wear 5 21 Camshaft Bearing Wear 5 22 KACR Inspection 5 23 KACR Removal 5 23 KACR Installation 5 24 Camshaft Chain Removal 5 24 Camshaft Chain Installation 5 25 Camshaft Chain Guide Wear 5 28 Cylinder Head 5 29 Cylinder Compression Measurement 5 29 Cylinder Head Removal 5 30 Cylinder Head Installation 5 30 Cylinder Head Cleaning 5 31 Cylinder Head Warp 5 31 Valves 5 32 Valve Clearance Inspection 5 32 Valve Clearance Adjustment 5 32 Valve Removal 5 32 Valve Installation 5 32 Valve Guide Removal 5 32 Valve Guide Installation 5 33 Valve to Guide Clearance Measurement 5 33 Valve Seat Inspection 5 34 Valve Seat Repair Valve Lapping 5 34 Cylinder and Piston 5 39 Cylinder Removal 5 39 Piston Removal
26. Remove Dust Seals A Fluid Seals B Bleed Valve C and Rubber Cap D Boots E and Caliper Holder F Caliper Assembly Replace the fluid seal A with a new one Apply brake fluid to the fluid seal and install it into the cylinder by hand Replace the dust seal B with a new one if it is damaged Apply brake fluid to the dust seal and install it into the cylinder by hand BRAKES 13 15 Calipers Apply brake fluid to the outside of the pistons A and push them into the cylinder by hand Take care that nei ther the cylinder nor the piston skirt gets scratched Replace the rubber boots B if they are damaged Apply a thin coat of silicone grease to the caliper holder shafts C D Silicone grease is a special high tempera ture water resistant grease Install Wave Washer E Tighten Torque Caliper Holder Shaft D 17 N m 1 7 kgf m 13 ft lb Install Caliper Holder F Bleed Valve G and Rubber Cap Torque Bleed Valves 5 4 N m 0 55 kgf m 48 in lb Install the anti rattle spring A in the caliper as shown Install the pads see Brake Pad Installation Fluid Seal Damage The fluid seals A around the piston maintain the proper pad disc clearance If the seals are not satisfactory pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature Replace the fluid seals in accordance with the Periodic Maint
27. Install the inner race A so that the flat side B faces outboard joint FINAL DRIVE 12 31 Front Axle Press the inner race A using the cap B in the rotor puller set 57001 1216 until it is bottomed Special Tool Rotor Puller M16 M18 M20 M22 1 5 57001 1216 Install Circlip A Special Tool Outside Circlip Pliers 57001 144 Slide the cage B on the inner race and install the steel balls C Apply the special grease A to the steel balls and cage Squeeze about half a tube 30 grams of the special grease A into the bearing cup B Insert the balls and cage assembly in the bearing cup strongly 12 32 FINAL DRIVE Front Axle Install the new retaining ring A so that the opening B is aligned with one of the projections C Tighten the small band Squeeze the remaining special grease A into the inboard joint boot B Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot Hold the axle at this setting Standard Length of Assembling Right Front Axle 161 1 mm 6 34 in A Left Front Axle 169 1 mm 6 66 in A Open the edge of the boot in order to eqalize the air pres sures Tighten the large band A and bend the tangs securely to hold down the end of the band Maximum Outside Diameter of Band 69 mm 2 72 in After tightening the outside diameter FINAL DRIVE 12 3
28. Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Mainte nance chapter BRAKES 13 9 Brake Fluid Brake Line Air Bleeding Bleed the air whenever brake parts are replaced or re assembled Remove the reservoir cap and fill the reservoir with new brake fluid Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir This bleeds the air from the master cylinder and the brake line NOTE Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer Bleed the brake line and the caliper as follows Hold the brake lever applied A Quickly open and close the valve B Release the brake lever C The fluid level must be checked several times during the bleeding operation and replenished as necessary NOTE If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have en tered the line If the brake lever action still feels soft or spongy tap the brake hose from bottom to top and air will rise up to the top part of the hose Slowly pump t
29. Seat Height 935 mm 36 81 in Dry Mass 274 kg 604 lb EUR 274 5 kg 605 lb Curb Mass Front 147 5 kg 325 lb EUR 148 kg 326 lb Rear 149 kg 329 lb Fuel Tank Capacity 19 5 L 5 2 US gal Performance Minimum Turning Radius 3 2 m 10 5 ft Engine Type 4 stroke SOHC V2 cylinders Cooling System Liquid cooled Bore and Stroke 85 66 mm 3 35 2 60 in Displacement 749 mL 45 7 cu in Compression Ratio 8 8 1 Maximum Horsepower 37 4 kW 50 9 PS 6 500 r min rpm US Maximum Torque 60 7 N m 6 2 kgf m 45 ft lb 5 000 r min rpm Carburetion System Carburetor Keihin CVKR 34 Starting System Electric Starter amp Recoil Starter Ignition System Digital DC CDI Timing Advance Electronically advanced Ignition Timing From 5 BTDC 1 150 r min rpm to 28 BTDC 5 000 r min rpm Spark Plug NGK CR7E DENSO U22ESR N Cylinder Numbering Method Front to rear 1 2 Firing Order 1 2 Valve Timing Inlet Open 20 BTDC Close 44 ABDC Duration 244 Exhaust Open 44 BBDC Close 20 ATDC Duration 244 Lubrication Aystem Forced lubrication wet sump GENERAL INFORMATION 1 9 General Specifications Items KVF750 A1 B1 Engine oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W 40 Capacity 2 6 L 2 75 US qt Drive Train Primary Reduction System Type Belt converter Reduction Ra
30. 0 15 mm 0 0039 0 0059 in If the valve clearance is not correct adjust it see Valve Clearance Adjustment Valve Clearance Adjustment Remove the valve adjusting caps Loosen the locknut and turn the adjusting screw until the clearance is correct Hold the adjusting screw A from turning and tighten the locknut B Torque Valve Adjusting Screw Locknuts 12 N m 1 2 kgf m 104 in lb Recheck the clearance If the clearance is incorrect repeat the adjustment proce dure If the clearance is correct perform the adjustment proce dure on the other valve Spark Arrester Cleaning WARNING To avoid burns wear gloves while cleaning the spark arrester Since the engine must be run dur ing this procedure the muffler will become hot Remove the drain plug A on the muffler In an open area away from combustible materials start the engine with the transmission in neutral Raise and lower engine speed while tapping on the muf fler with a rubber mallet until carbon particles are purged from the muffler WARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odor less poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death Stop the engine Install the drain plug PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Converter System Drive Belt Inspection Inspection of the d
31. 4 9 Water Pump 4 10 Water Pump Cover Removal 4 10 Water Pump Cover Installation 4 10 Water Pump Impeller Removal 4 10 Water Pump Impeller Installation 4 10 Water Pump Impeller Inspection 4 11 Water Pump Leakage Inspection 4 11 Mechanical Seal Replacement 4 11 Radiator 4 13 Radiator Removal 4 13 Radiator Installation 4 14 Radiator Fan Removal
32. FUEL SYSTEM 3 31 Fuel Tank Connect the fuel hoses to the fuel tap as follows Vacuum Hose A Fuel Pump Hose B Be sure to clamps C the fuel hoses to prevent leakage Fuel Tap Inspection Check the fuel tap filter screen A for any breaks or dete rioration If the filter screen has any break or is deteriorated it may allow dirt to reach the carburetor causing poor running Replace the fuel tap If the fuel tap leaks replace the damaged gasket A or O rings B Apply grease to the lever A Tighten Torque Fuel Tap Plate Screws A 0 8 N m 0 08 kgf m 7 in lb 3 32 FUEL SYSTEM Fuel Tank Fuel Tap Cleaning Remove Fuel Tap see Fuel Tap Removal Clean the fuel tap filter screen in a high flash point sol vent WARNING Clean the tap 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 pi lot light Because of the danger of highly flammable liquids do not use gasoline or low flash point sol vents to clean the tap A fire or explosion could re sult Pour high flash point solvent through the tap in PRI posi tion Dry the fuel tap with compressed air Install the fuel tap see Fuel Tap Installation FUEL SYSTEM 3 33 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump especially on a hard sur face Such a shock to the pump can damage it WARNING
33. 0 02 in This clearance is a setting range for the neutral position Move the rod F to right and check it will be back to left smoothly Tighten Torque Tie rod End Rear Locknut I 9 8 N m 1 0 kgf m 87 in lb Holding the rear tie rod end and tighten the front locknut J Torque Tie rod End Front Locknut 9 8 N m 1 0 kgf m 87 in lb NOTE The front locknut has left hand threads Do not lean the tie rod rear end after tightening the front locknut Right K Wrong L Check that the shift lever moves from right to left smoothly Install Spring M Trim Seal N Align the mark O of the grip P with the projection Q on the guide Tighten Torque Grip Hold Nut R 9 8 N m 1 0 kgf m 87 in lb CRANKSHAFT TRANSMISSION 10 21 Transmission Transmission Removal Split the crankcase see Crankcase Disassembly Remove Shift Shaft Cover Bolts A Shift Shaft Cover B Remove Shift Shaft Spring Bolt A Shift Shaft B Remove Reverse Idle Shaft A Spacer B Reverse Drive Gear C Needle Bearing and Spacer Shifter D Shift Rod E 10 22 CRANKSHAFT TRANSMISSION Transmission Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 Remove Spacer A Idle Gear Assembly B Washers and Spacer C Low and High Gears D Remove Needle Bearings A Remove the driven shaft B from the crankcase
34. Bulb 12 V 5 21 W Reverse Light Bulb EUR 12V 10W Alternator Type Three phase AC Rated Output 24 2 A 14 V 6 000 r min rpm Specifications are subject to change without notice and may not apply to every country US United States Model EUR Europe Model GENERAL INFORMATION 1 11 Unit Conversion Table Prefixes for Units Prefix Symbol Power mega M 1 000 000 kilo k 1 000 centi c 0 01 milli m 0 001 micro 0 000001 Units of Mass kg 2 205 lb g 0 03527 oz Units of Volume L 0 2642 gal US L 0 2200 gal imp L 1 057 qt US L 0 8799 qt imp L 2 113 pint US L 1 816 pint imp mL 0 03381 oz US mL 0 02816 oz imp mL 0 06102 cu in Units of Force N 0 1020 kg N 0 2248 lb kg 9 807 N kg 2 205 lb Units of Length km 0 6214 mile m 3 281 ft mm 0 03937 in Units of Torque N m 0 1020 kgf m N m 0 7376 ft lb N m 8 851 in lb kgf m 9 807 N m kgf m 7 233 ft lb kgf m 86 80 in lb Units of Pressure kPa 0 01020 kgf cm kPa 0 1450 psi kPa 0 7501 cmHg kgf cm 98 07 kPa kgf cm 14 22 psi cmHg 1 333 kPa Units of Speed km h 0 6214 mph Units of Power kW 1
35. Tighten Torque Tie rod Locknuts 37 N m 3 8 kgf m 27 ft lb 15 12 STEERING Steering Maintenance Steering Inspection Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Stem Straightness Remove the steering stem see Steering Stem Removal Check the steering stem for straightness Use a straightedge along the stem If the steering stem is bent replace the steering stem Steering Bearing Sleeve Lubrication Lubricate the steering stem bearings Remove the steering stem see Steering Stem Removal Wipe all the old grease off the steering stem bearing sleeves and out of the grease seals Apply Amoco Rykon Premium Grease No 2 EP Green to the steering stem A and the inside B of the both clamps Lubricate the steering stem bearing A Remove the steering stem bearing Pack the grease seal lips with grease Steering Stem Clamp Inspection Inspect the steering stem clamps A If roughness excessive play or seizure is found replace both clamps Steering Stem Bearing Inspection Inspect the spherical bearing A If roughness excessive play or seizure is found replace the steering stem bearing Inspect the upper and lower grease seals B If damage wear or deterioration is found replace the steering stem bearing STEERING 15 13 Steering Maintenance Steering Knuckle Bearing Inspection CAUTION Do not remove
36. Wind the tape on the splines of the axle shaft in order to protect the joint boot Install New Small Band A New Boot B Apply the special grease slightly on the inside of the new boot small diameter and install the boot on the axle shaft CAUTION Only the special grease that is included with the boot kit can be applied to the boots Install New Circlip C 12 56 FINAL DRIVE Rear Axle Apply the special grease slightly on the part A of the band installation in order to make easy to install the boot band Tighten the small boot band B Tighten the boot band A and bend the tangs B securely to hold down the end of the band Place the special grease tube nozzle in the bore of the housing and squeeze the tube A until the grease comes out from the joint bearing Tap the shaft end A straight with a plastic hammer until it is locked by the circlip Squeeze all of the special grease A into the new boot B and slide the boot onto the outboard joint C FINAL DRIVE 12 57 Rear Axle Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot Hold the axle at this setting Standard Length of Assembling Outboard 216 2 mm 8 51 in A Open the edge of the boot in order to equalize the air pressures Tighten the large band A and bend the tangs securely to hold down the end of the band Maximum Outside D
37. 5 Muffler Mounting Second Nuts 31 3 2 23 S L Apply a non permanent locking agent R Replacement Parts S Follow the specific tightening sequence 5 8 ENGINE TOP END Specifications Item Standard Service Limit Rocker Case Rocker Arm Inside Diameter 12 000 12 018 mm 0 4724 0 4731 in 12 05 mm 0 474 in Rocker Shaft Diameter 11 983 11 994 mm 0 4718 0 4722 in 11 96 mm 0 471 in Camshafts Cam Height Exhaust 35 363 35 477 mm 1 3922 1 3967 in 35 26 mm 1 388 in Inlet 35 622 35 736 mm 1 4024 1 4069 in 35 52 mm 1 398 in Camshaft Bearing Clearance 18 0 016 0 052 mm 0 0006 0 0020 in 0 14 mm 0 0055 in 22 0 020 0 062 mm 0 0008 0 0024 in 0 15 mm 0 0059 in Camshaft Journal Diameter 18 17 966 17 984 mm 0 7073 0 7080 in 17 94 mm 0 706 in 22 21 959 21 980 mm 0 8645 0 8653 in 21 93 mm 0 863 in Camshaft Bearing Inside Diameter 18 18 000 18 018 mm 0 7087 0 7094 in 18 08 mm 0 712 in 22 22 000 22 021 mm 0 8661 0 8670 in 22 08 mm 0 870 in Camshaft runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 0039 in KACR Kawasaki Automatic Compression Release KACR Operating Engine Speed 760 30 r min rpm Cylinder Head Cylinder Compression Usable Range Electric Starter 251 456 kPa 2 56
38. Align the punch marks B on the intermediate shaft and sprocket with the embossed mark C on the crankcase 5 26 ENGINE TOP END Camshaft Front Camshaft Chain Install the circlip A Special Tool Outside Circlip Pliers 57001 144 Rotate the crankshaft clockwise 270 Align the key grooves B on the crankshaft with the em bossed line C on the crankcase Move the intermediate shaft A to the left side of the en gine Engage the front camshaft chain B with the sprocket on the intermediate shaft Install left side view Position Plate A Tighten Torque Position Plate Bolts B 8 8 N m 0 90 kgf m 78 in lb Install Intermediate Shaft Chain Guide A front Tighten Torque Intermediate Shaft Chain Guide Bolts B 8 8 N m 0 90 kgf m 78 in lb Install Intermediate Shaft Chain Guide A Rear Washer B Circlip C Special Tool Outside Circlip Pliers 57001 144 ENGINE TOP END 5 27 Camshaft Install the intermediate shaft chain tensioner A as fol lows Release the stopper B and push the push rod C into the tensioner body Insert a wire D into the rod hole to hold the rod in place Install Intermediate Shaft Chain Tensioner A Tighten Torque Intermediate Shaft Chain Tensioner Bolts B 8 8 N m 0 90 kgf m 78 in lb Remove the wire C to free the push rod Confirm that the punch mark A o
39. Apply grease to the O ring Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft lb PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Rear Final Gear Case Oil Change Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle Park the vehicle so that it is level both side to side and front to rear Place an oil pan beneath the rear final gear case and remove the drain plug A WARNING When draining or filling the final gear case be care ful that no oil gets on the tire or rim because oil will deteriorate the tire Clean off any oil that inadver tently gets on them with a high flash point solvent After the oil has completely drained out install the drain plug with a new aluminum gasket Torque Oil Drain Plug 13 N m 1 3 kgf m 113 in lb Fill the final gear case up to the bottom of filler opening with the oil specified below Final Gear Case Oil Type MOBIL FLUID 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Capacity 0 72 L 0 76 US qt Do not use mixing the above oils Be sure the O ring A is in place and tighten the filler cap B Apply grease to the O ring Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft lb 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Universal Joint Lubrication Remove Rear Propeller Shaft see Final Drive chapter Force gre
40. Gasoline is extremely flammable and can be explo sive under certain conditions Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Do not smoke Turn the ignition switch OFF Disconnect the battery terminal To make fuel spillage minimum draw the fuel out from the fuel tank when the engine is cold Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately Fuel Pump Removal Remove Electrical Parts Case see Frame chapter Bolts A Fuel Hose B Remove Vacuum Hose A Fuel Hose B Remove Nuts A and Washers Fuel Pump B 3 34 FUEL SYSTEM Fuel Pump Fuel Pump Installation Install Bracket A Fuel Pump B Washers C and Nuts D Install Vacuum Hose A Fuel Hose Carburetor Side B Clamps C Install Fuel Hose Fuel Tap Side A Clamp B Bolts C Removed Parts Fuel Pump Inspection Remove the fuel pump see Fuel Pump Removal If the hose connection areas A of the fittings are dam aged replace the fuel pump Blow the air to the outlet fitting A and make sure does not flow the blown air from the inlet fitting B If the fuel pump does not operate as described replace it with a new one FUEL SYSTEM 3 35 Fuel Pump Inhale the air to the inlet fitting A and make sure does not inhale the blown air from the outlet fitting B If the
41. Measure the resulting clearance A between the shoe B and the post C on the movable sheave at two positions as shown D Arrow Mark Shoe Side Clearance Standard up to 0 20 mm 0 008 in and there must be kept a clearance which the movable sheave E moves smoothly until it touches the fixed sheave F with its own weight If the clearance is not the specified range adjust it using the following shoes Part Number Thickness Standard Shoe 49048 1090 7 5 mm 0 295 in 49048 1087 7 2 mm 0 283 in 49048 1088 7 3 mm 0 287 in 49048 1089 7 4 mm 0 291 in 49048 1091 7 6 mm 0 299 in 49048 1092 7 7 mm 0 303 in 49048 1093 7 8 mm 0 307 in 49048 1094 7 9 mm 0 311 in Adjustment Shoes 49048 1095 8 0 mm 0 315 in 6 18 CONVERTER SYSTEM Drive Pulley If the clearance is not the specified range after the above shoes are replaced use the spacer A 92026 0038 of the option part B Shoe C Spider D Post E Clearance Drive Pulley Assembly Install the ramp weight A as shown Tighten Torque Ramp Weight Nuts B 6 9 N m 0 70 kgf m 61 in lb Check that the ramp weights swing smoothly Hold the fixed sheave A with the drive pulley holder B in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 Clean the threads of the fixed sheave and spider Install Movable Sheave Spider A and Shoes B Align the arrow
42. 0 047 in 92180 0161 Backlash Adjustment Clean any dirt and oil off the bevel gear teeth Install the pinion gear assembly with the primary shim 1 0 mm 0 039 in thickness Assemble the rear final gear case see Rear Final Gear Case Assembly Install the ring gear with the primary shims 1 0 mm 0 039 in thickness Check the backlash during tightening the cover bolts and stop tightening them immediately if the backlash disap pears Then change the ring gear shim to a thinner one Temporarily install the rear axle in the gear case and hold it with a vise so that the ring gear is lower than the pinion gear Mount a dial gauge A so that the tip of the gauge is against the splined portion B of the pinion gear joint To measure the backlash move the pinion gear shaft back and forth C while holding the rear axle steady The difference between the highest and the lowest gauge reading is the amount of backlash Measure backlash at three locations equally spaced on the splines Rear Final Bevel Gear Backlash Standard 0 04 0 17 mm 0 002 0 007 in at pinion gear spline FINAL DRIVE 12 71 Rear Final Gear Case If the backlash is not within the standard replace the pinion gear shim s To increase backlash increase the thickness of the shim s To decrease backlash decrease the thickness of the shim s Change the thickness a little at a time Recheck the backlash and readjust
43. 57001 1520 Tighten Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in lb Drive Pulley Bolt C new left hand threads 93 N m 9 5 kgf m 69 ft lb 6 20 CONVERTER SYSTEM Drive Pulley Remove the drive pulley holder and install three drive pul ley cover bolts to the specified torque Adjust the installation length A of the drive pulley be tween the surface of the crankcase B and the collar C on the drive pulley as followings Drive Pulley Installation Length A Standard 149 85 150 95 mm 5 900 5 943 in Install the drive pulley measurement tool legs A and plate B on the crankcase C Special Tool Drive Pulley Measurement Tool 57001 1498 Measure the length D between the plate and collar E with vernier calipers F or a depth gauge Measurement Length D Standard 14 55 15 65 mm 0 573 0 616 in If the measurement is not within the specified range ad just it according to following table Status Quo Replacement Part Measurement Length Paint Color of Cover Replace Part Part Number Paint Color of Cover Blue Pulley Cover 14041 1161 No Paint No Paint Pulley Cover 14041 1159 Red less than 14 55 mm 0 573 in Red Drive Pulley Assembly 49093 0014 Blue Drive Pulley Assembly 49093 0014 No Paint Pulley Cover 14041 1160 Blue more than 15 65 mm 0 616 in Red Pulley Cover 14041 1161 No Pain
44. 8 3 kgf m 60 ft lb ELECTRICAL SYSTEM 17 1 17 Electrical System Table of Contents Parts Location 17 3 Exploded View 17 6 Specifications 17 12 Wiring Diagram 17 14 Special Tools 17 16 Precautions 17 17 Electrical Wiring 17 19 Wiring Inspection 17 19 Battery 17 20 Battery Removal 17 20 Battery Installation 17 20 Battery Activation 17 20 Precautions 17 22 Interchange 17 23 Charging Condition Inspection 17 24 Refreshing Charge 17 24 Charging System 17 26 Alternator Cover Removal 17 26 Alternator Cover Installation 17 27 Alternator Rotor Removal 17 28 Alternator Rotor Installation 17 28 Alternator Stator Removal 17 29 Alternator Stator Installation 17 29 Regulator Rectifier Output Voltage Inspection 17 29 Alternator Inspection 17 30 Regulator Rectifier Inspection 17 31 Ignition Sy
45. A onto the alternator rotor Special Tool Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 Holding the flywheel puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft CAUTION If the rotor is difficult to remove turn the puller while tapping the end of the puller Do not strike the alternator rotor Striking the rotor can cause the magnets to lose magnetism Alternator Rotor Installation Clean A the inside of the rotor and the end of the crank shaft Fit the rotor onto the crankshaft so that woodruff key B fits in the groove C in the hub of the rotor Install the alternator rotor A while turning the starter clutch gear B Apply molybdenum disulfide grease to the shaft of the torque limiter C Install the torque limiter ELECTRICAL SYSTEM 17 29 Charging System Alternator Stator Removal Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor A see Crankshaft Sensor Re moval Bolts B and Alternator Stator C Alternator Stator Installation Tighten Torque Alternator Stator Bolts 13 N m 1 3 kgf m 113 in lb Install Crankshaft Sensor see Crankshaft Sensor Installation Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads Regulator Rectifier Output Voltage Inspection Remove the seat see Fram
46. A straight out of the fuse box with needle nose pliers Fuse Installation If a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse of proper amperage Install the fuses on the original position as specified on the lid A Fuse Inspection 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 Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components APPENDIX 18 1 18 Appendix Table of Contents Troubleshooting Guide 18 2 Cable Wire and Hose Routing 18 7 18 2 APPENDIX Troubleshooting Guide NOTE 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
47. F Fixed Sheave G Drive Pulley Inspection If the sheave surfaces A appear damaged replace the sheaves 6 16 CONVERTER SYSTEM Drive Pulley If the cover bushing is damaged or worn replace the drive pulley cover Cover Bushing Inside Diameter A Standard 27 985 28 085 mm 1 1018 1 1057 in Service Limit 28 12 mm 1 107 in If the sheave bushing is damaged or worn replace it Sheave Bushing Inside Diameter A Standard 37 985 38 085 mm 1 4955 1 4994 in Service Limit 38 12 mm 1 501 in If the spider shoes A are damaged replace them Check the spider shoe side clearance see Spider Shoe Side Clearance Inspection If the ramp weights A in the movable sheave are dam aged or worn replace them If the pins B are damaged or worn replace them If the rollers A are damaged or worn replace the spider B If the washers C are damaged or worn replace the spi der CONVERTER SYSTEM 6 17 Drive Pulley If the spring is worn or damaged replace the spring Spring Free Length A Standard 60 4 mm 2 38 in Spider Shoe Side Clearance Adjustment Remove Drive Pulley see Drive Pulley Removal Drive Pulley Cover and Spring see Drive Pulley Disas sembly Temporarily install the following parts on the movable sheave Dowel Pins 2 Drive Pulley Cover Two Bolts at dowel pins Do not install the spring Turn the movable sheave counterclockwise
48. Friction Plates A Steel Plates P No 41080 1484 without holes Install Steel Plate A P No 41080 1483 two holes Insert the pins B into the holes of steel plate Install Dowel Pins A New Gasket B Tighten Torque Gasket Screws C 1 3 N m 0 13 kgf m 11 in lb Install Rear Final Gear Case Front Cover A Tighten Torque Rear Final Gear Case Front Cover Bolts B 24 N m 2 4 kgf m 17 ft lb Inspect Ball Bearing A see Bearing and Oil Seal section Oil Seal B see Bearing and Oil Seal section If they are damaged replace them Apply grease to the oil seal lips and O ring C Install Shim D Ring Gear E 12 68 FINAL DRIVE Rear Final Gear Case Install Shim A Rear Final Gear Case Right Cover B Apply a non permanent locking agent to the rear final gear case right cover bolts Tighten Torque Rear Final Gear Case Right Cover Bolts M12 A 93 N m 9 5 kgf m 69 ft lb Rear Final Gear Case Right Cover Bolts M10 B 49 N m 5 0 kgf m 36 ft lb Rear Final Gear Case Right Cover Bolts M8 C 24 N m 2 4 kgf m 17 ft lb Rear Final Gear Case Oil Drain Plug D 13 N m 1 3 kgf m 113 in lb Rear Final Bevel Gear Adjustment The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged After replacing any of the backlash related parts
49. L Cylinder Bolts 40 mm 1 6 in 9 8 1 0 87 in lb Cylinder Bolts 30 mm 1 2 in 9 8 1 0 87 in lb Front Cylinder Camshaft Chain Guide Bolt 20 2 0 14 Rear Cylinder Camshaft Chain Guide Bolt 20 2 0 14 Exhaust Pipe Cover Bolts 8 8 0 90 78 in lb Muffler Clamp Bolts 8 8 0 90 78 in lb Muffler Mounting First Nuts 15 1 5 11 S Muffler Mounting Second Nuts 31 3 2 23 S Muffler Cover Bolts 8 8 0 90 78 in lb Converter System Drive Pulley Bolt 93 9 5 69 R Lh Driven Pulley Nut 93 9 5 69 Drive Pulley Cover Bolt 13 1 3 113 in lb Ramp Waight Nuts 6 9 0 70 61 in lb Spider 275 28 203 Lh Joint Duct Bolts 8 8 0 90 78 in lb Converter Cover Bolts 8 8 0 90 78 in lb S Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb S Recoil Starter Recoil Starter Mounting Bolts 5 9 0 60 52 in lb L Engine Lubrication System Oil Filter 18 1 8 13 R Oil Pressure Switch 15 1 5 11 SS Oil Pipe Bolts 8 8 0 90 78 in lb Engine Drain Plug 20 2 0 14 Oil Pressure Relief Valve 15 1 5 11 L Oil Pump Bolts 8 8 0 90 78 in lb Chain Guide Bolts 8 8 0 90 78 in lb Oil Pump Drive Chain Tensioner Bolt 25 2 5 18 Oil Filter Mounting Bolts 25 2 5 18 L 15 mm Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb Engine Removal Installation Engine Bracket Mounting Bolts 72 7 3 53 PERIODIC MAINTENANCE 2 7 Torque and Locking A
50. R Replacement Parts S Follow the specific tightening sequence Si Apply silicone grease 13 4 BRAKES Exploded View BRAKES 13 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Variable Differential Control Lever Bolt L 2 Gasket Screws L 3 Bend both hooks after installing the spring G Apply grease L Apply a non permanent locking agent MF Apply MOBIL FLUID 424 or equivalent oil R Replacement Parts 13 6 BRAKES Specifications Item Standard Service Limit Brake Fluid Type DOT 3 or DOT 4 Front Disc Brake Pad lining thickness 4 0 mm 0 16 in 1 mm 0 04 in Disc thickness 3 3 3 7 mm 0 130 0 146 in 3 mm 0 12 in Disc runout TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in Rear Brake Lever Pedal and Cables Rear brake pedal position see text Rear brake lever free play 1 2 mm 0 04 0 08 in Rear brake pedal free play 15 25 mm 0 6 1 0 in BRAKES 13 7 Special Tool Inside Circlip Pliers 57001 143 13 8 BRAKES Brake Fluid WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid
51. Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in lb Fit the spark plug caps securely Pull up the spark pug caps lightly to make sure of the installation of the spark plug caps ELECTRICAL SYSTEM 17 35 Ignition System Spark Plug Cleaning Inspection Refer to the Spark Plug Cleaning Inspection in the Peri odic Maintenance chapter Spark Plug Gap Inspection Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter Ignition Coil Removal Front Side Remove Spark Plug Cap A Primary Lead Connectors B Bolt C Ignition Coil D Rear Side Remove Right Side Cover see Frame chapter Rubber Air Duct see Spark Plug Removal Spark Plug Cap A Remove Primary Lead Connectors A Bolt B Ignition Coil C Ignition Coil Installation Connect the primary leads to the ignition coil terminals as shown Front Side G W Lead Mark A BK Y Lead Mark Rear Side BL W Lead Mark A BK Y Lead Mark 17 36 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection Remove the ignition coil Measure the arcing distance with a coil tester A to check the condition of the ignition coil B Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance Ignition Coil Arcing Distance 7 mm
52. be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth con tact by replacing shims The amount of backlash is influenced by the ring gear position more than by the pinion gear position Tooth contact locations is influenced by the pinion gear position more than by the ring gear position FINAL DRIVE 12 69 Rear Final Gear Case Rear Final Gear Case Backlash related Parts 1 Pinion Gear 2 Pinion Gear Bearing Holder 3 Gear Case Right Cover 4 Ball Bearings 5 Ring Gear 6 Pinion Gear Shim s 7 Ring Gear Shim s 8 Ring Gear Shim s 12 70 FINAL DRIVE Rear Final Gear Case 6 Pinion Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1423 0 2 mm 0 008 in 92180 1424 0 5 mm 0 020 in 92180 1425 0 8 mm 0 031 in 92180 1426 1 0 mm 0 039 in 92180 1427 1 2 mm 0 047 in 92180 1428 7 Ring Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1417 0 2 mm 0 008 in 92180 1418 0 5 mm 0 020 in 92180 1419 0 8 mm 0 031 in 92180 1420 1 0 mm 0 039 in 92180 1421 1 2 mm 0 047 in 92180 1422 8 Ring Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 0166 0 2 mm 0 008 in 92180 0165 0 5 mm 0 020 in 92180 0164 0 8 mm 0 031 in 92180 0163 1 0 mm 0 039 in 92180 0162 1 2 mm
53. ing the bushing in the crankcase Using the pry points B split the crankcase halves Lift off the left crankcase half Crankcase Assembly CAUTION The right and left crankcase halves are machined at the factory in the assembled state so the crankcase halves must be replaced as a set NOTE Be certain that all parts are cleaned thoroughly before assembly Blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crank shaft WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or low flash point solvents to clean parts A fire or ex plosion could result 10 10 CRANKSHAFT TRANSMISSION Crankcase Press and insert the new ball bearings until they are bot tomed Special Tool Bearing Driver Set 57001 1129 A Ball Bearing B Ball Bearing sealed side towards crankcase Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole C Needle Bearing D Needle Bearing Insert it from outside Apply engine oil to the bearings Install Oil Pressure Relief Valve E see Engine Lubrication System chapter Install Rear Cylinder Camshaft Chain Guide A Tighten Torque Rear Cylinder Camshaft Chain Guide Bolt B 20 N m 2 0 kgf m 14
54. 0 15 mm 0 006 in 92180 1307 0 2 mm 0 008 in 92180 1308 0 5 mm 0 020 in 92180 1309 0 8 mm 0 031 in 92180 1310 1 0 mm 0 039 in 92180 1349 1 2 mm 0 047 in 92180 1350 12 22 FINAL DRIVE Output Bevel Gears Bevel Gear Backlash Adjustment The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position Remove the output drive idle gear see Output Drive Bevel Gear Removal Set up a dial gauge A against the output drive shaft spline groove to check gear backlash To measure the backlash turn the shaft clockwise and counterclockwise slightly so as not to move the mate gear A rod can be inserted through the lower hole of the hous ing and into contact with driven gear This may help to hold it still The difference between the highest and low est gauge reading is the amount of backlash If the backlash is not within the limit replace the shim s at the driven bevel gear Change the thickness a little at a time Recheck the backlash and readjust as necessary Output Bevel Gear Backlash Standard 0 05 0 11 mm 0 0020 0 0043 in at output drive shaft spline Tooth Contact Adjustment Tooth contact location is influenced by drive gear position more than by driven gear position Clean any dirt and oil off the bevel gear teeth Apply checking compound to 4 or 5 teeth on the output driven bevel gear NOTE Apply checking co
55. 0 28 in or more WARNING To avoid extremely high voltage shocks do not touch the ignition coil body or leads If the distance reading is less than the specified value the ignition coil or spark plug cap is defective To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclock wise If the arcing distance is as before the trouble is with the ignition coil If the arcing distance is normal the trouble is with the spark plug cap If a coil tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester Special Tool Hand Tester 57001 1394 NOTE The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage Measure the primary winding resistance A as follows Connect the tester between the coil terminals Set the tester to the 1 range Measure the secondary winding resistance B as follows Remove the plug cap by turning it counterclockwise Connect the tester between the spark plug lead and ter minal Set the tester to the 1 k range Ignition Coil Winding Resistance Primary Windings 0 09 0 13 Secondary Windings 3 8 5 8 k If the hand tester does not read as specified replace the coil To install the plug cap turn it clockwise ELECTRICAL SYSTEM 17 37 Ig
56. 22 Driven Pulley Assembly 6 23 Driven Pulley Installation 6 25 High Altitude Setting Information 6 27 Specifications 6 27 6 2 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 6 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Drive Pulley Bolt 93 9 5 69 R Lh 2 Driven Pulley Nut 93 9 5 69 3 Drive Pulley Cover Bolts 13 1 3 113 in lb 4 Ramp Weight Nuts 6 9 0 70 61 in lb 5 Spider 275 28 203 Lh G Apply grease Lh Left hand Threads R Replacement Parts WR Apply grease WR500 No 2 KYODO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA 6 4 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 6 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Converter Cover Bolts 8 8 0 90 78 in lb S 2 Joint Duct Bolts 8 8 0 90 78 in lb 3 Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb S G Apply grease M Apply molybdenum disulfide grease R Replacement Part S Follow the specific tightening sequence 6 6 CONVERTER SYS
57. 31 N m 3 2 kgf m 23 in lb Muffler Clamp Bolts 8 8 N m 0 90 kgf m 78 in lb Install Front Exhaust Cover J Middle Exhaust Cover K Rear Exhaust Cover L Torque Exhaust Cover Bolts 8 8 N m 0 90 kgf m 78 in lb 5 46 ENGINE TOP END Exhaust System Exhaust System Inspection Before removing the exhaust system check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp If there are signs of leakage around the exhaust pipe gas ket it should be replaced If the muffler to exhaust pipe joint leaks tighten the clamp Remove the exhaust pipe and muffler see Muffler and Exhaust Pipe Removal Inspect the gasket for damage and signs of leakage If the gasket is damaged or has been leaking replace it Check the exhaust pipe and muffler for dents cracks rust and holes If the exhaust pipe or muffler is damaged or has holes it should be replaced for best performance and least noise CONVERTER SYSTEM 6 1 6 Converter System Table of Contents Exploded View 6 2 Specifications 6 6 Special Tools
58. 4 65 kgf cm 36 66 psi 380 r min rpm Cylinder head warp 0 05 mm 0 002 in Valve Valve Clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in Valve Head Thickness Exhaust 0 8 mm 0 031 in 0 5 mm 0 020 in Inlet 0 5 mm 0 020 in 0 3 mm 0 012 in Valve Stem Bend TIR 0 05 mm 0 002 in ENGINE TOP END 5 9 Specifications Item Standard Service Limit Valve Stem Diameter Exhaust 4 955 4 970 mm 0 1951 0 1957 in 4 94 mm 0 1945 in Inlet 4 975 4 990 mm 0 1959 0 1965 in 4 96 mm 0 1953 in Valve Guide Inside Diameter Exhaust 5 000 5 012 mm 0 1969 0 1973 in 5 08 mm 0 20 in Inlet 5 000 5 012 mm 0 1969 0 1973 in 5 08 mm 0 20 in Valve Valve Guide Clearance Wobble Method Exhaust 0 09 0 17 mm 0 0035 0 0067 in 0 37 mm 0 0146 in Inlet 0 03 0 11 mm 0 0012 0 0043 in 0 31 mm 0 0122 in Valve Seat Cutting Angle 45 32 60 Valve Seating Surface Outside Diameter Exhaust 25 2 25 4 mm 0 992 1 000 in Inlet 29 4 29 6 mm 1 157 1 165 in Width Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in Valve
59. 6 7 Torque Converter 6 9 Torque Converter Cover Removal 6 9 Torque Converter Cover Installation 6 10 Torque Converter Cover Disassembly 6 10 Actuator Lever Engine Brake Control Lever Assembly Inspection 6 11 Torque Converter Cover Assembly 6 11 Drive Belt 6 13 Drive Belt Removal 6 13 Drive Belt Installation 6 13 Drive Belt Deflection Inspection 6 13 Drive Belt Deflection Adjustment 6 13 Drive Belt Inspection
60. Air Jet 100 Pilot Screw 2 1 4 turns out Carburetor Synchronization vacuum less than 2 7 kPa 2 cmHg difference between carburetors Starter Jet 82 Idle Speed 1 150 50 r min rpm Service Fuel Level Front 20 4 1 mm 0 80 0 04 in below the punch mark Rear 19 5 1 mm 0 77 0 04 in below the punch mark Float Height 2 9 1 mm 0 11 0 04 in Optional Parts Main Jet Altitude 0 1 200 m 0 3 900 ft Front 152 92063 1331 Rear 158 92063 1344 1 200 2 500 m 3 900 8 200 ft Front 145 92063 1017 Rear 152 92063 1331 2 500 3 500 m 8 200 11 500 ft Front 142 92063 1016 Rear 148 92063 1324 3 500 4 500 m 11 500 14 800 ft Front 135 92063 1014 Rear 140 92063 1013 Air Cleaner Air Cleaner Element Oil High quality foam air filter oil Refer to pg 6 27 for high altitude setting in the converter system FUEL SYSTEM 3 7 Special Tools Fuel Level Gauge 57001 1017 Pilot Screw Adjuster A 57001 1239 Carburetor Drain Plug Wrench Hex 3 57001 1269 Vacuum Gauge 57001 1369 3 8 FUEL SYSTEM Throttle Lever and Cable Throttle Lever Free Play Inspection Refer to the Thro
61. C on the spider with the arrow D on the movable sheave Insert the shoes so that the rubber side black small di ameter faces inward Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 Turn the wrench counterclockwise for tightening Torque Spider left hand threads 275 N m 28 kgf m 203 ft lb Remove the drive pulley wrench CONVERTER SYSTEM 6 19 Drive Pulley Install the spacer Put the spring A in the groove of the spider Align the arrows B on the drive pulley cover and spider Install Dowel Pins C Drive Pulley Cover Tighten Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in lb Clean the surface of the sheaves with an oil less cleaning fluid Drive Pulley Installation Clean the following portions with an oil less cleaning fluid such as trichloroethylene or acetone Fixed Sheave Tapered Portion A Crankshaft Tapered Portion B WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Install the drive pulley stepped waster and two washers on the drive pulley bolt as shown Crankcase Side A Stepped Washer B Two Washers C Bolt Head Side D Remove the three cover bolts A and install the drive pul ley holder B Special Tool Drive Pulley Holder
62. CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced 5 36 ENGINE TOP END Valves Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F Measure the outside diameter of the seating surface with vernier calipers If the outside diameter of the seating surface is too small repeat the 45 grind A until the diameter is within the specified range Original Seating Surface B NOTE Remove all pittings of flaws from 45 ground surface After grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier When the valve guide is replaced be sure to grind with 45 cutter for centering and good contact If the outside diameter A of the seating surface is too large make the 32 grind described below If the outside diameter of the seating surface is within the specified range measure the seat width as described be low Grind the seat at a 32 angle B until the seat O D is within the specified range To make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide Turn the h
63. Cap B Remove Element Cover Screw A Element Cover B Element C After removing the element stuff pieces of lint free clean cloth into the air cleaner ducts to keep dirt out of the car buretor and engine WARNING If dirt or dust is allowed to pass through into the carburetors the throttle may become stuck possi bly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Air Cleaner Element Installation Install Element Element Cover Tighten Torque Element Cover Screw 3 5 N m 0 35 kgf m 31 in lb Air Cleaner Element Cleaning and Inspection Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Air Cleaner Housing Removal Remove Side Covers see Frame chapter Air Cleaner Housing Cap Air Cleaner Element see Air Cleaner Element Removal FUEL SYSTEM 3 25 Air Cleaner Remove Screws A Element Holder B Spark Arrester C Remove Screw A Air Intake Duct B Air Cleaner Housing Bolt C Remove Air Cleaner Housing Bolt A Loosen the clamp screws A Remove Breather Hose A 3 26 FUEL SYSTEM Air Cleaner Remove Screw A Carburetor Breather Tank B Air Cleaner Housing C Air Cleaner Housing Installation Fit the projection A of the housing in the groove B of the joint duct C front and rear and t
64. Drive Bevel Gear Housing Bolts 26 2 7 20 Bearing Holder 137 14 101 L Bevel Gear Holder Nut 157 16 116 L Bearing Holder 118 12 87 L Output Shaft Holder Nut 157 16 116 L Rotor Mounting Bolts 12 1 2 104 in lb Output Drive Bevel Gear Cover Bolts 8 8 0 90 78 in lb Front Final Gear Case Variable Differential Control Shift Shaft Lever Bolt 8 8 0 90 78 in lb 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Front Final Gear Case Left Cover Bolts M6 9 8 1 0 87 in lb L Ring Gear Bolts 57 5 8 42 LB Front Final Gear Case Center Cover Bolts M6 9 8 1 0 87 in lb L Front Final Gear Case Center Cover Bolts M8 24 2 4 17 L Front Final Gear Case Oil Filler Cap 29 3 0 22 Pinion Gear Bearing Holder Nut 127 13 94 St Pinion Gear Bearing Holder 137 14 101 L Front Final Gear Case Coupling Nut 25 2 5 18 Front Final Gear Case Oil Drain Plug 15 1 5 11 2WD 4WD Actuator Mounting Bolts 9 8 1 0 87 in lb L S Variable Differential Control Cable Locknut 17 1 7 12 Variable Differential Control Lever Bolt L Front Final Gear Case Nuts 59 6 0 43 Rear Final Gear Case Rear Final Gear Case Front Cover Bolts 24 2 4 17 Gasket Screws 13 0 13 11 in lb Pinion Gear Bearing Holder Nut 157 16 116 L Pinion Gear Bearing Holder 137 14 101 L Rear Final Gear Case Right Cover Bolt
65. Final Gear Case Center Cover Bolts M8 1 3 24 N m 2 4 kgf m 17 ft lb Front Final Gear Case Center Cover Bolts M6 2 4 9 8 N m 1 0 kgf m 87 in lb Adjust the gear backlash and tooth contact pattern see Front Final Bevel Gear Adjustment Apply a non permanent locking agent to the cover bolts and tighten them to the specified torque in the tightening sequence 1 4 Apply a non permanent locking agent to the pinion gear bearing holder A and tighten it so that the deep recess B faces outward Special Tool Socket Wrench Hex 41 57001 1484 Torque Pinion Gear Bearing Holder 137 N m 14 kgf m 101 ft lb Install Dowel Pins A New Gasket B Steel Balls C FINAL DRIVE 12 41 Front Final Gear Case Install Cam Lever A Needle Bearing B Apply engine oil to the needle bearing Check the wear of the disc assembly as follows Measure the thickness of the inner disc A Select the width A of the disc assembly B in accordance with the thickness of the inner disc refer to the below table Thickness of Inner Disc Assembly Width A of Disc Assembly 2 4 mm 0 0945 in 16 7 17 3 mm 0 6675 0 6811 in 1 8 mm 0 0709 in 17 31 17 9 mm 0 6815 0 7047 in 1 2 mm 0 0472 in 17 91 18 5 mm 0 7051 0 7283 in Measure the width of the disc assembly at three locations and calculate average for three points NOTE B
66. Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft lb Brake Fluid Level Inspection Position the reservoir horizontal and check that the fluid level in the reservoir is higher than the lower level line A If the fluid level is lower than the lower level line check for fluid leakage of the brake line and add the fluid as follows Remove the reservoir cap and fill the reservoir to the up per level line A in the reservoir with the same type and brand of the fluid that is already in the reservoir And then install the reservoir cap WARNING Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified Tighten Torque Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in lb 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change Remove the reservoir cap and the rubber cap on the bleed valve Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer Fill the reservoir with new brake fluid Change the brake fluid as follows Open the bleed valve A Apply the brake lever and hold it B Close the bleed valve C Release the brake lever D Check the fluid level in the reservoir often replenishing it as necessary NOTE If the fluid in the reservoir runs completely out any time during fluid changi
67. Jet 1 Front 152 P No 92063 1331 STD 0 1 200 0 3 900 P No 39152 1081 STD C P No 92026 1603 t 1 mm 0 04 in Rear 158 P No 92063 1344 STD 1 200 2 500 3 900 8 200 P No 39152 1081 STD C P No 92026 1603 t 1 mm 0 04 in 1 Front Rear 145 P No 92063 1017 152 P No 92063 1331 2 500 3 500 8 200 11 500 P No 39152 1088 C1 P No 92026 1603 t 1 mm 0 04 in 2 Front Rear 142 P No 92063 1016 148 P No 92063 1324 3 500 4 500 11 500 14 800 P No 39152 1088 C1 P No 92026 1603 t 1 mm 0 04 in 2 Front Rear 135 P No 92063 1014 140 P No 92063 1013 C C1 Identification Marks qty quantity Refer to the Drive Pulley section in this chapter and Carburetor section in the Fuel System chapter for the parts replacement RECOIL STARTER 7 1 7 Recoil Starter Table of Contents Exploded View 7 2 Recoil Starter 7 4 Recoil Starter Removal 7 4 Recoil Starter Installation
68. Lead APPENDIX 18 21 Cable Wire and Hose Routing 1 Right Handlebar Switch Lead 2 Throttle Cable 3 Meter Lead 4 Variable Differential Control Cable 5 Parking Brake Cable 6 Choke Cable 7 Left Handlebar Switch Lead 8 Bands 9 Front Brake Light Switch Lead 10 Brake Hose 11 Tubes 12 Cables 13 Leads 14 Rear Brake Light Switch Lead 18 22 APPENDIX Cable Wire and Hose Routing 1 Air Intake Duct 2 Bands 3 Parking Brake Cable 4 Foot Brake Cable 5 Bracket 6 Clamp 7 Foot Brake Light Switch 8 Speed Sensor Lead Connector 9 Run the lead front side of frame pipe 10 Clamps 11 Reverse Switch Lead Connector 12 Neutral Switch Lead Connector 13 Forward Reverse Detecting Sensor Lead Connector 14 Apply grease Amoco Rykon Premium Grease No 2 EP Green APPENDIX 18 23 Cable Wire and Hose Routing 1 Fuse Box 2 Igniter 3 Main Harness 4 Clamp 5 Actuator Controller 6 Reset Connectors 7 Starter Circuit Relay Neutral 8 Electric Parts Case 9 Vehicle Down Sensor 10 Starter Circuit Relay Brake 11 Clamp 12 Radiator Fan Breaker 13 Starter Relay 14 Battery Cable 15 Run the cable under the case 18 24 APPENDIX Cable Wire and Hose Routing 1 Main Harness 2 Battery Cable 3 Bands 4 To Brake Switch 5 Clamps 6 Fuse Box Lead 7 To Igniter 8 To Actuator Controller 9 To Starter Relay 10 Battery Cable 11 Reset Connector 12 To Starter Circuit Relay Neutral 13
69. Locknuts 12 1 2 104 in lb G Apply grease M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 S Follow the specific tightening sequence SS Apply silicone sealant Three Bond TB1211F or GE SILICONES TRANSLUCENT RTV128 5 4 ENGINE TOP END Exploded View ENGINE TOP END 5 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Chain Tensioner Mounting Bolts 8 8 0 90 78 in lb 2 Chain Tensioner Cap Bolt 22 2 2 16 3 Position Plate Bolts 8 8 0 90 78 in lb 4 Intermediate Shaft Chain Guide Bolts 8 8 0 90 78 in lb 5 Intermediate Shaft Chain Tensioner Bolts 8 8 0 90 78 in lb 6 Camshaft Sprocket Bolts 12 1 2 104 in lb L 7 Cylinder Bolts 40 mm 1 6 in 9 8 1 0 87 in lb 8 Cylinder Bolts 30 mm 1 2 in 9 8 1 0 87 in lb 9 Front Cylinder Camshaft Chain Guide Bolt 20 2 0 14 10 Rear Cylinder Camshaft Chain Guide Bolt 20 2 0 14 G Apply grease L Apply a non permanent locking agent O Apply engine oil R Replacement Parts 5 6 ENGINE TOP END Exploded View ENGINE TOP END 5 7 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Exhaust Pipe Cover Bolts 8 8 0 90 78 in lb 2 Muffler Clamp Bolt 8 8 0 90 78 in lb 3 Muffler Cover Bolts 8 8 0 90 78 in lb 4 Muffler Mounting First Nuts 20 2 0 14 S
70. Motor Cable A Starter Motor Mounting Bolts B Clamp C Starter Motor D CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged Starter Motor Installation When installing the starter motor clean the starter mo tor lugs A and crankcase B where the starter motor is grounded If the O ring A shows wear or damage or if it is hard ened replace it with a new one Apply a small amount of engine oil to the O ring 17 46 ELECTRICAL SYSTEM Electric Starter System Install Starter Motor A Clamp B as shown Starter Motor Cable C Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 90 kgf m 78 in lb Starter Motor Terminal Nut 4 9 N m 0 50 kgf m 43 in lb Apply grease to the O ring D in the joint duct E Install Joint Duct and Collars F Clamp G as shown Tighten Torque Joint Duct Bolts H 8 8 N m 0 90 kgf m 78 in lb Starter Motor Disassembly Remove Starter Motor Bolts A Washers and O rings Left End Cover B Right End Cover C Yoke D To remove the brush plate assembly A remove the ter minal nut B Hold the brush spring A with needle nose pliers and pull the brush B off the holder ELECTRICAL SYSTEM 17 47 Electric Starter System Starter Motor Assembly Replace the O rings Install the brush plate assembly to the right end cover so that the projection A on the brush
71. Mounting Bolts Front Camshaft Chain Tensioner see Camshaft Chain Tensioner Removal Front Engine Mounting Bolt A Loosen Rear Engine Mounting Bolt B Remove Rocker Case Bolts A Loosen Rocker Case Bolt B 5 16 ENGINE TOP END Rocker Case Insert a suitable bar A under the front of the engine Lift A the front of the engine to remove the bolt B of the front right side on the rocker case Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame Rear Rocker Case Remove Front Rocker Case see this section Torque Converter Cover Upper Air Duct Using a wrench on the alternator bolt turn the crankshaft counterclockwise 270 until T R mark A is aligned with the notch B in the inspection window and the cam lobes are pointing away from the rocker arms the end of the compression stroke CAUTION Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case The rocker arms could bend the valves Remove Rear Camshaft Chain Tensioner see Camshaft Chain Tensioner Removal Rocker Case Bolts A Rear Rocker Case B Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame Rocker Case Installation Check that the crankshaft is positioned at TDC and at the end of the compression stroke CAUTION
72. NOTE On high beam the brightest point should be slightly be low horizontal with the vehicle on its wheels and the rider seated Adjust both headlights to the same an gle Headlight Bulb Replacement Remove Connector A Calmp B Screw C Remove Headlight Bolts A and Collasrs Headlight Body B Remove Bolts A Vertical Adjustment Screw B Spring and Nut Headlight Cover C Disconnect Connector A ELECTRICAL SYSTEM 17 55 Lighting System Turn the bulb socket A counterclockwise B and remove the bulb Align the mark A of a new bulb socket with the mark B of the headlight body Turn the bulb socket clockwise until it is stopped Disconnect the position light lead connector Turn the bulb socket A counterclockwise B and remove the bulb Align the mark A of a new bulb socket with the mark B of the headlight body Turn the bulb socket clockwise until it is stopped Install the removed parts A Bolt and Collar L 6 mm 0 24 in B Bolt and Collar L 4 mm 0 16 in C Bolt only 17 56 ELECTRICAL SYSTEM Lighting System Taillight Bulb Replacement Remove Taillight Lens Mounting Screws A Taillight Lens B Push the bulb A in turn it counterclockwise and pull it out Be sure the socket is clean Insert the new bulb by aligning the pins A with the grooves in the walls of the socket Push the
73. Outline This sensor has a weight A with two magnets inside and sends a signal to the igniter But when the vehicle banks 60 70 or more to either side in fact falls down the weight turns and shuts off the signal in the vehicle down sensor circuit The igniter senses this change and stops the fuel pump and the ignition system Hall IC B Vehicle down Sensor A Ground Terminal B BK Y Output Terminal C Y G Power Source Terminal D BR Constant Voltage Circuit E Hall IC Integrated Circuit F Vehicle down Sensor Circuit G Front H ELECTRICAL SYSTEM 17 41 Ignition System Vehicle down Sensor Removal CAUTION Never drop the vehicle down sensor especially on a hard surface Shock to the sensor can damage it Remove Rear Fender see Frame chapter Vehicle down Sensor Lead Connector A Screws B Vehicle down Sensor C Vehicle down Sensor Installation Install the vehicle down sensor A so that the sensor lead base faces forward B and the arrow mark C on the sensor points upward Tighten the screws securely WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by the sensor brackets Vehicle down Sensor Inspection NOTE Be sure t
74. Radiator Fan Motor Lead Connector A Install the fan motor breather hose B NOTE Do not apply lubricant at fitting hose region Install Radiator Hoses C Reserve Tank Hose D Clamps E Run the hoses according to the Cable Wire and Hose Routing section in the Appendix chapter Radiator Fan Removal Remove Radiator see Radiator Removal Radiator Fan Assembly Bolts A Fan Assembly B Radiator Fan Installation Install Radiator Fan Radiator Fan Mounting Nut Install Radiator Fan Assembly Tighten Torque Radiator Fan Assembly Bolts 4 9 N m 0 50 kgf m 43 in lb COOLING SYSTEM 4 15 Radiator Radiator Inspection Check the radiator core If there are obstructions to air flow remove the radiator and remove obstructions If the corrugated fins A are deformed carefully straighten them If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one Radiator Cleaning Refer to the Radiator Cleaning in the Periodic Mainte nance chapter Radiator Cap Inspection Check the condition of the top and bottom valve seals of the radiator cap If any one of them shows visible damage replace the cap Bottom Valve Seal A Top Valve Seal B Valve Spring C Install the cap A on a cooling system pressure tester B NOTE Wet the cap sealing surfaces w
75. Steering 15 6 Steering Stem Removal 15 6 Steering Stem Installation 15 6 Front Knuckle Removal 15 7 Front Knuckle Installation 15 8 Front Knuckle Bearing Removal 15 9 Front Knuckle Bearing Installation 15 10 Tie rod Removal 15 10 Tie rod Installation 15 10 Tie rod End Removal 15 10 Tie rod End Installation 15 10 Steering Maintenance
76. To Vehicle Down Sensor 14 To Starter Circuit Relay Brake 15 Accessory Connector 16 To Tail Brake Light 17 To Reverse Light Europe Model 18 Regulator Rectifier 19 Run the lead inside of frame pipe 20 White Tape 21 Run the lead under side of frame pipe 22 Insert the clamp into hole of frame 23 To Speed Sensor 24 Insert the band into hole of frame 25 To Engine Brake Actuator 26 To Drive Belt Failure Detection Switch 27 Engine Ground Lead Terminal 28 Frame Ground Lead APPENDIX 18 25 Cable Wire and Hose Routing 1 To Left Headlight 2 Run the radiator fan switch inside of frame pipe 3 Clamps 4 To Power Outlet Connector 5 Front Ignition Coil 6 To Air Temperature Sensor 7 Clamps 8 Main Harness 9 Rear Ignition Coil 10 Frame Ground Terminal 11 To Carburetor Heater 12 To Water Temperature Switch 13 To Radiator Fan Motor 14 To 2WD 4WD Actuator 15 To Ignition Switch 16 To Right Headlight 17 Radiator Cover 18 Band 18 26 APPENDIX Cable Wire and Hose Routing 1 Battery 2 Red Cap 3 From Starter Motor 4 Run the battery cable under the frame pipe 5 Insert the clamp info the hole of bottom side APPENDIX 18 27 Cable Wire and Hose Routing 1 Belt Converter Intake Duct 2 Bands 3 Rear Final Gear Case Breather Tube 4 Rear Final Gear Case MODEL APPLICATION Year Model Beginning Frame No 2005 KVF750 A1 JKAVFDA1 5B500001 or JKAVF750AAB600001 2005 KVF750 B1 JKA
77. Use the standard spark plug or its equivalent Spark Plug Gap Inspection Measure the gap A with a wire type thickness gauge If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 7 0 8 mm 0 028 0 032 in PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Brake Light Switch Inspection Turn on the ignition switch Check the operation of the rear brake light switch by de pressing the brake pedal If it does not as specified adjust the brake light timing Brake Light Timing Standard On after about 10 mm 0 4 in of pedal travel A Brake Light Timing Adjustment Remove the right hootboard see Frame chapter Adjust the brake light switch A up or down To change the switch position turn the adjusting nut B CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment Drive Belt Failure Detection System Inspection Remove Seat see Frame chapter Check the drive belt failure detection system according to following chart 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures Joint Boots Inspection Front Axle Knuckle Joint Boot Inspection Visually inspect the front axle joint boots A If the joint boot is torn worn deteriorated or leaks gre
78. any bearings for inspection Remove the steering knuckle see Steering Knuckle Re moval Turn A the bearing back and forth while checking for roughness or binding If roughness or binding is found replace the bearing Examine the bearing seal B for tears or leakage If the seal is torn or is leaking replace the bearing Tie rod End Inspection Inspect each spherical bearing A If roughness excessive play or seizure is found replace the tie rod end Inspect each boot B If damage wear or deterioration is found replace the tie rod end Steering Knuckle Joint Inspection Inspect each spherical bearing A If roughness excessive play or seizure is found replace the steering knuckle joint Inspect each boot B If damage wear or deterioration is found replace the steering knuckle joint 15 14 STEERING Handlebar Handlebar Removal Remove Meter Unit see Electrical System chapter Throttle Case Front Brake Master Cylinder Left hand Switch Housing Rear Brake Lever Assembly Handlebar Holder Bolts A and Bracket B Handlebar Holders C Handlebar D Handlebar Installation Align the punch mark A on the handlebar with the mating surface end B of the steering stem Install the bracket A Tighten the holder front bolts B first and then the rear bolts C Torque Handlebar Holder Bolts 29 N m 3 0 kgf m 22 ft lb If the holder is correc
79. applicable regulations of the California Air Resources Board 1 Crankcase Emission Control System A sealed type crankcase emission control system is used to eliminate blow by gases The blow by gases are led to the breather chamber through the crankcase Then it is led to the air cleaner Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase and then returned back to the bottom of crankcase 2 Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing character istics The carburetor has been calibrated to provide lean air fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system A maintenance free ignition system provides the most favorable ignition timing and helps main tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations
80. as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2004 Kawasaki Heavy Industries Ltd Second Edition 1 Jul 6 2004 LIST OF ABBREVIATIONS A ampere s lb pounds s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celcius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s ohm s L liter s Read OWNER S MANUAL before operating EMISSION CONTROL INFORMATION To protect the environment in which we all live Kawasaki has incorporated crankcase emission 1 and exhaust emission 2 control systems in compliance with
81. boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Fluid Recommendation Use extra heavy duty brake fluid only from a container marked DOT3 or DOT4 Recommended Disc Brake Fluid Type DOT 3 or DOT 4 Brake Fluid Level Inspection
82. carburetor overflow hose to a suitable container Turn out the carburetor drain plugs A a few turns and drain the fuel system Special Tool Carburetor Drain Plug Wrench Hex 3 B 57001 1269 Check to see if water or dirt comes out Tighten the drain plugs If any water or dirt appears during the above inspection clean the fuel system carburetor fuel pump fuel tank fuel hose PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE In dusty areas the element should be cleaned more frequently than the recommended interval After riding through rain or muddy terrains the element should be cleaned immediately Also if there is a break in the element material or any other damage to the element replace the element with a new one WARNING Clean the element in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the foam element Remove the air cleaner element see Fuel System chap ter Clean the element A in a bath of high flash point solvent Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged Inspect the element for damage If it is torn punctured or harde
83. condition Check the throttle lever free play see Throttle Lever Free Play Inspection in Periodic Maintenance chapter Throttle Cable Installation Lubricate the throttle cable before installation Route the cable correctly according to the Appendix chap ter WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition Check the throttle cable see Throttle Lever Free Play In spection in Periodic Maintenance chapter Throttle Case Inspection With the throttle cable disconnected from the throttle lever the lever should move freely and return smoothly by spring If the lever is heavy disassemble the throttle case clean and lubricate the throttle case Examine the lever and case for cracks Replace the case assembly if it is cracked Throttle Cable Lubrication and Inspection Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Main tenance chapter lubricate the cable Refer to the General Lubrication in the Periodic Mainte nance chapter for the cable lubrication and inspection 3 10 FUEL SYSTEM Choke Lever and Cable Choke Lever Free Play Inspection Refer to the Choke Lever Free Play Inspection in the Pe riodic Maintenance chapter Choke Lever Free Play Adjustment Refer to the Choke Lever Free Play Adjustment in the Periodic Maintenance chapter Choke Le
84. flux detection method Detection Angle More than 65 5 for each bank Detection Time Within 0 5 1 0 second Output Voltage in the text Electric Starter System Starter Motor Commutator Diameter 28 mm 1 10 in 27 mm 1 06 in Brush Length 12 5 mm 0 49 in 5 mm 0 20 in Fuel Level Sensor Fuel Level Sensor Resistance Full Level Position 120 Empty Level Position 3 Actuator Control System Actuator Resistance in the text Forward Reverse Detecting Sensor Resistance 1 2 1 6 k Carburetor Heater System Carburetor Heater Resistance 11 20 Switches Brake Light Switch Timing ON after 10 mm 0 4 in of pedal travel ELECTRICAL SYSTEM 17 13 Specifications Item Standard Service Limit Radiator Fan Switch Resistance Rising Temperature From OFF to ON at 96 100 C 205 212 F Falling Temperature From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 OFF More than 1 M Coolant Temperature Warning Light Switch Resistance Rising Temperature From OFF to ON at 112 118 C 234 244 F Falling Temperature From ON to OFF at 108 111 C 226 232 F ON less than 0 5 OFF More than 1 M 17 14 ELECTRICAL SYSTEM Wir
85. for proper operation CAUTION Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed 17 22 ELECTRICAL SYSTEM Battery Gently remove the container from the battery Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance NOTE Charging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge Place the strip A of caps loosely over the filler ports Newly activated sealed batteries require an initial charge Standard Charge 1 2 A 5 10 hours If using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Optimate III Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 If the above chargers are not available use equivalent one NOTE Charging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 8 volts repeat charging cycle After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t
86. ft lb Press and insert the new ball bearings A until they are bottomed Special Tool Bearing Driver Set 57001 1129 Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole B Needle Bearing C Needle Bearing Insert it from outside Apply engine oil to the bearings Install the ball bearing A so that the stepped side faces outside B Install Plates C Apply a non permanent locking agent to the bearing po sition plate screws D Tighten Torque Bearing Position Plate Screws 4 9 N m 0 50 kgf m 43 in lb CRANKSHAFT TRANSMISSION 10 11 Crankcase Be sure the following parts are in place in the right crankcase half Crankshaft Transmission Shafts and Shift Rod A Spacers B Oil Tube C Oil Screen D O ring Apply Grease E Dowel Pins F Apply liquid gasket A to mating surface of the left crankcase half Sealant Kawasaki Bond 92104 1063 or Three Bond 1216 Apply a non permanent locking agent to the area C 12 mm 0 47 in except for the tip D 2 3 mm 0 08 0 12 in Left Crankcase Bolt M8 3 Tighten the right and left crankcase bolts M8 following the tightening sequence 1 8 Torque Crankcase Bolts M8 20 N m 2 0 kgf m 14 ft lb 1 2 5 6 L 75 mm 2 95 in 3 4 7 8 L 110 mm 4 33 in Tighten Torque Crankcase Bolts M6 9 8 N m 1 0 kgf
87. fuel pump does not operate as described replace it with a new one COOLING SYSTEM 4 1 4 Cooling System Table of Contents Exploded View 4 2 Coolant Flow Chart 4 4 Specifications 4 6 Special Tools amp Sealant 4 7 Coolant 4 8 Coolant Deterioration Inspection 4 8 Coolant Level Inspection 4 8 Coolant Draining 4 8 Coolant Filling 4 8 Pressure Testing
88. gasoline or low flash point solvents NOTE While cleaning the screen check for any metal particles that might indicate internal engine damage Check the screen carefully for any damage holes broken wires or gasket pulling off If the screen is damaged replace it Oil Pressure Measurement NOTE Measure the oil pressure after the engine is warmed up Remove the oil pressure switch and attach the oil pres sure gauge A and adapter B Special Tools Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 Oil Pressure Standard 430 kPa 4 4 kgf cm 62 6 psi 4 000 r min rpm 120 C 248 F of oil temp If the oil pressure is much lower than the standard inspect the relief valve oil pump and or crankshaft bearing insert wear If the oil pressure is much higher than the standard in spect the oil filter oil screen and other areas of the lubri cation system for clogging Stop the engine Remove the oil pressure gauge and adapter WARNING Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed Apply silicone sealant to the oil pressure switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Oil Pressure Switch 15 N m 1 5 kgf m 11 ft lb ENGINE LUBRICATION SYSTEM 8 9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal Split the
89. gear shim s change the pinion gear shim s to correct the backlash before checking the tooth contact pattern Bevel Gear Inspection Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged Differential Gear Inspection Visually check the differential gears A for scoring chip ping or other damage Replace the differential gears as a set if either gear is damaged Also inspect the differential gear shaft B gear case C and cover D where the differential gears rub If they are scored discolored or otherwise damaged re place them as a set FINAL DRIVE 12 51 Front Final Gear Case 12 52 FINAL DRIVE Rear Propeller Shaft Rear Propeller Shaft Removal Remove Footboard see Frame chapter Slide the rubber boots A Push the front universal joint B rearward and remove the front end C from the engine Remove the rear propeller shaft A from the vehicle Rear Propeller Shaft Installation Wipe off any old grease Splines A of Propeller Shaft and Universal Joint Output Shaft of Engine Pinion Gear of Rear Final Gear Case Inspect O rings B and boots C for damage If any doubt exists replace it with a new one Apply molybdenum disulfide grease Spline A and Inside B of Propeller Shaft C Install Boots D FINAL DRIVE 12 53 Rear Propeller Shaft Apply molybdenum dis
90. harness Position the clamp within an angle of 60 22 60 18 12 APPENDIX Cable Wire and Hose Routing 1 Rear Final Gear Case Breather Tube 2 Front Final Gear Case Breather Tube 3 Fuel Breather Tube 4 Radiator Fan Motor Breather Tube 5 Bands 6 Main Harness 7 Outside 8 Fix breather tube to right frame pipe 9 Water Hose 10 Water Hose 11 Radiator Mounting Bracket 12 Damper 13 Collar 14 Radiator Screen 15 Nut 16 Frame Pipe 17 about 5 mm 0 20 in APPENDIX 18 13 Cable Wire and Hose Routing 1 Not crush fan motor breather tube to pull it 2 Clamps 3 Fan Motor Breather Tube 4 Fan Motor Lead Connector 5 To Thermostat 6 To Water Pump 7 Water Hose 8 Band 9 Reserve Tank 18 14 APPENDIX Cable Wire and Hose Routing 1 Water Hose 2 Water Pipe 3 Coolant Temperature Warning Light Switch 4 Water Hose 5 Thermostat 6 Clamp 7 Reserve Tank 8 Reverse Switch Lead 9 Neutral Switch Lead 10 Clamp 11 Forward Reverse Detecting Sensor Lead Connector 12 Run the forward reverse detecting sensor lead outside of neutral and reverse switch leads APPENDIX 18 15 Cable Wire and Hose Routing 1 Clamp 2 2WD 4WD Actuator Lead 3 Air Intake Duct 4 Band 5 Front Final Gear Case 6 Carburetor Air Vent Tube 7 No Interference 18 16 APPENDIX Cable Wire and Hose Routing 1 Maine Harness 2 Drive Belt Failure Detecting Switch Lead 3 Engine Brake Actuator Lead 4 Starter Motor
91. in severe injury or death The pulleys of the belt drive torque converter are precision balanced components de signed to operate within certain rpm limits Disas sembly assembly and servicing procedures of the pulley assemblies must be followed closely Modi fications to the engine or pulleys that increase rpm may cause failure CAUTION Do not turn the ignition switch OFF position from ON position while the torque converter cover is re moved If it is done the learning control of Kawasaki Engine Brake Control system works and the engine brake actuator works an error operation NOTE If the drive belt failure detection system is activated by abnormal belt the drive belt failure detection switch is damaged Make sure to replace the torque converter cover see Torque Converter Cover Removal Installa tion Torque Converter Cover Removal Confirm that the ignition switch is in OFF position Remove Right Side Cover see Frame chapter Clamp Screws A and Clamps Rubber Air Duct B Remove Actuator Lead Connector and Drive Belt Failure Detec tion Switch Lead Connector A Torque Converter Cover Bolts B Torque Converter Cover C 6 10 CONVERTER SYSTEM Torque Converter Torque Converter Cover Installation Check the actuator lever assembly installation length see Torque Converter Cover Assembly Fit the trim seal into the converter cover Set the trim seal juncture in the area A when insert
92. in the new rim Remove the valve cap lubricate the stem with a soap and water solution and pull the stem A through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber Mount the tire on the new rim see Tire Installation Install the wheel see Wheel Installation Install the air valve cap WHEELS TIRES 11 11 Tires Tire Removal Remove the wheel Unscrew the valve core to deflate the tire Use a proper valve core tool A Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire Remove the tire from the rim using a suitable commer cially available tire changer NOTE The tires cannot be removed with hand tools because they fit the rims tightly Tire Installation Inspect the rim see Wheel Rim Inspection Replace the air valve with a new one CAUTION Replace the air valve with whenever the tire is re placed Do not reuse the air valve Check the tire for wear and damage see Tire Inspection in Periodic Maintenance chapter Lubricate the tire beads and rim flanges with a soap and water soluti
93. it is incorrect adjust the adjusting bolt Brake Pedal Position Adjustment Remove Right Footboard see Frame chapter Loosen the locknut A and turn the adjusting bolt B until the brake pedal is correctly positioned Tighten the locknut Check the brake pedal free play see Brake Pedal Free Play Inspection Rear Brake Lever Free Play Inspection Refer to the Rear Brake Lever Free Play Inspection in the Periodic Maintenance chapter Brake Pedal Free Play Inspection Refer to the Brake Pedal Free Play Inspection in the Pe riodic Maintenance chapter Rear Brake Lever and Pedal Free Play Adjustment Refer to the Rear Brake Lever and Pedal Free Play Ad justment in the Periodic Maintenance chapter Brake Pedal Removal Remove Right Footboard see Frame chapter Loosen the locknut and the adjusting bolt A Remove Brake Switch Spring B Cotter Pin Washer Pin and Brake Cable Joint C Cotter Pin and Washer D O ring and Brake Pedal E Spring BRAKES 13 21 Rear Brake Lever Pedal and Cables Brake Pedal Installation Apply grease Brake Pedal Pivot A O ring B Install Spring A Brake Pedal B Apply grease O rings C Install Brake Cable Joint and Pin D Brake Switch Spring E Washers F Replace the cotter pins G with new ones Bend both side hooks H of switch spring E after in stalling the spring Adjust the brake pedal positi
94. m 87 in lb A L 40 mm 1 57 in B L 65 mm 2 56 in Grease the lip A of the oil seal B and press the seal 3 mm 0 12 in C inwards from the end of the boss 10 12 CRANKSHAFT TRANSMISSION Crankcase Install the breather tube A on the crankcase fitting Align the white line on the tube with the mark B on the crankcase Face the open end of the clamp C towards the left side D as shown Apply grease to the steel ball A and spring B Install Steel Ball Spring Washer C Shift Shaft Positioning Bolt D Tighten Torque Shift Shaft Positioning Bolt 25 N m 2 5 kgf m 18 ft lb Check Crankshaft and driven shaft turn freely If any of the shafts do not turn freely split the crankcase to locate the problem CRANKSHAFT TRANSMISSION 10 13 Crankshaft Connection Rod Crankshaft Removal Split the crankcase see Crankcase Disassembly Remove the crankshaft A from the crankcase using a press Crankshaft Installation The left shaft A of the crankshaft is longer than the right shaft B Apply engine oil to the both main journals Insert the right crankshaft tapered end the shorter end into the right crankcase using a press and two crankshaft jigs Special Tools Crankshaft Jig 57001 1174 2 Connecting Rod Removal Remove the crankshaft see Crankshaft Removal Remove the connecting rods A from the crankshaft NOTE
95. not indicate 0 0 B replace the meter unit Check that when the TIME SET A and SET RESET B buttons are pushed the time C will reset If the meter function does not work replace the meter unit Check 3 Speedometer Check Connect the wires in the same manner as Check 1 The speed equivalent to the input frequency is indicated in the oscillator A if the square wave is input into terminal 1 Indicates approximately 40 mph if the input frequency is approximately 789 Hz Indicates approximately 40 km h if the input frequency is approximately 526 Hz If the meter function does not work replace the meter unit ELECTRICAL SYSTEM 17 65 Meter Check 4 Odometer Check Connect the wires in the same manner as Check 3 Pushing the MODE button A cycles the odometer B Raise the input frequency of the oscillator to see the result of this inspection If the value indicated by the odometer does not work re place the meter unit Check 5 Trip Meter A B Check Connect the wires in the same manner as Check 3 Pushing the MODE button A cycles the trip meter A or B B Raise the input frequency of the oscillator to see the result of this inspection If the value indicated by the trip meter A or B does not increase replace the meter unit Check 6 Fuel Meter Check Connect the wires in the same manner as Check 1 The first segment LCD A should flash It the segment LCD d
96. of oil Wheels Tires Tire Inspection Examine the tire for damage and wear If the tire is cut or cracked replace it Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement Remove any foreign objects from the tread After re moval check for leaks with a soap and water solution Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places If any measurements are less than the service limit re place the tire Tire Tread Depth Service Limit Front 3 mm 0 12 in Rear 4 mm 0 16 in Standard Tire Front AT 25 8 12 DUNLOP KT191 Tubeless Rear AT 25 10 12 DUNLOP KT195 Tubeless PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Final Drive Variable Differential Control Lever Play Inspection Pull the variable differential control lever A towards the handlebar grip B with a spring scale until it reads 30 N 3 kgf 7 lb of force The differential control in the front final gear case must be locked then the clearance C between the control lever and grip should be 20 mm 0 8 in If the clearance is not the specified length adjust the ca ble Differential Control Lever Lock Position Length Standard 20 mm 0 8 in Variable Differential Control Lever Play Adjustment Remove Handlebar Cover Screws A Remove Handleba
97. of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance Use proper tools and genuine Kawasaki Vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual care fully Don t take shortcuts Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the I
98. of the lever if this is not done BRAKES 13 11 Master Cylinder Master Cylinder Disassembly Remove Master Cylinder see Master Cylinder Removal Brake Lever Pivot Nut A Brake Lever Pivot Bolt B Brake Lever C Dust Cover D Circlip E Piston F Spring G Special Tool Inside Circlip Pliers 57001 143 CAUTION Do not remove the secondary cup H from the pis ton since removal will damage it Master Cylinder Assembly Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake Take care not to scratch the piston or the inner wall of the cylinder Apply brake fluid to the removed parts and to the inner wall of the cylinder Tighten Torque Brake Lever Pivot Bolt 6 0 N m 0 60 kgf m 53 in lb Brake Lever Pivot Bolt Locknut 6 0 N m 0 60 kgf m 53 in lb 13 12 BRAKES Master Cylinder Master Cylinder Inspection Visual Inspection Disassemble the master cylinder see Master Cylinder Disassembly Check that there are no
99. oil to the cylinder bore and piston skirt Install Dowel Pins A New Cylinder Base Gasket B ENGINE TOP END 5 41 Cylinder and Piston Install Cylinder Clamp A rear only Tighten Torque Cylinder Bolts B 9 8 N m 1 0 kgf m 87 in lb Install Chain Guide C Apply oil to the O ring on the oil pipe D and insert the pipe Cylinder Wear Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the three locations total of six measure ments shown in the figure If any of the cylinder inside diameter measurements ex ceeds the service limit replace the cylinder 10 mm 0 4 in A 60 mm 2 4 in B 20 mm 0 8 in C Cylinder Inside Diameter Standard 84 994 85 006 mm 3 3462 3 3467 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 85 10 mm 3 350 in or more than 0 05 mm 0 0020 in difference between any two measurements Piston Wear Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the pis ton Piston Diameter Standard 84 964 84 979 mm 3 3450 3 3456 in Service Limit 84 81 mm 3 3390 in Piston Cylinder Clearance Subtract the piston diameter from the cyl
100. plastic parts from the carburetor as possible before cleaning the carbure tor with a cleaning solution This will prevent dam age or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged 3 22 FUEL SYSTEM Carburetor Disassemble the carburetor and clean all the metal parts in a carburetor cleaning solution Rinse the parts in water and dry them with compressed air Blow through the air and fuel passages with compressed air Remove the float valve spray cleaning solution from the valve seating surface into the fuel passage and clean the strainer press fitted with compressed air A Assemble the carburetor see Carburetor Assembly Carburetor Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the carburetor see Carburetor Removal Before disassembling the carburetors check the fuel level see Fuel Level Inspection Turn the throttle cable pulley A to check
101. plate fits into the groove on the right end cover Install the O ring insulators B and washer C in that order on the terminal bolt Tighten Torque Starter Motor Terminal Locknut 6 9 N m 0 70 kgf m 61 in lb Install the washers A Install the armature B between the brushes Install the yoke A onto the right end cover B aligning the marks C on the yoke and right end cover Install the washers A Install the plate A on the left end cover B 17 48 ELECTRICAL SYSTEM Electric Starter System Align the mark A on the left end cover with the mark B on the yoke Tighten Torque Starter Motor Bolts 4 9 N m 0 50 kgf m 43 in lb Commutator Cleaning Inspection Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves Measure the diameter A of the commutator Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection Using the 1 range measure the resistance between any two commutator segments A If there is a high resistance or no reading between any two segments a winding is open Replace the starter motor Using the highest range measure the resistance between the segments and the shaft B If there is any reading at all t
102. pound or hammer When properly installed the strip of the caps will be level with the top of the battery CAUTION Once the strip of the caps A is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE To ensure maximum battery life and customer satisfac tion it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 volts repeat the charging cycle and load test If still below 12 8 volts the battery is defective Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the sealing plug to add water is very dangerous Never do that 2 Refreshing charge ELECTRICAL SYSTEM 17 23 Battery If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal caps du
103. proper amount of play Tighten the locknut securely Idle Speed Inspection Start the engine and warm it up thoroughly With the engine idling turn the handlebar to both sides to check for any changes in the idle speed If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted incorrectly routed or damaged Be sure to correct any of these conditions before riding WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an un safe riding condition Check idle speed with a suitable tachometer If the idle speed is out of the specified range adjust it see Idle Speed Adjustment Idle Speed Standard 1 150 50 r min rpm 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment Start the engine and warm it up thoroughly Turn the idle adjusting screw A until the idle speed is correct Open and close the throttle a few times to make sure that the idle speed is within the specified range Fuel System Cleanliness Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the check valve A at the end of the carburetor overflow hose B Run the lower end of the
104. replace parts as necessary PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent LB Apply a non permanent locking agent Three Bond TB2471 Blue Lh Left hand Threads MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant Kawasaki Bond 56019 120 St Stake the fasteners to prevent loosening TB Apply a non permanent locking agent Three Bond TB1363A Red Torque Fastener N m kgf m ft lb Remarks Fuel System Idle Adjusting Screw Bracket Bolt 8 8 0 90 78 in lb Element Cover Screw 3 5 0 35 31 in lb Element Holder Screws 3 5 0 35 31 in lb Clamp Bracket Bolt 9 8 1 0 87 in lb Fuel Pump Mounting Nuts 7 8 0 80 69 in lb Fuel Tap Plate Screws 0 8 0 08 7 in lb Fuel Tap Mounting Bolts 4 9 0 50 43 in lb Fuel Tap Cover Screws 9 8 1 0 87 in lb Fuel Tap Bracket Bolts 7 8 0 80 69 in lb Fuel Level Sensor Mounting Bolts 2 0 0 20 18 in lb Cooling System Radiator Mounting Bolts 8 8 0 90 78 in
105. replace the O rings with new ones Apply molybdenum disulfide grease to the splines of the shafts on the output bevel gear and front final gear case First install the rear end and then install the front end Slip the two O ring clamps into the groove on the small rubber boot O rings D Boots E Spring F Spring Seat G Front H 12 26 FINAL DRIVE Front Axle Front Axle Removal Drain the front final gear case oil see Front Final Gear Case Oil Change in Periodic Maintenance chapter Remove Front Wheel see Wheels Tires chapter Knuckle see Steering chapter Pull the front axle A in a straight line out of the front final gear case Front Axle Installation Wipe the old grease off the splines of the axle and the gear case oil seal Visually inspect the splines of the axle If they are badly worn or chipped replace the axle with a new one Apply molybdenum disulfide grease to the axle splines Apply grease to the gear case oil seal Insert the left axle so that the teeth A fit in the grooves B Tap A the end of the front axle lightly and install the front axle NOTE The axle shaft must not come off easily Front Axle Joint Boot Inspection Refer to the Front Axle Joint Boot Inspection in the Peri odic Maintenance chapter Front Axle Joint Boot Replacement Outboard Joint Boot Removal Remove Front Axle see Front Axle Removal Boot Bands A S
106. scratches rust or pitting on the inner wall of the master cylinder A and on the outside of the piston B If the master cylinder or piston shows any damage re place them Inspect the primary C and secondary D cups If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups Check the dust cover E for damage If it is damaged replace it Check that the relief F and supply G ports are not plugged If the relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with compressed air Check the piston return spring H for any damage If the spring is damaged replace it BRAKES 13 13 Calipers Caliper Removal Remove the front wheel see Wheels Tires chapter Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Unscrew the caliper mounting bolts B and detach the caliper C from the disc Unscrew the banjo bolt and remove the brake hose D from the caliper CAUTION Immediately wash away any brake fluid that spills NOTE If the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Caliper Disas sembly Caliper Installation Install the caliper and brake hose l
107. seals B in the movable sheave assembly so that the oil seal surface is flush C with the sleeve end Apply D grease WR500 No 2 KYODO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA to the inner surfaces of the busings 6 24 CONVERTER SYSTEM Driven Pulley Align the paint mark 0 A on the movable sheave B with the point C on the fixed sheave D for phase fit of the sheaves In that case the opening A and hole B will be matched easily Apply grease WR500 No 2 KYODO YUSHI POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA to the seating surface A of the pins and insert them into the holes in the movable sheave Draw the movable sheave onto the fixed sheave and ap ply grease of 1 g 0 035 oz to all openings A Grease WR500 No 2 KYODO YUSHI or POWER LITE WR 2 KYODO YUSHI or SERAN HV TOTAL FINA NOTE Do not heap up the grease out of the openings Check that the O rings A are in good condition If any of the O rings are damaged replace them Apply grease to the O rings CONVERTER SYSTEM 6 25 Driven Pulley Hold the drive amp driven pulley holder in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 Screw the guide bar into the holder Special Tool Spring Holder Set 57001 1483 Put the driven pulley A onto the guide bar Put the thrust plate B so that the alloy side gray faces the mo
108. side Oil Seals C Circlip D Special Tool Inside Circlip Pliers 57001 143 Remove Ball Joint Bearing E rear side Needle Bearing F front side Front Lower Suspension Arm Remove Bolts A Collar B Axle Guard C Collars D rear side Oil Seals E Circlips F Special Tool Inside Circlip Pliers 57001 143 Remove Ball Joint Bearing G rear side Sleeve H front side Needle Bearing I front side 14 14 SUSPENSION Suspension Arms Front Suspension Arm Assembly Apply grease Ball Joint Bearing Needle Bearing Install the following parts as shown Front Upper Suspension Arm Front A Press the needle bearing B until it is stopped Press the ball joint bearing C until it is stopped Install New Circlip Special Tool Inside Circlip Pliers 57001 143 Apply grease Oil Seal Lips Install Sleeve front side Collar rear side Install the following parts as shown Front Lower Suspension Arm Front Side A Needle Bearing B 7 5 0 1 mm 0 295 0 004 in C Rear Side A Circlip B front side Ball Joint Bearing C Circlip D rear side Special Tool Inside Circlip Pliers 57001 143 Apply grease Oil Seal Lips Install Sleeve front side Collars rear side SUSPENSION 14 15 Suspension Arms Rear Suspension Arm Removal Remove Rear Wheels see Wheels Tires chapter Mounting Bolts and Nuts A Rear Upper
109. so that the projection side B faces outward Special Tool Socket Wrench 57001 1482 C Torque Bevel Gear Holder Nut 157 N m 16 kgf m 116 ft lb Press the new outer ball bearing until it is bottomed Output Driven Bevel Gear Removal Remove Swingarm see Suspension chapter and Front Propeller Shaft see Front Propeller Shaft Removal or Engine see Engine Removal Installation chapter Output Driven Bevel Gear Housing Bolts A Output Driven Bevel Gear Housing B 12 18 FINAL DRIVE Output Bevel Gears Tap lightly the front end A of the output driven bevel gear shaft using a plastic mallet The output driven bevel gear shaft assembly comes off with the housing Output Driven Bevel Gear Installation Apply grease O ring A Install the output driven bevel gear shaft assembly Tighten Torque Output Driven Bevel Gear Housing Bolts 26 N m 2 7 kgf m 20 ft lb Output Driven Bevel Gear Disassembly Remove Output Driven Bevel Gear Housing Assembly see Out put Driven Bevel Gear Removal Oil Seal Hold the holder A in a vise and set the housing assembly B on the holder Special Tool Output Shaft Holder 57001 1570 Remove Output Shaft Holder Nut A Special Tool Socket Wrench B 57001 1482 Remove the output shaft A from the housing B using a press FINAL DRIVE 12 19 Output Bevel Gears Hold the housing assembly A with the holder B
110. so that the air in the engine and radiator can escape CAUTION Soft or distilled water must be used with the an tifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages considerably reducing the efficiency of the cooling system Water and Coolant Mixture Ratio when shipping Soft Water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 2 2 L 2 3 US qt NOTE Choose a suitable mixture ratio by referring to the coolant manufacturer s directions Bleed the air from the cooling system as follows Start the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant Tap the radiator hoses to force any air bubbles caught inside Stop the engine and add coolant up to the radiator filler neck Install the radiator cap Remove the reserve tank cap Fill the reserve tank up to the F mark A with coolant and install the cap Start the engine warm it up thoroughly until the radiator fan turns on and then stop the engine Check the coolant level in the reserve tank after the en gine cools down If the coolant level is lower than the low level line add coolant to the full level line CAUTION Do not add more coolant above the full level line PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE Ch
111. solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 O Apply engine oil R Replacement Part 10 6 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting Rod Bend TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Big End Side Clearance 0 16 0 46 mm 0 0063 0 0181 in 0 7 mm 0 028 in Connecting Rod Big End Bearing Insert Crankpin Clearance 0 028 0 052 mm 0 0011 0 0020 in 0 09 mm 0 0035 in Crankpin Diameter 39 984 40 000 mm 1 5742 1 5748 in 39 97 mm 1 5736 in Marking None 39 984 39 992 mm 1 5742 1 57449 in 39 993 40 000 mm 1 57452 1 5748 in Connecting Rod Big End Inside Diameter 43 000 43 016 mm 1 6929 1 6939 in Marking None 43 000 43 008 mm 1 6929 1 69323 in 43 009 43 016 mm 1 69326 1 6935 in Connecting Rod Big End Bearing Insert Thickness Brown 1 482 1 486 mm 0 05835 0 05850 in Yellow 1 486 1 490 mm 0 05850 0 05866 in Green 1 490 1 494 mm 0 05866 0 05882 in Connecting Rod Big End Bearing Insert Selection Bearing Insert Con rod Big End Bore Diameter Markin
112. that the throttle butterfly valves B move smoothly and return back with the spring tension If the throttle valves do not move smoothly replace the carburetor FUEL SYSTEM 3 23 Carburetor Disassemble the carburetors see Carburetor Disassem bly Clean the carburetor see Carburetor Cleaning Check the vacuum piston diaphragm A and the O rings B on the float bowl pilot screw coasting enricher and starter plunger cap If any of the diaphragm or O rings are not in good condi tion replace them Check the plastic tip A of the float valve needle It should be smooth without any grooves scratches or tears If the plastic tip is damaged C replace the float valve B Push the rod D in the other end of the float valve needle and then release it E If it does not spring out replace the float valve Check the tapered portion A of the pilot screw B for wear or damage If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it Check that the vacuum piston moves smoothly in the car buretor body The surface of the piston must not be ex cessively worn If the vacuum piston does not move smoothly or if it is very loose in the carburetor body replace both the body and the vacuum piston 3 24 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal Remove Seat see Frame chapter Clips A Air Cleaner Housing
113. the specified pressure Check the tire pressure using an air pressure gauge NOTE Kawasaki provides the air pressure gauge P N 52005 1082 with the owner s tool kit Tire Air Pressure when cold Front 35 kPa 0 35 kgf cm 5 0 psi Rear 35 kPa 0 35 kgf cm 5 0 psi Install the air valve cap Install the wheel see Wheel Installation Wipe off the soap and water solution on the tire and dry the tire before operation WARNING Do not operate the vehicle with the water and soap still around the tire beads They will cause tire sep aration and a hazardous condition may result Tire Inspection Refer to the Tire Inspection in the Periodic Maintenance chapter WHEELS TIRES 11 13 Front Hub Front Hub Removal Remove Cap A Cotter Pin B cut Loosen the axle nut C Remove the wheel see Wheel Removal Remove the caliper by taking off the mounting bolts and let the caliper hang free Remove the axle nut A and pull off the front hub B and brake disc Separate the brake disc from the front hub Front Hub Installation Install the brake disc see Brakes chapter Wipe dry the spline portion of the hub Wipe dry the threads and seating surface of the nuts Install the front wheel temporary Tighten Torque Front Axle Nuts 197 N m 20 kgf m 145 ft lb Remove the front wheel Insert a new cotter pin A NOTE When in
114. the valve Repeat the process with a fine grinding compound A Lapper B Valve Seat C Valve The seating area should be marked about in the middle of the valve face If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it Be sure to remove all grinding compound before assem bly When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in Periodic Maintenance chapter 5 38 ENGINE TOP END Valves ENGINE TOP END 5 39 Cylinder and Piston Cylinder Removal Remove Cylinder Head see Cylinder Head Removal Oil Pipe A Chain Guide B Cylinder Bolts C Cylinder D Cylinder Base Gasket Piston Removal Remove the cylinder block see Cylinder Removal Place a piece of clean cloth under the piston and remove the piston pin snap rings A from the outside of each pis ton CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall Using the piston pin puller assembly special tool re move the piston pins Special Tools Piston Pin Puller Assembly A 57001 910 Piston Pin Puller Adapter 14 B 57001 1211 Remove the piston Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oi
115. through muddy terrains the radiator screen and the radiator should be cleaned immediately Remove Front Guard see Frame chapter Front Fender see Frame chapter Radiator Screen Mounting Screws A Radiator Screen B Clean the radiator screen in a bath of tap water and then dry it with compressed air or by shaking it Clean the radiator CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun away more than 0 5 m 20 in from the radiator core A Hold the steam gun perpendicular to the core sur face Run the steam gun following the core fin direction 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and Connection Inspection The high pressure inside the radiator hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks B or bulges C are noticed Check that the hoses are securely connected and clamps are tightened correctly Coolant Change WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wash
116. to the cable both ends Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber Variable Differential Control Cable Inspection With the variable differential control cable disconnected at both ends the cable should move freely within the cable housing If the cable does not move freely after lubricating if the cable is frayed or if the housing is kinked replace the cable Front Final Gear Case Removal Drain the gear case oil see Front Final Gear Case Oil Change in Periodic Maintenance chapter 12 36 FINAL DRIVE Front Final Gear Case Remove Front Fender see Frame chapter Front Wheels see Wheels Tires chapter Steering Stem see Steering chapter Front Axles see Front Axle Removal Right Upper Suspension Arm see Suspension chapter Right Front Shock Absorber see Suspension chapter Front Propeller Shaft see Front Propeller Shaft Re moval Actuator Lead Connector disconnect Variable Differential Control Cable Lower End Air Duct A Brake Hose Joint Bolt B Remove Front Final Gear Case Bolts A Remove Bracket Bolts A Bracket Remove the rear final gear case A as shown Front Final Gear Case Installation Install the gear case bolts from the vehicle left side Torque Front Final Gear Case Nuts 59 N m 6 0 kgf m 43 ft lb Install the removed parts Fill the front final gear case with the specified oil see Front Final Ge
117. 0 8 4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W 40 Capacity 2 1 L 2 2 US qt when filter is not removed 2 2 L 2 3 US qt when filter is removed 2 6 L 2 7 US qt when engine is completely dry Oil Pressure Measurement Oil Pressure 4 000 r min rpm Oil Temperature 120 C 248 F 430 kPa 4 4 kgf cm 62 6 psi ENGINE LUBRICATION SYSTEM 8 5 Special Tools amp Sealant Oil Pressure Gauge 10 kgf cm 57001 164 Oil Pressure Gauge Adapter PT 1 8 57001 1033 Oil Filter Wrench 57001 1249 Kawasaki Bond Silicone Sealant 56019 120 8 6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1 Front Camshaft 2 Oil Filter 3 Crankshaft 4 Oil Pressure Switch 5 Oil Pipes 6 Oil Pump 7 Relief Valve 8 Transmission Idle Shaft 9 Oil Screen 10 Transmission Driven Shaft 11 Rear Camshaft 12 Breather Hose 13 To Air Cleaner ENGINE LUBRICATION SYSTEM 8 7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure accident and injury Oil Level Inspection Park the vehicle so that it is level both side to side and front to rear If the oil has just been changed start the engine and run it for several minutes to fill the oil filter CAUTION A
118. 0 ft lb Install the rotor A so that the projections B face out ward Tighten Torque Rotor Mounting Bolts C 12 N m 1 2 kgf m 104 in lb Install Output Drive Idle Gear New Circlip Special Tool Outside Circlip Pliers 57001 144 FINAL DRIVE 12 15 Output Bevel Gears Apply grease O rings A Install Output Drive Bevel Gear Cover B Tighten Torque Output Drive Bevel Gear Cover Bolts C 8 8 N m 0 90 kgf m 78 in lb Install Forward Reverse Detecting Sensor A Tighten Torque Forward Reverse Detecting Sensor Mounting Bolt 15 N m 1 5 kgf m 11 ft lb Output Drive Bevel Gear Disassembly Remove Output Drive Bevel Gear Housing A see Output Drive Bevel Gear Removal Look through the hole B in the housing Turn the bevel gear C until the groove of the output drive bevel gear holder nut is seen Tighten the nut holding bolts A 4 securely into the grooves B of the bevel gear holder nut C in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 D Output Drive Bevel Gear Housing E Outer Ball Bearing F Inner Ball Bearing G Bearing Holder H Output Drive Bevel Gear 12 16 FINAL DRIVE Output Bevel Gears Hold the output drive bevel gear housing A in a vise Loosen the bevel gear B using an Allen wrench about four rotations Remove one nut holding bolt and look at through
119. 04 0 08 in Brake Pedal Free Play 15 25 mm 0 6 1 0 in Electrical System Spark Plug Gap 0 7 0 8 mm 0 028 0 032 in Rear Brake Light Switch Timing ON after 10 mm 0 4 in of pedal travel PERIODIC MAINTENANCE 2 13 Special Tools Oil Filter Wrench 57001 1249 Carburetor Drain Plug Wrench Hex 3 57001 1269 Flywheel amp Pulley Holder 57001 1343 Filler Cap Driver 57001 1454 Pulley Holder Attachment 57001 1472 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection Check that the throttle lever A moves smoothly from full open to close and the throttle closes quickly and com pletely in all steering positions by the return spring If the throttle lever does not return properly check the throttle cable routing lever free play and cable damage Then lubricate the throttle cable Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change If the idle speed increases check the throttle lever free play and the cable routing Stop the engine and check the throttle lever free play B If the free play is not within the specified range adjust the cable Throttle Lever Free Play Standard 2 3 mm 0 08 0 12 in Throttle Lever Free Play Adjustment Remove the handle cover see Mu
120. 1 Battery CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the dedicated electrolyte container for correct electrolyte volume Place the battery on a level surface Check to see that the sealing sheet has no peeling tears or holes in it Remove the sealing sheet NOTE The battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge Remove the electrolyte container from the vinyl bag Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE Do not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE Do not tilt the electrolyte container Check the electrolyte flow If no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container
121. 2 35 Rear brake plates replace every 10 000 km 6 000 mi 2 35 Bolts and nuts tighten 2 41 Front brake pad wear inspect 2 32 Brake light switch inspect 2 37 Steering inspect 2 36 Differential control lever play inspect 2 29 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart First FREQUENCY Service Regular Service OPERATION After 10 hrs or 100 km 60 mi of use Every 10 days or 200 km 120 mi of use Every 30 days or 600 km 360 mi of use Every 90 days 1 700 km 1 100 mi or when belt indicator light turns on 100 hrs of use whichever comes first Every year of use See page Tire wear inspect 2 28 Front and rear final gear case oil change 2 30 2 31 Rear propeller shaft universal joint lubrication 2 32 General lubrication 2 40 Front brake fluid level inspect 2 33 Front brake fluid change 2 34 Front brake hoses and connections inspect 2 32 Front brake master cylinder piston assembly and dust seal replace 2 years 2 34 Front brake caliper piston seal and dust seal replace 2 years 2 34 Front brake hose replace 4 years 2 33 Service more frequently when operated in mud dust or other harsh riding conditions or when carrying heavy loads or pulling a trailer Clean adjust lubricate torque or
122. 3 Front Axle While the band is held at the diameter above tap down the tangs A of the clamp 12 34 FINAL DRIVE Front Final Gear Case Front Final Gear Case Oil Level Inspection Park the vehicle so that it is level both side to side and front to rear Remove the filler cap CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case Check the oil level The oil level should come to the bot tom of the filler opening A If it is insufficient first check the front final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case Be sure the O ring is in place and tighten the filler cap Apply grease to the O ring Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft lb Front Final Gear Case Oil Change Refer to the Front Final Gear Case Oil Change in the Pe riodic Maintenance chapter Variable Differential Control Lever Play Inspection Refer to the Variable Differential Control Lever Play In spection in the Periodic Maintenance chapter Variable Differential Control Lever Play Adjustment Refer to the Variable Differential Control Lever Play Ad justment in the Periodic Maintenance chapter Variable Differential Control Lever Removal Remove Handlebar Cover Plate Bolt A Cable Stopper Plate B Variable Differential Control Lever Bolt C Washe
123. 3 19 Carburetor Remove Diaphragm A O ring B Carburetor Assembly WARNING Fuel spilled from the carburetors is hazardous CAUTION Do not apply force to the jet or overtighten it or this could damage the jet or the carburetor body requiring replacement Install the float valve needle in the valve seat and hook the needle hanger A onto the float tang Insert the float pivot pin B into the pivot post and the float Tighten the screw C Set the float to the standard height see Service Fuel Level Adjustment Insert the jet needle A into the hole in the center of the vacuum piston B and place the spring seat C over the needle Slip the needle through the hole in the center of the vac uum piston and put the spring seat A on the top of the needle Turn the seat so that it does not block the hole B at the bottom of the vacuum piston After installing the upper chamber cover check that the vacuum piston slides up and down smoothly without bind ing in the carburetor bore 3 20 FUEL SYSTEM Carburetor Fit the projection A of the vacuum piston diaphragm in the recess B of the body After installing the upper chamber cover check to make sure that the vacuum piston moves smoothly in the car buretor body Carburetor Separation Remove Carburetor see Carburetor Removal Screws A Fuel Hose Fittings B Remove Cotter Pins A Collars and Washer
124. 30 ENGINE TOP END Cylinder Head Cylinder Head Removal Drain the coolant see Coolant Change in Periodic Main tenance chapter Remove Carburetor see Fuel System chapter Exhaust Pipe see Engine Top End chapter Thermostat see Cooling System chapter Spark Plug Cap A Water Pipe Bolt B Left Water Pipe C Remove Water Pipe Bolts A Right Water Pipe B Vacuum Hoses C Rocker Case see Rocker Case Removal Camshaft see Camshaft Removal Remove Cylinder Head Bolt M6 A Cylinder Head Bolts M10 B and Washers Cylinder Head C and Gasket Lift the cylinder head to clear the dowel pins in the cylin der and slide the cylinder head out of the frame Cylinder Head Installation Apply oil to the O rings on the oil pipe A and insert the pipe Install Camshaft Chain Guides B Dowel Pins C New Cylinder Head Gasket D Tighten Torque Front Cylinder Camshaft Chain Guide Bolt 20 N m 2 0 kgf m 14 ft lb Apply molybdenum disulfide oil to the threads and seating surface of the cylinder head bolts and both sides of the washers Tighten the cylinder head bolts A following the tightening sequence as shown First Torque Cylinder Head Bolts M10 25 N m 2 5 kgf m 18 ft lb Final Torque Cylinder Head Bolts M10 49 N m 5 0 kgf m 36 ft lb Tighten the cylinder head bolts M6 B Torque Cylinder Head Bolts M6 9 8 N m 1 0 kgf m 87 i
125. 360 PS kW 1 341 HP PS 0 7355 kW PS 0 9863 HP Units of Temperature PERIODIC MAINTENANCE 2 1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Torque and Locking Agent 2 5 Specifications 2 11 Special Tools 2 13 Periodic Maintenance Procedures 2 14 Fuel System 2 14 Throttle Lever Free Play Inspection 2 14 Throttle Lever Free Play Adjustment 2 14 Choke Lever Free Play Inspection 2 14 Choke Lever Free Play Adjustment 2 15 Idle Speed Inspection 2 15 Idle Speed Adjustment 2 16 Fuel System Cleanliness Inspection 2 16 Air Cleaner Element Cleaning and Inspection 2 17 Air Cleaner Draining 2 17 Fuel Hose and Connection Inspection 2 18 Fuel Hose Replacement 2 18 Cooling System 2 19 Radiator Cleaning 2 19 Radiator Hose and Connection Inspection 2 20 Coolant Change 2 20 Engine Top End
126. 37 Apply a non permanent locking agent to the threads of the output shaft holder nut A and tighten it so that the projection side B faces outward Special Tool Socket Wrench 57001 1482 Torque Output Shaft Holder Nut 157 N m 16 kgf m 116 ft lb Apply grease to the oil seal and press it so that it is flush with the end surface of the housing Output Bevel Gears Adjustment The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged When replacing any one of the backlash related parts be sure to check and adjust the backlash and tooth contact First adjust the backlash and then tooth contact by replac ing shims These two adjustments are of critical importance and must be carried out in the correct sequence using the procedures shown FINAL DRIVE 12 21 Output Bevel Gears Output Bevel Gear Backlash related Parts 1 Ball Bearings 2 Drive Bevel Gear Shims 3 Output Drive Bevel Gear 4 Bearing Housings 5 Output Driven Bevel Gear 6 Output Driven Shaft 7 Driven Bevel Gear Shims Drive Bevel Gear Shims for Tooth Contact Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1311 0 2 mm 0 008 in 92180 1312 0 5 mm 0 020 in 92180 1313 0 8 mm 0 031 in 92180 1314 1 0 mm 0 039 in 92180 1351 1 2 mm 0 047 in 92180 1352 Driven Bevel Gear Shims for Backlash Adjustment Thickness Part Number
127. 4 2 Specifications 14 6 Special Tools 14 7 Shock Absorbers 14 8 Front Shock Absorber Preload Adjustment 14 8 Front Shock Absorber Removal 14 8 Front Shock Absorber Installation 14 8 Front Shock Absorber Inspection 14 9 Front Shock Absorber Scrapping 14 9 Rear Shock Absorber Preload Adjustment 14 9 Rear Shock Absorber Removal 14 9 Rear Shock Absorber Installation 14 10 Rear Shock Absorber Inspection
128. 4 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary Example 2 Increase the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or decrease the thick ness of the driven bevel gear shim s by 0 1 mm 0 004 in to correct the pattern shown below Repeat in 0 1 mm 0 004 in steps if necessary 12 24 FINAL DRIVE Output Bevel Gears Bevel Gears Inspection Visually check the bevel gears A for scoring chipping or other damage Replace the bevel gears as a set if either gear is dam aged FINAL DRIVE 12 25 Front Propeller Shaft Front Propeller Shaft Removal Slip the O ring clamps off the grooves on the small rubber boots A and then pull the boot Push the front propeller shaft A rearward and remove the front end B from the front final gear case Remove the front propeller shaft from the vehicle Front Propeller Shaft Installation Wipe off any old grease on the splines of the propeller shaft A and the coupling B Inspect the splines of the propeller shaft and the coupling If the splines are twisted or damaged in any way replace the parts as needed Apply molybdenum disulfide grease to all splines Replace the circlip C with a new one if it is removed Wipe off any old grease on the splines of the shafts in the engine and front final gear case Inspect the O rings on those shafts for damage If any doubt exists
129. 49 Starter Circuit Relay Inspection 17 50 Starter Motor Clutch Removal 17 52 Starter Motor Clutch Installation 17 52 Starter Motor Clutch Inspection 17 52 Torque Limiter Inspection 17 53 Lighting System 17 54 Headlight Beam Vertical Adjustment 17 54 Headlight Bulb Replacement 17 54 Taillight Bulb Replacement 17 56 Radiator Fan System 17 58 Radiator Fan Circuit Inspection 17 58 Radiator Fan Motor Inspection 17 58 Radiator Fan Breaker Inspection 17 58 Radiator Fan Breaker Installation 17 59 Fuel Level Sensor 17 60 Fuel Level Sensor Removal 17 60 Fuel Level Sensor Installation 17 60 Fuel Level Sensor Inspection 17 60 Meter 17 62 Multifunction Meter Unit Removal 17 62 Multifunction Meter Unit Inspection 17 63 Drive Belt Failure Mode Memory Clearing Procedure 17 68 Actuator Control System 17 72 2WD 4WD Actuator Removal 17 72 2WD 4WD Actuator Installation 17 72 Engine Brake Actuator Removal 17 72 Engine Brake Actuator Installation 17 73 Actuator Control System Outline 17 73 17 2 ELECTRICAL SYSTEM Actuator Control System Troubleshooting
130. 5 5 Rear Axle Nuts 265 27 195 R Replacement Parts S Follow the specific tightening sequence W Apply water or soap and water solution 11 4 WHEELS TIRES Specifications Item Standard Service Limit Wheel Alignment Toe in of front wheels 10 10 mm 39 0 39 in at 1G Tires Standard tire Front AT 25 8 12 DUNLOP KT191 Tubeless Rear AT 25 10 12 DUNLOP KT195 Tubeless Tire air pressure when cold Front 35 kPa 0 35 kgf cm 5 0 psi Rear 35 kPa 0 35 kgf cm 5 0 psi Maximun tire air pressure 250 kPa 2 5 kgf cm 36 psi to seat beads when cold Tire tread depth Front 3 mm 0 12 in Rear 4 mm 0 16 in WHEELS TIRES 11 5 Special Tool Jack 57001 1238 11 6 WHEELS TIRES Wheel Alignment Toe in is the amount that the front wheels are closer to gether in front than at the rear at the axle height When there is toe in the distance A Rear is the greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slip ping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are build in and require no adjust ment A Rear B Fr
131. 5 11 11 2WD 4WD Actuator Mounting Bolts 9 8 1 0 87 in lb L S 12 Variable Differential Control Cable Locknut 17 1 7 12 13 Variable Differential Control Lever Bolt L 14 Front Final Gear Case Nuts 59 6 0 43 G Apply grease L Apply a non permanent locking agent LB Apply a non permanent locking agent Three Bond TB2471 Blue M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts S Follow the specific tightening sequence St Stake the fasteners to prevent loosening 12 8 FINAL DRIVE Exploded View FINAL DRIVE 12 9 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Rear Final Gear Case Front Cover Bolts 24 2 4 17 2 Gasket Screws 1 3 0 13 11 in lb 3 Pinion Gear Bearing Holder Nut 157 16 116 L 4 Pinion Gear Bearing Holder 137 14 101 L 5 Rear Final Gear Case Right Cover Bolts M12 93 9 5 69 L 6 Rear Final Gear Case Right Cover Bolts M10 49 5 0 36 L 7 Rear Final Gear Case Right Cover Bolts M8 24 2 4 17 L 8 Rear Final Gear Case Oil Filler Cap 29 3 0 22 9 Rear Final Gear Case Oil Drain Plug 13 1 3 113 inlb 10 Bracket Bolts 59 6 0 43 11 Rear Final Gear Case Nuts 59 6 0 43 TB G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MF Apply MOBIL FLUID 424 or equivalent oil R Replacement Parts S Follow the specific tightening sequence
132. 8 Standard 0 016 0 052 mm 0 0006 0 0020 in Service Limit 0 14 mm 0 0055 in Camshaft Bearing Clearance 22 Standard 0 020 0 062 mm 0 0008 0 0024 in Service Limit 0 15 mm 0 0059 in If any clearance exceeds the service limit measure the diameter of the camshaft journal Camshaft Journal Diameter 18 Standard 17 966 17 984 mm 0 7073 0 7080 in Service Limit 17 94 mm 0 706 in Camshaft Journal Diameter 22 Standard 21 959 21 980 mm 0 8645 0 8653 in Service Limit 21 93 mm 0 863 in If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again If the clearance still remains out of the limit replace the cylinder head and the rocker case CAUTION The cylinder head and rocker case are machined as a set and must be replaced as a set ENGINE TOP END 5 23 Camshaft KACR Inspection The Kawasaki Automatic Compression Release KACR momentarily opens the exhaust valves on the compression stroke at very low speeds This allows some of the com pression pressure to escape making it easy to turn over the engine during starting Due to the simplicity of the mechanism no periodic main tenance is needed There are only two symptoms of prob lems with the KACR mechanism A compression is not re leased during starting and compression is released during running 1 If compression is no
133. 9 15 10 STEERING Steering Front Knuckle Bearing Installation The marked side of the bearing faces outward Press in the bearing until it is bottomed A V Block Special Tool Bearing Driver Set B 57001 1129 Replace the circlip with a new one Special Tool Inside Circlip Pliers 57001 143 Tie rod Removal Remove Front Wheels see Wheels Tires chapter Cotter Pin and Tie rod End Nuts A Tie rod B CAUTION When removing the tie rod be careful not to bend it Do not loosen the locknuts C at the end of the tie rod adjusting sleeve or the toe in of the front wheels will be changed Tie rod Installation The right and left tie rods are identical Tighten Torque Tie rod End Nuts 42 N m 4 3 kgf m 31 ft lb Inspect the toe in see Wheels Tires chapter Tie rod End Removal Remove the tie rod see Tie rod Removal Holding the tie rod flattened area A loosen the locknut B and unscrew the tie rod end C NOTE The locknut near the L mark on the tie rod has left hand threads Turn the wrench clockwise for loosening CAUTION Do not remove the grease seal It is packed with grease Tie rod End Installation Check that the boot lip A is on the shank B STEERING 15 11 Steering Install the tie rod ends so that the tie rod has the correct length A and both visible thread lengths B are equal Tie rod Length Standard 393 3 mm 15 48 in
134. 961 Install the new inserts in the connecting rod and check insert crankpin clearance with the plastigage CRANKSHAFT TRANSMISSION 10 17 Crankshaft Connection Rod Crankshaft Runout Measure the crankshaft runout If the measurement exceeds the service limit replace the crankshaft Crankshaft Runout Standard TIR 0 04 mm 0 0016 in or less Service Limit TIR 0 10 mm 0 0039 in Crankshaft Main Bearing Journal Wear Measure the diameter A of the crankshaft main journal Crankshaft Main Journal Diameter Standard 41 984 42 000 mm 1 6529 1 6535 in Service Limit 41 96 mm 1 652 in If any journal has worn past the service limit replace the crankshaft with a new one Measure the main bearing bore diameter A in the crankcase halves Crankcase Main Bearing Bore Diameter Standard 42 025 42 041 mm 1 6545 1 6552 in Service Limit 42 08 mm 1 6567 in If there is any signs of seizure damage or excessive wear replace the crankcase halves as a set 10 18 CRANKSHAFT TRANSMISSION Transmission Shift Lever Removal Set the shift lever in the neutral position Remove Right Side Cover see Frame chapter Shift Shaft Lever Bolt A Remove the shift shaft lever B from the shift shaft Remove Nut A Shift Lever Assembly B Front C Remove Tie rod End Bolt A Tie rod B Remove Oil Seals A Collar B CRANKSHAFT TRANSMISSI
135. Appendix chapter Radiator Cover Removal Remove Front Fender see Front Fender Removal Clamps A both sides Radiator Cover Screws B and collars Remove Radiator Cover Screws A and Collars Radiator Cover B Radiator Cover Installation Set the corner line A and bottom line B of the radiator cover Install Radiator Cover Screws and Collars FRAME 16 17 Guards Front Guard Removal Remove Screws A and Collars Bolts B and Collars Front Guard Cover C Bolts D and Collars Remove Front Carrier Bracket Bolts A Radiator Cover Screws B and Collars Front Guard Bolts C both sides Remove the front guard D from the radiator bottom stop pers B Front Guard Installation Insert the radiator bottom stoppers in the grommet in the front guard Install Front Guard A Front Guard Bolts B Tighten Torque Front Guard Bolts 37 N m 3 8 kgf m 27 ft lb Front Carrier Bracket Bolts 32 N m 3 3 kgf m 24 ft lb Install Radiator Cover Screws Front Guard Cover A Screws B and Collars C Bolts D and Collars E Front Bottom Guard Removal Remove Bolts A and Collars Front Bottom Guard B 16 18 FRAME Guards Front Bottom Guard Installation Install the front bottom guard A between the frame and engine bottom guard B Install Bolts C and Collars D Engine Bottom Guard Removal Remove Bolts A and Colla
136. BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Controller Power Supply Voltage Standard near Battery Voltage If the reading is not battery voltage check the wiring har ness 30 A fuse or ignition switch Check 4 Speed Sensor Inspection NOTE Be sure the battery is fully charged Support the vehicle on a stand or a jack so that the wheels are off the ground Remove Seat see Frame chapter Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector P Terminal 5 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Spin a rear wheel measure the voltage Speed Sensor Output Voltage Standard repeat from 0 to 5 V If the reading is not standard replace the speed sensor When installing a new O ring on the speed sensor apply grease all around the O ring Insert the speed sensor to the fully seated position before tightening the mounting bolt for the sensor NOTE If the sensor is not fully seated before tightening the bolt the O ring can be damaged and oil may leak 17 78 ELECTRICAL SYSTEM Actuator Control System Check 5 2WD 4WD Shift Switch Inspection NOTE Be sure the bat
137. BRUTE FORCE 750 4 4i KVF 750 4 4 All Terrain Vehicle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information 1 j Periodic Maintenance 2 j Fuel System 3 j Cooling System 4 j Engine Top End 5 j Converter System 6 j Recoil Starter 7 j Engine Lubrication System 8 j Engine Removal Installation 9 j Crankshaft Transmission 10 j Wheels Tires 11 j Final Drive 12 j Brakes 13 j Suspension 14 j Steering 15 j Frame 16 j Electrical System 17 j Appendix 18 j BRUTE FORCE 750 4 4i KVF 750 4 4 All Terrain Vehicle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate
138. Be sure to position the crankshaft is at TDC of the end of the compression stroke The rocker arms could bend the valves ENGINE TOP END 5 17 Rocker Case Apply silicone sealant to the outer surface of the cap A and the cylinder head upper surface B as shown Sealant Three Bond TB1211F or GE SILICONES TRANSLUCENT RTV128 Tighten the rocker case bolts following the tightening se quence shown Torque Rocker Case Bolts 8 8 N m 0 90 kgf m 78 in lb 1 2 3 4 L 55 mm 2 2 in with washers Torque Rocker Case Bolts 9 8 N m 1 0 kgf m 87 in lb 5 6 L 130 mm 5 1 in A L 30 mm 1 2 in B L 25 mm 1 0 in Lift the front of the engine to install the bolt of the front right side on the front rocker case Check the valve clearance and adjust it if necessary Apply grease to the O ring A Tighten Torque Valve Adjusting Cap Bolts B 8 8 N m 0 90 kgf m 78 in lb Rocker Arm Removal Remove Rocker Case see Rocker Case Removal Rocker Shaft Bolts A 5 18 ENGINE TOP END Rocker Case Using a M8 bolt A remove the rocker shaft B Remove Rocker Arm C Washers D Mark and record the rocker arm location so it can be in stalled in the original position The rocker arms come off with the rocker shafts Rocker Arm Installation Apply engine oil Rocker Shafts A Hole in Rocker Arms B Apply grease to the O rings C In
139. Bushing A press Tighten Torque Rear Shock Absorber Mounting Nuts B 34 N m 3 5 kgf m 25 ft lb Rear Shock Absorber Inspection Check the bushings A in the upper and lower pivots If bushings are worn cracked hardened or otherwise damaged replace them Shock Absorber Spring Replacement The spring replacements of front and rear shock ab sorbers are the same procedure The spring end of the rear shock absorber has a blue paint Remove Shock Absorber see Front or Rear Shock Absorber Re moval Use the spring compressor A and compress the spring of the shock absorber Special Tool Spring Compressor 57001 1087 SUSPENSION 14 11 Shock Absorbers Remove Spring Seat Stopper A Remove Spring Compressor Spring Guide A Spring B Spring Adjusting Sleeve C Install Spring Adjusting Sleeve A Install the replaced spring B so that the small end faces downwards Install Spring Guide Use the spring compressor and install the spring seat stopper A so that recess side B faces upwards Remove the spring compressor Rear Shock Absorber Scrapping WARNING Since the rear shock absorber contains nitrogen gas do not incinerate or disassemble the rear shock absorber Before a rear shock absorber is scrapped drill a hole at a point about 15 mm 0 59 in A up from the bottom of the cylinder to release the nitrogen gas completely Wear safety gla
140. Cable 5 Clamp 6 Drive Belt Failure Detecting Switch 7 Engine Brake Actuator APPENDIX 18 17 Cable Wire and Hose Routing 1 Vacuum Hose to rear cylinder head with blue line 2 Connect the thick side of hose to the fuel pump 3 Fuel Hose to carburetor with red line 4 Clamps 5 Vacuum Hose to front cylinder head 6 Fuel Pump 7 Rubber Cover 8 Air Temperature Sensor 18 18 APPENDIX Cable Wire and Hose Routing 1 Rear Brake Lever 2 Parking Brake Lock Lever 3 Variable Differential Control Cable 4 Cable Adjuster 5 Variable Differential Control Lever 6 Handle Holder Clamp 7 Variable Differential Operating Lever 8 Fit the dust cap 9 27 35 mm 1 1 1 4 in APPENDIX 18 19 Cable Wire and Hose Routing 1 Clamp 2 Bands 3 Radiator Fan Motor Breather Tube 4 Fuel Breather Tube 5 Final Gear Case Breather Tubes 6 Joint 7 Tube 8 Dampers 9 Bands 10 220 mm 8 66 in 11 60 mm 2 36 in 12 L Formed Side 18 20 APPENDIX Cable Wire and Hose Routing 1 Right Headlight Lead 2 Radiator Cover 3 Frame Ground Lead 4 Horn Switch Lead Australia and Europe Models 5 Alternator Crankshaft Sensor and Oil Pressure Switch Leads 6 Rear Brake Light Switch Lead 7 2WD 4WD Shift Switch Lead 8 Left Handlebar Switch Lead 9 Meter Lead 10 Front Brake Light Switch Lead 11 Bands 12 Left Headlight Lead 13 Radiator Fan Switch Lead 14 Ignition Coil Primary Lead 15 Radiator Fan Motor
141. Carrier Installation 16 9 Front Carrier Bracket Installation 16 9 Rear Carrier Removal 16 9 Rear Carrier Installation 16 9 Rear Carrier Bracket Installation 16 10 Fenders 16 11 Front Fender Removal 16 11 Front Fender Installation 16 11 Rear Fender Removal 16 11 Rear Fender Installation 16 12 Covers 16 13 Middle Cover Removal
142. ECTRICAL SYSTEM 17 79 Actuator Control System Disconnect the speed sensor lead connector Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector P Terminal 5 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Measure the controller output voltage for the speed sen sor Controller Output Voltage to speed sensor Standard 5 0 25 V If the reading is not standard replace the actuator con troller unit Disconnect the 2WD 4WD shift switch lead connector Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector G Terminal 7 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Measure the controller output voltage for the 2WD 4WD shift switch Controller Output Voltage to 2WD 4WD shift switch Standard 5 0 25 V If the reading is not standard replace the actuator con troller unit 17 80 ELECTRICAL SYSTEM Actuator Control System Support the vehicle on a stand or a jack so that the wheels are off the ground Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector W R T
143. Gear 16T F Left Differential Gear Case G Ring Gear Assembly Press the bearing A on the left differential gear case B until it is bottomed Apply engine oil C to the spider gears and the spider gear shaft Apply molybdenum disulfide grease D to the left side gear 16T E Install Left Side Gear 16T Spider Gears 10T F Spider Gear Shaft G and Pins H Apply engine oil A to the spider gears Apply molybdenum disulfide grease B to the right side gear 16T C Install Right Side Gear 16T Differential Gear Case Cover D Ring Gear E Apply a non permanent locking agent Three Bond TB2471 Blue to the ring gear bolts F and tighten them Torque Ring Gear Bolts 57 N m 5 8 kgf m 42 ft lb NOTE Keep the ring gear assembly at more than 20 C 68 F for six hours after tightening the bolts FINAL DRIVE 12 45 Front Final Gear Case LSD Clutch Torque Inspection If the vehicle has the following symptoms check the LSD Limited Slip Differential clutch torque The handlebar is hard to turn The front final gear case overheats Abnormal noises come from the front final gear case when rounding a curve Ensure 2WD mode Support the vehicle so that the front wheels are off the ground Remove One Front Wheel see Wheels Tires chapter Front Axle Nut Cotter Pin Secure the other side front wheel from rotating Measure the clutch torque us
144. IOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM US MODEL only To minimize the noise emissions from this product Kawasaki has equipped it with effective intake and exhaust silencing systems They are designed to give optimum performance while maintaining a low noise level Please do not remove these systems or alter them in any which results in an increase in noise level Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use
145. KI Connections Crankshaft Sensor Lead Adapter Hand Tester Black White Red Blue Black Turn the ignition switch on and rotate the engine for 4 5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 2 V or more If the peak voltage is lower than the standard inspect the crankshaft sensor Alternator Rotor Inspection Check the timing projection A for damage such as chip ping or grooving If the timing projection on the rotor is visibly damaged replace the alternator rotor Ignition Timing Test Remove the ignition timing inspection plug Attach a timing light A and a tachometer in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 Start the engine and aim the timing light at the timing mark on the alternator rotor Run the engine at the speeds specified and note the align ment of the timing marks 17 40 ELECTRICAL SYSTEM Ignition System A F or R mark Ignition Timing Engine speed r min rpm Slot B aligned with 1 100 and below Advanced mark C on alternator rotor 5 000 and above Advanced mark D on alternator rotor NOTE Do not mix up the timing marks with mark A If the ignition timing is incorrect replace the igniter and the crankshaft sensor Vehicle down Sensor
146. Mark and record the locations of the connecting rods and their big end caps B so that they can be installed in their original positions Remove the connecting rod big end nuts and take off the rod and cap with the bearing inserts Connecting Rod Installation CAUTION If the connecting rods bearing inserts or crank shaft are replaced with new ones select the bearing insert and check clearance with a plastigage before assembling the engine to be sure the correct bear ing inserts are installed Apply molybdenum disulfide oil Inner Surface A of Bearing Inserts Face the OUT marks B of both connecting rods to wards the outsides of the crankshaft Fit the connecting rod cap so that the grooves C of the cap and connecting rod are on the same side 10 14 CRANKSHAFT TRANSMISSION Crankshaft Connection Rod Apply molybdenum disulfide oil Threads A of Connecting Rod Big End Cap Bolts Seating Surface B of Connecting Rod Big End Cap Nuts C Tighten Torque Connecting Rod Big End Cap Nuts 34 N m 3 5 kgf m 25 ft lb Crankshaft Connecting Rod Cleaning After removing the connecting rods from the crankshaft clean them with a high flash point solvent Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages Connecting Rod Bend Remove the connecting rod big end bearing inserts and reinstall the
147. NAL DRIVE 12 1 12 Final Drive Table of Contents Exploded View 12 3 Specifications 12 10 Special Tools 12 11 Output Bevel Gears 12 14 Output Drive Bevel Gear Removal 12 14 Output Drive Bevel Gear Installation 12 14 Output Drive Bevel Gear Disassembly 12 15 Output Drive Bevel Gear Assembly 12 17 Output Driven Bevel Gear Removal 12 17 Output Driven Bevel Gear Installation 12 18 Output Driven Bevel Gear Disassembly 12 18 Output Driven Bevel Gear Assembly 12 19 Output Bevel Gears Adjustment 12 20 Bevel Gears Inspection 12 24 Front Propeller Shaft 12 25 Front Propeller Shaft Removal 12 25 Front Propeller Shaft Installation 12 25 Front Axle 12 26 Front Axle Removal 12 26 Front Axle Installation 12 26 Front Axle Joint Boot Inspection 12 26 Front Axle Joint Boot Replacement 12 26 Front Final Gear Case 12 34 Front Final Gear Case Oil L
148. ON 10 19 Transmission Shift Lever Installation Twist the tie rod end A and tie rod end locknut B to bottom of the screw and then turn back to dimension with 77 10 C as shown Tighten the locknut against the tie rod end Torque Tie rod End Locknut 20 N m 2 0 kgf m 14 ft lb Apply molybdenum disulfide grease Outside of Tie rod End Collar D Apply grease to the oil seals and install them Tighten Torque Tie rod End Bolt E 9 8 N m 1 0 kgf m 87 in lb Align the mark A on the shaft end with the slit B of the shift shaft lever Position the shift shaft lever end C on the boss center D of the crankcase Install Bracket E Shift Lever Assembly Nut F Tighten Torque Shift Lever Assembly Nut 20 N m 2 0 kgf m 14 ft lb Tie rod End Nut G 20 N m 2 0 kgf m 14 ft lb 10 20 CRANKSHAFT TRANSMISSION Transmission Install Guide A Tighten Torque Shift Lever Assembly Bracket Bolts B 20 N m 2 0 kgf m 14 ft lb Set the lever assembly in the neutral position C while turning the tie rod D NOTE Do not turn the shift shaft E when setting the lever assembly on neutral position Turn the tie rod until the rod F of the shift lever assembly contact with the guide G and then the tie rod can be turned until 1 8 At that time the clearance H which can be made between the rod and the guide is 0 0 5 mm 0
149. P END 5 35 Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the valve seat for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE 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 Prior to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following 60 Cutter angle B 37 5 Outer diameter of cutter C 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
150. R sticks open Engine stalls when moving off Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Front or rear final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Igniter trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Front or rear final gear case overheating Insufficient oil Bevel gears maladjusted LSD clutches in front final gear case malad justment Coolant incorrect Coolant level too low Coolant deteriorated Thick coolant Cooling system component incorrect Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken 18 4 APPENDIX Troubleshooting Guide Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Cooling system component incorrec
151. RIVE Exploded View FINAL DRIVE 12 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Output Driven Bevel Gear Housing Bolts 26 2 7 20 2 Output Drive Bevel Gear Housing Bolts 26 2 7 20 3 Bearing Holder 137 14 101 L 4 Bevel Gear Holder Nut 157 16 116 L 5 Bearing Holder 118 12 87 L 6 Output Shaft Holder Nut 157 16 116 L 7 Rotor Mounting Bolts 12 1 2 104 in lb 8 Output Drive Bevel Gear Cover Bolts 8 8 0 90 78 in lb G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 R Replacement Parts 12 6 FINAL DRIVE Exploded View FINAL DRIVE 12 7 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Variable Differential Control Shift Shaft Lever Bolt 8 8 0 90 78 in lb 2 Front Final Gear Case Left Cover Bolts M6 9 8 1 0 87 in lb L 4 S 3 Ring Gear Bolts 57 5 8 42 LB 4 Front Final Gear Case Center Cover Bolts M6 9 8 1 0 87 in lb L 5 Front Final Gear Case Center Cover Bolts M8 24 2 4 17 L 6 Front Final Gear Case Oil Filler Cap 29 3 0 22 7 Pinion Gear Bearing Holder Nut 127 13 94 St 8 Pinion Gear Bearing Holder 137 14 101 L 9 Front Final Gear Case Coupling Nut 25 2 5 18 10 Front Final Gear Case Oil Drain Plug 15 1
152. Seat Removal Remove the seat A by lift the latch lever B and then pulling the seat up to the rear Seat Installation Insert the front seat hooks A into the receivers B in the bracket Insert the rear seat hooks A into the dampers B Push the rear part of the seat down to engage the latches C FRAME 16 9 Carriers Front Carrier Removal Remove Front Carrier Bolts A Collars Front Carrier B Front Carrier Installation Install Long Collars L 44 6 mm 1 8 in A Short Collars L 21 6 mm 0 9 in B Front Carrier C Tighten Torque Front Carrier Bolts D L 70 mm 2 8 in 25 N m 2 5 kgf m 18 ft lb Front Carrier Bolts E L 50 mm 2 0 in 25 N m 2 5 kgf m 18 ft lb Front Carrier Bracket Installation Install Front Carrier Bracket A Tighten Torque Front Carrier Bracket Bolts B 32 N m 3 3 kgf m 24 ft lb Rear Carrier Removal Remove Rear Carrier Bolts A Collars B Rear Carrier C Rear Carrier Installation Install Collar A Carrier B Carrier Bolts L 41 mm 1 61 in C Carrier Bolts L 14 mm 0 55 in D Carrier Bolts L 25 mm 0 98 in E 16 10 FRAME Carriers Rear Carrier Bracket Installation Install Rear Carrier Bracket A Tighten Torque Rear Carrier Bracket Bolts B 37 N m 3 8 kgf m 27 ft lb FRAME 16 11 Fenders Front Fender Removal Remove Seat s
153. Spring Free Length Exhaust 41 3 mm 1 626 in 39 5 mm 1 555 in Inlet 41 3 mm 1 626 in 39 5 mm 1 555 in Cylinder Piston Cylinder Inside Diameter 84 994 85 006 mm 3 3462 3 3467 in 85 10 mm 3 350 in Piston Diameter 84 964 84 979 mm 3 3450 3 3456 in 84 81 mm 3 3390 in Piston Cylinder Clearance 0 015 0 042 mm 0 0006 0 0017 in Piston Ring Groove Clearance Top 0 04 0 08 mm 0 0016 0 0032 in 0 18 mm 0 0071 in Second 0 03 0 07 mm 0 0012 0 0028 in 0 17 mm 0 0067 in Piston Ring Groove Width Top 1 03 1 05 mm 0 0405 0 0413 in 1 13 mm 0 0445 in 5 10 ENGINE TOP END Specifications Item Standard Service Limit Second 1 02 1 04 mm 0 0402 0 0409 in 1 12 mm 0 0441 in Piston Ring Thickness Top 0 97 0 99 mm 0 0382 0 0390 in 0 90 mm 0 035 in Second 0 97 0 99 mm 0 0382 0 0390 in 0 90 mm 0 035 in Piston Ring End Gap Top 0 20 0 30 mm 0 0079 0 0118 in 0 60 mm 0 0236 in Second 0 30 0 45 mm 0 0118 0 0177 in 0 75 mm 0 0295 in Oil 0 20 0 70 mm 0 0079 0 0276 in 1 00 mm 0 0394 in ENGINE TOP END 5 11 Special Tools and Sealant Outside Circlip Pliers 57001 144 Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 Piston Pin Puller A
154. Starter Relay 18 Battery 12 V 12 Ah 19 Engine Ground Terminal 17 72 ELECTRICAL SYSTEM Actuator Control System 2WD 4WD Actuator Removal Drain the front final gear case oil see Front Final Gear Case Oil Change in Periodic Maintenance chapter Remove Actuator Lead Connector A Clamp B Remove Actuator Mounting Bolts A Actuator B 2WD 4WD Actuator Installation When installing the pin A apply engine oil to the rod of the actuator and install the collar B on the actuator and then press the pin Apply grease to the O ring C Apply molybdenum disulfide grease to the collar Insert the collar into the groove D of the shifter so that the long side E faces downward Apply a non permanent locking agent to the actuator mounting bolts and tighten them following the tightening sequence 1 3 Torque 2WD 4WD Actuator Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Engine Brake Actuator Removal Confirm that the ignition switch is in OFF position Remove Torque Converter Cover see Converter System chap ter Actuator Mounting Bolts A Actuator B ELECTRICAL SYSTEM 17 73 Actuator Control System Engine Brake Actuator Installation Apply grease and Install O ring A Apply molybdenum disulfide grease to the pin B Apply grease to the trim seal A and install the cover B Insert the pin into the collar A of the engine brake lever assem
155. Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Recoil starter not operating Recoil starter spring broken Recoil starter pawl not engaging 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 Fuel pump damaged or circuit open short Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Crankshaft sensor trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted
156. Suspend the fan switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer B in the coolant NOTE The switch and thermometer must not touch the con tainer sides or bottom Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table If the hand tester does not show the specified values re place the switch Radiator Fan Switch Resistance Rising Temperature From OFF to ON at 96 100 C 205 212 F Falling Temperature From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 OFF More than 1 M ELECTRICAL SYSTEM 17 87 Switches Coolant Temperature Warning Light Switch Inspection Remove Coolant Temperature Warning Light Switch see Cooling System chapter Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged Suspend an accurate thermometer B in the coolant NOTE The switch and thermometer must not touch the con tainer sides or bottom Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently Using the hand tester measure th
157. Suspension Arm B Remove Stabilizer Joint A Hold the joint bolt with an Allen wrench B and remove the nut C Remove Mounting Bolts and Nuts A Rear Lower Suspension Arm B Rear Suspension Arm Installation Install Rear Upper Suspension Arm Rear Lower Suspension Arm Suspension Arm Pivot Bolts and Nut temporary Rear Shock Absorber Mounting Bolt lower Stabilizer Joint Tighten Torque Rear Suspension Arm Pivot Nuts 48 N m 4 8 kgf m 35 ft lb Rear Shock Absorber Mounting Nuts 34 N m 3 5 kgf m 25 ft lb Stabilizer Joint Nut 48 N m 4 8 kgf m 35 ft lb Hold the joint bolt with an Allen wrench and tighten the nut Install Front Wheels see Wheels Tires chapter 14 16 SUSPENSION Suspension Arms Rear Suspension Arm Disassembly Rear Upper Suspension Arm Remove out the bushings A Front Lower Suspension Arm Remove Screw A Bolts B Collars C Axle Guard D Collars E rear side Oil Seals F Circlips G Special Tool Outside Circlip Pliers 57001 144 Remove Ball Joint Bearing H rear side Sleeve I front side Needle Bearing J front side Rear Suspension Arm Assembly Apply grease Ball Joint Bearing Needle Bearing Rear Upper Suspension Arm Install the bushings A using a press SUSPENSION 14 17 Suspension Arms Rear Lower Suspension Arm Install the following parts as shown Front Side A Needle Beari
158. T 13 Reverse Idle Shaft 14 Reverse Driven Gear 16T 15 Reverse Driven Output Gear 16T 16 Idle Shaft 17 Spacer 20 3 33 2 0 18 Driven Output Gear 18T 19 Driven Hi Gear 30T 20 Driven Low Gear 36T 21 Needle Bearing CRANKSHAFT TRANSMISSION 10 27 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary Removal may damage them Using a press or puller remove the ball bearing and or three needle bearings NOTE In the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing Three new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection Re moval may damage them Check the ball bearings Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do
159. TB Apply a non permanent locking agent Three Bond 1363A Red 12 10 FINAL DRIVE Specifications Item Standard Service Limit Output Bevel Gear Case Output Bevel Gear Backlash 0 05 0 11 mm 0 0020 0 0043 in at output drive shaft spline Front Final Gear Case Gear Case Oil same engine oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W 40 Oil Level Filler opening bottom Capacity 0 43 L 0 45 US qt Coupling Bushing Inside Diameter 13 000 13 018 mm 0 5118 0 5125 in 13 048 mm 0 5137 in LSD Clutch Torque when variable differential control lever is released 15 20 N m 1 5 2 0 kgf m 11 14 ft lb when variable differential control lever is pulled in 157 N m 16 kgf m 116 ft lb or more Bevel Gear Backlash 0 10 0 20 mm 0 004 0 008 in at pinion gear spline Rear Final Gear Case Gear Case Oil Type MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Oil Level Filler opening bottom Capacity 0 9 L 0 95 US qt Rear Final Bevel Gear Backlash 0 04 0 17 mm 0 002 0 007 in at pinion gear spline FINAL DRIVE 12 11 Special Tools Bearing Puller 57001 135 Steering Stem Bearing Driver 57001 137 Inside Circl
160. TEM Specifications Item Standard Service Limit Torque Converter Actuator Lever Guide Shoe 6 mm 0 24 in Drive Belt Belt Width 29 7 30 3 mm 1 169 1 193 in 28 0 mm 1 102 in Belt Deflection 22 27 mm 0 87 1 06 in Drive Pulley Shoe Side Clearance Up to 0 20 mm 0 008 in in the text Cover Bushing Inside Diameter 27 985 28 085 mm 1 1018 1 1057 in 28 12 mm 1 107 in Sheave Bushing Inside Diameter 37 985 38 085 mm 1 4955 1 4994 in 38 12 mm 1 501 in Spring Free Length 60 4 mm 2 38 in Driven Pulley Sheave Bushing Inside Diameter 40 000 40 039 mm 1 5748 1 5763 in 40 07 mm 1 578 in Spring Free Length 99 5 mm 3 92 in CONVERTER SYSTEM 6 7 Special Tools Circlip Pliers 57001 154 Flywheel amp Pulley Holder 57001 1343 Drive amp Driven Pulley Holder 57001 1412 Drive Pulley Puller Bolt 57001 1429 Pulley Holder Attachment 57001 1472 Drive amp Driven Pulley Holder 57001 1473 Drive Pulley Wrench 57001 1474 Spring Holder Set 57001 1483 Drive Pulley Measurement Tool 57001 1498 Actuator Lever Measurement Tool 57001 1499 6 8 CONVERTER SYSTEM Special Tools Drive Pulley Holder 57001 1520 CONVERTER SYSTEM 6 9 Torque Converter WARNING Excessive imbalance or operating rpm could cause torque converter pulley failure resulting
161. VFDB1 5B500001 This digit in the frame number changes from one machine to another Part No 99924 1334 02 Printed in Japan
162. Valve to Guide Clearance Measurement If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface Move C the stem back and forth to measure valve valve guide clearance Repeat the measurement in a direction at a right angle to the first If the reading exceeds the service limit replace the guide NOTE The reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 09 0 17 mm 0 0035 0 0067 in Inlet 0 03 0 11 mm 0 0012 0 0043 in Service Limit Exhaust 0 37 mm 0 0146 in Inlet 0 31 mm 0 0122 in 5 34 ENGINE TOP END Valves Valve Seat Inspection Remove the valve see Valve Removal Check the valve seating surface A between the valve B and valve seat C Coat the valve seat with machinist s dye Push the valve into the guide Rotate the valve against the seat with a lapping tool Pull the valve out and check the seating pattern on the valve head It must be the correct width and even all the way around Measure the outside diameter D of the seating pattern on the valve seat If the outside dia
163. WD 4WD shift switch If the 2WD 4WD shift switch is normal replace the actu ator controller unit ELECTRICAL SYSTEM 17 81 Actuator Control System Check 7 Forward Reverse Detecting Sensor Inspection Disconnect forward reverse detecting sensor lead con nector A Measure the forward reverse detecting sensor resis tance Connect the hand tester between the BK lead and the W lead Set the tester to the k range Special Tool Hand Tester 57001 1394 Forward Reverse Detecting Sensor Resistance Standard 1 2 1 6 k If the reading is not within the specified range replace the forward reverse detecting sensor Using the highest resistance measure the resistance be tween forward reverse detecting sensor leads and chas sis ground If the tester reading is less than infinity indicates a short replace the forward reverse detecting sensor Check 8 Indicator Light LCD Inspection Refer to Check 7 2WD 4WD Indicator Lights Check in Multifunction Meter Unit Inspection 17 82 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Circuit 1 Speed Sensor 2 Forward Reverse Detecting Sensor 3 2WD 4WD Actuator 4 Engine Brake Actuator 5 Actuator Controller 6 Ignition Switch 7 Controller Fuse 10 A 8 Main Fuse 30 A 9 Multifunction Meter 10 2WD 4WD Shift Switch 11 Igniter 12 Belt Failure Detection Switch 13 Starter Relay 14 Battery 15 Engine Ground Te
164. Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Igniter trouble Crankshaft sensor trouble Ignition coil trouble Battery voltage low Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Starter plunger stuck open Air cleaner clogged poorly sealed or miss ing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive APPENDIX 18 3 Troubleshooting Guide Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn
165. ad Check fuel leakage from the carburetors WARNING Fuel spilled from the carburetors is hazardous Adjust the idle speed see Idle Speed Adjustment in Pe riodic Maintenance chapter Check the throttle cable see Throttle Lever Free Play In spection in Periodic Maintenance chapter Carburetor Disassembly Remove the carburetors see Carburetor Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light NOTE The carburetors can be disassembled in the joined state 3 18 FUEL SYSTEM Carburetor Remove the upper chamber cover A spring B and vac uum piston C CAUTION During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm Remove the jet needle D from the vacuum piston These can be detached together with the spring seat E Do not remove the pilot screw if possible synchronization of the carburetors is necessary if pilot screws are removed see Pilot Screw Adjustment Remove Screws A Float Chamber B Remove Screw A Float Pivot Pin B Float C and Float Needle Valve Pilot Jet D Main Jet E Starter Jet F Remove Screws A Coasting Enricher Cover B FUEL SYSTEM
166. ain the coolant see Coolant Change in Periodic Main tenance chapter Remove Coolant Reserve Tank Water Hose A Water Pump Cover Bolts B Water Pump Cover C Water Pump Cover Installation Install Knock Pins A New Gasket B Tighten Torque Water Pump Cover Bolts 8 8 N m 0 90 kgf m 78 in lb Water Pump Impeller Removal Drain the coolant see Coolant Draining Remove Water Pump Cover see Water Pump Cover Removal Loosen the water pump impeller A counterclockwise Water Pump Impeller Installation Apply a small amount of coolant on the sliding surface A of the mechanical seal and the sealing seat Install the impeller on the water pump shaft and tighten the impeller Torque Water Pump Impeller 7 9 N m 0 80 kgf m 69 in lb COOLING SYSTEM 4 11 Water Pump Water Pump Impeller Inspection Visually inspect the impeller A If the surface is corroded or the blades are damaged re place the impeller Water Pump Leakage Inspection Check the drainage catch tank A at the bottom of the water pump body for coolant leakage If there is a coolant leak the mechanical seal in the pump could be damaged Replace the mechanical seal with a new one see Mechanical Seal Replacement Mechanical Seal Replacement Remove Water Pump Impeller see Water Pump Impeller Re moval Alternator Cover see Electrical System chapter Take the bearing A out of the al
167. al Hold the rotor with the flywheel holder and take out the starter motor clutch bolts A Special Tool Flywheel Holder 57001 1313 Take out the one way clutch A Starter Motor Clutch Installation Install the one way clutch so that the flange A fits on the recess B of the race Apply a non permanent locking agent Starter Motor Clutch Bolts Tighten Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft lb Starter Motor Clutch Inspection Remove Alternator Rotor see Alternator Rotor Removal Fit the starter clutch gear into the starter motor clutch If the alternator rotor turns counterclockwise A freely from the starter clutch gear but not clockwise B the clutch is operating correctly If the clutch does not operate correctly or if it makes noise disassemble it and examine each part visually Re place any worn or damaged parts NOTE Examine the starter clutch gear A Replace it if it is worn or damaged ELECTRICAL SYSTEM 17 53 Electric Starter System Torque Limiter Inspection Remove Alternator Rotor see Electrical System chapter Remove the torque limiter A and visually inspect it If the limiter has wear discoloration or other damage replace it as a unit 17 54 ELECTRICAL SYSTEM Lighting System Headlight Beam Vertical Adjustment Turn the adjusting screw A on each headlight rim in or out to adjust the headlight vertically
168. aliper from the disc see Caliper Removal Remove Pad Mounting Bolts A Remove Brake Pads A Brake Pad Installation Push the caliper piston in by hand as far as it will go Be sure that the anti rattle spring is in place Install Brake Pads Pad Mounting Bolts Tighten Torque Pad Mounting Bolts 17 N m 1 7 kgf m 13 ft lb WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brake will not function on the first application if this is not done Brake Pad Wear Inspection Refer to the Front Brake Pad Wear Inspection in the Pe riodic Maintenance chapter 13 18 BRAKES Brake Discs Disc Cleaning Poor braking can be caused by oil on a disc Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Disc Removal Remove Front Hub see Wheels Tires chapter Brake Disc Mounting Bolts A Brake Disc B Disc Installation The disc must be installed with the marked side A facing toward the steering knuckle Apply a non permanent locking agent to the brake disc mounting bolts Tighten Torque Brake Disc Mounting Bolts 37 N m 3 8 kgf m 27 ft lb After i
169. ange Electric Starter 251 456 kPa 2 56 4 65 kgf cm 36 66 psi 380 r min rpm The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Carbon accumulation on piston cylinder head and in combustion chamber possibly due to damaged valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Remove the carbon deposits and replace damaged parts if necessary Incorrect cylinder head gasket thickness Replace the gasket with a standard part Damaged or missing compression release cam spring Replace the spring Cylinder compression is higher than usable range Compression release weights do not move smoothly Replace the compression release unit Gas leakage around cylinder head Replace damaged gasket and check cylinder head warp Bad condition of valve seating Repair if necessary Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or piston ring grooves Replace the piston and or the piston rings Cylinder compression is lower than usable range Compression release weights do not move smoothly Replace the compression release unit 5
170. ar Case Oil Change in Periodic Mainte nance chapter FINAL DRIVE 12 37 Front Final Gear Case Front Final Gear Case Disassembly Remove Front Final Gear Case see Front Final Gear Case Re moval Variable Differential Control Shift Shaft Lever Bolt A and Nut B Variable Differential Control Shift Shaft Lever C 2WD 4WD Actuator see Electrical System chapter Hold the front final gear case with the gear holder amp socket wrench A in a vise Special Tool Gear Holder amp Socket Wrench Hex 24 57001 1489 Remove Front Final Gear Case Coupling Nut A Washer B Front Final Gear Case Coupling C Shifter D Oil Seals E Remove Front Final Gear Case Left Cover Bolts A Front Final Gear Case Left Cover B Variable Differential Control Shift Shaft Spring Remove Outer Disc A Needle Bearing 12 38 FINAL DRIVE Front Final Gear Case Remove Housing A and Differential Disc Assembly B Inner Disc Needle Bearing Remove Cam Plate A Remove Steel Balls A Gasket B Dowel Pins C Front Final Gear Case Center Cover Bolts M6 D Front Final Gear Case Center Cover Bolts M8 E Front Final Gear Case Center Cover F Remove Ring Gear Assembly A Shim s B Hold the front final gear case right cover A in a vise and remove the bearing holder using the socket wrench B Special Tool Socket Wrench Hex 41 57001 1484 If the holder seems
171. as necessary Tooth Contact Adjustment Clean any dirt and oil off the bevel gear teeth Apply checking compound to 4 or 5 teeth of the pinion gear NOTE Apply checking compound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear The checking compound must be smooth and firm with the consistency of tooth paste Special compounds are available at automotive supply stores for the purpose of checking gear tooth patterns and contact Use one of these for checking the bevel gears Assemble the rear final gear case see Rear Final Gear Case Assembly Turn the pinion gear for one revolution in the drive and reverse coast direction while creating drag on the ring gear Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe If the tooth contact pattern is incorrect replace the pinion gear shim s following the examples shown see Correct Tooth Contact Pattern in the Front Final Bevel Gear Ad justment section Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are repla
172. ase replace the joint boot or front axle assembly see Final Drive chapter Visually inspect the knuckle joint boots B If the joint boot is torn worn deteriorated or leaks grease replace the knuckle see Steering Knuckle sec tion in Steering chapter Front Propeller Shaft Boot Inspection Visually inspect the boots A of the front propeller shaft If damage tear or deterioration is found replace the boots see Front Propeller Shaft section in Final Drive chapter Tie rod End Boot Inspection Visually inspect the tie rod end boots A of the tie rods If the boot is torn worn deteriorated or leaks grease replace the tie rod end see Steering chapter Rear Propeller Shaft Joint Boot Inspection Visually inspect the boots A of the rear propeller shaft If the joint boot is torn worn or deteriorated replace the joint boot and check the propeller shaft see Rear Pro peller Shaft section in Final Drive chapter Rear Axle Stabilizer Joint Boot Inspection Visually inspect the rear axle joint boots A If the joint boot is torn worn deteriorated or leaks grease replace the joint boot or rear axle assembly see Final Drive chapter Visually inspect the stabilizer joint boots B If the joint boot is torn worn deteriorated or leaks grease replace the stabilizer joint see Suspension chapter 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lub
173. ase into the grease nipples A until the grease comes out from the nipple and wipe off any excess grease B Grease Gun Brakes Front Brake Pad Wear Inspection Check the lining thickness A of the pads in each caliper If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard 4 mm 0 16 in Service Limit 1 mm 0 04 in Front Brake Hoses and Connections Inspection Inspect the brake hose and fittings for deterioration cracks and signs of leakage The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Front Brake Hose Replacement Pump the brake fluid out of the line as explained in the Brake Fluid Change Remove the banjo bolts at both ends of the brake hose and pull the hose off the vehicle Immediately wipe up any brake fluid that spills CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately Use a new flat washer for each side of the hose fittings Install the new brake hose in its place see Appendix chapter and tighten the banjo bolts Torque Brake
174. ash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment Press the bearing on the pinion gear until it is bottomed Install the pinion gear bearing holder nut A so that the projection B faces outward Tighten Special Tool Pinion Gear Holder m1 0 57001 1485 Torque Pinion Gear Bearing Holder Nut 127 N m 13 kgf m 94 ft lb Stake C the nut with a punch at three positions to secure it Front Final Bevel Gear Adjustment The backlash distance one gear will move back and forth without moving the mate gear and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged Above two adjustments are of critical importance and must be carried out following the correct sequence and method When any one of the backlash related parts are replaced check and adjust the bevel gear backlash and tooth con tact by replacing shims The amount of backlash is influenced by the ring gear position more than by the pinion gear position Tooth contact location is influenced by the pinion gear po sition more than by the ring gear position FINAL DRIVE 12 47 Front Final Gear Case Front Final Gear Case Backlash related Parts 1 Pinion Gear Shim s 2 Ring Gear Right Shim s 3 Ring Gear Left Shim s 4 Front Final Gear Case Center Cover 5 Front Final Gear Case Right Cover 6 Ball Bearings 7 Ri
175. asteners retorque them to the speci fied torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not listed in the appropriate chapter see the Basic Torque Table see Torque and Locking Agent For each fastener first loosen it by 1 2 turn then tighten it If cotter pins are damaged replace them with new ones Bolts Nuts and Fasteners to be checked Wheels Front Axle Nuts and Cotter Pins Rear Axle Nuts and Cotter Pins Wheel Nuts Brakes Front Brake Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Brake Lever Pivot Nut Front Brake Caliper Mounting Bolts Brake Pedal Cotter Pin Steering Suspension Handlebar Clamp Bolts Stem Clamp Bolts Stem Bearing Housing Bolts Tie rod End Nuts and Cotter Pins Tie rod Adjusting Sleeve Locknuts Shock Absorber Mounting Bolts and Nuts Suspension Arm Pivot Bolts Steering Knuckle Pivot Nuts and Cotter Pins Engine Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Front Final Drive Gear Case Bracket Bolts Others Footboard Mounting Bolts Throttle Mounting Bolts Carrier Mounting Bolts FUEL SYSTEM 3 1 3 Fuel System Table of Contents Exploded View 3 2 Specifications 3 6 Special Tools 3 7 Throttle Lever and Cable
176. at To check valve opening temperature suspend the ther mostat A and an accurate thermometer B in a container of water with the heat sensitive portions C in almost the same depth NOTE The thermostat must be completely submerged and the thermostat and thermometer must not touch the con tainer sides or bottom Gradually raise the temperature of the water while stirring the water gently for even temperature If the measurement is out of the specified range replace the thermostat Thermostat Valve Opening Temperature 69 5 72 5 C 157 162 F 4 18 COOLING SYSTEM Radiator Fan Switch Radiator Fan Switch Removal CAUTION The fan switch should never be allowed to fall on a hard surface Such a shock to the part can damage it Drain the coolant see Coolant Change in Periodic Main tenance chapter Remove Radiator Cover see Frame chapter Disconnect the fan switch leads Remove the radiator fan switch A Radiator Fan Switch Installation Tighten Torque Radiator Fan Switch 18 N m 1 8 kgf m 13 ft lb Fill the coolant see Coolant Change in Periodic Mainte nance chapter Radiator Fan Switch Inspection Refer to the Electrical System chapter COOLING SYSTEM 4 19 Coolant Temperature Warning Light Switch Coolant Temperature Warning Light Switch Removal CAUTION The coolant temperature warning light switch should never be allowed to fall on a hard su
177. away any coolant that spills on the frame engine or wheels Since coolant is harmful to the human body do not use for drinking Remove Left Footboard see Frame chapter Front Fender see Frame chapter Radiator Cover Screws A and Collars Remove Radiator Cover Screws A and Collars Radiator Cover B PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Remove Clamp A Reserve Tank Screws B Reserve Tank C with Hose Remove the reserve tank cap and pour the coolant into a container Place a container under the drain plug A at the bottom of the water pump B then remove the drain plug Remove the radiator cap A in two steps First turn the cap counterclockwise to the first step Then push and turn it further in the same direction and remove the cap The coolant will drain from the radiator and engine Place a container under the drain plug A at the front cylinder then remove the drain plug Place a container under the drain plug A at the rear cylin der then remove the drain plug 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tighten the drain plug Torque Coolant Drain Plug 8 8 N m 0 90 kgf m 78 in lb Support the vehicle on a stand or the jack so that the front wheels are off the ground This makes air bleeding easier Fill the radiator up to the radiator filler neck A with coolant NOTE Pour in the coolant slowly
178. bly B Wipe off any protruding grease Tighten the actuator mounting bolts following the tighten ing sequence 1 3 Torque Engine Brake Actuator Mounting Bolts 8 8 N m 0 90 kgf m 78 in lb Actuator Control System Outline The actuator controller has a microprocessor that detects vehicle speed state of the selectable 2WD 4WD shift switch ignition switch and the forward reverse movement of the vehicle in order to control the engine brake actuator and selectable 2WD 4WD actuator 17 74 ELECTRICAL SYSTEM Actuator Control System Actuator Control System Actuator Control System Troubleshooting When the actuator fails the controller enters failure mode and the indicator light illuminates 2WD and 4WD alternately A 2WD Indicator Light LCD B 4WD Indicator Light LCD ELECTRICAL SYSTEM 17 75 Actuator Control System Failure Indication Pattern and Failure Part No Failure Indication Pattern Failure Part 1 Selectable 2WD 4WD actuator 2 Engine brake actuator 3 Both the selectable 2WD 4WD actuator and the engine brake actuator Malfunction Mode No Malfunction Mode Probable Faulty Part Location Check Number 2WD 4WD actuator 1 Controller power supply 3 1 Speed sensor 4 The 2WD 4WD actuator does not operate correctly 2WD 4WD shift switch 5 Controller 6 Engine brake actuator 2 Controller power supply 3 2 Speed sensor 4 The engine brake actuator does n
179. bulb in turn it clockwise and release it It should lock in position ELECTRICAL SYSTEM 17 57 Lighting System Lighting System Circuit 1 Multifunction Meter 2 Reverse Switch 3 Reverse Light EUR and GB models 4 Main Fuse 30 A 5 Front Brake Light Switch 6 Parking Brake Light Switch 7 Rear Brake Light Switch 8 Position Light Right 9 Headlight Right 10 Headlight Left 11 Position Light Left 12 Light Dimmer Switch 13 Reset Connector 14 Ignition Switch 15 Starter Relay 16 Battery 17 Engine Ground Terminal 18 Tail Brake Lights 17 58 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection Remove Screw A Left Lower End of Radiator Cover B Disconnect the leads from the radiator fan switch A Using an auxiliary wire B connect the radiator fan switch leads If the fan rotates inspect the fan switch If the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Radiator Fan Motor Inspection Disconnect the connector A in the fan lead Using two auxiliary wires supply battery B voltage to the fan motor If the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Motor Leads BL Battery BK Battery Radiator Fan Breaker Inspection Remove Seat see Frame chapter Radiator Fan Breaker A Inspect the breaker for operation Connect 12 V Batter
180. ced Much less 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 black leads and chassis ground Any reading less than infinity indicates a short neces sitating stator replacement If the stator coils have normal resistance but the voltage check shows the alternator to be defective then the rotor magnetism has probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 ELECTRICAL SYSTEM 17 31 Charging System Regulator Rectifier Inspection Remove Connectors A disconnect Bolts B and Regulator Rectifier C Rectifier Circuit Check Check conductivity of the following pair of terminals Rectifier Circuit Inspection W BK1 W BK2 W BK3 Tester connection BK Y BK1 BK Y BK2 BK Y BK3 The resistance should be low in one direction and more than ten times as much in the other direction If any two leads are low or high in both directions the rectifier is defective and must be replaced NOTE The actual meter reading varies with the meter and the individual rectifier Generally speaking the lower read ing should be from zero to one half of the scale Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a c
181. ced Repeat the shim change procedure as nec essary NOTE If the backlash is out of the standard range after changing the pinion gear shim s change the ring gear shim s to correct the backlash before checking the tooth contact pattern 12 72 FINAL DRIVE Rear Final Gear Case Pinion Gear Unit Disassembly Remove Pinion Gear Unit A see Rear Final Gear Case Disas sembly Hold the pinion gear bearing holder nut B with the socket wrench C in a vise and loosen the pinion gear shaft using the pinion gear holder D Special Tools Socket Wrench 57001 1363 Pinion Gear Holder 57001 1281 Remove the ball bearing E as necessary Special Tool Bearing Puller 57001 135 Pinion Gear Unit Assembly The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be re placed as a set Visually inspect the bearing for abrasion color change or other damage If there is any doubt as to the condition of a bearing re place the bearing Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Front Final Bevel Gear Adjustment Press the bearing A on the pinion gear until it is bot tomed Install the pinion gear bearing holder nut B so that the projection C faces outward Apply a non permanent locking agent to the pinion gear bearing holder nut A and tighten it Spec
182. ch hole Install Shift Shaft Cover Tighten Torque Shift Shaft Cover Bolts 8 8 N m 0 90 kgf m 78 in lb Shift Fork Bending Visually inspect the shift fork If the fork is bent replace the shift rod with a new one A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 Shift Fork Gear and Shifter Groove Wear Measure the thickness of the shift fork ears A and mea sure the width B of the gear groove and shifter If the thickness of a shift fork ear is less than the service limit the shift rod must be replaced Shift Fork Ear Thickness Standard 5 9 6 0 mm 0 2322 0 2362 in Service Limit 5 8 mm 0 228 in If the groove is worn over the service limit the shifter must be replaced Shifter Groove Width Standard 6 05 6 15 mm 0 2382 0 2421 in Service Limit 6 25 mm 0 2460 in CRANKSHAFT TRANSMISSION 10 25 Transmission Transmission and Shift Mechanism Inspection Visually inspect Gears Dogs of Gear and Shifter If they are damaged or worn excessively replace them 10 26 CRANKSHAFT TRANSMISSION Transmission 1 Driven Shaft 2 Spacer 17 3 30 2 0 3 Reverse Gear 12T 4 Spacer 21 2 29 1 6 5 Shifter 6 Snap Ring 7 Washer T 1 5 8 Spacer 28 2 34 5 1 6 9 Spacer Hi and Low 10 Spacer 48 2 54 3 1 0 11 Drive Hi Gear 26T 12 Drive Low Gear 20
183. connecting rod big end cap Select an arbor A of the same diameter as the connect ing rod big end and insert the arbor through the connect ing rod big end Select an arbor of the same diameter as the piston pin and at least 100 mm 3 94 in long and insert the arbor B through the connecting rod small end On a surface plate set the big end arbor on a V block C With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm 3 94 in length to determine the amount of connecting rod bend If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 008 3 94 in Connecting Rod Twist With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over a 100 mm 3 94 in length of the arbor to de termine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 008 3 94 in CRANKSHAFT TRANSMISSION 10 15 Crankshaft Connection Rod Connecting Rod Big End Side Clearance Measure the side clearance of the connecting rod big end A Insert a thickness gauge B between the big end and ei ther cra
184. crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation See crankcase assembly See Crankshaft Transmission chapter Apply a non permanent locking agent to the threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft lb Oil Pressure Relief Valve Inspection Remove the relief valve Using a wooden stick push the inner valve to make sure that the valve A moves smoothly and that it returns to its original position by the force of the spring B NOTE The relief valve cannot be disassembled and it must be inspected in the assembled state If the valve movement is not smooth wash the relief valve with high flash point solvent and use compressed air to remove any foreign particles from it WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents If the valve does not move smoothly even after washing it replace the relief valve The oil pressure relief valve is precision made with no allowance for replacement of individual parts 8 10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove Alternator Rotor and Starter Clutch Gear see El
185. crap the removed boot bands Slide the joint boot toward the inboard joint FINAL DRIVE 12 27 Front Axle Tap the bearing housing A straight B with a plastic ham mer to separate it from the shaft CAUTION Do not tap on the cage Be careful not get hurt when the housing comes out If the splined portion of shaft cracked or damaged during disassembling of outboard joint do not reuse the shaft Remove Circlip A Boot B Small Band C Outboard Joint Boot Installation Clean the axle shaft by wiping off the used grease on it Wind the tape on the splines of the axle shaft in order to protect the joint boot Install New Small Band A New Boot B Apply the special grease slightly on the inside of the new boot small diameter and install the boot on the axle shaft CAUTION Only the special grease that is included with the boot kit can be applied to the boots Install New Circlip C Apply the special grease slightly on the part A of the band installation in order to make easy to install the boot band Tighten the small boot band B 12 28 FINAL DRIVE Front Axle Tighten the boot band A and bend the tangs B securely to hold down the end of the band Place the special grease tube nozzle in the bore of the housing and squeeze the tube A until the grease comes out from the joint bearing Tap the shaft end A straight with a plastic hammer until it i
186. crease it The rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 6 mm 0 063 in change in belt deflection NOTE When using the plural spacers install the thick spacer to the movable sheave side and thin spacer to the fixed sheave side Spacers Part No Thickness 92026 0034 0 3 mm 0 012 in 92026 1569 0 6 mm 0 024 in 92026 1617 0 8 mm 0 032 in 92026 1565 1 0 mm 0 039 in 92026 1570 1 4 mm 0 055 in PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Assemble the driven pulley see Converter System chap ter With the transmission in neutral rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection Measure the belt deflection again and repeat the above procedures until it is within the standard range Using the flywheel amp pulley holder and pulley holder at tachment tighten the driven pulley nut Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft lb Actuator Lever Engine Brake Control Lever Assembly Inspection Measure the width A of the plastic guide shoe B of the actuator lever assembly If the guide contact area width is greater than the service limit replace the actuator lever assembly Actuator Lever Guide Shoe Service Limit 6 mm 0 24 in Engine Lub
187. d Ratio Soft water 50 coolant 50 Freezing Point 35 C 31 F Total Amount 2 2 L 2 3 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 14 18 psi Thermostat Valve Opening Temperature 69 5 72 5 C 157 162 F Valve Full Opening Lift 8 mm or more 85 C 185 F COOLING SYSTEM 4 7 Special Tools amp Sealant Bearing Driver Set 57001 1129 Bearing Remover Shaft 9 57001 1265 Bearing Remover Head 10 12 57001 1266 Kawasaki Bond Silicone Sealant 56019 120 4 8 COOLING SYSTEM Coolant Coolant Deterioration Inspection Visually inspect the coolant in the reserve tank A If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system If the coolant gives off an abnormal smell check for cool ing system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection NOTE Check the level when the engine is cold room or ambi ent temperature Check the coolant level in the reserve tank with the vehi cle held perpendicularly Reserve Tank A F full Mark B L low Mark C If the coolant level is lower than the L mark Remove the reser
188. d friction plates in accordance with the specified interval see Rear Final Gear Case sec tion in the Final Drive chapter Rear Brake Lever Free Play Inspection Check the rear brake lever free play A Pull the rear brake lever lightly until the brake is applied If the play is incorrect adjust it Rear Brake Lever Free Play Standard 1 2 mm 0 04 0 08 in Brake Pedal Free Play Inspection Check the brake pedal free play A Depress the brake pedal lightly by hand until the brake is applied If the free play is incorrect adjust it Brake Pedal Free Play Standard 15 25 mm 0 6 1 0 in Rear Brake Lever and Pedal Free Play Adjustment NOTE Since the rear brake lever and pedal free play adjust ments affect each other make them at the same time Rear Brake Lever Loosen the knurled locknut A and turn the adjuster B at the rear brake lever in as far as it will go Tighten the locknut Turn the brake lever adjuster A at the rear end of the brake cable until the rear brake lever has the correct amount of play Brake Pedal Turn the brake pedal adjuster B at the rear end of the brake cable until the brake pedal has the correct amount of play Operate the pedal a few times to see that it returns to its rest position immediately upon release Rotate the rear wheels to check for brake drag Check braking effectiveness If there is any doubt as to the co
189. dance with the Periodic Maintenance Chart clean the spark arrester Spark Arrester Cleaning Refer to the Spark Arrester Cleaning in the Periodic Main tenance chapter Muffler and Exhaust Pipe Removal Remove Seat see Frame chapter Left Side Cover see Frame chapter Bolts A Rear Exhaust Pipe Cover B Bolts C Middle Exhaust Pipe Cover D Remove Bolts A Front Exhaust Pipe Cover B Remove Rear Exhaust Pipe Nuts A Remove Muffler Clamp Bolt A Muffler Mounting Bolts B and Washers Muffler C and Rear Exhaust Pipe ENGINE TOP END 5 45 Exhaust System Remove Front Exhaust Pipe Nuts A Move the front exhaust pipe rear end A under the fuel tank and remove the pipe forward Muffler and Exhaust Pipe Installation If the muffler cover A is removed tighten them Torque Muffler Cover Bolts B 8 8 N m 0 90 kgf m 78 in lb Replace the exhaust pipe gaskets C and clamp gasket D with new ones Install But do not tighten the following nuts and bolts Front Exhaust Pipe E Clamp F Muffler and Nuts Rear Exhaust Pipe G and Nuts Muffler Mounting Bolts H and Washers I Tighten Exhaust Pipe Nuts evenly Tighten the muffler mounting first nut M flange nut and then the second nut N Hold the first nut while tightening the second nut Torque Muffler Mounting First Nuts 20 N m 2 0 kgf m 14 ft lb Muffler Mounting Second Nuts
190. diated from the bulb Take care not to short the leads that are directly con nected to the battery positive terminal to chassis ground Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc De fective wires and bad connections will affect electrical sys tem operation Measure coil and winding resistance when the part is cold at room temperature Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Light green W White DG Dark green O Orange Y Yellow 17 18 ELECTRICAL SYSTEM Precautions Electrical Connectors Female Connectors A Male Connectors B ELECTRICAL SYSTEM 17 19 Electrical Wiring Wiring Inspection Visually inspect the wiring for signs of burning fraying etc If any wiring is defective replace the damaged wiring Pull each connector A apart and inspect 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 Use the wiring diagram to find the ends of the lead whic
191. e Caliper Piston Seal and Dust Seal Replacement 2 34 Rear Brake Plates Replacement 2 35 Rear Brake Lever Free Play Inspection 2 35 Brake Pedal Free Play Inspection 2 35 Rear Brake Lever and Pedal Free Play Adjustment 2 35 Steering 2 36 Steering Inspection 2 36 Electrical System 2 36 Spark Plug Cleaning Inspection 2 36 Spark Plug Gap Inspection 2 36 Brake Light Switch Inspection 2 37 Brake Light Timing Adjustment 2 37 Drive Belt Failure Detection System Inspection 2 37 Joint Boots Inspection 2 39 Front Axle Knuckle Joint Boot Inspection 2 39 Front Propeller Shaft Boot Inspection 2 39 Tie rod End Boot Inspection 2 39 Rear Propeller Shaft Joint Boot Inspection 2 39 Rear Axle Stabilizer Joint Boot Inspection 2 39 General Lubrication 2 40 2 2 PERIODIC MAINTENANCE Lubrication 2 40 Bolts and Nuts Tightening 2 41 Tightness Inspection 2 41 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this char
192. e assembly to the specified length while relieving the air pressure inside the inboard boot Hold the axle at this setting Standard Length of Assembling Inboard 174 6 mm 6 87 in A Open the edge of the boot in order to eqalize the air pres sures Tighten the large band A Assemble it the same as the outboard joint boot noting this setting Maximum Outside Diameter of Band 79 7 mm 3 14 in After tightening the outside diameter While the band is held at the diameter above tap down the tangs A of the band FINAL DRIVE 12 61 Rear Final Gear Case Rear Final Gear Case Oil Level Inspection Park the vehicle so that it is level both side to side and front to rear Remove the filler cap CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case Check the oil level The oil level should come to the bot tom of the filler opening A If it is insufficient first check the rear final gear case for oil leakage remedy it if necessary and add oil through the filler opening Use the same type and brand of oil that is already in the final gear case Apply grease to the O ring B Be sure the O ring is in place Torque Oil Filler Cap 29 N m 3 0 kgf m 22 ft lb Rear Final Gear Case Oil Change Refer to the Rear Final Gear Case Oil Change in the Pe riodic Maintenance chapter Rear Final Gear Case Removal Remove Rear Fender s
193. e careful not to damage the facing surface C on the outer plates If the width is within the specified range install the inner disc and disc assembly If the width is not within the specified range replace the disc assembly Install Inner Disc A Disc Assembly B and Housing C 12 42 FINAL DRIVE Front Final Gear Case Apply engine oil to the needle bearing A Install Needle Bearing Outer Disc B Apply engine oil to the variable front differential control shaft A Install the shaft and spring B in the front final gear case left cover C as shown Turn the shaft counterclockwise and insert the tab A of the shift shaft into the groove B of the cam plate Install Front Final Gear Case Left Cover C Apply a non permanent locking agent to the cover bolts 1 4 and tighten them following the tightening sequence as shown Torque Front Final Gear Case Left Cover Bolts M6 1 8 9 8 N m 1 0 kgf m 87 ft lb 1 4 L 60 mm 2 4 in 5 8 L 30 mm 1 2 in Apply grease to the oil seal lip A Press the oil seal B in the coupling C to the specified position as shown D 1 mm 0 04 in Special Tools Oil Seal Driver 18 5 57001 1505 Driver Holder 57001 1132 NOTE 57001 1132 is included in Bearing Driver Set 57001 1129 FINAL DRIVE 12 43 Front Final Gear Case Apply molybdenum disulfide grease to the spline A in the
194. e chapter Check the battery condition see Battery section Warm up the engine to obtain actual alternator operating conditions Check that the ignition switch is turned off and connect a hand tester to the battery terminals Special Tool Hand Tester 57001 1394 Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off The readings should show nearly battery voltage when the engine speed is low and as the engine speed in creases the readings should also increase Regulator Rectifier Output Voltage Connections Tester Range Tester to Tester to Reading 25 V DC Battery Battery 14 15 V Turn off the ignition switch and disconnect the hand tester If the regulator rectifier output voltage is between the val ues given in the table the charging system is working nor mally If the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open If the battery voltage does not increase as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective 17 30 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures short open or loss in rot
195. e fillet E or be as near as possible to the step F Fit the fuel pump inlet hoses onto the Y joint fully until each end of the inlet hose touches the second raised rib Fuel Hose Replacement WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove Right Side Cover see Frame chapter Electric Parts Case see Frame chapter Rear Fender see Frame chapter Turn the fuel tap to the ON position PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Remove Clamps A Fuel Hoses B Replace the fuel hoses with new ones When installing the fuel hose route the hose according to Cable Wire and Hose Routing section in Appendix chapter When installing the fuel hose avoid sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed Fit the fuel hose onto the pipe fully and install the clamps beyond the raised rib see Fuel Hose and Connection In spection Cooling System Radiator Cleaning CAUTION Clean the radiator screen and the radiator in ac cordance with the Periodic Maintenance Chart In dusty areas they should be cleaned more fre quently than the recommended interval After riding
196. e internal resistance of the switch across the connector and the body at the temperatures shown in the table If the hand tester does not show the specified values re place the switch Coolant Temperature Warning Light Switch Resistance Rising Temperature From OFF to ON at 112 118 C 234 244 F Falling Temperature From ON to OFF at 108 111 C 226 232 F ON Less than 0 5 OFF More than 1 M Switch Inspection Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms For the handlebar switches ignition switch refer to tables in the Wiring Diagram If the switch has an open or short repair or replace it with a new one 17 88 ELECTRICAL SYSTEM Switches Neutral Switch Connection A Neutral Switch Reverse Switch Connections B Reverse Switch 2WD 4WD Shift Switch Oil Pressure Switch Connections Engine Iubrication system is in good condition Drive Belt Failure Detection Switch If the drive belt failure detection system is activated by abnormal belt the drive belt failure detection switch is dam aged Make sure to replace the torque converter cover see Converter System chapter Remove Torque Converter Cover see Converter System chap ter A Drive Belt Failure Detection Switch ELECTRICAL SYSTEM 17 89 Fuses Fuse Removal Remove Seat see Frame chapter Lid A Pull the fuses
197. e rod Locknuts 37 3 8 27 Steering Stem Bearing Joint Bolts 23 2 3 17 L Steering Stem Bottom End Nut 62 6 3 46 Front Knuckle Joint Nuts 29 3 0 22 Master Cylinder Clamp Bolts 9 0 0 92 80 in lb Variable Differential Control Lever Bolt L Frame Front Guard Bolts 37 3 8 27 Front Carrier Bolts L 50 mm 2 0 in 25 2 5 18 Front Carrier Bolts L 70 mm 2 8 in 25 2 5 18 Front Carrier Bracket Bolts 32 3 3 24 Rear Carrier Bolts L 14 mm 0 6 in 54 5 5 40 Rear Carrier Bolts L 41 mm 1 6 in 54 5 5 40 Rear Carrier Bracket Bolts 42 4 3 31 Footboard Bracket Bolts 37 3 8 27 Hitch Bracket Bolts 82 8 3 60 Electrical System Starter Motor Mounting Bolts 8 8 0 90 78 in lb Starter Motor Terminal Nut 4 9 0 50 43 in lb Starter Motor Terminal Locknut 6 9 0 70 61 in lb Starter Motor Bolts 4 9 0 50 43 in lb Starter Motor Clutch Bolts 34 3 5 25 L Alternator Stator Bolts 13 1 3 113 in lb Crankshaft Sensor Mounting Bolts 5 9 0 60 52 in lb Alternator Cover Plugs 18 1 8 13 Alternator Rotor Bolt 127 13 94 Alternator Cover Bolts 8 8 0 90 78 in lb Spark Plugs 13 1 3 113 in lb 2WD 4WD Actuator Mounting Bolts 9 8 1 0 87 in lb L S Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb Forward Reverse Detectring Sensor Mounting Bolt 15 1 5 11 Speed Sensor Mounting Bolt 8 8 0 90 78 in lb Neutral Pos
198. eck the valve clearance only when the engine is cold at room temperature Remove Left Side Cover see Frame chapter Battery Case see Frame chapter Valve Adjusting Caps A Recoil Starter see Recoil Starter chapter Remove the timing inspection plug A Special Tool Filler Cap Driver B 57001 1454 Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until T F mark A on the alter nator rotor aligns with the notch B as shown the end of the compression stroke in the front cylinder head Measure the clearance for all four valves one at a time between the end of the valve stem and the adjusting screw A with the thickness gauge B Valve Clearance when cold Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in If the valve clearance is not correct adjust it see Valve Clearance Adjustment 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Then turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until T R mark A on the alternator rotor aligns with the notch B as shown the end of the compression stroke in the rear cylinder head Measure the clearance for all four valves one at a time between the end of the valve stem and the adjusting screw with the thickness gauge Valve Clearance when cold Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10
199. ectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit ELECTRICAL SYSTEM 17 33 Charging System Charging System Circuit 1 Ignition Switch 2 Fuse Box 3 Main Fuse 30 A 4 Load 5 Alternator 6 Regulator rectifire 7 Starter Relay 8 Battery 12 V12 Ah 9 Engine Ground Terminal 17 34 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and igniter Use the standard regulator rectifier or the igniter will be damaged Spark Plug Removal Front Side Remove Spark Plug Cap A Using a spark plug wrench remove the spark plug B Rear Side Remove Right Side Cover see Frame chapter Clamp Screws A and Clamps Rubber Air Duct B Remove Spark Plug Cap A Using a spark plug wrench A remove the spark plug Spark Plug Installation
200. ectrical System chapter Oil Pump Drive Chain Tensioner Bolt A Chain Guide Bolt B and Collar Chain Guide C Remove Oil Pump Bolts A Oil Pump Drive Chain B and Oil Pump Assembly C Remove Circlip A Inner Rotor B Outer Rotor C Oil Pump Drive Shaft D Oil Pump Cover E Oil Pump Installation Apply engine oil Oil Pump Shaft Inner and Outer Rotors Install Oil Pump Drive Shaft Oil Pump Cover Inner Rotor Outer Rotor New Circlip Check to see that the dowel pins A are in place Apply engine oil to the oil pump hole B ENGINE LUBRICATION SYSTEM 8 11 Oil Pump Install the oil pump drive chain A with the oil pump as sembly B Tighten Torque Oil Pump Bolts C 8 8 N m 0 90 kgf m 78 in lb Install Chain Guide A and Collar B Tighten Torque Chain Guide Bolt 8 8 N m 0 90 kgf m 78 in lb Apply grease to the O ring A Install Pin B Spring C O ring Oil Pump Drive Chain Tensioner Bolt D Tighten Torque Oil Pump Drive Chain Tensioner Bolt 25 N m 2 5 kgf m 18 ft lb 8 12 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal Engine Left Side Oil Pipe Remove Alternator Cover see Electrical System chapter Oil Pump see Oil Pump Removal Oil Pipe Bolts A Oil Pipes B Engine Right Side Oil Pipe Remove Drive Pulley see Torque Converter chapter Plate Bolts A Plate B Remove O
201. ee Frame chapter Fuel Tank see Fuel System chapter Rear Wheels see Wheels Tires chapter Rear Propeller Shaft Rear Propeller Shaft Removal Rear Axles see Rear Axle Removal Brake Cable Rear Ends Brake Cam Lever Rear Final Gear Case Bolts A and Washers rear Remove Bracket Bolts A Collars B Bracket C 12 62 FINAL DRIVE Rear Final Gear Case Remove the rear final gear case A as shown Rear Final Gear Case Installation Install Rear Final Gear Case Bracket A Collars B Bracket Bolts C D Front E Hole Washers rear side Apply a non permanent locking agent Three Bond 1363A Red to the rear final gear case nuts Tighten Torque Rear Final Gear Case Nuts F 72 N m 7 3 kgf m 53 ft lb Bracket Bolts 59 N m 6 0 kgf m 43 ft lb Install Removed Parts see applicable chapters Rear Final Gear Case Disassembly Remove Rear Final Gear Case see Rear Final Gear Case Re moval Rear Final Gear Case Right Cover Bolts M8 A Rear Final Gear Case Right Cover Bolts M10 B Rear Final Gear Case Right Cover Bolts M12 C Using the pry points A remove the rear final gear case right cover B C Arrow Marks Remove Ring Gear Shims FINAL DRIVE 12 63 Rear Final Gear Case Remove Rear Final Gear Case Front Cover Bolts A Rear Final Gear Case Front Cover Assembly B Remove Gasket Screws A Gasket B Remove Set Pins A wit
202. ee Seat Removal Front Carrier see Front Carrier Removal Left and Right Side Covers see each Side Cover Re moval Middle Cover Quick Rivets A both sides Bolts B Remove Screws A and Collars Remove Screws A and Collars Front Fender B Front Fender Installation Install Screws and Collars Quick Rivets Install Front Carrier see Front Carrier Installation Rear Fender Removal Disconnect Tail Brake Light Lead Connector A Bolts A and Collars 16 12 FRAME Fenders Remove Seat see Seat Removal Rear Carrier see Rear Carrier Removal Screws A and Collars Remove Screws A and Collars Remove Screws A and Collars Bolts B and Collars Fuel Tank Cap C Rear Fender D Install the fuel tank cap after removing the rear fender Rear Fender Installation Connect Tail Brake Light Lead Connector Install Rear Fender Dampers A and Collars B Rear Carrier see Rear Carrier Installation FRAME 16 13 Covers Middle Cover Removal Remove Middle Cover Screws A and Collars Remove Middle Cover Screw A and Collar Disconnect Reverse Power Assist Switch Lead Connectors A Remove the middle cover A as shown Middle Cover Installation Connect Reverse Power Assist Switch Lead Connectors Install Middle Cover A Middle Cover Screws B and Collars C 16 14 FRAME Covers Left Side Cover Removal Re
203. eels see Wheels Tires chapter Rear Knuckle see Suspension chapter Upper Suspension Arm A see Suspension chapter Pull the rear axle A in a straight line out of the rear final gear case Rear Axle Installation Wipe off any old grease Splines A of Axle Gear Case Oil Seal B Visually inspect the splines of the axle If they are badly worn or chipped replace the axle with a new one Apply molybdenum disulfide grease to the axle splines Apply grease top the gear case oil seal Tap A the end of the rear axle straight and install the rear axle NOTE The axle shaft must not come off easily Rear Axle Joint Boot Inspection Refer to the Axle Joint Boot Inspection in the Periodic Maintenance chapter FINAL DRIVE 12 55 Rear Axle Rear Axle Joint Boot Replacement Outboard Joint Boot Removal Remove Rear Axle see Rear Axle Removal Boot Bands A Scrap the removed boot bands Slide the joint boot B toward the inboard joint Tap the bearing housing A straight B with a plastic ham mer to separate it from the shaft CAUTION Do not tap on the cage Be careful not get hurt when the housing comes out If the splined portion of shaft cracked or damaged during disassembling of outboard joint do not reuse the shaft Remove Circlip A Boot B Small Band C Outboard Joint Boot Installation Clean the axle shaft by wiping off the used grease on it
204. enance Chart or under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in inner and outer pad wear d the seal is stuck to the piston If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Friction Boot Damage Replace the dust seals A in accordance with the Peri odic Maintenance Chart or check that the dust seals and friction boots B are not cracked worn swollen or other wise damaged If they show any damage replace them 13 16 BRAKES Calipers Piston and Cylinder Damage Visually inspect the piston A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scored or rusty Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts A If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature Check to see that the caliper holder shafts are not badly worn or stepped and that the rubber friction boots B are not damaged If the rubber friction boot is damaged replace the rubber friction boot If caliper holder shaft is damaged replace the caliper holder shaft and rubber friction boot as a unit BRAKES 13 17 Brake Pads Brake Pad Removal Detach the c
205. ensor Lead Connector C Digital Volt Meter D Needle Adapters E Special Tool Needle Adapter Set 57001 1457 Connection to Connector 5 V circuit Meter Connector Y G Lead F Meter Connector BK Y Lead G Turn the ignition switch ON and measure the output volt age with the connector joined Vehicle down Sensor Power Output Voltage Standard 0 4 1 4 V with sensor arrow mark pointed up Tilt the sensor 60 70 or more H right or left and mea sure the output voltage The time lag is from 0 5 to 1 second Vehicle down Sensor Power Output Voltage Standard 3 7 4 4 V with sensor tilted 60 70 or more right or left If the output voltage is out of the specified replace the vehicle down sensor ELECTRICAL SYSTEM 17 43 Ignition System Ignition System Troubleshooting 17 44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1 Ignition Switch 2 Reverse Switch 3 Speed Sensor 4 Fuse Box Main Fuse 30 A 5 Multifunction Meter 6 Belt Failure Detection Switch 7 Engine Stop Switch 8 Reverse Power Assist Switch Override 9 Reset Connector 10 Crankshaft Sensor 11 Ignition Coils 12 Spark Plugs 13 Battery 14 Engine Ground Terminal 15 Igniter 16 Vehicle down Sensor ELECTRICAL SYSTEM 17 45 Electric Starter System Starter Motor Removal Remove Air Intake Rubber Duct A Remove Joint Duct A and Collars Remove Starter
206. erminal 15 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Spin a rear wheel as forward rotation After the wheels stop and one second elapses turn OFF the ignition switch After two seconds elapses measure the controller output voltage for the engine brake actuator until the actuator stops Controller Output Voltage to engine brake actuator Standard 5 12 V If the reading is not standard check the forward reverse detecting sensor If the forward reverse detecting sensor is normal replace the actuator controller unit Support the vehicle on a stand or a jack so that the wheels are off the ground Run the engine and shift to the 4WD position Stop the engine and turn OFF the ignition switch Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector W Y Terminal 13 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Shift to the 2WD position Measure the controller output voltage for the 2WD 4WD actuator until the actuator stops Controller Output Voltage to 2WD 4WD actuator Standard 5 12 V If the reading is not standard check the 2
207. eth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear The checking compound must be smooth and firm with the consistency of tooth paste Special compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use one of these for check ing the bevel gears Assemble the front final gear case see Front Final Gear Case Assembly It is not necessary to install the variable front differential control unit Turn the pinion gear shaft A for one revolution in the drive and reverse coast direction while creating a drag on the ring gear Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth 12 50 FINAL DRIVE Front Final Gear Case The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe If the tooth contact pattern is incorrect replace the ring gear shim s following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shim s are replaced Repeat the shim change procedure as nec essary NOTE If the backlash is out of the standard range after changing the ring
208. evel Inspection 12 34 Front Final Gear Case Oil Change 12 34 Variable Differential Control Lever Play Inspection 12 34 Variable Differential Control Lever Play Adjustment 12 34 Variable Differential Control Lever Removal 12 34 Variable Differential Control Lever Installation 12 34 Variable Differential Control Cable Installation 12 35 Variable Differential Control Cable Lubrication 12 35 Variable Differential Control Cable Inspection 12 35 Front Final Gear Case Removal 12 35 Front Final Gear Case Installation 12 36 Front Final Gear Case Disassembly 12 37 Front Final Gear Case Coupling Inspection 12 39 Front Final Gear Case Assembly 12 39 Oil Seal Installation 12 43 Ring Gear Disassembly 12 44 Ring Gear Assembly 12 44 LSD Clutch Torque Inspection 12 45 Pinion Gear Unit Disassembly 12 45 Pinion Gear Unit Assembly 12 46 Front Final Bevel Gear Adjustment 12 46 Bevel Gear Inspection 12 50 Differential Gear Inspection 12 50 Rear P
209. g Remove Tensioner Mounting Bolts A Camshaft Chain Tensioner B Camshaft Chain Tensioner Installation Push the stopper A to release the ratchet and push the push rod B into the tensioner body 5 14 ENGINE TOP END Camshaft Chain Tensioner Tighten Torque Chain Tensioner Mounting Bolts 8 8 N m 0 90 kgf m 78 in lb Install Pin A and Spring B Washer C and Chain Tensioner Cap Bolt D Tighten Torque Chain Tensioner Cap Bolt 22 N m 2 2 kgf m 16 ft lb ENGINE TOP END 5 15 Rocker Case Rocker Case Removal Front Rocker Case Remove Front Fender see Frame chapter Recoil Starter see Recoil Starter chapter Timing Inspection Plug A Special Tool Filler Cap Driver B 57001 1454 Remove Valve Adjusting Caps Using a wrench on the alternator bolt turn the crankshaft counterclockwise until T F mark A is aligned with the notch B in the inspection window and the cam lobes are pointing away from the rocker arms the end of the compression stroke CAUTION Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case The rocker arms could bend the valves Drain the coolant see Coolant Change section in Periodic maintenance chapter Remove Thermostat and Water Pipes see Cooling System chap ter Front and Rear Propeller Shafts see Final Drive chap ter Air Cleaner Housing
210. g Crankpin Diameter Marking Size Color Part Number None Brown 92028 1963 None None Yellow 92028 1962 None Green 92028 1961 Crankshaft Runout TIR 0 04 mm 0 0016 in or less TIR 0 10 mm 0 0039 in Crankshaft Main Journal Diameter 41 984 42 000 mm 1 6529 1 6535 in 41 96 mm 1 652 in Crankshaft Main Bearing Bore Diameter 42 025 42 041 mm 1 6545 1 6552 in 42 08 mm 1 6567 in CRANKSHAFT TRANSMISSION 10 7 Specifications Item Standard Service Limit Transmission Shift fork Ear Thickness 5 9 6 0 mm 0 2322 0 2362 in 5 8 mm 0 228 in Shift Groove Width 6 05 6 15 mm 0 2382 0 2421 in 6 25 mm 0 2460 in 10 8 CRANKSHAFT TRANSMISSION Special Tools and Sealant Outside Circlip Pliers 57001 144 Bearing Driver Set 57001 1129 Crankshaft Jig 57001 1174 CRANKSHAFT TRANSMISSION 10 9 Crankcase Crankcase Disassembly Remove Engine see Engine Removal Installation chapter Starter Motor see Electrical System chapter Oil Filter Recoil Starter Cylinder Blocks and Pistons see Engine Top End chap ter Intermediate Shaft and Chains see Engine Top End chapter Right Crankcase Bolt M6 A Right Crankcase Bolts M8 B Remove Shift Shaft Positioning Bolt A Washer Spring and Steel Ball Left Crankcase Bolts M6 B Left Crankcase Bolts M8 C Wrap the teeth on the sprockets A by taping for protect
211. g agent to the camshaft sprocket bolts C Tighten Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 in lb Cam Wear Remove the camshaft Measure the height A of the cam with a micrometer If the cams are worn past the service limit replace the camshaft Cam Height Standard Exhaust 35 363 35 477 mm 1 3922 1 3967 in Inlet 35 622 35 736 mm 1 4024 1 4069 in Service Limit Exhaust 35 26 mm 1 388 in Inlet 35 52 mm 1 398 in 5 22 ENGINE TOP END Camshaft Camshaft Bearing Wear The journal wear is measured using plastigage press gauge which is inserted into the clearance to be mea sured The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled Cut strips of plastigage to journal width Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case Install the rocker case tightening the bolts in the correct sequence to the specified torque see Rocker Case In stallation NOTE Do not turn the camshaft when the plastigage is be tween the journal and rocker case Remove the rocker case and measure the plastigage width A to determine the clearance between the journal and the rocker case Measure the widest portion of the plastigage Camshaft Bearing Clearance 1
212. g the adjusting screw check for dirt or blockage and then check the pilot screw settings Special Tool Pilot Screw Adjuster A 57001 1239 Check the carburetor synchronization again NOTE Do not turn the pilot screws carelessly during carburetor synchronization You may cause poor running at low engine speed Check idle speed Fuel System Cleanliness Inspection Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter Carburetor Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 3 16 FUEL SYSTEM Carburetor Remove Air Cleaner Housing see Air Cleaner Housing Removal Drain the fuel from the carburetors Remove Fuel Hose A Heater and Ground Lead Connectors B Remove Screws A and Throttle Link Case Cover B Remove Locknut A Throttle Cable Lower End B Loosen the carburetor clamp screws C Remove the carburetor out of the frame Remove Screw A Holder Plate B Remove Starter Plunger A FUEL SYSTEM 3 17 Carburetor Remove Screw A Holder Plate B Starter Plunger Carburetor Installation Confirm the groove of the carburetor holder A fits on the projection B of the cylinder he
213. gent Torque Fastener N m kgf m ft lb Remarks Engine Mounting Bolt 62 6 3 46 Engine Mounting Nut 62 6 3 46 Crankshaft Transmission Connecting Rod Big End Cap Nuts 34 3 5 25 MO Engine Drain Plug 20 2 0 14 Crankcase Bolts M8 75 mm 2 95 in 20 2 0 14 S Crankcase Bolts M8 110 mm 4 33 in 20 2 0 14 S Crankcase Bolt M8 110 mm 4 33 in 20 2 0 14 S L 1 Crankcase Bolts M6 40 mm 1 57 in 9 8 1 0 87 in lb Crankcase Bolts M6 65 mm 2 56 in 9 8 1 0 87 in lb Bearing Position Plate Screws 4 9 0 50 43 in lb L Grip Hold Nut 9 8 1 0 87 in lb Shift Lever Assembly Bracket Bolts 20 2 0 14 Tie rod End Front Locknut 9 8 1 0 87 in lb Lh Tie Rod End Rear Locknut 9 8 1 0 87 in lb Tie rod End Nut 20 2 0 14 Shift Lever Assembly Nut 20 2 0 14 Tie rod End Bolt 9 8 1 0 87 in lb Shift Shaft Positioning Bolt 25 2 5 18 Shift Shaft Spring Bolt 25 2 5 18 L Shift Shaft Cover Bolts 8 8 0 90 78 in lb Tie rod End Locknut 20 2 0 14 Neutral Position Switch 15 1 5 11 Reverse Position Switch 15 1 5 11 Wheel Tires Tie rod Locknuts 37 3 8 27 Tie rod End Nuts 42 4 3 31 Wheel Nuts First Torque 15 1 5 11 S Wheel Nuts Final Torque 76 7 8 56 S Front Axle Nuts 197 20 145 Rear Axle Nuts 265 27 195 Final Drive Output Bevel Gears Output Driven Bevel Gear Housing Bolts 26 2 7 20 Output
214. gnition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE This note symbol indicates points of par ticular interest for more efficient and con venient operation Indicates a procedural step or work to be done Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 1 General Information Table of Contents Before Servicing
215. gth Standard 149 33 150 47 mm 5 879 5 924 in Remove the trim seal Install the actuator lever measurement tool plate A and rods B on the torque converter cover C and tighten the two cover bolts Special Tool Actuator Lever Measurement Tool 57001 1499 Set the rod ends on the resin tips D Measure the recess length E between the plate and rods with Vernier calipers F or depth gauge Measurement Length E Standard 1 33 2 47 mm 0 052 0 097 in If the measurement is less than 1 33 mm 0 052 in use the actuator lever assembly 13236 0046 of yellow paint If the measurement is more than 2 47 mm 0 097 in use the actuator lever assembly 13236 0047 of green paint If the length is not within the specified length after the actuator lever assembly is replaced replace the torque converter cover and install the actuator lever assembly 13236 0048 6 12 CONVERTER SYSTEM Torque Converter Actuator Lever Assemblies Part Number Paint Color A Length B 13236 0046 Yellow 0 4 0 1 mm 0 016 0 004 in 13236 0048 None 1 0 0 1 mm 0 039 0 004 in 13236 0047 Green 1 6 0 1 mm 0 063 0 004 in CONVERTER SYSTEM 6 13 Drive Belt Drive Belt Removal Remove the drive pulley A see Drive Pulley Removal NOTE Before removing observe the direction the belt s printed information A such as manufacturer s name is facing so that it may be rei
216. h is suspected of being a problem Connect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 Set the tester to the 1 range If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary 17 20 ELECTRICAL SYSTEM Battery Battery Removal Turn off the ignition switch Remove Seat see Frame chapter Battery Holder Bolts A and Collars Battery Holder B Disconnect the battery negative cable C first and then the positive cable D Take out the battery E Battery Installation Turn off the ignition switch Install Rubber Dampers A Clamp Nut B Connect the positive cable first and then the negative Put a light coat of grease on the terminals to prevent cor rosion Install Battery Holder C Collars D Battery Holder Bolts E Battery Activation Electrolyte Filling Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name for KVF750 A1 KMX 14 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance ELECTRICAL SYSTEM 17 2
217. h Steel Plates B and Friction plates C Remove Brake Cam Plate A Brake Camshaft B and Spring Remove Steel Balls A 12 64 FINAL DRIVE Rear Final Gear Case Remove Pinion Gear Bearing Holder A Hold the rear final gear case A in a vise and remove the bearing holder using the socket wrench B Special Tool Socket Wrench Hex 50 57001 1478 If the holder seems too difficult to break free apply heat to softer the locking agent Remove Pinion Gear Unit A Shim s B Drill out the spring pin A with a drill bit of the 3 mm 0 12 in diameter and remove it Remove the needle bearing B Rear Final Gear Case Assembly A Rear Final Gear Case Press Ball Bearing B until bottomed Oil Seal C until bottomed Special Tool Bearing Driver Set 57001 1129 Apply Grease Oil Seal Lip Press the face of the needle bearing D is flush with the end of the housing Insert the spring pin E FINAL DRIVE 12 65 Rear Final Gear Case Rear Final Gear Case Right Cover Assembly A Rear Final Gear Case Right Cover Press Ball Bearing until bottomed Special Tool Bearing Driver 54 3 B 57001 1488 A Rear Final Gear Case Right Cover B Ball Bearing Press Oil Seal C until bottomed Special Tool Bearing Driver Set 57001 1129 Apply Grease Oil Seal Lips D Rear Final Gear Case Front Cover Assembly A Rear Final Gear Case Fr
218. han the punch mark E F Front Carburetor G Rear Carburetor Run the engine at idle speed Loosen the carburetor drain screw Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 Wait until the fuel level in the gauge settles Hold the gauge vertically and lower it slowly so that the additional graduation aligns with punch mark NOTE Do not align the additional graduation on the gauge lower than the punch mark If it is lowered and then raised the gauge will show a fluid level that is higher than the actual level which will require a remeasure ment Read the fuel level H If the fuel level is incorrect adjust it Fuel Level Standard Front 20 4 1 mm 0 80 0 04 in below the punch mark Rear 19 5 1 mm 0 77 0 04 in below the punch mark Stop the engine Tighten the drain screw Repeat the same procedure for the other carburetor 3 14 FUEL SYSTEM Carburetor Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch to OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the carburetors and drain the fuel Remove the float chamber Remove the screw A Slide out the pivot pin B and remove the float C Bend the tang A on the float arm ve
219. he armature has a short Replace the starter motor NOTE Even if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one ELECTRICAL SYSTEM 17 49 Electric Starter System Starter Motor Brush Length Measure the overall length A of each brush Starter Motor Brush Length Standard 12 5 mm 0 49 in Service Limit 5 mm 0 20 in If any is worn down to the service limit replace the brush plate assembly Brush Assembly Inspection Using the 1 range measure the resistance as shown A Terminal Bolt and Positive Brush B Brush Plate and Negative Brush If there is not close to zero ohms the brush lead has an open Replace the brush plate assembly Brush Plate and Terminal Bolt Inspection Using the highest range measure the resistance as fol lows A Terminal Bolt and Right Hand End Cover B Terminal Bolt and Brush Plate If there is any reading the brush holder assembly has a short Replace the brush plate assembly Starter Relay Inspection Remove Seat see Frame chapter Starter Relay A Connect the hand tester A and a 12 V battery B to the starter relay as shown If the relay does not work as specified the re
220. he battery is fully charged Vehicle down Sensor Power Source Voltage Remove Seat see Frame chapter Vehicle down Sensor Lead Connector Connect Vehicle down Sensor Lead Connector A harness side Digital Volt Meter B I Connections to Connector 12 V circuit Meter Connector BR Lead C Meter Connector BK Y Lead D Turn the ignition switch ON and measure the power source voltage Vehicle down Sensor Power Source Voltage Standard Battery Voltage Turn the ignition switch OFF If there is no battery voltage check the following Main Fuse 30 A Ignition Switch Wiring for Vehicle down Sensor Power Source 17 42 ELECTRICAL SYSTEM Ignition System II Connections to Connector 5 V circuit Vehicle down Sensor Lead Connector A harness side Digital Volt Meter B Meter Connector Y G Lead E Meter Connector BK Y Lead D Turn the ignition switch ON and measure the power source voltage Vehicle down Sensor Power Source Voltage Standard about 5 V Turn the ignition switch OFF If there is no standard voltage check the following Igniter Wiring for Vehicle down Sensor Power Source Vehicle down Sensor Output Voltage Remove the vehicle down sensor see Vehicle down Sensor Removal Connect the vehicle down sensor A to the connector of the harness Hold the sensor almost vertical B with the arrow mark pointed up Connect Vehicle down S
221. he brake lever in the same manner as above Tighten Torque Bleed Valves 5 4 N m 0 55 kgf m 48 in lb Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings 13 10 BRAKES Master Cylinder Master Cylinder Removal Remove Brake Hose Banjo Bolt A Master Cylinder Clamp Bolts B Master Cylinder C CAUTION Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Master Cylinder Installation Align the punch mark A on the handlebar with the mating surface end of the master cylinder clamp The master cylinder clamp must be installed with the UP mark A upwards Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 9 0 N m 0 92 kgf m 80 in lb Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb Bleed the brake line after master cylinder installation see Brake Line Air Bleeding Check the brake for good braking power no braking brag and no fluid leakage WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application
222. he rubber dampers A on the frame as shown If the dampers are damaged or deteriorated replace them Install the fuel tank with case and tighten the bolts Check the damper A on the damper bracket B If the damper is damaged or deteriorated replace it Tighten the damper bracket bolt Install the check valve so that the arrow A faces fuel tank B Black Color C Blue Color Install Hose A Clamps B 3 30 FUEL SYSTEM Fuel Tank Install Vacuum Hose A and Clamp B Fuel Level Sensor Lead Connector Install the removed parts Fuel Tank Cleaning Remove the fuel tank and drain it see Fuel Tank Re moval Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits WARNING Clean the tank in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank A fire or explosion could result Pour the solvent out the tank Dry the tank with compressed air Install the fuel tank see Fuel Tank Installation Fuel Tap Removal Remove Fuel Pump see Fuel Pump Removal Fuel Tap Mounting Bolts A Vacuum Hose B Fuel Tap C Fuel Tap Installation Be sure the O ring A is in good condition to prevent leak age
223. heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings Oil seals Grease seals circlips or cot
224. heel With the front wheels on the ground set the handlebar straight ahead At the level of the axle height measure the distance be tween the scribed or painted lines for both front and rear of the front tires Subtract the measurement of the front from the measure ment of the rear to get the toe in If the toe in is not in the specified range go on to the Toe in Adjustment procedure Toe in of Front Wheels Standard 10 10 mm 0 39 0 39 in at 1G Toe in Adjustment Loosen the locknuts A B and turn the tie rod C the same number of turns on both sides to achieve the spec ified toe in NOTE The locknut B near the L mark D on the tie rod has left hand threads Turn the locknut clockwise for loos ening 11 8 WHEELS TIRES Wheel Alignment NOTE The toe in will be near the specified value if the tie rod length A is 393 3 mm 15 48 in on each tie rod CAUTION Adjust the tie rod length so that the visible thread length B is even on both ends of the tie rod Un even thread length could cause tie rod damage Check the toe in Tighten Torque Tie rod Locknuts 37 N m 3 8 kgf m 27 ft lb Test ride the vehicle WHEELS TIRES 11 9 Wheels Rims Wheel Removal Loosen the wheel nuts A Support the vehicle on a stand or a jack so that the wheels are off the ground Special Tool Jack 57001 1238 Remove Wheel Nuts Wheel Wheel Insta
225. hicle which had an ordinary battery as original equipment the sealed battery s life will be shortened 17 24 ELECTRICAL SYSTEM Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage Remove the battery see Battery Removal CAUTION Be sure to disconnect the negative lead first Measure the battery terminal voltage NOTE Measure with a digital voltmeter A which can be read to one decimal place voltage If the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 8 V or more Refreshing Charge Remove the battery A see Battery Removal Refresh charge by following method according to the bat tery terminal voltage WARNING This battery is sealed type Never remove seal sheet B even at charging Never add water Charge with current and time as stated below Terminal Voltage 11 5 less than 12 5 V Standard Charge 1 2 A 5 10 h see following chart Quick Charge 6 0 A 1 0 h CAUTION If possible do not quick charge If the quick charge is done due to unavoidable circumstances do the standard charge later on Terminal Voltage less than 11 5 V Charging Method 1 2 A 20 h ELECTRICAL SYSTEM 17 25 Battery NOTE Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more tha
226. ial Tools Socket Wrench B 57001 1363 Pinion Gear Holder C 57001 1281 Torque Pinion Gear Bearing Holder Nut 157 N m 16 kgf m 116 ft lb FINAL DRIVE 12 73 Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close toler ances the clearance cannot normally be measured CAUTION Do not remove any bearings for inspection except the right rear axle bearing Turn each bearing in the case or hub back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing Check the needle bearings A The rollers in the needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage If the bearing is damaged replace the bearing 12 74 FINAL DRIVE Bearing and Oil Seal Oil Seal Inspection Inspect the oil seals A Replace any if the lips are misshapen discolored indicat ing that the rubber has deteriorated hardened or been otherwise damaged BRAKES 13 1 13 Brakes Table of Contents Exploded View 13 2 Specifications 13 6 Special Tool 13 7 Brake Fluid 13 8 Brake Fluid Recommendation 13 8 Brake Fluid Level Inspection
227. iameter of Band 80 2 mm 3 16 in After tightening the outside diameter Inboard Joint Boot Removal Remove Rear Axle see Rear Axle Removal Boot Bands A Scrap the removed boot bands Slide the joint boot toward the outboard joint Remove the retaining ring A Separate to the axle shaft Remove the steel balls A Slide the cage B toward the outboard joint 12 58 FINAL DRIVE Rear Axle Remove Circlip A Special Tool Outside Circlip Pliers B 57001 144 Remove Inner Race A Cage B Inboard Joint Boot C Boot Band D Inboard Joint Boot Installation Install New Small Band A New Inboard Joint Boot B Cage C Install the inner race A so that the flat side B faces outboard joint Install Circlip A Special Tool Outside Circlip Pliers 57001 144 Slide the cage B on the inner race and install the steel balls C FINAL DRIVE 12 59 Rear Axle Apply the special grease A to the steel balls and cage Squeeze about half a tube 30 grams of the special grease A into the bearing cup B Insert the balls and cage assembly in the bearing cup strongly Install the new retaining ring A so that the opening B is aligned with one of the projections C Tighten the small band Squeeze the remaining special grease A into the inboard joint boot B 12 60 FINAL DRIVE Rear Axle Compress the axl
228. ighten the clamp screws Install Dust Seal A Air Cleaner Housing Cover B C Inside Install the air cleaner housing and joint duct on the carbu retor Install Breather Hose and Clamp Carburetor Breather Tank Fit the joint duct on the fitting of the carburetor securely and tighten the clamp screws Tighten the air cleaner housing bolts Install the spark arrester A so that the swelling faces upward FUEL SYSTEM 3 27 Air Cleaner Apply the soap and water solution over the trim seal A Install Element Holder Tighten Torque Element Holder Screws 3 5 N m 0 35 kgf m 31 in lb Install Element see Air Cleaner Element Installation 3 28 FUEL SYSTEM Fuel Tank Fuel Tank Removal Remove Electrical Parts Case see Frame chapter Rear Fender see Frame chapter Storage Case A Optional Part Check Valve Hose B Remove Two Right Footboard Bolts A Insert a thin driver A in the clamp B to clear its stopper and slide the clamp forward Move the main harness A inside as shown Remove Fuel Level Sensor Lead Connector B Vacuum Hose C Fuel Hose D Bolts E Damper Bracket Bolt F Damper Bracket G Remove Fuel Tank A with Tank Case B FUEL SYSTEM 3 29 Fuel Tank Fuel Tank Installation Check the insulators A on the tank case If the insulators are damaged or deteriorated replace them Check t
229. il Pipe Bolt A Oil Pipe B Engine Inside Oil Pipe Remove Cylinder Head see Engine Top End chapter Oil Pipe A Oil Pipe Installation Replace the O ring A with new ones if they are damaged Apply engine oil to the O rings before installation Tighten Torque Oil Pipe Bolts 8 8 N m 0 90 kgf m 78 in lb ENGINE REMOVAL INSTALLATION 9 1 9 Engine Removal Installation Table of Contents Exploded View 9 2 Engine Removal Installation 9 4 Engine Removal 9 4 Engine Installation 9 5 9 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 9 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Engine Bracket Mounting Bolts 72 7 3 53 2 Engine Mounting Bolts 62 6 3 46 3 Engine Mounting Nut 62 6 3 46 9 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Removal Remove Engine Oil drain Coolant drain Muffler and Exhaust Pipe see Engine Top End chapter Footboards see Frame chapter Carb
230. imit 39 97 mm 1 5736 in If the crankpin has worn past the service limit replace the crankshaft with a new one 10 16 CRANKSHAFT TRANSMISSION Crankshaft Connection Rod If the measured crankpin diameter A is not less than the service limit but does not coincide with the original diameter marking on the crankshaft make a new mark on it Crankpin Diameter Marks None 39 984 39 992 mm 1 5742 1 57449 in 39 993 40 000 mm 1 57452 1 5748 in Crankpin Diameter Mark B mark or no mark Measure the connection rod big end inside diameter and mark each connecting rod big end in accordance with the inside diameter Tighten the big end nuts to the specified torque Torque Connecting Rod Big End Cap Nuts 34 N m 3 5 kgf m 25 ft lb NOTE The mark already on the big end should almost coincide with the measurement because of little wear Connecting Rod Big End Inside Diameter Marks None 43 000 43 008 mm 1 6929 1 69323 in 43 009 43 016 mm 1 69326 1 6935 in Diameter Mark A or no mark Select the proper bearing insert A in accordance with the combination of the connecting rod and crankshaft coding Size Color B Big End Bearing Insert Selection Bearing Insert Con rod Big End Bore Diameter Mark Crankpin Diameter Mark Size Color Part Number None Brown 92028 1963 None None Yellow 92028 1962 None Green 92028 1
231. in a vise Special Tool Holder amp Guide Arbor 57001 1476 Remove Bearing Holder C Special Tool Socket Wrench Hex 50 D 57001 1478 If the holder seems too difficult to break free apply heat to softer the locking agent Remove Ball Bearing Special Tool Oil Seal amp Bearing Remover 57001 1058 Remove the output driven bevel gear A from the output shaft B using the bearing puller C and spacer D Special Tools Bearing Puller 57001 135 Output Shaft Holder amp Spacer m1 25 57001 1479 Output Driven Bevel Gear Assembly Press the new ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 Hold the housing assembly A with the holder B in a vise Special Tool Holder amp Guide Arbor 57001 1476 12 20 FINAL DRIVE Output Bevel Gears Apply a non permanent locking agent to the threads of the bearing holder A and tighten it Special Tool Socket Wrench Hex 50 B 57001 1478 Torque Bearing Holder 137 N m 14 kgf m 101 ft lb Hold the holder A in a vise and set the output shaft B on the holder Special Tool Output Shaft Holder 57001 1570 Press the output driven bevel gear C using the driver D until it is bottomed Special Tool Steering Stem Bearing Driver 57001 137 Press the housing assembly A using the driver B until it is bottomed Special Tool Steering Stem Bearing Driver 57001 1
232. inder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 015 0 042 mm 0 0006 0 0017 in 5 42 ENGINE TOP END Cylinder and Piston Piston Ring Piston Ring Groove Wear Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 04 0 08 mm 0 0016 0 0032 in Second 0 03 0 07 mm 0 0012 0 0028 in Service Limit Top 0 18 mm 0 0071 in Second 0 17 mm 0 0067 in If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Piston Ring Groove Width Measure the piston ring groove width Use a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top 1 03 1 05 mm 0 0405 0 0413 in Second 1 02 1 04 mm 0 0402 0 0409 in Service Limit Top 1 13 mm 0 0445 in Second 1 12 mm 0 0441 in If the width of any of the two grooves is wider than the service limit at any point replace the piston Piston Ring Thickness Measure the piston ring thick
233. ing Diagram ELECTRICAL SYSTEM 17 15 Wiring Diagram 17 16 ELECTRICAL SYSTEM Special Tools Timing Light 57001 1241 Flywheel Holder 57001 1313 Hand Tester 57001 1394 Flywheel Puller Assembly M38 1 5 M35 1 5 57001 1405 Peak Volt Adapter 57001 1415 Needle Adapter Set 57001 1457 Drive Pulley Holder 57001 1520 ELECTRICAL SYSTEM 17 17 Precautions There are a number of important precautions that should be taken when servicing electrical systems Learn and ob serve all the rules below Do not reverse the battery lead connections This will burn out the diodes in the electrical parts Always check battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system tests The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them To prevent damaging 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 Because of the high current never keep the starter button depressed when the starter motor will not turn over or the current may burn out the starter motor windings Only use an illumination bulb rated for the voltage or wattage specified in the wiring diagram or the handle cover could be warped by excessive heat ra
234. ing a torque wrench A Turn the wrench evenly The clutch torque is the mean torque reading during about a quarter turn of the wrench LSD Clutch Torque When variable differential control lever is released Standard 15 20 N m 1 5 2 0 kgf m 11 14 ft lb LSD Clutch Torque When variable differential control lever is pulled in Standard 157 N m 16 kgf m 116 ft lb or more If the clutch torque is out of the specified range check the width of the disc assembly see Front Final Gear Case Assembly NOTE The correct type of oil must be installed Pinion Gear Unit Disassembly Remove Pinion Gear Unit see Front Final Gear Case Disassem bly Pry open the staking of the pinion gear bearing holder nut with a small chisel Hold the pinion gear unit A with the pinion gear holder B in a vise and remove the pinion gear bearing holder nut C Special Tool Pinion Gear Holder m1 0 57001 1485 Remove the ball bearing only if required Special Tool Bearing Puller 57001 135 12 46 FINAL DRIVE Front Final Gear Case Pinion Gear Unit Assembly The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact They must be re placed as a set Visually inspect the bearing for abrasion color change or other damage If there is any doubt as to the condition of a bearing re place the bearing Be sure to check and adjust the bevel gear backl
235. ing agent to the camshaft sprocket bolts C and tighten them Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 in lb Camshaft Chain Removal Remove left side view Rear and Front Camshafts see Camshaft Removal Alternator Rotor see Electrical System chapter Oil Pump see Engine Lubrication System chapter Intermediate Shaft Chain Tensioner A Circlip B and Washer Special Tool Outside Circlip Pliers 57001 144 Remove Intermediate Shaft Chain Guides C Position Plate Bolts D and Position Plate ENGINE TOP END 5 25 Camshaft Remove right side view Torque Converter see Converter System chapter Using a M6 bolt A pull out the cover B Remove left side view Circlip A Special Tool Outside Circlip Pliers 57001 144 Remove Intermediate Shaft Sprocket B Intermediate Shaft Drive Chain C Rear Camshaft Chain D Front Camshaft Chain right side Camshaft Chain Installation Rear Camshaft Chain Align the key grooves A on the crankshaft with the em bossed line B on the crankcase left side view Face the arrow A of the rear camshaft sprocket upward Align the marks B on the weights with the rear cylinder head upper surface C Place the rear camshaft chain D onto the rear camshaft sprocket Engage the camshaft and intermediate shaft chains on the intermediate shaft sprocket A and insert the inter mediate shaft left side view
236. ip Pliers 57001 143 Outside Circlip Pliers 57001 144 Oil Seal amp Bearing Remover 57001 1058 Bearing Driver Set 57001 1129 Rotor Puller M16 M18 M20 M22 1 5 57001 1216 Pinion Gear Holder 57001 1281 Socket Wrench 57001 1363 Holder amp Guide Arbor 57001 1476 12 12 FINAL DRIVE Special Tools Socket Wrench Hex 50 57001 1478 Output Shaft Holder amp Spacer m1 25 57001 1479 Nut Holding Bolts 57001 1481 Socket Wench 57001 1482 Socket Wrench Hex 41 57001 1484 Pinion Gear Holder m1 0 57001 1485 Bearing Driver 54 3 57001 1488 Gear Holder amp Socket Wrench Hex 24 57001 1489 Hexagon Wench Hex 41 57001 1491 Oil Seal Driver 18 5 57001 1505 FINAL DRIVE 12 13 Special Tools Oil Seal Driver 70 57001 1506 Output Shaft Holder 57001 1570 12 14 FINAL DRIVE Output Bevel Gears Output Drive Bevel Gear Removal Remove Oil Pipe A Engine Left and Outside see Engine Lubri cation System chapter Output Drive Bevel Gear Cover Bolts B Output Drive Bevel Gear Cover C Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 Remove Output Drive Idle Gear B Remove Output Drive Bevel Gear Housing Bolts A Output Drive Bevel Gear Housing B Output Drive Bevel Gear Installation Install the output drive bevel gear housing Tighten Torque Output Drive Bevel Gear Housing Bolts 26 N m 2 7 kgf m 2
237. ith water or coolant to prevent pressure leakage Watching the pressure gauge slowly pump the pressure tester to build up the pressure The relief valve opens indicated by the gauge hand flicks downward The relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 14 18 psi If the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one 4 16 COOLING SYSTEM Thermostat Thermostat Removal Drain the coolant see Coolant Change in Periodic Main tenance chapter Remove Side Cover see Frame chapter Coolant Temperature Warning Light Switch Lead Con nector A Water Pipe Bolt B Remove Thermostat Housing Cover Bolts A Thermostat Housing Cover B Thermostat Thermostat Installation Install Thermostat A Be sure to install the O ring B on the housing cover Tighten Torque Thermostat Housing Cover Bolts 8 8 N m 0 90 kgf m 78 in lb Water Pipe Mounting Bolt 8 8 N m 0 90 kgf m 78 in lb Add coolant see Coolant Change in Periodic Mainte nance chapter Thermostat Inspection Remove the thermostat and inspect the thermostat valve A at room temperature If the valve is open replace the valve with a new one COOLING SYSTEM 4 17 Thermost
238. ition Coil D Air Temperature Sensor E Spark Plug Cap A Spark Plug B Crankshaft Sensor C Reverse Position Switch D Neutral Position Switch E Starter Motor F Oil Pressure Warning Light Switch G Alternator H Forward Reverse Detecting Sensor I 17 4 ELECTRICAL SYSTEM Parts Location Frame Ground Lead A Water Temperature Switch B 2WD 4WD Actuator C Engine Brake Actuator D Spark Plug A Engine Ground Lead B Ignition Coil C Frame Ground Lead D Rear Brake Light Switch E Speed Sensor F Drive Belt Failure Detection Switch G Engine Brake Actuator H Regulator Rectifier A ELECTRICAL SYSTEM 17 5 Parts Location Multifunction Meter A SET RESET Button B Belt Check Indicator Light C Neutral Indicator Light D Reverse Indicator Light E Oil Pressure Warning Indicator Light F 4WD Indicator Light G 2WD Indicator Light H Coolant Temperature Warning Symbol I Fuel Level Gauge J TIME SET Button K Clock L Speedometer M Trip Meter Odometer Hour Meter N MODE Button O 17 6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 17 7 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Starter Motor Mounting Bolts 8 8 0 90 78 in lb 2 Starter Motor Terminal Nut 4 9 0 50 43 in lb 3 Starter Motor Terminal Locknut 6 9 0 70 61 in lb 4 Starter Motor Bolts 4 9 0 50 43 in lb 5 Starter Motor Cl
239. ition Switch 15 1 5 11 Reverse Position Switch 15 1 5 11 Ignition Coil Mounting Bolts 8 8 0 90 78 in lb 2 10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Radiator Fan Switch 18 1 8 13 Coolant Temperature Warning Light Switch 6 9 0 70 61 in lb SS Oil Pressure Switch 15 1 5 11 SS Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb Regulator Rectifier Mounting Bolts 8 8 0 90 78 in lb Fuel Level Sensor Mounting Bolts 2 0 0 20 18 in lb The tables below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners of Engine Parts Threads dia Mark of Torque mm in bolt head N m kgf m ft lb 6 0 24 9T 12 15 1 2 1 5 104 130 in lb 6 0 24 7T 7 8 9 8 0 8 1 0 69 87 in lb 6 0 24 4T 3 9 4 9 0 4 0 5 35 43 in lb 8 0 31 7T 18 22 1 8 2 2 13 16 8 0 31 4T 10 14 1 0 1 4 87 122 in lb 10 0 39 7T 39 44 4 0 4 5 29 33 10 0 39 4T 20 24 2 0 2 4 14 17 5 0 20 4T 2 2 2 6 0 22 0 27 19 23 in lb Basic Torque for General Fasteners of Frame Parts Threads dia Torque mm in N
240. l ring with your thumbs in the same manner Cylinder Piston Installation NOTE If a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston rings 5 40 ENGINE TOP END Cylinder and Piston NOTE The oil ring rails have no top or bottom Install the oil ring expander A in the bottom piston ring groove so the ends B butt together Install the oil ring steel rails one above the expander and one below it Spread the rail with your thumbs but only enough to fit the rail over the piston Release the rail into the bottom piston ring groove Do not mix up the top ring and second ring Install the top ring A so that the R mark B faces up Install the second ring C so that the RN mark D faces up The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 F of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails C Oil Ring Expander D F mark E must be faced toward Front Side for front and rear pistons Opening Positions G Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole When installing the piston pin snap ring compress it only enough to install it and no more Apply engine
241. ladjusted Rear final gear case Damaged side gears or pinions Front final gear case Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Rear brake noise Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc not properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level too high Black Smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Damaged steering knuckle joint Damage tie rod end LSD clutch maladjusted front final gear case Noise when turning Damaged side gear or pinion front final gear case Worn LSD clutch friction plates Front final gear case Handlebar shakes or excessively vibrates Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem clamp bolt loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm be
242. lay is defec tive Replace the relay Testing Relay Hand Tester Range 1 range Criteria When battery is connected 0 When battery is disconnected 17 50 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection Remove Seat see Frame chapter Starter Circuit Relay A Brake Switch Circuit Starter Circuit Relay B Neutral Switch Circuit The starter circuit relays for the brake and neutral switch circuits are identical Connect the hand tester A and a 12 V battery B to the starter circuit relay C as shown If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range 1 Criteria When battery is connected 0 When battery is disconnected Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 ELECTRICAL SYSTEM 17 51 Electric Starter System Electric Starter Circuit 1 Starter Button 2 Engine Stop Switch 3 Parking Brake Light Switch 4 Front Brake Light Switch 5 Rear Brake Light Switch 6 Main Fuse 30 A 7 Starter Circuit Relay Brake 8 Reset Connector 9 Ignition Switch 10 Starter Motor 11 Starter Relay 12 Battery 13 Engine Ground Terminal 14 Starter Circuit Relay Neutral 15 Neutral Switch 17 52 ELECTRICAL SYSTEM Electric Starter System Starter Motor Clutch Removal Remove the alternator rotor see Alternator Rotor Re mov
243. lb Radiator Fan Switch 18 1 8 13 Radiator Fan Assembly Bolts 4 9 0 50 43 in lb Thermostat Housing Cover Bolts 8 8 0 90 78 in lb Coolant Temperature Warning Light Switch 6 9 0 70 61 in lb SS Air Bleeder Bolt 8 8 0 90 78 in lb Water Pump Cover Bolts 8 8 0 90 78 in lb Coolant Drain Plug 8 8 0 90 78 in lb Water Pump Impeller 7 8 0 80 69 in lb Water Pipe Mounting Bolts 8 8 0 90 78 in lb Engine Top End Rocker Case Bolts 55 mm 2 2 in 8 8 0 90 78 in lb S Rocker Case Bolts 130 mm 5 1 in 9 8 1 0 87 in lb S Rocker Case Bolts 30 mm 1 2 in 9 8 1 0 87 in lb S Rocker Case Bolts 25 mm 1 0 in 9 8 1 0 87 in lb S Cylinder Head Bolts M10 first torque 25 2 5 18 S MO Cylinder Head Bolts M10 final torque 49 5 0 36 S Cylinder Head Bolts M6 9 8 1 0 87 in lb 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Valve Adjusting Cap Bolts 8 8 0 90 78 in lb Water Pipe Mounting Bolts 8 8 0 90 78 in lb Rocker Shaft Bolts 20 2 0 14 Valve Adjusting Screw Locknuts 12 1 2 104 in lb Chain Tensioner Mounting Bolts 8 8 0 90 78 in lb Chain Tensioner Cap Bolt 22 2 2 16 Position Plate Bolts 8 8 0 90 78 in lb Intermediate Shaft Chain Guide Bolts 8 8 0 90 78 in lb Intermediate Shaft Chain Tensioner Bolts 8 8 0 90 78 in lb Camshaft Splocket Bolts 12 1 2 104 in lb
244. ling per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Non Permanent Locking Agent clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent Do not apply them excessively Exces sive application can clog oil passages and cause serious damage GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to
245. llation Check the tire rotation mark A on the tire and install the wheel accordingly NOTE The direction of the tire rotation B is shown by an arrow on the tire sidewall Position the wheel so that the air valve A is toward the outside of the vehicle Wipe dry the taper surface of the rim Wipe dry the threads and the taper surface of the nuts First tighten the wheel nuts in a criss cross pattern First Torque Wheel Nuts 15 N m 1 5 kgf m 11 ft lb Finally tighten the wheel nuts in a criss cross pattern Final Torque Wheel Nuts 76 N m 7 8 kgf m 56 ft lb NOTE The nuts are the self locking type and must be replaced when they are worn and can be turned by hand after repeated removing and installing Wheel Rim Inspection Examine both sides of the rim for dents A If the rim is dented replace it 11 10 WHEELS TIRES Wheels Rims If the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing sur faces with fine emery cloth if necessary Wheel Rim Replacement Remove the wheel see Wheel Removal Disassemble the tire from the rim see Tire Removal Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve Plastic Cap A Valve Core B Stem Seal C Valve Stem D Valve Seat E Valve Opened F Install a new air valve
246. llow the engine to idle for several minutes so that oil may reach all parts of the engine Racing a dry engine may cause severe damage Stop the engine and wait several minutes for all the oil to drain back to the sump Unscrew the oil filler cap A wipe its dipstick B dry and tighten it into the filler opening Unscrew the oil filler cap and check the oil level The oil level should be between the upper H and lower L level lines C If the level is too high suck the excess oil out the filler hole with a syringe or other suitable device If the level is too low add oil through the filler hole Use the same type and make of oil that is already in the engine Engine Oil Change Refer to the Engine Oil Change in the Periodic Mainte nance chapter Oil Filter Change Refer to the Oil Filter Change in the Periodic Maintenance chapter Oil Screen Removal Split the crankcase see Crankshaft Transmission chap ter Pull the oil screen A out of the crankcase 8 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning Clean the oil screen A thoroughly whenever it is removed for any reason Clean the oil screen with a high flash point solvent and remove any particles stuck to it WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use
247. lot Jet 8 Main Jet 9 Needle Jet 10 Pilot Screw 11 Priming Pump 12 Air Temperature Sensor G Apply grease O Apply engine oil CA Canada Model 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Element Cover Screw 3 5 0 35 31 in lb 2 Element Holder Screws 3 5 0 35 31 in lb 3 Clamp Bracket Bolt 9 8 1 0 87 in lb 4 Fuel Pump Mounting Nuts 7 8 0 80 69 in lb 5 Fuel Tap Plate Screws 0 8 0 08 7 in lb 6 Fuel Tap Mounting Bolts 4 9 0 50 43 in lb 7 Fuel Tap Cover Screws 9 8 1 0 87 in lb 8 Fuel Tap Bracket Bolts 7 8 0 80 69 in lb 9 Fuel Level Sensor Mounting Bolts 2 0 0 20 18 in lb 10 Fuel Pump 11 Insert the fuel breather tube end into the hole of the right frame AD Apply adhesive agent G Apply grease R Replacement Part W Apply water or soap and water solution 3 6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Case and Cable Throttle Lever Free Play 2 3 mm 0 08 0 12 in Choke Lever and Cable Choke Lever Free Play about 3 mm 0 12 in Carburetor Make Type KEIHIN CVKR 34 Main Jet Front 152 Rear 158 Main Air Jet 70 Needle Jet 6 Jet Needle Front NFKK Rear NFKL Pilot Jet 38 Pilot
248. lt Indicator Light LED 3 Water Temperature Sensor 4 2WD 4WD LCD Indicator 5 Fuel Gauge Fuel Indicator LCD Segments 6 Meter Illumination 7 Reverse Indicator Light LED 8 Neutral Indicator Light LED 9 Ignition 10 Battery 11 Oil Pressure Warning Indicator Light LED 12 Battery LED Light Emitting Diode LCD Liquid Crystal Display Check 1 LCD Segments Check Using auxiliary wires connect a 12 V battery to the meter unit connector as follows Connect the battery positive terminal to terminal 10 Connect the battery negative terminal to terminal 12 Connect terminal 9 to the battery terminal When the terminal 9 is connected all the LCD segments appear for one second When the terminal 9 is disconnected all the LCD seg ments disappear If this display function does not work replace the meter unit 17 64 ELECTRICAL SYSTEM Meter Check 2 MODE and TIME SET Buttons Operation Check Connect the wires in the same manner as Check 1 Check that when the MODE button A is pushed and held continuously the display B cycles through the four modes ODO TRIP A TRIP B Hour ODO If this display function does not work replace the meter unit Cycle the meter to TRIP A or TRIP B mode Check that when the SET RESET button A is pushed the display turns to 0 0 If this display function does
249. ltifunction Meter Unit Removal in the Electrical System chapter Slide the rubber cover off the adjuster at the throttle case Loosen the locknut A and turn the throttle cable upper adjuster B until the cable has proper amount of play Tighten the locknut and reinstall the rubber cover If the free play cannot be adjusted by using the upper ca ble adjuster remove the left side cover see Frame chap ter and then use the cable adjusting nuts A at the lower end of the throttle cable and make the necessary free play Choke Lever Free Play Inspection Check if the choke lever A returns properly and if the inner cable slides smoothly Make sure that the choke lever returns to its released po sition all the way To determine the amount of choke cable play at the lever pull the choke lever to the left until feeling the operation of the lever tough the amount of choke lever is equivalent to that of cable play The proper amount of play ranges about 3 mm 0 12 in at the choke lever If the free play is not within the specified range adjust the cable Choke Lever Free Play B Standard about 3 mm 0 12 in PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures Choke Lever Free Play Adjustment Remove Handlebar Cover Screws A Remove Handlebar Cover Screws A Handlebar Cover Front B Loosen the locknut A of the choke cable Turn the adjuster B until the cable has
250. m 0 24 in Engine Lubrication System Engine Oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE10W 40 Capacity 2 1 L 2 2 US qt When filter is not removed 2 2 L 2 3 US qt When filter is removed 2 6 L 2 7 US qt When engine is completely dry Wheels Tires Tire Tread Depth Front 3 mm 0 12 in Rear 4 mm 0 16 in Standard tire Front AT 25 8 12 DUNLOP KT191 Tubeless Rear AT 25 10 12 DUNLOP KT195 Tubeless 2 12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Front Final Gear Case Gear Case Oil Type API SF or SG API SH or SJ of JASO MA class Viscosity SAE 10W 40 Oil Level Filler opening bottom Capacity 0 40 L 0 42 US qt Rear Final Gear Case Gear Case Oil Type MOBIL Fluid 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Oil level Filler opening bottom Capacity 0 72 L 0 76 US qt Brakes Front Brake Fluid Type DOT 3 or DOT 4 Front Disc Brake Pad Lining Thickness 4 mm 0 16 in 1 mm 0 04 in Rear Brake Lever Pedal and Cables Rear Brake Lever Free Play 1 2 mm 0
251. m kgf m ft lb 5 0 20 3 4 4 9 0 35 0 5 30 43 in lb 6 0 24 5 9 7 8 0 6 0 8 52 69 in lb 8 0 31 14 19 1 4 1 9 10 0 13 5 10 0 39 25 34 2 6 3 5 19 0 25 12 0 47 44 61 4 5 6 2 33 45 14 0 55 73 98 7 4 10 0 54 72 16 0 63 115 155 11 5 16 0 83 115 18 0 71 165 225 17 0 23 0 125 165 20 0 79 225 325 23 33 165 240 PERIODIC MAINTENANCE 2 11 Specifications Item Standard Service Limit Fuel System Throttle Lever Free Play 2 3 mm 0 08 0 12 in Choke Lever Free Play about 3 mm 0 12 in Idle Speed 1 150 50 r min rpm Air Cleaner Element Oil High quality foam air filter oil Cooling System Coolant Type Recommended Permanent type antifreeze Color Green Mixed Ratio Soft water 50 Coolant 50 Freezing Point 35 C 31 F Total Amount 2 2 L 2 3 US qt Engine Top End Valve Clearance Exhaust 0 20 0 25 mm 0 0079 0 0098 in Inlet 0 10 0 15 mm 0 0039 0 0059 in Converter System Belt Width 29 7 30 3 mm 1 169 1 193 in 28 0 mm 1 102 in Belt Deflection 22 27 mm 0 87 1 06 in Actuator Lever Guide Shoe Wear 6 m
252. meter of the valve seating pattern is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Exhaust 25 2 25 4 mm 0 992 1 000 in Inlet 29 4 29 5 mm 1 157 1 165 in NOTE The valve stem and guide must be in good condition or this check will not be valid If the valve seating pattern is not correct repair the seat see Valve Seat Repair Measure the seat width E of the portion where there is no build up carbon white portion of the valve seat with vernier calipers If the width is too wide too narrow or uneven repair the seat see Valve Seat Repair F Good G Too Wide H Too Narrow J Uneven Valve Seating Surface Width Exhaust 0 5 1 0 mm 0 02 0 04 in Inlet 0 5 1 0 mm 0 02 0 04 in Valve Seat Repair Valve Lapping Using the valve seat cutters A repair the valve seat Special Tools Valve Seat Cutters Exhaust Valves Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 28 57001 1119 Valve Seat Cutter 60 30 57001 1123 Inlet Valves Valve Seat Cutter 45 30 57001 1187 Valve Seat Cutter 32 33 57001 1199 Valve Seat Cutter 60 30 57001 1123 Holder and Bar Valve Seat Cutter Holder 5 57001 1208 B Valve Seat Cutter Holder Bar 57001 1128 C If the manufacturer s instructions are not available use the following procedure ENGINE TO
253. mm 0 47 in 11 White Mark Face the mark backwards and align it with the crankcase mark 12 Face the seal of the bearing to the left side outward G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket Kawasaki Bond 92104 1063 or Three Bond 1216 M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil solution mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 1 O Apply engine oil S Follow the specific tightening sequence 10 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 10 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Grip Hold Nut 9 8 1 0 87 in lb 2 Shift Lever Assembly Bracket Bolts 20 2 0 14 3 Tie rod End Front Locknut 9 8 1 0 87 in lb Lh 4 Tie rod End Rear Locknut 9 8 1 0 87 in lb 5 Tie rod End Nut 20 2 0 14 6 Shift Lever Assembly Nut 20 2 0 14 7 Tie rod End Bolt 9 8 1 0 87 in lb 8 Shift Shaft Positioning Bolt 25 2 5 18 9 Shift Shaft Spring Bolt 25 2 5 18 L 10 Shift Shaft Cover Bolts 8 8 0 90 78 in lb 11 Tie rod End Locknut 20 2 0 14 12 Neutral Position Switch 15 1 5 11 13 Reverse Position Switch 15 1 5 11 14 Do not apply a non permanent locking agent to this end G Apply grease L Apply a non permanent locking agent Lh Left hand Threads M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil
254. move Seat see Seat Removal Middle Cover Screws Storage Case Screws A Storage Case B Remove Screws A and Collars Remove Screws A and Collars Left Side Cover B Left Side Cover Installation Install Left Side Cover A Insulator B Screws C and Collars D Washers E Storage Case Right Side Cover Removal Remove Seat see Seat Removal Middle Cover Screws Ignition Switch Nut A Storage Case Screws B Storage Case C FRAME 16 15 Covers Remove Shift Knob A Screws B and Collars Remove Screws A and Collars Left Side Cover B Right Side Cover Installation Install Right Side Cover A Screws B and Collars C Washer D Install Storage Case Fit the projection A on the ignition switch into the recess in the storage case Tighten the nut B securely Electrical Parts Case Removal Remove Seat see Frame chapter Rear Fender see Frame chapter Fuse Box A Vehicle down Sensor Lead Connector B disconnect Remove the following parts from the case Starter Circuit Relays C Radiator Fan Breaker D Starter Relay E Reset Connector F Actuator Controller G Igniter H 16 16 FRAME Covers Remove Screw A Bolts B Electrical Parts Case C Electrical Parts Case Installation Install Removed Parts Connect the vehicle down sensor lead connector Route the electrical parts leads according to the
255. mpound to the teeth in a thin even coat with a fairly stiff paint brush If painted too thickly the exact tooth pattern may not appear The checking compound must be smooth and firm with the consistency of tooth paste Special compounds are available from automotive sup ply stores for the purpose of checking differential gear tooth patterns and contact Use this for checking the bevel gears Turn the output driven shaft for 3 or 4 turns in the drive and reverse coast directions while creating a drag on the drive bevel gear shaft Check the drive pattern and coast pattern of the bevel gear teeth The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth and a little closer to the toe of the tooth If the tooth contact pattern is incorrect replace the shim s at the drive bevel gear and shim s at the driven bevel gear following the examples shown Then erase the tooth contact patterns and check them again Also check the backlash every time the shims are replaced Repeat the shim change procedure as necessary NOTE If the backlash is out of the standard range after chang ing shims correct the backlash before checking the tooth contact pattern FINAL DRIVE 12 23 Output Bevel Gears Example 1 Decrease the thickness of the drive bevel gear shim s by 0 1 mm 0 004 in and or increase the thickness of the driven bevel gear shim s by 0 1 mm 0 00
256. n lb ENGINE TOP END 5 31 Cylinder Head Cylinder Head Cleaning Remove the cylinder head see Cylinder Head Removal Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool Wash the head with a high flash point solvent Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air Cylinder Head Warp Clean the cylinder head see Cylinder Head Cleaning Lay a straightedge across the lower surface of the cylinder head Use a thickness gauge A to measure the space between the straightedge B and the head at several locations Cylinder Head Warp Service Limit 0 05 mm 0 002 in If the cylinder head is warped more than the service limit replace it If the cylinder head is warped less than the service limit repair the head by lapping the lower surface with emery paper secured to a surface plate first No 200 then No 400 5 32 ENGINE TOP END Valves Valve Clearance Inspection Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal Remove the cylinder head see Cylinder Head Removal Mark and record the valve location so it can be installed in the original position Using the valve spring compressor assembly remove the valve Special Tools Valve Spring Com
257. n 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current D decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C Determine battery condition after refreshing charge Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement 12 8 V or higher Good 12 0 12 5 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable Replace 17 26 ELECTRICAL SYSTEM Charging System Alternator Cover Removal Drain Coolant see Cooling System chapter Oil see Periodic Maintenance chapter Remove Recoil Starter see Recoil Starter chapter Water Pump Impeller see Cooling System chapter Torque Converter Cover see Converter System chap ter Remove the three bolts of the drive pulley cover A Install the drive pulley holder B tightening the remove three bolts C Special Tool Drive Pulley Holder 57001 1520 Holding the drive pulley with the drive pulley holder loosen the alternator rotor bolt A Remove Alternator Rotor Bolt Pulley B Remove Collar A Install the M6 bolts B to the collar and remove it Remove Al
258. n be adjusted for differ ent terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Position Spring Force Setting Load Terrain Speed 1 Soft Light Smooth Low 2 STD 3 4 5 Stronger Hard Heavy Rough High Turn the adjusting sleeve on front shock absorber to the desired position with the wrench Special Tool Steering Stem Nut Wrench 57001 1100 Front Shock Absorber Removal Support the vehicle on a stand or a jack so that the front wheels are off the ground Special Tool Jack 57001 1238 While holding the front wheels remove the lower and up per shock absorber mounting bolts A nuts and wash ers Remove the front shock absorber B Front Shock Absorber Installation Apply grease to the inside of bushing A and grease seal lips B Install Collar C Install Bushing A press Tighten Torque Front Shock Absorber Mounting Nuts B 34 N m 3 5 kgf m 25 ft lb SUSPENSION 14 9 Shock Absorbers Front Shock Absorber Inspection Check the bushings A in the upper and lower pivots If bushings are worn cracked hardened or otherwise damaged replace them Front Shock Absorber Scrapping WARNING Since the front shock absorber contains nitrogen gas do not incinerate or disassemble the front shock abso
259. n off the ignition switch Remove the seat see Frame chapter Disconnect both sets of 4 pin connectors A in the elec trical parts case Reconnect these 4 pin connectors to their opposite gray to black and black to gray as shown Turn on the ignition switch Observe the belt check indicator light A It should be flashing quickly Disconnect the belt switch at the 2 pin connectors A above the torque converter cover Observe the belt check indicator light It should be flashing slowly Let it flash for at least five seconds NOTE More than five seconds is OK While observing the belt check indicator light turn off the ignition switch Disconnect the mismatched 4 pin connector sets and re connect them normally Black to black gray to gray A 17 70 ELECTRICAL SYSTEM Meter Connect the belt switch 2 pin connector A Turn on the ignition switch Confirm that no belt check indicator light is flashing Put the connectors back and bend the clamps ELECTRICAL SYSTEM 17 71 Meter Meter Circuit 1 Multifunction Meter 2 Neutral Switch 3 Reverse Switch 4 Coolant Temperature Switch 5 Actuator Controller 6 2WD 4WD Switch 7 Speed Sensor 8 Main Fuse 30 A 9 Fuel Level Sensor 10 Igniter 11 Belt Failure Detection Switch 12 Oil Pressure Switch 13 Frame Ground Terminal Meter 14 Light Dimmer Switch 15 Reset Connector 16 Ignition Switch 17
260. n the intermediate shaft sprocket Right Side is aligned with the embossed mark B on the crankcase Face the arrow mark A upward Align the marks B on the weights with the front cylinder head upper surface C Place the front camshaft chain on the front camshaft sprocket Apply grease to the O ring A and install the cover B into the right side of the crankcase so that the tapped hole C faces outward 5 28 ENGINE TOP END Camshaft Install Rocker Cases see Rocker Case Installation Camshaft Chain Tensioners see Camshaft Chain Ten sioner Installation Check the valve clearances see Valve Clearance Inspec tion Camshaft Chain Guide Wear Visually inspect the rubber on the guides If the rubber is damaged cut or is missing pieces replace the guide ENGINE TOP END 5 29 Cylinder Head Cylinder Compression Measurement NOTE Use the battery which is fully charged Warm up the engine thoroughly and stop the engine Remove the spark plug see Electrical System chapter Attach the compression gauge A and adapter B firmly into the spark plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 1 0 57001 1458 Hold the throttle wide open and crank the engine with the electric starter or the recoil starter several times When the gauge stops rising stop cranking and read the gauge Cylinder Compression Usable R
261. nditions of the brake check the brake parts for wear or damage 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection Turn the handlebar left and right and check the steering action If the steering action is not smooth or if the steering binds or catches before the stop lubricate the steering stem bearing NOTE The cables and wires will have some effect on the steer ing action which must be taken into account Check the steering action again If steering stem bearing lubrication does not remedy the problem inspect the steering stem for straightness steer ing stem clamps and tie rod bearings If you feel looseness or if the steering rattles as it turns check the tightness of the steering bolts and nuts Tighten loose bolts and nuts to the specified torque see Steering chapter and check the steering action again If the steering action does not change by tightening the bolts and nuts inspect the steering stem clamps steer ing stem bearings tie rod bearings and steering knuckle joints Electrical System Spark Plug Cleaning Inspection Remove the spark plug see Electrical System chapter Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a wire brush or other suitable tool If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug
262. ned replace it After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess oil then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the element Air Cleaner Draining If any water or oil accumulates in the tube drain it by taking off the tube plug A After draining be sure to install the tube plug and clamp firmly 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose and Connection Inspection The fuel hoses are designed to be used throughout the vehicle life without any maintenance however if the ve hicle is not properly handled the pressure inside the fuel line can cause fuel to leak A or the hose to burst Check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed Check that the hoses are securely connected and clamps are installed correctly When installing the fuel hoses route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Fit the fuel hose A onto the fitting fully and install the plate clamp B beyond the raised rib C 1 2 mm 0 0039 0 0078 in D The hose end must reach th
263. ness Use a micrometer to measure at several points around the ring Piston Ring Thickness Standard Top 0 97 0 99 mm 0 0382 0 0390 in Second 0 97 0 99 mm 0 0382 0 0390 in Service Limit Top 0 90 mm 0 035 in Second 0 90 mm 0 035 in If any of the measurements is less than the service limit on either of the rings replace all the rings NOTE When using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston ENGINE TOP END 5 43 Cylinder and Piston Piston Ring End Gap Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 20 0 30 mm 0 0079 0 0118 in Second 0 30 0 45 mm 0 0118 0 0177 in Oil 0 20 0 70 mm 0 0079 0 0276 in Service Limit Top 0 60 mm 0 0236 in Second 0 75 mm 0 0295 in Oil 1 00 mm 0 0394 in If the end gap of either ring is greater than the service limit replace all the rings 5 44 ENGINE TOP END Exhaust System This vehicle is equipped with a spark arrester approved for off road use by the U S Forest Service It must be prop erly maintained to ensure its efficiency In accor
264. ng B 7 5 0 1 mm 0 295 0 004 in C Rear Side A Circlip B front side Ball Joint Bearing C Circlip D rear side Special Tool Inside Circlip Pliers 57001 143 Apply grease Oil Seal Lips Install Sleeve front side Collars rear side Stabilizer Removal Remove Rear Wheels see Wheels Tires chapter Stabilizer Joint A Hold the joint bolt with an Allen wrench B and remove the nut C Remove Stabilizer Holder Bolts A Stabilizer Holders B Dampers and Stabilizer C 14 18 SUSPENSION Suspension Arms Stabilizer Installation Install Dampers A and Stabilizer B Stabilizer Holders C and Bolts Tighten Torque Stabilizer Holder Bolts D 23 N m 2 3 kgf m 17 ft lb Install Stabilizer Joints E Hold the joint bolt with an Allen wrench and tighten the nut Torque Stabilizer Joint Nuts F 48 N m 4 8 kgf m 35 ft lb Install Rear Wheels see Wheels Tires chapter STEERING 15 1 15 Steering Table of Contents Exploded View 15 2 Specifications 15 4 Special Tools 15 5
265. ng air will enter the line and the sys tem must be bled Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid changes WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are not known Tighten Torque Bleed Valves 5 4 N m 0 55 kgf m 48 in lb Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fittings If necessary bleed the air from the brake line see Brake Line Air Bleeding section in Brakes chapter WARNING If the brake lever has a soft or spongy feeling when it is applied there might be air in the brake line or the brake may be defective Since it is dan gerous to operate the vehicle under such condi tions bleed the air from the brake line immediately Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement Refer to the Master Cylinder section in the Brakes chap ter for Front Brake Master Cylinder Piston Assembly and Dust Seal Replacement Front Brake Caliper Piston Seal and Dust Seal Replacement Refer to the Caliper section in the Brakes chapter for Front Brake Caliper Piston Seal and Dust Seal Replacement PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Rear Brake Plates Replacement Replace the steel plates an
266. ng Gear 8 Ring Gear Assembly 9 Pinion Gear 12 48 FINAL DRIVE Front Final Gear Case 1 Pinion Gear Shims for Backlash Adjustment Thickness Part Number 0 15 mm 0 006 in 92180 1408 0 2 mm 0 008 in 92180 1409 0 5 mm 0 020 in 92180 1410 0 7 mm 0 028 in 92180 1411 0 8 mm 0 031 in 92180 1412 0 9 mm 0 035 in 92180 1413 1 0 mm 0 039 in 92180 1414 1 1 mm 0 043 in 92180 1415 1 2 mm 0 047 in 92180 1416 2 Ring Gear Right Shims for Tooth Contact Adjustment Thickness Parts Number 0 15 mm 0 006 in 92180 1399 0 2 mm 0 008 in 92180 1400 0 5 mm 0 020 in 92180 1401 0 7 mm 0 028 in 92180 1402 0 8 mm 0 031 in 92180 1403 0 9 mm 0 035 in 92180 1404 1 0 mm 0 039 in 92180 1405 1 1 mm 0 043 in 92180 1406 1 2 mm 0 047 in 92180 1407 3 Ring Gear Left Shims for Tooth Contact Adjustment Thickness Parts Number 0 15 mm 0 006 in 92180 1390 0 2 mm 0 008 in 92180 1391 0 5 mm 0 020 in 92180 1392 0 7 mm 0 028 in 92180 1393 0 8 mm 0 031 in 92180 1394 0 9 mm 0 035 in 92180 1395 1 0 mm 0 039 in 92180 1396 1 1 mm 0 043 in 92180 1397 1 2 mm 0 047 in 92180 1398 Backlash Adjustment Check and adjust the gear backlash when any of the backlash related parts are replaced with new ones Clean any dirt and oil off the bevel gear teeth Assemble the front final gear case see Front Final Gea
267. nition System Ignition Coil Primary Peak Voltage Inspection NOTE Be sure the battery is fully charged Remove the spark plug cap see Spark Plug Removal but do not remove the spark plug Measure the primary peak voltage as follows Connect a commercially peak voltage adapter A to the hand tester B 250 V DC range Install the needle adapter C on the peak voltage adapter leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Brand KOWA SEIKI Insert the needle adapter into the terminal of the G W front or BL W rear primary lead D Install a new spark plug E into the spark plug cap and ground it to the engine F Ignition Coil WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections Turn the ignition switch ON rotate the engine for 4 5 seconds with the transmission in neutral to measure the primary peak voltage Repeat the measurements 5 times for one ignition coil Ignition Coil Primary Peak Voltage Standard 120 V or more Repeat the test for the other ignition coil If the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection If the ignition coils and crankshaft sensor are normal see the Ignition System Troubleshooting chart on page 17 43 Crank
268. nk web to determine clearance Connecting Rod Big End Side Clearance Standard 0 16 0 46 mm 0 0063 0 0181 in Service Limit 0 7 mm 0 028 in If the clearance exceeds the service limit replace the con necting rod with new one and then check clearance again If clearance is too large after connecting rod replacement the crankshaft also must be replaced Connecting Rod Big End Bearing Crankpin Wear Measure the bearing insert crankpin A clearance with plastigage B Tighten the big end cap nuts to the specified torque Torque Connecting Rod Big End Cap Nuts 34 N m 3 5 kgf m 25 ft lb NOTE Do not move the connecting rod and crankshaft during clearance measurement Connecting Rod Big End Bearing Insert Crankpin Clearance Standard 0 028 0 052 mm 0 0011 0 0020 in Service Limit 0 09 mm 0 0035 in If the clearance is within the standard no bearing insert replacement is required If the clearance is between 0 052 mm 0 0020 in and the service limit 0 09 mm 0 0035 in replace the bear ing inserts A with inserts painted green B Check in sert crankpin clearance with plastigage The clearance may exceed the standard slightly but it must not be less than the minimum in order to avoid bearing seizure If the clearance exceeds the service limit measure the diameter of the crankpin Crankpin Diameter Standard 39 984 40 000 mm 1 5742 1 5748 in Service L
269. not spin the bearing while it is dry and oil it with engine oil Spin A the bearing by hand to check its condition If the bearing is noisy does not spin smoothly or has any rough spots replace it Check the needle bearings The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage If there is any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 11 1 11 Wheels Tires Table of Contents Exploded View 11 2 Specifications 11 4 Special Tool 11 5 Wheel Alignment 11 6 Steering Centering Inspection 11 6 Steering Centering Adjustment
270. nstallation 16 20 Footboard Bracket installation 16 20 Trailer Hitch Bracket 16 21 Trailer Hitch Bracket Removal 16 21 Trailer Hitch Bracket Installation 16 21 16 2 FRAME Exploded View FRAME 16 3 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Front Guard Bolts 37 3 8 27 2 Front Carrier Bolts L 50 mm 2 0 in 25 2 5 18 3 Front Bolts L 70 mm 2 8 in 25 2 5 18 4 Front Carrier Bracket Bolts 32 3 3 24 5 Rear Carrier Bolts L 14 mm 0 6 in 54 5 5 40 6 Rear Carrier Bolts L 41 mm 1 6 in 54 5 5 40 7 Rear Carrier Bracket Bolts 37 3 8 27 CN Canada Model 16 4 FRAME Exploded View FRAME 16 5 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Footboard Bracket Bolts 42 4 3 31 2 Hitch Bracket Bolts 82 8 3 60 3 Trailer Hitch Bracket OP Optional Parts 16 6 FRAME Exploded View FRAME 16 7 Exploded View OP Optional Parts 16 8 FRAME Seat
271. nstalled on the pulleys to rotate in the same direction as originally installed Lift the drive belt B off the driven pulley C Drive Belt Installation NOTE Be sure the printed information faces the same direc tion so the belt rotates in the same direction as origi nally installed When installing a new belt install it so the printed information A can be read from beside the vehicle Installation is basically the reverse of removal Loop the belt B over the driven pulley C Install the drive pulley see Drive Pulley Installation Put the transmission in neutral and rotate the driven pul ley to allow the belt to return to the top A of the sheaves before measuring belt deflection Drive Belt Deflection Inspection Refer to the Drive Belt Deflection Inspection in the Peri odic Maintenance chapter Drive Belt Deflection Adjustment Refer to the Drive Belt Deflection Adjustment in the Peri odic Maintenance chapter Drive Belt Inspection Refer to the Drive Belt Inspection in the Periodic Mainte nance chapter 6 14 CONVERTER SYSTEM Drive Pulley Drive Pulley Removal Remove the torque converter cover see Torque Con verter Cover Removal Remove the three cover bolts A and install the drive pul ley holder B Special Tool Drive Pulley Holder 57001 1520 Tighten the three cover bolts Torque Drive Pulley Cover Bolts 13 N m 1 3 kgf m 113 in lb Lo
272. nstalling the discs check the disc runout Com pletely clean off any grease that has gotten on either side of the disc with a high flash point solvent Do not use one which will leave an oily residue Disc Wear Measure the thickness of each disc at the point A where it has worn the most Replace the disc if it has worn past the service limit Disc Thickness Standard 3 3 3 7 mm 0 130 0 146 in Service Limit 3 mm 0 12 in Disc Runout Jack up the vehicle so that the wheels are off the ground Remove the front wheels and turn the handlebar fully to one side Set up a dial gauge against the disc A and measure the disc runout If the runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in BRAKES 13 19 Brake Hoses Brake Hose Inspection Refer to the Front Brake Hose and Connections Inspec tion in the Periodic Maintenance chapter Brake Hose Replacement Refer to the Front Brake Hose Replacement in the Peri odic Maintenance chapter 13 20 BRAKES Rear Brake Lever Pedal and Cables Brake Pedal Position Inspection NOTE The position of the brake pedal has been decided by the position of the adjusting bolt A Check that the adjusting bolt is in the correct position as shown Adjusting Bolt Position B Standard 5 6 mm 0 20 0 24 in between Frame and Bolt Head If
273. nt or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Brake Doesn t Hold Front brake Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad overworn or worn unevenly Oil grease on pads and disc Disc worn or warped Brake overheated Rear Brake Brake not properly adjusted Plates worn Brake parts worn or damaged Kawasaki Engine Brake Control and Selectable 2WD 4WD System Malfunction Actuators failed Speed sensor short or open Forward Reverse detecting sensor short or open Actuator controller failed Controller 10A fuse blown Battery disconnected 18 6 APPENDIX Troubleshooting Guide Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator rectifier trouble Battery trouble APPENDIX 18 7 Cable Wire and Hose Routing 1 Tube 2 Clamps 3 Align the white paint mark on the tube with the adjustment ma
274. oes not flash replace the meter unit Connect terminal 5 to the battery terminal When terminal 5 is connected one segment in the fuel gauge should appear every 15 seconds CAUTION When all segments appeared disconnect the termi nal 5 If this display function does not work replace the meter unit Check 7 2WD 4WD Indicator Lights Check Connect the wires in the same manner as Check 1 The 2WD indicator light LCD A should appear 17 66 ELECTRICAL SYSTEM Meter Connect terminal 4 to the battery terminal The 4WD indicator light LCD A should appear If this display function does not work replace the meter unit Check 8 Coolant Temperature Warning Symbol Check Connect the wires in the same manner as Check 1 Connect terminal 3 to the battery terminal The coolant temperature warning symbol LCD A should appear If this display function does not work replace the meter unit Check 9 Oil Pressure Warning Light Check Connect the wires in the same manner as Check 1 Connect terminal 11 to the battery terminal ELECTRICAL SYSTEM 17 67 Meter The oil pressure warning light LED A should flash If the LED light does not flash replace the meter unit Check 10 Neutral Indicator Light Check Connect the wires in the same manner as Check 1 Connect terminal 8 to the battery terminal The neutral indicat
275. older one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding After making the 32 grind return to the seat O D mea surement step above To measure the seat width use vernier calipers to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above ENGINE TOP END 5 37 Valves If the seat width is too wide make the 60 A grind de scribed below If the seat width is within the specified range lap the valve to the seat as described below Grind the seat at a 60 angle until the seat width is within the specified range To make the 60 grind fit 60 cutter into the holder and slide it into the valve guide Turn the holder while pressing down lightly After making the 60 grind return to the seat width mea surement step above Correct Width B Lap the valve to the seat once the seat width and O D are within the ranges specified above Put a little coarse grinding compound on the face of the valve in a number of places around the valve head Spin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and
276. olts B Steering Clamps C Grease Seals Cut the band A and pull the steering stem B out of the frame Remove Cotter Pin A Steering Stem Bottom End Nut B Collar C Steering Stem Bearing D Steering Stem Installation Full grease up the seal grooves A in the steering stem bearing Install Collar Tighten Torque Steering Stem Bottom End Nut 62 N m 6 3 kgf m 46 ft lb Bend both ends of the cotter pin STEERING 15 7 Steering Apply a non permanent locking agent Steering Stem Bearing Joint Bolts A Tighten Torque Steering Stem Bearing Joint Bolts 23 N m 2 3 kgf m 17 ft lb Apply Amoco Rykon Premium Grease No 2 EP Green Inside of Steering Clamp A Oil Seals B Install Collars A Apply above grease to the inside of steering clamp B Tighten Torque Steering Stem Clamp Bolts A 25 N m 2 5 kgf m 18 ft lb Tie rod End Nuts 42 N m 4 3 kgf m 31 ft lb Bend the tabs of the washer B toward the bolt head Inspect the toe in see Wheels Tires chapter Front Knuckle Removal Remove Front Wheel and Hub see Wheel Tiers chapter Brake Caliper see Brakes chapter Cotter Pin A CAUTION Do not loosen the locknuts B at the ends of the tie rod or the toe in of the front wheels will be changed 15 8 STEERING Steering Hold the flat surfaces A of the tie rod end with a thin wrench B and remo
277. on or water WARNING Do not use the lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation Check the tire rotation mark A on the tire and install the tire on the rim accordingly The tires should be installed on the rims so that each air valve is toward the outside of the vehicle NOTE The direction of the tire rotation B is shown by an arrow on the tire sidewall Install the tire on the rim using a suitable commercially available tire changer Lubricate the tire beads again and center the tire on the rim 11 12 WHEELS TIRES Tires Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 kgf cm 36 psi WARNING Do not inflate the tire to more than the maximum tire air pressure Overinflation can explode the tire with possibility of injury and loss of life Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B If the rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire After the beads are properly seated check for air leaks Apply a soap and water solution around the tire bead and check for bubbles Deflate the tire to
278. on see Brake Pedal Posi tion Brake Cable Removal Remove Right Rear Flap see Frame chapter Unscrew the adjusters A at the rear ends of the cables and pull the cables out of the joints B and cable mounts Loosen the knurled locknut A at the rear brake lever and screw in the adjuster B Line up the slots C in the brake lever knurled locknut and adjuster and then free the cable from the lever D Remove the brake lever cable from the frame 13 22 BRAKES Rear Brake Lever Pedal and Cables Remove Circlip A Cotter Pin Washer and Pin B Brake Pedal Cable C Brake Cable Installation Grease the brake cable front ends Replace the cotter pin with a new one Route the brake cables according to the Cable Wire and Hose Routing section in Appendix chapter Adjust the brake pedal and rear brake lever Brake Cable Lubrication Whenever the brake cable is removed lubricate the cable as follows Lubricate the cable with a penetrating rust inhibitor BRAKES 13 23 Internal Wet Brake Internal Wet Brake Disassembly Refer to Rear Final Gear Case section in Final Drive chap ter Internal Wet Brake Assembly Refer to Rear Final Gear Case section in Final Drive chap ter SUSPENSION 14 1 14 Suspension Table of Contents Exploded View 1
279. ont Amount of Toe in Distance A and B are measured at axle height with the vehicle sitting on the ground or at 1G Steering Centering Inspection Test ride the vehicle If the handlebar is straight when the vehicle is traveling in a straight line go on to the Toe in Inspection procedure Otherwise go on to the Steering Centering Adjustment procedure Steering Centering Adjustment Hold a straightedge A against the rear wheel rim on one side at axle height With the handlebar straight ahead loosen the locknuts A B and turn the tie rod C until the front wheel on that side is parallel to the straightedge NOTE The locknut B near the L mark D on the tie rod has left hand threads Turn the wrench clockwise for loos ening CAUTION Adjust the tie rod so that the visible thread length A is even on both ends of the tie rod or the threads could be damaged WHEELS TIRES 11 7 Wheel Alignment Repeat the straightedge procedure on the other side of the vehicle Now the front wheels are parallel to each other and to the center line of the vehicle Front Wheel A Vehicle Center Line B Parallel each other C Straightedges D Rear Wheels E Go on to the Toe in Inspection procedure Toe in Inspection Apply a heavy coat of chalk or a paint line near the center of the front tires Using a needle nose scriber make a thin mark near the center of the chalk coating while turning the w
280. ont Cover Press Ball Bearing B until bottomed Special Tool Bearing Driver Set 57001 1129 Press the faces of the oil seals C are flush with the ends of the housing Apply Grease Oil Seal Lips Rear Final Gear Case Assembly Visually check the pinion gear A and ring gear B for scoring chipping or other damage Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Rear Final Bevel Gear Adjustment Insert the shim s and pinion gear unit A Apply a non permanent locking agent to the pinion gear bearing holder and tighten it Special Tool Socket Wrench Hex 50 57001 1478 Torque Pinion Gear Bearing Holder 137 N m 14 kgf m 101 ft lb 12 66 FINAL DRIVE Rear Final Gear Case When installing a new pinion gear bearing holder A in stall the holder so that the no coating area B one pitch thread faces gear case C D Locking Agent Coating Area Install Brake Camshaft A Spring B Install Steel Balls A Install Brake Cam Plate A Fit the cam plate and brake camshaft B as shown Install Steel Plate A P No 41080 1483 two holes Set Pins B and Springs C FINAL DRIVE 12 67 Rear Final Gear Case Install alternately
281. or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Other Carburetor vacuum piston doesn t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Front or rear final gear case oil viscosity too high Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Crankshaft sensor trouble Igniter trouble Ignition coil trouble Drive belt failure detection switch activated Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Main air jet clogged Bleed holes of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C
282. or light LED A should go on If the LED light does not go on replace the meter unit Check 11 Reverse Indicator Light Check Connect the wires in the same manner as Check 1 Connect terminal 7 to the battery terminal The reverse indicator light LED A should go on If the LED light does not go on replace the meter unit 17 68 ELECTRICAL SYSTEM Meter Check 12 Meter Illumination Check Connect the wires in the same manner as Check 1 Connect terminal 6 to battery terminal The meter illumination A should go on If the illumination does not go on replace the meter unit Check 13 Belt Check Indicator Light check Connect the wires in the same manner as Check 1 Connect terminal 2 to the battery terminal The belt check indicator light LED A should go on It the LED does not go on replace the meter unit Drive Belt Failure Mode Memory Clearing Procedure A flashing BELT check indicator LED Light Emitting Diode light means that the drive belt failure detection system has activated The belt check indicator light will illuminate and stay on when activated by the 100 hour belt check system NOTE Follow the instruction on page 2 25 of this Service Man ual to complete the necessary inspections After completing the inspections follow these instruc tions to clear the system memory and turn off the light ELECTRICAL SYSTEM 17 69 Meter Tur
283. or magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromag netic field or just by aging will result in low output To check the alternator output voltage perform the follow ing procedures Disconnect the alternator connector A Connect a hand tester B as shown in the table Start the engine Run it at the rpm given in the table Note the voltage readings total 3 measurements Alternator Output Voltage Connections Reading Tester Range Tester to Tester to 3 000 rpm 250 V AC One black lead Another black lead 38 58 V If the output voltage is within the values in the table the alternator is operating correctly and the regulator rectifier is damaged A much lower reading indicates that the al ternator is defective Check the stator coil resistance as follows Stop the engine Disconnect the alternator connector Connect a hand tester as shown in the table Note the readings total 3 measurement Stator Coil Resistance 20 C 68 F Connections Tester Range Tester to Tester to Reading 1 One black lead Another black lead 0 29 0 43 If there is more resistance than shown in the table or no reading infinity for any two leads the stator has an open and must be repla
284. orrosion When the engine starts the water pump coupled with the oil pump turns and the coolant circulates The thermostat is a wax pellet type which opens or closes with coolant temperature changes The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level When coolant temperature is below 69 5 72 5 C 157 162 F the thermostat closes so that the coolant flow is restricted through the air bleeder hole causing the engine to warm up more quickly When coolant temperature is more than 69 5 72 5 C 157 162 F the thermostat opens and the coolant flows When the coolant temperature goes up beyond 96 100 C 205 212 F the radiator fan switch conducts to operate the radiator fan The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds This increases up the cooling action of the radiator When the temperature is below 91 95 C 195 203 F the fan switch opens and the radiator fan stops In this way this system controls the engine temperature within narrow limits where the engine op erates most efficiently even if the engine load varies The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating As the engine warms up the coolant in the radiator and the water jacket expands The excess coolant flows through the radiator cap and hose to the re
285. osen the drive pulley bolt C left hand threads hold ing the drive pulley with the drive pulley holder NOTE The drive pulley bolt has left hand threads Turn the wrench clockwise for loosening Remove the drive pulley bolt two washers and the stepped washer but do not remove the drive pulley holder yet Remove the drive pulley A from the crankshaft by screw ing the drive pulley puller bolt B clockwise while holding the drive pulley with the drive pulley holder C Special Tool Drive Pulley Puller Bolt 57001 1429 Drive Pulley Disassembly Hold the drive amp driven pulley holder 57001 1473 A and the tapered guide of the holder 57001 1412 B in a vise so that the upper surface on the holder is 7 mm 0 28 in C above the vise Special Tools Drive amp Driven Pulley Holder 57001 1473 Drive amp Driven Pulley Holder 57001 1412 Set the pulley onto the pulley holder Remove Drive Pulley Cover Bolts A Drive Pulley Cover B CONVERTER SYSTEM 6 15 Drive Pulley Remove Spring A Spacer Put the drive pulley wrench A on the spider B and tighten the bolt C Special Tool Drive Pulley Wrench 57001 1474 Turn the wrench clockwise and remove the spider with the movable sheave NOTE The spider has left hand threads Turn the wrench clockwise for loosening Remove Spider A Shoes B Nuts C Ramp Weight Pin D Ramp Weight E Movable Sheave
286. ot operate correctly F R detecting sensor 7 Controller 6 3 Indicator light LCD 8 The 2WD 4WD indicator light does not switch Controller 6 17 76 ELECTRICAL SYSTEM Actuator Control System Check 1 2WD 4WD Actuator Inspection Remove Actuator Lead Connector A Clamp B Measure the resistance between the following terminals in the actuator lead connector A Special Tool Hand Tester 57001 1394 Actuator Internal Resistance 4 Red 6 Black 3 15 1 Orange 3 Blue 3 5 6 5 k 2 Yellow 3 Blue 630 3 720 If any reading is not within the specified range replace the 2WD 4WD actuator Check 2 Engine Brake Actuator Inspection Remove Actuator Lead Connector A Measure the resistance between the following terminals in the actuator lead connector A Special Tool Hand Tester 57001 1394 Actuator Internal Resistance 4 Red 6 Black 3 15 1 Orange 3 Blue 3 5 6 5 k 2 Yellow 3 Blue 630 5 330 If any reading is not within the specified range replace the engine brake actuator ELECTRICAL SYSTEM 17 77 Actuator Control System Check 3 Controller Power Supply Inspection NOTE Be sure the battery is fully charged Remove Seat see Frame chapter Connect Controller Connector A Hand Tester B range DC 25 V Tester Connector BR Terminal 9 Tester Connector
287. ower end Replace the washers that are on each side of hose fitting with new ones Tighten Torque Brake Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb Check the fluid level in the brake reservoir Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid leakage WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc The brakes will not function on the first application of the lever if this is not done 13 14 BRAKES Calipers Caliper Disassembly Remove Caliper see Caliper Removal Pads see Brake Pad Removal Anti rattle Spring Using compressed air remove the piston Cover the caliper opening with a clean heavy cloth A Remove the piston by lightly applying compressed air B to where the brake line fits into the caliper WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers NOTE If compressed air is not available do as follows with the brake hose connected to the caliper Prepare a container for brake fluid Remove the pads see Brake Pad Removal and anti rattle spring Pump the brake lever to remove the caliper piston
288. pressor Assembly 57001 241 A Valve Spring Compressor Adapter 22 57001 1202 B Valve Installation Replace the valve stem oil seal If a new valve is to be used check the valve to guide clearance see this chapter If there is too little clearance ream the valve guide see Valve Guide Installation If there is too much clearance install a new valve guide see Valve Guide Removal and Valve Guide Installation Check the valve seat see Valve Seat Inspection Apply a thin coat of molybdenum disulfide grease to the valve stem Install each spring so that the closed coil end faces down wards The green paint on the spring faces upwards Valve Stem A Oil Seal B Spring Seat C Spring D Retainer E Split Keepers F Closed Coil End G Valve Guide Removal Remove Valve see Valve Removal Valve Stem Oil Seal Hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 5 57001 1203 ENGINE TOP END 5 33 Valves Valve Guide Installation Lightly oil the valve guide outer surface Using the valve guide arbor A drive the valve guide B until its flange touches the cylinder head Special Tool Valve Guide Arbor 5 57001 1203 Ream the valve guide with the valve guide reamer A if may be necessary to ream the guide even if the old guide is reused Special Tool Valve Guide Reamer 5 57001 1204
289. r Measure the output voltage between W Y terminal and battery terminal tester range DC 25 V Air Temperature Sensor less than 8 C 46 4 F Output Voltage 8 16 V near battery voltage If the voltage is less than DC 0 1 V replace the sensor Warm up the sensor A more than 22 C 71 6 F with a hand Measure the output voltage between W Y terminal and battery terminal tester range DC 2 5 V Air Temperature Sensor more than 22 C 71 6 F Output Voltage less than 0 1 V If the voltage is 8 16 V replace the sensor ELECTRICAL SYSTEM 17 85 Carburetor Heater System Carburetor Heater Inspection Disconnect Carburetor Heater Lead Connectors A Ground Lead Connector B Using the hand tester measure the resistance of the heater Connect the tester between the heater terminal and the ground terminal If the tester does not read as specified replace the heater Carburetor Heater Resistance 11 20 Carburetor Heater System Circuit 1 Carburetor Heaters 12 V 23 W 2 Air Temperature Sensor 3 Ignition Switch 4 Main Fuse 30 A 5 Alternator 6 Starter Relay 7 Battery 8 Engine Ground Terminal 17 86 ELECTRICAL SYSTEM Switches Brake Light Switch Adjustment Refer to the Brake Light Switch Inspection and Adjust ment in the Periodic Maintenance chapter Radiator Fan Switch Inspection Remove Radiator Fan Switch see Cooling System chapter
290. r Case Assembly It is not necessary to install the variable front differential control unit Check the backlash during tightening of the front final gear case center cover bolts and stop tightening them imme diately if the backlash disappears Then change the ring gear shim to a thicker one Temporarily install the right front axle in the gear case and hold it in a vise so that the ring gear is lower than the pinion gear FINAL DRIVE 12 49 Front Final Gear Case Mount a dial gauge A so that the tip of the gauge is against the splined portion B of the pinion gear shaft To measure the backlash move the pinion gear shaft back and forth C while holding the front axle steady The difference between the highest and the lowest gauge reading is the amount of backlash Measure backlash at three locations equally spaced on the splines Front Final Bevel Gear Backlash Standard 0 10 0 20 mm 0 004 0 008 in at pinion gear spline If the backlash is not within the limit replace the pinion gear shims To increase backlash increase the thickness of the shim s To decrease backlash decrease the thick ness of the shim s Change the thickness a little at a time Recheck the backlash and readjust as necessary Tooth Contact Adjustment Clean any dirt and oil off the bevel gear teeth Apply checking compound to 4 or 5 teeth on the pinion gear NOTE Apply checking compound to the te
291. r see Converter Sys tem chapter Put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Measure the belt deflection A as shown Place a straightedge B on top of the belt between the drive pulley C and the driven pulley D Use a ruler to push the belt away from the straightedge Push hard but with no more force than 59 N 6 kgf 13 lb Belt Deflection Standard 22 27 mm 0 87 1 06 in If the belt deflection is not within the specified range ad just the deflection by adding or removing spacers on the fixed sheave of the driven pulley When adjusting the deflection less is better than more Less deflection will maintain better performance for more time as the belt width decreases by normal wear which causes the deflection to increase with usage Drive Belt Deflection Adjustment Disassemble the driven pulley see Converter System chapter If the belt deflection is more than 27 mm 1 06 in remove the spacers to decrease it The rule of thumb is 0 1 mm 0 004 in change in spacer thickness equals about 1 3 mm 0 051 in change in belt deflection If the adjustment cannot be done within the specified range even if the shim is removed replace the drive belt If the belt deflection is less than 22 mm 0 87 in add the spacers A to in
292. r Cover Screws A Handlebar Cover Front B Loosen the locknut A of the differential control cable Turn the adjuster B until the cable has proper amount of play Tighten the locknut securely 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Final Gear Case Oil Change Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle Park the vehicle so that it is level both side to side and front to rear Remove the front side cover see Frame chapter Place an oil pan beneath the front final gear case and remove the drain plug A WARNING When draining or filling the final gear case be care ful that no oil gets on the tire or rim Clean off any oil that inadvertently gets on them with a high flash point solvent After the oil has completely drained out install the drain plug with a new aluminum gasket and tighten it Torque Oil Drain Plug 15 N m 1 5 kgf m 11 ft lb Fill the gear case up to the bottom of filler opening with the oil specified below Front Final Gear Case Oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W 40 Capacity 0 40 L 0 42 US qt NOTE Depending on the atmospheric temperature of your rid ing area the engine oil viscosity should be changed ac cording to the chart Be sure the O ring A is in place and tighten the filler cap B
293. r and Collar Variable Differential Control Lever D Variable Differential Control Cable Upper End Variable Differential Control Lever Installation Install Variable Differential Control Cable Upper End Variable Differential Control Lever A Apply a non permanent locking agent to the variable dif ferential control lever bolt B Install Variable Differential Control Lever Bolt Washer C and Collar D Tighten Install Cable Stopper Plate E Plate Bolt F Check the variable differential control lever play see Vari able Differential Control Lever Play Inspection in Periodic Maintenance chapter FINAL DRIVE 12 35 Front Final Gear Case Variable Differential Control Cable Installation Lubrication the variable differential control cable before installation Route the cable correctly according to the Appendix chap ter WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe operating condition Tighten Torque Variable Differential Control Cable Locknut A 17 N m 1 7 kgf m 12 ft lb Check the variable differential control lever play see Vari able Differential Control Lever Play Inspection in Periodic Maintenance chapter Variable Differential Control Cable Lubrication Whenever the variable differential control cable is re moved lubricate the cable as follows Apply a small amount of multi purpose grease
294. rber Before a front shock absorber is scrapped drill a hole at a point about 15 mm 0 59 in A up from the bottom of the cylinder 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 Rear Shock Absorber Preload Adjustment The spring adjusting sleeve A on rear shock absorber has 5 positions so that the spring can be adjusted for differ ent terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following table Spring Action Position Spring Force Setting Load Terrain Speed 1 Soft Light Smooth Low 2 STD 3 4 5 Stronger Hard Heavy Rough High Remove the axle guard Turn the adjusting sleeve on rear shock absorber to the desired position with the wrench Special Tool Steering Stem Nut Wrench 57001 1100 Rear Shock Absorber Removal Support the vehicle on a stand or a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 While holding the rear wheels remove the lower and up per shock absorber mounting bolts A nuts and wash ers Remove the rear shock absorber B 14 10 SUSPENSION Shock Absorbers Rear Shock Absorber Installation Apply grease to the inside of bushing A and grease seal lips B Install Collar C Install
295. re Warning Light Switch 6 9 0 70 61 in lb SS 3 Oil Pressure Switch 15 1 5 11 SS 4 Oil Pressure Switch Terminal Bolt 1 5 0 15 13 in lb 5 Regulator Rectifier Mounting Bolts 8 8 0 90 78 in lb 6 Fuel Level Sensor Mounting Bolts 2 0 0 20 18 in lb 7 Radiator Fan Breaker OP Optional Parts for U S A and Canada models R Replacement Part Fuel Pump Gasket SS Apply silicone sealant Kawasaki Bond 56019 120 17 12 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery Capacity 12 V 12 Ah Charging System Alternator Type Three phase AC Charging Voltage 14 15 V Regulator Rectifier Output Voltage Alternator Output Voltage 38 58 V 3 000 r min rpm Stator Coil Resistance 0 29 0 43 Ignition System Spark Plug Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in Spark Plug Cap Resistance 3 75 6 25 k Ignition Coil 3 Needle Arcing Distance 7 mm 0 28 in or more Primary Winding Resistance 0 09 0 13 Secondary Winding Resistance 3 8 5 8 k Primary Peak Voltage 120 V or more Crankshaft Sensor Resistance 423 517 Crankshaft Sensor Peak Voltage 2 V or more Vehicle Down Sensor Detection Method Magnetic
296. rface Such a shock to the part can damage it Drain the coolant see Coolant Change in Periodic Main tenance chapter Disconnect the switch lead connector A Remove the switch B Coolant Temperature Warning Light Switch Installation Apply silicone sealant to the threads of the switch and tighten it Sealant Kawasaki Bond Silicone Sealant 56019 120 Torque Coolant Temperature Warning Light Switch 6 9 N m 0 70 kgf m 61 in lb Fill the coolant see Coolant Change in Periodic Mainte nance chapter Coolant Temperature Warning Light Switch Inspection Refer to the Electrical System chapter ENGINE TOP END 5 1 5 Engine Top End Table of Contents Exploded View 5 2 Specifications 5 8 Special Tools and Sealant 5 11 Camshaft Chain Tensioner 5 13 Camshaft Chain Tensioner Removal 5 13 Camshaft Chain Tensioner Installation 5 13 Rocker Case 5 15 Rocker Case Removal 5 15 Rocker Case Installation 5 16 Rocker Arm Removal 5 17 Rocker Arm Installation 5 18 Rocker Arm Inspection 5 18 Rocker Shaft Diameter Measurement 5 19 Camshaft
297. rication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime Lubricate the points listed below with indicated lubricant NOTE Whenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation Cables Lubricate with Cable Lubricant Brake Cables Throttle Cable Choke Cables Variable Differential Control Cable Lubricate the cables by seeping the oil between the cable and housing The cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant With the cable disconnected at the both ends the cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable Points Lubricate with Grease Throttle Inner Cable Ends A Choke Cable Lower End Brake Cable Ends Variable Differential Control Cable Ends PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Slide Points Lubricate with Grease Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft Bolts and Nuts Tightening Tightness Inspection Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition If there are loose f
298. rication System Engine Oil Change Support the vehicle so that it is level side to side and front to back after warming up the engine Remove the engine drain plug A to drain the oil The oil in the filter can be drained by removing the filter see Oil Filter Change Replace the drain plug gasket with a new one Tighten Torque Engine Drain Plug 20 N m 2 0 kgf m 14 ft lb Pour in the specified type and amount of oil Engine Oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE 10W 40 Amount 2 1 L 2 2 US qt When filter is not removed 2 2 L 2 3 US qt When filter is removed 2 6 L 2 7 US qt When engine is completely dry NOTE Although 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement Drain the engine oil Remove the oil filter A with the oil filter wrench B Special Tool Oil Filter Wrench 57001 1249 Replace the filter with a new one When installing the oil filter be careful of the following Apply oil to the gasket A before installation Tighten the filter with the oil filter wrench Special Tool Oil Filter Wrench 57001 1249 Torque Oil Filter 18 N m 1 8 kgf m 13 ft lb Pour in the specified type and amount
299. ring refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative lead re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system has no prob lem WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medical attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electri cal system Therefore replace a sealed battery only on a vehicle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a ve
300. rive belt is required at least every 90 days of vehicle use average 12 mile day not to exceed 1 700 km 1 100 mile or belt indicator light turn on 100 hours of use counted by the hour meter More frequent inspection is necessary if the vehicle is subjected to hard usage WARNING Neglect abuse or failure to maintain the transmis sion can result in a severely worn or damaged drive belt locking up the transmission and wheels This can cause the operator to lose control and have an accident resulting in injury or death Remove the torque converter cover see Converter Sys tem chapter Measure the width A of the belt at several locations with a pair of suitable straightedges B as shown If any measurements exceed the service limit replace the belt Belt Width Standard 29 7 30 3 mm 1 169 1 193 in Service Limit 28 0 mm 1 102 in Check the belt A for abnormal wear B Measure the width C of the belt at abnormal wear point If any measurements exceed 0 5 mm 0 02 in replace the belt When using the belt of large abnormal wear the drive belt failure detection switch could be activated Check the belt for cracks breaks or peeling If necessary replace the belt with a new one Belt A Crack B Broken C Peeling D NOTE Whenever the belt is replaced inspect the drive and the driven pulleys Drive Belt Deflection Inspection Remove the torque converter cove
301. riven Pulley Confirm the paint mark 0 A on the movable sheave B in alignment with the point C on the fixed sheave D for phase fit of the sheaves Wipe off the molybdenum disulfide grease Remove the four pins A with a thin standard tip screw driver B Remove the movable sheave from the fixed sheave Remove Spacer s A for Drive Belt Deflection Adjustment Driven Pulley Inspection If the sheave surfaces A appear damaged replace the sheaves Replace the sheave with uneven wear on the belt con tacting surfaces A Sheave Surface B Straight Edge CONVERTER SYSTEM 6 23 Driven Pulley If the sheave bushings A are damaged or worn replace the movable sheave Sheave Bushing Inside Diameter Standard 40 000 40 039 mm 1 5748 1 5763 in Service Limit 40 07 mm 1 578 in Inspect seals for damage If seals are damaged replace the movable sheave If the splines A are damaged or worn replace the fixed sheave If the spring is damaged or worn replace the spring Spring Free Length A Standard 99 5 mm 3 92 in If the spring coils are distorted replace the spring Driven Pulley Assembly Clean off any grease or dirt on the movable and fixed sheaves and dry them with a clean cloth Install Spacers A for Drive Belt Deflection Adjustment see Periodic Maintenance chapter Apply grease to the oil seal lips A Press the oil
302. rk on the crankcase 4 Starter Motor 5 Install the oil pressure switch lead not to interfere with starter motor 18 8 APPENDIX Cable Wire and Hose Routing 1 Starter Motor Lead 2 Engine Ground Lead Install the lead so that the flat side of the lower terminal faces toward the engine 3 Install the clamp on the engine ground lead 4 Drive Belt Failure Detecting Switch Lead Connector 5 Engine Brake Actuator Lead Connector 6 Clamps APPENDIX 18 9 Cable Wire and Hose Routing 1 Clamp 2 Vacuum Hose 3 Clamps 4 Boot 5 Clamps 6 Choke Cable Plunger 7 Water Hose 8 White Paint 9 Mark 10 Water Pipe 11 Coolant Catch Tank 12 Ignition Coil 13 Ignition Coil Lead 18 10 APPENDIX Cable Wire and Hose Routing 1 Air Cleaner Cover 2 Breather Tank 3 Breather Hoses 4 Breather Hose 5 Check Valve 6 Duct Screw 7 Air Intake Duct 8 Drain Tube 9 Drain Tube 10 Engine Breather Hose APPENDIX 18 11 Cable Wire and Hose Routing 1 Main Harness 2 Bands 3 Vacuum Hose Blue Line 4 Ignition Coil Lead 5 Torque Converter Air Duct 6 Fuel Hose Red Line 7 Vacuum Hose 8 Clamps 9 Drain Hose 10 Crankshaft Sensor Lead 11 Oil Pressure Switch Lead 12 Alternator Lead 13 2WD 4WD Actuator Lead 14 Plug 15 Frame Pipe 16 Rear Final Gear Case Breather Hose 17 Starter Motor Cable 18 Engine Ground Leads 19 No Interference 20 Engine Side 21 Install the clamp so it does not interfere with the
303. rminal ELECTRICAL SYSTEM 17 83 Drive Belt Failure Detection System If the drive belt failure detection system activated by ab normal belt the drive belt failure detection switch is dam aged Make sure replace the torque converter cover see Converter System chapter Drive Belt Failure Detection System Inspection Refer to the Drive Belt Failure Detection System Inspec tion in the Periodic Maintenance chapter Drive Belt Failure Detection System Circuit 1 Multifunction Meter 2 Actuator Controller 3 2WD 4WD Shift Switch 4 Main Fuse 30 A 5 Igniter 6 Drive Belt Failure Detecting Switch 7 Ignition Switch 8 Starter Relay 9 Battery 10 Engine Ground Terminal 17 84 ELECTRICAL SYSTEM Carburetor Heater System Air Temperature Sensor Inspection Remove Air Cleaner Housing see Fuel System chapter Air Temperature Sensor A Connect the battery A and hand tester B to the sensor lead connector C Special Tool Hand Tester 57001 1394 Battery Red and Yellow Leads Black Lead Hand Tester White Lead Black Lead CAUTION Use the sensor within 30 80 C 22 176 F If it is used without the specified range the sensor will be damaged Suspend the sensor A in a container of cold water of less than 8 C 46 4 F so that the temperature sensing part B is submerged as shown C Ice Suspend an accurate thermometer D in the wate
304. ropeller Shaft 12 52 Rear Propeller Shaft Removal 12 52 Rear Propeller Shaft Installation 12 52 Rear Propeller Shaft Joint Boot Inspection 12 53 Rear Propeller Shaft Inspection 12 53 Rear Axle 12 54 Rear Axle Removal 12 54 Rear Axle Installation 12 54 Rear Axle Joint Boot Inspection 12 54 Rear Axle Joint Boot Replacement 12 55 Rear Final Gear Case 12 61 Rear Final Gear Case Oil Level Inspection 12 61 Rear Final Gear Case Oil Change 12 61 Rear Final Gear Case Removal 12 61 Rear Final Gear Case Installation 12 62 Rear Final Gear Case Disassembly 12 62 Rear Final Gear Case Assembly 12 64 Rear Final Gear Case Right Cover Assembly 12 65 Rear Final Gear Case Front Cover Assembly 12 65 12 2 FINAL DRIVE Rear Final Gear Case Assembly 12 65 Rear Final Bevel Gear Adjustment 12 68 Pinion Gear Unit Disassembly 12 72 Pinion Gear Unit Assembly 12 72 Bearing and Oil Seal 12 73 Ball or Needle Bearing Inspection 12 73 Oil Seal Inspection 12 74 FINAL DRIVE 12 3 Exploded View Blank page 12 4 FINAL D
305. rs B Engine Bottom Guard C Engine Bottom Guard Installation Confirm Damper D Install Engine Bottom Guard Bolts and Collars Rear Bottom Guard Removal Remove Bolts M6 A and Collars Bolt M8 B and Collar Rear Bottom Guard C Rear Bottom Guard Installation Install Rear Bottom Guard A Bolt M8 B and Collar Bolts M6 C and Collars FRAME 16 19 Flaps and Footboards Left Footboard Removal Remove Screws A and Collars Bolts B and Collars Remove Screws A and Collars Bolts B and Collars Left Footboard C Left Footboard Installation Install Left Footboard A Bolts B and Collars C Screws D and Collars E Right Footboard Removal Remove Screws A and Collars Bolts B and Collars Remove Screws A and Collars Bolts B and Collars Right Footboard C 16 20 FRAME Flaps and Footboards Right Footboard Installation Install Right Footboard A Bolts B and Collars C Screws D and Collars E Footboard Bracket installation Install Footboard Bracket A Tighten Torque Footboard Bracket Bolts B 42 N m 4 3 kgf m 31 ft lb FRAME 16 21 Trailer Hitch Bracket Trailer Hitch Bracket Removal Remove Trailer Hitch Bracket Bolts A Trailer Hitch Bracket B Trailer Hitch Bracket Installation Install the trailer hitch bracket A as shown Tighten Torque Hitch Bracket Bolts 82 N m
306. ry slightly to change the float height Float Height Standard 2 9 1 mm 0 11 0 04 in Measure the float height A from the mating surface B of float by tilting the carburetor so that the tang of the float C just touches the needle rod D At this time the float valve E rod must not be depressed Increasing the float height lowers the fuel level and de creasing the float height raises the fuel level Assemble the carburetor and recheck the fuel level If the fuel level cannot be adjusted by this method the float or the float valve is damaged Carburetor Synchronization Inspection Remove Side Covers see Frame chapter Throttle Link Case Cover Check idle speed Remove the front vacuum hose A and install the vacuum hose for vacuum gauge FUEL SYSTEM 3 15 Carburetor Remove the rear vacuum hose A and install the vacuum hose for vacuum gauge Connect Vacuum Gauge A Special Tool Vacuum Gauge 57001 1369 Connect the fuel hose of a suitable fuel tank B to the carburetor Start the engine and read the intake vacuum of each car buretor when idling If the vacuum is out of the specified range adjust it Carburetor Synchronization Vacuum Standard Less than 2 7 kPa 2 cmHg difference between carburetors Carburetor Synchronization Adjustment Turn the adjust screw A to synchronize the carburetors If the carburetor synchronization cannot be obtained by usin
307. s 10 6 Special Tools and Sealant 10 8 Crankcase 10 9 Crankcase Disassembly 10 9 Crankcase Assembly 10 9 Crankshaft Connection Rod 10 13 Crankshaft Removal 10 13 Crankshaft Installation 10 13 Connecting Rod Removal 10 13 Connecting Rod Installation 10 13 Crankshaft Connecting Rod Cleaning 10 14 Connecting Rod Bend
308. s Link Arm B Remove Link Case Screws A Link Case B Separate the Carburetors Carburetor Joining Install link case and tighten link case screws Apply grease to the link pins A Install the link arm as shown Washers B Collars C Link Arm D Cotter Pins E Bend the ends of the cotter pins Install the fuel hose fittings and tighten the screws FUEL SYSTEM 3 21 Carburetor Visually synchronize the throttle butterfly valves Check to see that all throttle valves open and close smoothly without binding when turning the pulley Visually check the clearance A between the throttle valve and the carburetor bore in each carburetor If there is a difference between two carburetors turn the balance adjusting screw A to obtain the same clearance Install the carburetors see Carburetor Installation Adjust the synchronization see Synchronization Adjust ment Carburetor Cleaning WARNING Clean the carburetor in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the carburetor CAUTION Do not use compressed air on an assembled carbu retor the float may be crushed by the pressure and the vacuum piston diaphragm may be damaged Remove as many rubber or
309. s M12 93 9 5 69 L Rear Final Gear Case Right Cover Bolts M10 49 5 0 36 L Rear Final Gear Case Right Cover Bolts M8 24 2 4 17 L Rear Final Gear Case Oil Filler Cap 29 3 0 22 Rear Final Gear Case Oil Drain Plug 13 1 3 113 in lb Bracket Bolts 59 6 0 43 Rear Final Gear Case Nuts 72 7 3 53 TB Brakes Reservoir Cap Screws 1 5 0 15 13 in lb Brake Lever Pivot Bolt 6 0 0 60 53 in lb Brake Lever Pivot Bolt Locknut 6 0 0 60 53 in lb Master Cylinder Clamp Bolts 9 0 0 92 80 in lb S Bake Hose Banjo Bolt 25 2 5 18 Brake Caliper Mounting Bolts 25 2 5 18 Bleed Valves 5 4 0 55 48 in lb Brake Disc Mounting Bolts 37 3 8 27 L Caliper Holder Shaft 17 1 7 13 Pad Mounting Bolts 17 1 7 13 Variable Differential Control Lever Bolt L Gasket Screws L Suspension Front Shockabsorber Mounting Nuts 34 3 5 25 Front Suspension Arm Pivot Nuts 42 4 3 31 Front Knuckle Joint Nuts 29 3 0 22 Rear Shockabsorber Mounting Nuts 34 3 5 25 PERIODIC MAINTENANCE 2 9 Torque and Locking Agent Torque Fastener N m kgf m ft lb Remarks Stabilizer Holder Bolts 23 2 3 17 Stabilizer Joint Nuts 48 4 8 35 Rear Suspension Arm Pivot Nuts 48 4 8 35 Rear Knuckle Mounting Nuts 48 4 8 35 Steering Handlebar Holder Bolts 29 3 0 22 S Steering Stem Clamp Bolts 25 2 5 18 Tie rod End Nuts 42 4 3 31 Ti
310. s locked by the circlip Squeeze all of the special grease A into the new boot B and slide the boot onto the outboard joint C Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot Hold the axle at this setting Standard Length of Assembling Right Front Axle 178 6 mm 7 03 in A FINAL DRIVE 12 29 Front Axle Left Front Axle 178 6 mm 7 03 in A Open the edge A of the boot in order to equalize the air pressures Tighten the large band A and bend the tangs securely to hold down the end of the band Maximum Outside Diameter of Band 80 2 mm 3 16 in After tightening the outside diameter Inboard Joint Boot Removal Remove Front Axle see Front Axle Removal Boot Bands A Scrap the removed boot bands Slide the joint boot toward the outboard joint B Remove the retaining ring A Separate to the axle shaft 12 30 FINAL DRIVE Front Axle Remove the steel balls A Slide the cage B toward the center of the axle Remove Circlip A Special Tool Outside Circlip Pliers B 57001 144 Remove the inner race A using a suitable bearing re mover B Remove the inboard joint boot C Inboard Joint Boot Installation Wind the tape on the splines of the axle shaft in order to protect the joint boot Install New Small Band A New Inboard Joint Boot B Cage C
311. serting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment It should be within 30 degree Loosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut 11 14 WHEELS TIRES Front Hub Front Hub Disassembly Assembly If any hub bolt A is damaged replace it Remove the hub bolt from hub B using a press Press the hub bolt using a press WHEELS TIRES 11 15 Rear Hub Rear Hub Removal Remove Cap A Cotter Pin B Loosen the axle nut C Remove Wheel see Wheel Removal Axle Nut A Rear Hub B Rear Hub Installation Wipe dry the spline portion of the hub Wipe dry the threads and seating surface of the nuts Tighten Torque Rear Axle Nuts 265 N m 27 kgf m 195 ft lb Insert a new cotter pin A NOTE When inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment It should be within 30 degree Loosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut 11 16 WHEELS TIRES Rear Hub Rear Hub Disassembly Assembly If any hub bolt A is damaged replace it Remove the hub bolt from hub B using a press Press the hub bolt using a press FI
312. serve tank to be stored there temporarily Conversely as the engine cools down the coolant in the radiator and the water jacket contract and the stored coolant flows back to the radiator from the reserve tank The radiator cap has two valves One is a pressure valve which holds the pressure in the system when the engine is running When the pressure exceeds 93 123 kPa 0 95 1 25 kgf cm 14 18 psi the pressure valve opens and releases the pressure to the reserve tank As soon as pressure escapes the valve closes and keeps the pressure at 93 123 kPa 0 95 1 25 kgf cm 14 18 psi When the engine cools down another small valve vacuum valve in the cap opens As the coolant cools the coolant contracts to form a vacuum in the system The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator COOLING SYSTEM 4 5 Coolant Flow Chart 1 Radiator 2 Radiator Cap 3 Radiator Fan Switch 4 Radiator Fan 5 Coolant Temperature Warning Light Switch 6 Thermostat 7 Cylinder 8 Cylinder Head 9 Water Pump 10 Reserve Tank Black Painted Arrow Hot Coolant White Painted Arrow Cold Coolant 4 6 COOLING SYSTEM Specifications Item Standard Service Limit Coolant Provided when Shipping Type Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixe
313. shaft Sensor Removal Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Mounting Bolts A Plate B Crankshaft Sensor C 17 38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Installation Install Stator Coil Leads A Plate B Crankshaft Sensor C Tighten Torque Crankshaft Sensor Mounting Bolts 5 9 N m 0 60 kgf m 52 in lb Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads Crankshaft Sensor Inspection Remove the seat see Frame chapter Disconnect the crankshaft sensor lead connector A Measure the crankshaft sensor resistance Connect a hand tester between the BK W lead and the BL lead Set the tester to the 100 range Crankshaft Sensor Resistance 423 517 If the tester does not read as specified replace the crank shaft sensor ELECTRICAL SYSTEM 17 39 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE Be sure the battery is fully charged Remove the spark plug caps but do not remove the spark plugs Disconnect Crankshaft Sensor Lead Connector A Set the hand tester B to the 10 V DC range Connect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Brand KOWA SEI
314. shifter B and inner surface C of the coupling Install the shifter and coupling on the pinion gear shaft D Apply grease to the oil seal lip E Press the oil seal F in the front final gear case so that the oil seal surface is flush G with the case end Special Tool Oil Seal Driver 70 57001 1506 Hold the front final gear case with the gear holder amp socket wrench A in a vise Special Tool Gear Holder amp Socket Wrench Hex 24 57001 1489 Install Washer A Front Final Gear Case Coupling Nut B Tighten Torque Front Final Gear Case Coupling Nut 25 N m 2 5 kgf m 18 ft lb Install the variable differential control shaft lever A on the shift shaft B so that the punch mark C on the lever aligns with the punch mark D on the shaft as shown E 45 8 50 4 mm 1 803 1 984 in Tighten Torque Variable Differential Control Shift Shaft Lever Bolt F 8 8 N m 0 90 kgf m 78 in lb Oil Seal Installation Press the oil seal A in the front final gear case left cover B to the dimension as shown C 4 6 5 6 mm 0 18 0 22 in 12 44 FINAL DRIVE Front Final Gear Case Ring Gear Disassembly Remove Ring Gear Assembly see Front Final Gear Case Disas sembly Ring Gear Bolts A Ring Gear B Remove Differential Gear Case Cover A Right Side Gear 16T B Pins C Spider Gear Shaft D Spider Gears 10T E Left Side
315. ssembly 57001 910 Valve Seat Cutter 45 27 5 57001 1114 Valve Seat Cutter 32 28 57001 1119 Valve Seat Cutter 60 30 57001 1123 Valve Seat Cutter Holder Bar 57001 1128 Valve Seat Cutter 45 30 57001 1187 Valve Seat Cutter 32 33 57001 1199 5 12 ENGINE TOP END Special Tools and Sealant Valve Spring Compressor Adapter 22 57001 1202 Valve Guide Arbor 5 57001 1203 Valve Guide Reamer 5 57001 1204 Valve Seat Cutter Holder 5 57001 1208 Piston Pin Puller Adapter 14 57001 1211 Filler Cap Driver 57001 1454 Compression Gauge Adapter M10 1 0 57001 1458 Kawasaki Bond Silicone Sealant 56019 120 ENGINE TOP END 5 13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type cam chain tensioner The push rod does not return to its original position once it moves out to take up cam chain slack Ob serve all the rules listed below When removing the tensioner do not take out the mounting bolts only partway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the cam chain timing and damage the valves Remove Cap Bolt A and Washer Pin and Sprin
316. sses when drilling the hole as the gas may blow out bits of drilled metal when the hole opens 14 12 SUSPENSION Suspension Arms Front Suspension Arm Removal Remove Front Wheels see Wheels Tires chapter Wheel Hub A Bolt B and Brake Hose C from Suspension Arm Brake Caliper from Brake Disk Knuckle Joint D see Steering chapter Front Shock Absorber Mounting Bolt E lower Remove Suspension Arm Pivot Bolt A Front Upper Suspension Arm B and Knuckle Remove Tie rod End Guard Bolts A Suspension Arm Pivot Bolts B Front Lower Suspension Arm C and Knuckle Remove the knuckle joint A from the suspension arm B using a suitable nut C as shown SUSPENSION 14 13 Suspension Arms Front Suspension Arm Installation Clean the taper surface A of the suspension arm B and shank of the knuckle joint Install Front Upper Suspension Arm Front Lower Suspension Arm Suspension Arm Pivot Bolts and Nut temporary Knuckle Joint see Steering chapter Front Shock Absorber Mounting Bolt lower Tighten Torque Front Suspension Arm Pivot Nuts 42 N m 4 3 kgf m 31 ft lb Front Knuckle Joint Nut 29 N m 3 0 kgf m 22 ft lb Front Shock Absorber Mounting Bolt 34 N m 3 5 kgf m 25 ft lb Install Brake Hose Front Wheels see Wheels Tires chapter Front Suspension Arm Disassembly Front Upper Suspension Arm Remove Collar A rear side Sleeve B front
317. stall Wave Washers D as shown Rocker Arms as shown Rocker Shafts and O rings Tighten Torque Rocker Shaft Bolts E 20 N m 2 0 kgf m 14 ft lb Rocker Arm Inspection Inspect the area A on the rocker arm where the cam rubs If the rocker arm is scored discolored or otherwise dam aged replace it Also inspect the camshaft lobes Inspect the end of the valve clearance adjusting screws B where it contacts the valve stem If the end of the adjusting screw is mushroomed or dam aged in any way or if the screw will not turn smoothly replace it Also inspect the end of the valve stem Measure the inside diameter C of the rocker arm with a dial bore gauge If the rocker arm inside diameter is larger than the service limit replace it Also check the rocker shaft diameter see Rocker Shaft Diameter Measurement Rocker Arm Inside Diameter Standard 12 000 12 018 mm 0 4724 0 4731 in Service Limit 12 05 mm 0 474 in ENGINE TOP END 5 19 Rocker Case Rocker Shaft Diameter Measurement Measure the diameter A of the rocker shaft where the rocker arm pivots on it with a micrometer If the rocker shaft diameter is smaller than the service limit replace it Also check the rocker arm inside diameter see Rocker Arm Inspection Rocker Shaft Diameter Standard 11 983 11 994 mm 0 4718 0 4722 in Service Limit 11 96 mm 0 471 in 5 20 ENGINE TOP END Camshaft Camshaf
318. stem 17 34 Spark Plug Removal 17 34 Spark Plug Installation 17 34 Spark Plug Cleaning Inspection 17 35 Spark Plug Gap Inspection 17 35 Ignition Coil Removal 17 35 Ignition Coil Installation 17 35 Ignition Coil Inspection 17 36 Ignition Coil Primary Peak Voltage Inspection 17 37 Crankshaft Sensor Removal 17 37 Crankshaft Sensor Installation 17 38 Crankshaft Sensor Inspection 17 38 Crankshaft Sensor Peak Voltage Inspection 17 39 Alternator Rotor Inspection 17 39 Ignition Timing Test 17 39 Vehicle down Sensor Outline 17 40 Vehicle down Sensor Removal 17 41 Vehicle down Sensor Installation 17 41 Vehicle down Sensor Inspection 17 41 Electric Starter System 17 45 Starter Motor Removal 17 45 Starter Motor Installation 17 45 Starter Motor Disassembly 17 46 Starter Motor Assembly 17 47 Commutator Cleaning Inspection 17 48 Armature Inspection 17 48 Starter Motor Brush Length 17 49 Brush Assembly Inspection 17 49 Brush Plate and Terminal Bolt Inspection 17 49 Starter Relay Inspection 17
319. t Drive Pulley Covers Part Number Paint Color A Length B 14041 1159 Red 24 0 mm 0 945 in 14041 1160 Blue 25 4 mm 1 000 in 14041 1161 No Paint 24 7 mm 0 972 in Measure the length again after the drive pulley cover is replaces If the length is not within the specified length replace the drive pulley assembly CONVERTER SYSTEM 6 21 Driven Pulley Driven Pulley Removal Remove Torque Converter Cover see Torque Converter Cover Removal Drive Pulley see Drive Pulley Removal Drive Belt see Drive Belt Removal Using the flywheel amp pulley holder A and attachments B remove the driven pulley nut C and washers Nut has R H threads Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Remove Driven Pulley Driven Pulley Disassembly Hold the drive amp driven pulley holder A in a vise Special Tool Drive amp Driven Pulley Holder 57001 1473 Screw the guide bar B into the holder Special Tool Spring Holder Set 57001 1483 Put the driven pulley C on the guide bar Tighten the nut D and compress the spring with the spring holder E Special Tool Spring Holder Set 57001 1483 Remove the circlip A with circlip pliers B Special Tool Circlip Pliers 57001 154 Remove the nut and spring holder C Remove Spring Seats A Spring B Thrust Plate C 6 22 CONVERTER SYSTEM D
320. t Radiator fan switch trouble Thermostat trouble Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly in stalled too loose Shifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive pulley spring incorrect installed too tight Driven pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift arm bent or seized Gear stuck on the shaft Shift tie rod maladjusted Shift tie rod damaged Jumps out of gear Shifter groove worn Gear dogs worn Shift block worn Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Drive shaft output shaft and or gear splines worn Overshifts Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Abnormal Engine Noise Knocking Igniter trouble Carbon built
321. t Removal Remove Camshaft Chain Tensioners see Camshaft Chain Ten sioner Removal Rocker Cases see Rocker Case Removal Camshafts A Support the chain using a suitable tool Camshaft Installation Using a wrench on the alternator bolt turn the crankshaft clockwise until T R mark A is aligned with the notch B in the inspection window The rear camshaft A has a groove B First install the rear camshaft Face the arrow A of the rear camshaft sprocket upward left side view Engage the rear camshaft chain with the rear camshaft sprocket Align the marks B on the weights with the rear cylinder head upper surface Using a wrench on the alternator bolt turn the crankshaft clockwise 270 Align the T F mark A with the notch B in the inspection window ENGINE TOP END 5 21 Camshaft Face the arrow A of the front camshaft sprocket upward right side view Engage the front camshaft chain with the front camshaft sprocket Align the marks B on the weights with the front cylinder head upper surface Install Rocker Cases see Rocker Case Installation Camshaft Chain Tensioners see Camshaft Chain Ten sioner Installation Check the valve clearance see Valve Clearance Inspec tion Camshaft Assembly Install the KACR unit A sprocket on the camshaft so that the unit fits onto the camshaft pins B Apply a non permanent lockin
322. t released during starting the weights are not returning to their rest position Remove the camshaft see Camshaft Removal Remove the KACR unit Visually inspect the spring If damaged deformed or missing replace the spring Remove the spring and move the weights back and forth If the weights do not move smoothly replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Rest Position compression is released B Weights C Spring 2 If compression is released while the engine is running the weights are not swinging out Remove the spring and move the weights back and forth If the weights do not move easily from the retracted po sition replace the KACR unit Also inspect the exhaust rocker arm for any damage and replace the rocker arm if necessary A Running Position compression is not released B Weights C Spring KACR Removal Remove Camshaft see Camshaft Removal Camshaft Sprocket Bolts A KACR Unit B 5 24 ENGINE TOP END Camshaft Remove Circlips A Weights B Spring C NOTE Do not remove the shaft A and pin B If the parts are removed they cannot be reinstalled KACR Installation Install Weights Circlips Spring A Hook the spring from the outside with the open side of the hook inwards Install KACR Unit Hook the arms B on the pins Apply a non permanent lock
323. t to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected First FREQUENCY Service Regular Service OPERATION After 10 hrs or 100 km 60 mi of use Every 10 days or 200 km 120 mi of use Every 30 days or 600 km 360 mi of use Every 90 days 1 700 km 1 100 mi or when belt indicator light turns on 100 hrs of use whichever comes first Every year of use See page ENGINE Converter drive belt wear inspect 2 25 Converter drive belt deflection inspect 2 25 Drive belt failure detection system function inspect 2 37 Engine brake control lever inspect 2 27 Air cleaner inspect 2 17 Throttle lever play inspect 2 14 Choke lever play inspect 2 14 Idle speed inspect 2 15 Valve clearance inspect 2 23 Fuel system cleanliness inspect 2 16 Engine oil change 2 27 Oil filter replace 2 28 Spark plug clean and gap 2 36 Spark arrester clean 2 24 Fuel hoses and connections inspect 2 18 Fuel hose replace 4 years 2 18 Radiator clean 2 19 Radiator hoses and connections check 2 20 Coolant change 2 years 2 20 CHASSIS Joint boots inspect 2 39 Rear brake pedal and lever play inspect
324. ter pins must be replaced with new ones whenever disassembled Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given 1 4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally when installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit Then tighten them according to the specified se quence to prevent case warpage or deformation which can lead to malfunction Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets and O rings after disassembly can reduce sea
325. ternator and Crankshaft Sensor Lead Connectors dis connect Alternator Cover Bolts A Alternator Cover B ELECTRICAL SYSTEM 17 27 Charging System Alternator Cover Installation Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces Check that the dowel pins A are in place and fit a new gasket on the crankcase Check that the bearing B is in place Fit the grommets A into the notch in the cover Grease the alternator cover oil seal Tighten Torque Alternator Cover Bolts 8 8 N m 0 90 kgf m 78 in lb Check that the O ring A in the collar B is in good con dition Apply grease to the O ring Install the collar on the alternator cover Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1520 Install the pulley A so that the holes of the pulley fit on the pins B of the collar Tighten Torque Alternator Rotor Bolt C 127 N m 13 kgf m 94 ft lb Install the removed parts see appropriate chapter Pour Coolant see Coolant Change section in the Periodic Maintenance chapter Engine Oil see Engine Oil Change section in the Peri odic Maintenance chapter 17 28 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal Remove Alternator Cover see Alternator Cover Removal Ball Bearing A Thread the flywheel puller
326. ternator cover using the bearing remover Special Tools Bearing Remover Shaft 9 B 57001 1265 Bearing Remover Head 10 12 C 57001 1266 Press out the mechanical seal A and oil seal B from the inside of the alternator cover with the bearing driver set C Special Tool Bearing Driver Set 57001 1129 CAUTION If either the mechanical seal oil seal or the ball bearing is removed make sure to replace all of them simultaneously with a new one Be careful not to block the inspection hole with the oil seal If the inspection hole is blocked the coolant may pass through the oil seal and flow into the crankcase 4 12 COOLING SYSTEM Water Pump Apply heat resistance grease on the oil seal lip From outside the alternator cover press and insert the oil seal A flush B in the direction as shown Special Tool Bearing Driver Set 57001 1129 From inside the alternator cover press and insert the ball bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 Using a suitable socket A and the bearing driver B press and insert a new mechanical seal C until its flange stops at the step D of the hole Special Tool Bearing Driver Set 57001 1129 Clean the sliding surface of a new mechanical seal with a high flash point solvent and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica tion Apply coolant to the s
327. tery is fully charged Remove Seat see Frame chapter Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector G Terminal 7 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Push the switch to the 4WD position Controller Output Voltage at 2WD 4WD Shift Switch OFF 4WD Standard about 5 V If the reading is not standard check the 2WD 4WD shift switch or actuator controller unit Push the switch to the 2WD position Controller Output Voltage at 2WD 4WD Shift Switch ON 2WD Standard 0 V If the reading is not standard check the 2WD 4WD shift switch or actuator controller unit Check 6 Controller Unit Inspection NOTE Be sure the battery is fully charged Remove Seat see Frame chapter Connect Controller Connector A Hand Tester B range DC 10 V Tester Connector O Terminal 2 Tester Connector BK Y Terminal 10 Install the needle adapters on the tester leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Turn ON the ignition switch Measure the controller output voltage for the actuators Controller Output Voltage to Actuators Standard 4 8 0 2 V If the reading is not standard replace the actuator con troller unit EL
328. that flows through the gauge when measuring it with a tester is very low thus making the measurement easily affected by the oxidized film of the resistance plate and resulting in excessive resistance Therefore make sure to wipe the resistance plate with alcohol before taking a measurement If the readings are not as specified replace the fuel pump assembly Fuel Level Sensor Resistance Standard Full Level Position C 120 Empty Level Position D 3 ELECTRICAL SYSTEM 17 61 Fuel Level Sensor Fuel Level Sensor Circuit 1 Multifunction Meter 2 Fuel Level Sensor 3 Ignition Switch 4 Main Fuse 30 A 5 Starter Relay 6 Battery 7 Engine Ground Terminal 17 62 ELECTRICAL SYSTEM Meter Multifunction Meter Unit Removal Remove Handle Cover Screws A Remove Handle Cover Screws A Handle Cover Front B Remove Meter Lead Connectors A Handle Cover Screws B Remove Handle Cover Screw A Handle Cover Rear B Remove Bracket Mounting Screws A Meter and Bracket B Upper Damper ELECTRICAL SYSTEM 17 63 Meter Remove Multifunction Meter Mounting Nuts A and Washers Bracket B Multifunction Meter Unit C CAUTION Do not drop the meter unit Multifunction Meter Unit Inspection Remove Multifunction Meter Unit see Multifunction Meter Unit Removal CAUTION Do not drop the meter unit A Meter Unit Lead Connector 1 Speed Sensor Pulse 2 Be
329. the hole If the groove of the bevel gear holder nut is not seen loosen the other three bolts Drive the gear shaft end using a copper mallet until the grooves of the bearing holder nut can be seen again Retighten the nut holding bolts 4 securely into the groove of the bevel gear holder nut in the output drive bevel gear housing Special Tool Nut Holding Bolts 57001 1481 Repeat the above procedure and remove the bevel gear from the housing Remove the bearing holder A using the hexagon wrench B Special Tool Hexagon Wrench Hex 41 57001 1491 If the holder seems too difficult to break free apply heat to softer the locking agent Remove Outer Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 Remove Output Drive Bevel Gear Holder Nut Inner Ball Bearing A Special Tool Oil Seal amp Bearing Remover B 57001 1058 FINAL DRIVE 12 17 Output Bevel Gears Output Drive Bevel Gear Assembly Press the new inner ball bearing until it is bottomed Special Tool Bearing Driver Set A 57001 1129 Apply a non permanent locking agent to the threads of the bearing holder A and tighten it so that the deep side B faces outward Torque Bearing Holder 118 N m 12 kgf m 87 ft lb Press the output drive bevel gear until it is bottomed Apply a non permanent locking agent to the threads of the bevel gear holder nut A and tighten it
330. the trim seal in the cover B 10 mm 0 39 in Check Drive Belt Failure Detection Switch see Switch Inspec tion section in Electric System chapter Set A the switch lever B to the ON mark side C Converter Cover D Front E NOTE The failure detection system is activated when the switch is in the ON position This is the normal running mode Engine rpm is limited when the switch is in the OFF position Tighten loosely 3 Bolt 1 and 2 Bolts Press the cover downward and tighten the cover bolts following the tightening sequence as shown Torque Converter Cover Bolts 8 8 N m 0 90 kgf m 78 in lb A Clamp Torque Converter Cover Disassembly Remove Torque Converter Cover see Torque Converter Cover Removal Engine Brake Actuator see Electrical System chapter Circlip A Spring B Actuator Lever Assembly C CONVERTER SYSTEM 6 11 Torque Converter Actuator Lever Engine Brake Control Lever Assembly Inspection Refer to the Actuator Lever Engine Brake Control Lever Assembly Inspection in the Periodic Maintenance chap ter Torque Converter Cover Assembly Install New Circlip Spring Actuator Lever Assembly Engine Brake Actuator see Electrical System chapter Measure the installation length A of the actuator lever assembly between the cover end B and resin tips C on the actuator lever assembly as follows Actuator Lever Assembly Installation Len
331. the lip of seal before installing the seal Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil or grease as specified Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color GENERAL INFORMATION 1 7 Model Identification KVF750 A1 Left Side View KVF750 A1 Right Side View The KVF750 B1 is a camouflage surface treated model and identical to the KVF750 A1 the base model in every other aspect controls features and specifications 1 8 GENERAL INFORMATION General Specifications Items KVF750 A1 B1 Dimensions Overall Length 2 192 mm 86 30 in Overall Width 1 177 mm 46 34 in Overall Height 1 249 mm 49 17 in Wheelbase 1 283 mm 50 51 in Ground Clearance 269 mm 10 59 in
332. tio 3 122 0 635 Transmission Type 2 speed and reverse Gear Ratios Forward High 3 098 30 26 29 18 20 12 Low 4 833 36 20 29 18 20 12 Reverse 4 028 16 12 18 16 29 18 20 12 Final Drive System Type Shaft 2WD 4WD Reduction Ratio 4 375 35 8 Overall Drive Ratio Forward High 42 32 8 61 Low 66 02 13 43 Reverse 55 01 11 19 Front Final Gear Case Oil Type API SF or SG API SH or SJ with JASO MA class Viscosity SAE10W 40 Capacity 0 40 L 0 42 US qt Rear Final Gear Case Oil Type MOBIL FLUID 424 CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Capacity 0 72 L 0 76 US qt Frame Type Double tubular Caster Rake Angle 5 5 Camber 0 King Pin Angle 11 Trail 28 mm 1 10 in Tread Front 915 mm 36 23 in Rear 875 mm 34 45 in 1 10 GENERAL INFORMATION General Specifications Items KVF750 A1 B1 Front tire Type Tubeless Size AT25 8 12 Rear tire Type Tubeless Size AT25 10 12 Suspension Front Type Double Wishbone Wheel Travel 171 mm 6 73 in Rear Type Double Wishbone Wheel Travel 200 mm 7 87 in Brake Front Disc 2 Rear Enclosed wet multi plate Parking Brake Enclosed wet multi plate Electrical Equipment Battery 12 V 12 Ah Headlight Type Semi sealed beam Bulb 12 V 40 40 W 2 Tail brake Light
333. tion Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Pilot Screw Adjustment Adjust the pilot screw if necessary Remove the air cleaner cover see Frame chapter Turn the carburetor pilot screw A all the way in until it seats lightly Special Tool Pilot Screw Adjuster A 57001 1239 B CAUTION Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement Back the pilot screw out the specified number of turns Carburetor Pilot Screw Setting Standard 2 1 4 turns out Service Fuel Level Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Park the vehicle on a level surface Remove Side Covers see Frame chapter Throttle Link Case Cover Carburetor Drain Hose FUEL SYSTEM 3 13 Carburetor Connect two suitable hoses A to the fuel level gauge B and the float chamber of the carburetors Special Tool Fuel Level Gauge 57001 1017 Mark the additional graduation C 15 mm 0 59 in higher than the top graduation D Hold the gauge so that the additional graduation is placed slightly higher t
334. tly installed there will be no gap D at the front and an even gap E at the rear after tightening Install Right Switch Housing Throttle Case A Front Brake Lever Master Cylinder B Punch Mark C D 70 mm 2 76 in Install the left switch housing C on the handlebar B so that the opening angle is 40 A or less NOTE Do not open the housing more than 40 the built in parts in the housing may be damaged STEERING 15 15 Handlebar Install Left Switch Housing A Rear Brake Lever Assembly B Punch Mark C D 6 mm 0 24 in FRAME 16 1 16 Frame Table of Contents Exploded View 16 2 Seat 16 8 Seat Removal 16 8 Seat Installation 16 8 Carriers 16 9 Front Carrier Removal 16 9 Front
335. too difficult to break free apply heat to softer the locking agent Remove Pinion Gear Bearing Holder FINAL DRIVE 12 39 Front Final Gear Case Remove Pinion Gear Unit A Shim s Front Final Gear Case Coupling Inspection If the coupling bushing A is damaged or worn replace the front final gear case coupling Front Final Gear Case Coupling Bushing Inside Diameter B Standard 13 000 13 018 mm 0 5118 0 5125 in Service Limit 13 048 mm 0 5137 in Front Final Gear Case Assembly Install Ball Bearing A Needle Bearing B Press the ball bearing and needle bearing until they are bottomed Install Circlip C Special Tool Inside Circlip Pliers 57001 143 Install Oil Seal D Insert the oil seal so that the rubber surface is flush E with the end of hole Apply grease to the oil seal lip Visually check the pinion gear and ring gear for scoring chipping or other damage Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact Insert the pinion gear in the front final gear case right cover 12 40 FINAL DRIVE Front Final Gear Case Install Ring Gear Assembly Apply grease to the O ring A on the front final gear case center cover Install Front Final Gear Case Center Cover A Tighten the cover bolts following the tightening sequence as shown Torque Front
336. ttle Lever Free Play Inspection in the Periodic Maintenance chapter Throttle Lever Free Play Adjustment Refer to the Throttle Lever Free Play Adjustment in the Periodic Maintenance chapter Throttle Case Removal Disassembly Remove the throttle case screws A and pull the case open Slide the cable adjuster dust cover out of place Remove the rubber cover A Pull the cable tip A out of the throttle lever catch with the throttle lever opened Loosen the locknut B and unscrew the adjuster C Disassemble the throttle case as follows Remove the throttle lever screw D lockwasher and flat washer and lift the throttle lever E and return spring from the case Pull the throttle control lever F out of the case Throttle Case Assembly Installation Lubricate the throttle case and cable before assembly in stallation Be certain that the return spring is correctly installed on the throttle lever A FUEL SYSTEM 3 9 Throttle Lever and Cable Swing the throttle control lever so that the carburetor throt tle valve is fully open Turn the throttle limiter screw A until it is spaced about 1 mm 0 04 in B away from the throttle lever stop C Tighten the locknut D NOTE Refer to the Owner s Manual for the function of the throt tle limiter and adjustment procedure of it WARNING Operation with an improperly assembled throttle case could result in an unsafe riding
337. ulfide grease Spline A on Output Shaft of Engine Spline B on Pinion Gear of Rear Final Gear Case Install O rings C Spring D Rear Universal Joint E Align the front universal joint yoke F with the rear univer sal joint yoke G as shown Install the front end H of the propeller shaft Push the rear universal joint forward I and install the rear end J of the rear universal joint on the pinion gear of rear final gear case Install the rubber boots and fit the O rings in the groove of the boots Rear Propeller Shaft Joint Boot Inspection Refer to the Rear Propeller Shaft Joint Boot Inspection in the Periodic Maintenance chapter Rear Propeller Shaft Inspection Remove the rear propeller shaft see Rear Propeller Shaft Removal Check that the universal joints A work smoothly without rattling or sticking If it does rattle or stick the universal joint is damaged Replace the propeller shaft with a new one Visually inspect the splines B on the propeller shaft If they are badly worn chipped or loose replace the pro peller shaft Also inspect the splines on the rear end of the output shaft and the pinion gear in the final gear case If splines are badly worn chipped or loose replace the output shaft and the pinion gear 12 54 FINAL DRIVE Rear Axle Rear Axle Removal Drain the rear final gear case oil see Rear Final Gear Case Oil Change Remove Rear Wh
338. under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle c Addition of components or accessories that result in the vehicle exceeding the stan dards d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW THE V
339. up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guides worn Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Wear guides worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Front or rear final gear case noise Insufficient lubricant Incorrect oil Front final gear case Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted APPENDIX 18 5 Troubleshooting Guide Worn LSD clutch friction plate Front final gear case Thrust plug ma
340. ur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light Check to be sure the rectifier circuit is correct before con tinuing Regulator Circuit Test 1st Step Connect the test light A and the 12 V battery B to the regulator rectifier C as shown Check Y1 Y2 and Y3 terminal respectively If the test light turns on the regulator rectifier is defective If the test light does not turn on continue the test 17 32 ELECTRICAL SYSTEM Charging System Regulator Circuit Test 2nd Step Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step Apply 12 V to the BR terminal Check Y1 Y2 and Y3 terminals If the test light turns on the regulator rectifier is defective If the test light does not turn on continue the test Regulator Circuit Test 3rd Step Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step Momentarily apply 24 V to the BR terminal by adding a 12 V battery Check Y1 Y2 and Y3 terminals CAUTION Do not apply more than 24 V to the regulator recti fier Do not leave the 24 V applied for more than a few seconds or the unit will be damaged If the test light did not light when the 24 V was applied momentarily to the BR terminal the regulator rectifier is defective If the regulator r
341. uretor see Fuel System chapter Alternator Lead Connector A Crankshaft Sensor Lead Connector B Oil Pressure Switch Lead Connector C Remove Water Pipe A and Thermostat Housing B Air Rubber Duct C Front Propeller Shaft D Remove Ignition Coil A rear Spark Plug Cap B Shift Shaft Lever C Vacuum Hoses D Engine Brake Actuator Lead Connector E Drive Belt Failure Detection Switch Lead Connector F Remove Speed Sensor Lead Connector A Rear Propeller Shaft B Remove Water Pipe A Spark Plug Cap B ENGINE REMOVAL INSTALLATION 9 5 Engine Removal Installation Remove Coolant Reserve Tank A Neutral Switch Lead Connector B Reverse Switch Lead Connector C Forward Reverse Detecting Sensor Lead Connector D Water Hose E Remove Footboard Brackets A Engine Mounting Bolts B Engine Mounting Bracket C Remove the engine A as shown Engine Installation Install Engine Engine Mounting Bolts temporary Engine Bracket and Bolts Tighten Torque Engine Bracket Mounting Bolts 72 N m 7 3 kgf m 53 ft lb Engine Mounting Bolt 62 N m 6 3 kgf m 46 ft lb Engine Mounting Nut 62 N m 6 3 kgf m 46 ft lb CRANKSHAFT TRANSMISSION 10 1 10 Crankshaft Transmission Table of Contents Exploded View 10 2 Specification
342. urfaces of the rubber seal and seal ing seat A and press the rubber seal B and sealing seat into the impeller by hand until the seat bottoms out Tighten the water pump impeller by turning the bolt clock wise Torque Water Pump Impeller 7 9 N m 0 80 kgf m 69 in lb COOLING SYSTEM 4 13 Radiator Radiator Removal WARNING The radiator fan is connected directly to the bat tery The radiator fan may start even if the ignition switch is off NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS CONNECTED TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES Drain the coolant see Coolant Change in Periodic Main tenance chapter Remove Radiator Cover see Frame chapter Radiator Fan Motor Lead Connector A Reserve Tank Hose B Radiator Fan Switch Lead Connectors C Radiator Hose D Remove Radiator Hose A Fan Motor Breather Hose B Remove Radiator Bolts A Radiator 4 14 COOLING SYSTEM Radiator Pull the projections A out of from the dampers B and remove radiator C CAUTION Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency Radiator Installation Insert the projections of the radiator in the dampers Install Dampers A Collars B Tighten Torque Radiator Mounting Bolts C 8 8 N m 0 90 kgf m 78 in lb Connect
343. using a press Transmission Installation Insert the driven shaft in the crankcase until it is bottomed using a press Apply engine oil to the needle bearings and install them Install the following parts on the low gear A Needle Bearings B Spacer C P No 92026 1599 48 2 54 3 1 0 High Gear D CRANKSHAFT TRANSMISSION 10 23 Transmission Install Idle Shaft A with Gear Assembly B Spacer C Spacer D P No 92026 1599 48 2 54 3 1 0 Apply engine oil to the inner surface of the spacer E Install the spacer E so that the stepped side F faces outward Install Spacer Toothed Washer A Circlip Special Tool Outside Circlip Pliers 57001 144 Apply engine oil Shift Rod A and Shift Fork Ear B Needle Bearing C Install Shift Rod with Shifter Spacer D Needle Bearing Install Reverse Drive Gear A Spacer B Install Reverse Idle Shaft A 10 24 CRANKSHAFT TRANSMISSION Transmission Apply molybdenum disulfide oil to the shift shaft A Install Shift Shaft Spring Bolt B Spring C Guide D Apply a non permanent locking agent Shift Shaft Spring Bolt Tighten Torque Shift Shaft Spring Bolt 25 N m 2 5 kgf m 18 ft lb When a new bushing A and oil seal B are installed in the shift shaft cover C press and insert the new bushing and oil seal so that their surfaces are flush with the end of the ea
344. utch Bolts 34 3 5 25 L 6 Alternator Stator Bolts 13 1 3 113 in lb 7 Crankshaft Sensor Mounting Bolts 5 9 0 60 52 in lb 8 Alternator Cover Plugs 18 1 8 13 9 Alternator Rotor Bolt 127 13 94 10 Alternator Cover Bolts 8 8 0 90 78 in lb G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts 17 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 17 9 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Spark Plugs 13 1 3 113 in lb 2 2WD 4WD Actuator Mounting Bolts 9 8 1 0 87 in lb L S 3 Engine Brake Actuator Mounting Bolts 8 8 0 90 78 in lb 4 Forward Reverse Detecting Sensor Mounting Bolt 15 1 5 11 5 Speed Sensor Mounting Bolt 8 8 0 90 78 in lb 6 Neutral Position Switch 15 1 5 11 7 Reverse Position Switch 15 1 5 11 8 Ignition Coil Mounting Bolts 8 8 0 90 78 in lb 9 Igniter 10 Actuator Controller 11 Vehicle Down Sensor 12 Power Outlet Connector 120 W 13 Air Temperature Sensor 14 Carburetor Heaters 15 Ground Terminal G Apply grease L Apply a non permanent locking agent S Follow the specific tightening sequence 17 10 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 17 11 Exploded View Torque No Fastener N m kgf m ft lb Remarks 1 Radiator Fan Switch 18 1 8 13 2 Coolant Temperatu
345. vable sheave Install Spring Seat C 18 5 mm 0 728 in Spring D Spring Seat E 9 3 mm 0 366 in Circlip F Tighten nut A and compress the spring with the spring holder B Special Tool Spring Holder Set 57001 1483 Install a new circlip C with circlip pliers D Special Tool Circlip Pliers 57001 154 Remove the driven pulley from the spring holder set Clean the surface of the sheaves with an oil less cleaning fluid Driven Pulley Installation Clean the transmission driven shaft A Install Driven Pulley NOTE When engaging the spline on the driven pulley with the spline B on the shaft do not damage the pulley s spline If any damage occurs remove it with a file Clean the threads of the driven shaft and driven pulley ends to open the air vent passage Wipe off any extra grease Wipe off any protruding grease A 6 26 CONVERTER SYSTEM Driven Pulley Install two washers A on the shaft as shown Crankcase Side B Bolt Head Side C Using a flywheel amp pulley holder A and attachments B tighten the driven pulley nut C Special Tools Flywheel amp Pulley Holder 57001 1343 Pulley Holder Attachment 57001 1472 Torque Driven Pulley Nut 93 N m 9 5 kgf m 69 ft lb CONVERTER SYSTEM 6 27 High Altitude Setting Information Specifications Altitude Drive Pulley Carburetor m ft Ramp Weights Spring Spacer qty Main
346. ve tank cap A then add coolant to the F mark B CAUTION For refilling add the specified mixture of coolant and soft water Adding water alone dilutes the coolant and degrades its anticorrosion properties The diluted coolant can attach the aluminum engine parts In an emergency soft water can be added But the diluted coolant must be returned to the cor rect mixture ration within a few days If coolant must be added often or the reserve tank has run completely dry there is probably leakage in the cooling system Check the system for leaks Coolant Draining Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling Refer to the Coolant Change in the Periodic Maintenance chapter COOLING SYSTEM 4 9 Coolant Pressure Testing Remove the radiator cap and install a cooling system pressure tester A on the radiator filler neck NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leakage Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi CAUTION During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 123 kPa 1 25 kgf cm 18 psi Watch the gauge for at least 6 seconds If the pressure holds steady the system is alright If the pressure drops soon check for leaks 4 10 COOLING SYSTEM Water Pump Water Pump Cover Removal Dr
347. ve the tie rod end nut C and wash ers Tap the tie rod end shaft lightly and remove the tie rod end from the knuckle Remove Cotter Pins and Front Knuckle Joint Nuts A Install a suitable nut A M12 to the knuckle joint end temporary as shown Tap B the knuckle joint end and remove the joint from the front suspension arm C Install a suitable nut A M12 to the knuckle joint end temporary Tap the knuckle joint end and remove the knuckle B Front Knuckle Installation Inspect the spherical bearings in the knuckle joints A If roughness excessive play or seizure is found replace the knuckle joint STEERING 15 9 Steering Check the joint boot A is not torn worn deteriorated or is leaking grease If it is found replace the knuckle joint Clean the shanks B of the knuckle joint Clean the taper surface A in the front suspension arm B Install Washers A and Knuckle Joint Nuts B Tighten Torque Front Knuckle Joint Nuts 29 N m 3 0 kgf m 22 ft lb Tie rod End Nuts 42 Nm 4 3 kgfm 31 ftlb Install the new cotter pins C and bend its both ends Front Knuckle Bearing Removal Remove Front Knuckle see Front Knuckle Removal Circlip A Special Tool Inside Circlip Pliers B 57001 143 Drive the bearing A out using a suitable bearing driver from the bearing driver set Special Tool Bearing Driver Set 57001 112
348. ver and Cable Removal Remove the air cleaner housing see Air Cleaner Housing Removal Remove the carburetor from the carburetor holder see Carburetor Removal Remove the screws A and holder plates B from both carburetors Pull out the starter plungers Hold the starter plunger springs compressed and free the choke cable lower ends A from the plungers B Remove Choke Lever Mounting Screw A Plane Washer and Wave Washer Switch Case Mounting Screws B Free the choke cable upper end A from the choke lever B FUEL SYSTEM 3 11 Choke Lever and Cable Pull off the retaining clip A Fit the cable end A in the grommet B and free the cable from the switch case Pull the cable out of the vehicle Choke Lever and Cable Installation Lubricate the choke cable before installation Install the wave washer plane washer and screw in that order Route the choke cable according to the Appendix chapter WARNING Operation with an incorrectly routed or damaged cable could result in an unsafe riding condition Choke Cable Lubrication and Inspection Whenever the choke cable is removed or in accordance with the Periodic Maintenance chart in the Periodic Main tenance chapter lubricate the cable Refer to the General Lubrication in the Periodic Mainte nance chapter for the cable lubrication and inspection 3 12 FUEL SYSTEM Carburetor Idle Speed Inspec
349. y A 0 6 Resistance B Radiator Fan Breaker C Switch D If the circuit in the breaker will not open within 60 seconds replace the breaker ELECTRICAL SYSTEM 17 59 Radiator Fan System Radiator Fan Breaker Installation Install Radiator Fan Breaker A Holder B Connect White Lead C Blue White Lead D E Electrical Parts Case F Right Side Radiator Fan Circuit 1 Radiator Fan Breaker 2 Radiator Fan Switch 3 Main Fuse 30 A 4 Radiator Fan 5 Starter Relay 6 Battery 12 V12 Ah 7 Engine Ground Terminal 17 60 ELECTRICAL SYSTEM Fuel Level Sensor Fuel Level Sensor Removal Remove Seat see Frame chapter Electrical Parts Case see frame chapter Fuel Level Sensor Lead Connector A Fuel Level Sensor Mounting Bolts B Fuel Level Sensor C Fuel Level Sensor Installation Install New Gasket Fuel Level Sensor Tighten Torque Fuel Level Sensor Mounting Bolts 2 0 N m 0 20 kgf m 18 in lb Fuel Level Sensor Inspection Remove Fuel Level Sensor see Fuel Level Sensor Removal Check that the float moves up and down smoothly without binding It should go down under its own weight If the float does not move smoothly replace the fuel pump assembly Using a hand tester A measure the resistance across the terminals in the fuel pump lead connector B Special Tool Hand Tester 57001 1394 NOTE In contrast to the normal measuring method the current

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