Home

When inserting the cotter pin, if the slots in the nut do

1. 13 25 Caliper Holder Shaft Wear 13 25 Brake Pads 13 26 Front Brake Pad Removal 13 26 Front Brake Pad Installation 13 26 Rear Brake Pad Removal 13 26 Rear Brake Pad Installation 13 27 Brake Pad Wear Inspection 13 27 Brake DISCS x 13 28 Brake Disc Cleaning 13 28 Front Brake Disc Removal 13 28 Front Brake Disc Installation 13 28 Rear Brake Disc Removal 13 28 Rear Brake Disc Installation 13 29 Disc Wear 13 29 Disc 13 29 Front Brake Disc Guard Removal 13 29 Front Brake Disc Guard Installation Proportioning Valve Rear Brake Proportioning Valve 1 Proportioning Valve Installation 13 31 Rear Brake Proportioning Valve 1 5 13 31 Brake 13 32 Brake Hose Inspection 13 32 Brake Hose Replacement 13 32 Brake Lever and Pedal 13 33 Brake Pedal Removal 13 33 Brake Pedal Installation 13 33 Parking Brake erede 13 34 Parking Brak
2. reden Front Fender Installation pp Rear Fender Removal Rear Fender Installation 2 etg ase Ee te e eee ea Cet OE er oe eR ede bug Storage Case eoe dee Itu un MATE weitere Storage Case Pat cota Left Side Cover Removal ee Left Side Cover Installation m m Right Side Cover Removal Right Side Cover InstallatiQn Side Inner Cover Removal th Front Guard Removal Front Guard Installation een eat Front Bottom Guard Removal Front Bottom Guard 4 4 16 19 5 16 20 Left Footboard Removal Seedy dey aa un 16 20 Left Footboard Installation 2 2 4 16 20 Right Footboard REMOVAL tee 16 20 Right Footboard Installation ser essen 16 21 Footboard Bracket 2 0
3. nnn 3 18 Air Cleaner Element Cleaning and 3 19 AirCleaner DRAMA ets 3 19 Air Cleaner Housing Removal 0 3 19 Air Cleaner Housing Installation ee ea 3 20 eases AER ERR 3 21 Fuel Tank Removal ed nic ee 3 21 Fuel Tank Installatiothe s 22 8 De 3 22 Fuel Tap Removal tss ir eri em n de FERRE anheben ans 3 22 Fuel Tap Installations oie ite ri ri e E RARE skin RR can 3 23 Fuel Tank and Fuel Tap Cleaning pp 3 23 Fuel Filter GO 3 23 Fuel Filter Installation ee ERE EB ec adds Eng n 3 23 Fuel Filter INS pecto yor eit trie tet a teet eet Te er d a RU PAS M da d 3 24 3 2 FUEL SYSTEM Exploded View FUEL SYSTEM 3 3 Exploded View Nof I Fuel Tank and nus 2 12 Weimb 2 Front 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View 1 Front G Apply grease R Replacement Parts 3 6 FUEL SYSTEM Specifications Item Standard Throttle Lever and Cable Throttle Lever Free Play Carburetor Type Idle Speed Main Jet Float Height Air Cleaner Air Cleaner Element Oil 1 4 mm 0 04 0 16 in CVK32 1 500 100 r min rpm 108 17 0 2 mm 0 669 0 08 in
4. 14 10 Suspension ATMS ceste cote th tete etae ders pedcs qe ai n eere bri 14 11 Suspension Arm 14 11 Suspension Arm Installation 14 11 Suspension Arm Disassembly xice c cccapecceteeciasccceddcentnedasueechactebechabenteacAcpagadeasbvaagenebees 14 12 SUSPENSION Am Assembly id dp decry rel 14 12 rior igo ccr 14 13 SwIngarmeROImoVal uesic re 14 13 TENET 14 14 swingarm Disassembly 6 ei 14 15 Swingarm ASsemBly ana tech EUR eoi ae bc 14 16 Swingarm Bearing 5 eet reete rere ne einen 14 17 Swingarm Bearing Lubrication pp 14 17 14 2 SUSPENSION Exploded View HM020368W5 C SUSPENSION 14 3 Exploded View No Fastener Torque Nm kgm 1 Steering Knuckle Pivot Nuts 30 Front Shock Absorber Mounting Nuts 39 4 0 29 R 3 Suspension Arm Mounting Nuts 44 4 5 32 R 4 Front R Replacement Parts 14 4 SUSPENSION Exploded View SUSPENSION 14 5 Exploded View 2 Swingarm Pivot Right Shaft 116 11 8 85 6 3 Swingarm Pivot Bolt Left Shaft 11 1 1 97 in Ib 4 Swingarm Pivot Locknut 116 11 8 85 6 5 Front G Apply grease L Apply a non
5. nene nnne nnne rannan nunen nennen 16 21 Footboard Bracket 16 21 16 2 FRAME Exploded View Exploded View FRAME 16 3 No Fastener Xorque Nm kgm fb Footboard Bracket Bolts 26 2 7 19 Front Carrier Bracket Bolts 26 2 7 Front Carrier Bolts M8 26 27 19 Rear Carrier Bolts M8 26 2 7 Front Guard Bolts 26 2 7 19 6 Front 16 4 FRAME Exploded View FRAME 16 5 Exploded View I 4 a 27 9 2 Front R Replacement Parts 16 6 FRAME Exploded View 227 GER CLER H0020788W5 C FRAME 16 7 Exploded View 1 Front R Replacement Parts 16 8 FRAME Seat Seat Removal Remove the seat by lifting the latch lever A of the under rear end of the seat and then pulling the seat up to the rear Seat Installation e Insert the front seat hooks A into the receivers B in the bracket e Push the rear part of the seat down to engage the latch C Pull up the rear end of the seat to make sure it is securely locked Carriers FRAME 16 9 Front Carrier Removal e Remove Bands A Both Sides Cut Front Carrier Bolts M6 B Both Sides Collars Both Sides Front Carrier Bolts M8 C Both Sides Front Carrier D Front Carrier Installation
6. Electric Starter System ELECTRICAL SYSTEM 17 41 Reduction Gears Inspection e Remove Alternator Rotor see Alternator Rotor Removal Remove the reduction gears A and visually inspect it x lf the limiter has wear discoloration or other damage replace it as a unit 118166 17 42 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 NOTE OOn 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 Removal e Disconnect the headlight connector A Open the clamps B e Remove Headlight Mounting Bolts A Headlight Body B Headlight Installation e Installation is the reverse of removal Headlight Bulb and City Light Bulb Replacement e Remove Headlight Body see Headlight Removal Bolts A ELECTRICAL SYSTEM 17 43 Lighting System Remove the screws A to separate the headlight B and headlight cover C Slide the dust cover A Disconnect the connector A Push the hooks B to unlock the headlight bulb Remove the bulb When handling the quartz halogen bulb never touch the glass portion with bare hands Always use a clean cloth Oil contamination from hands or dirty rags ca
7. 3 9 Choke Lever Removal 4 3 9 Choke Lever Installation 4 3 9 Choke Lever Lubrication pp 3 9 Choke Cable Retrioval o dece No ideae 3 10 Choke Cable nennen nns 3 10 Choke Capile Lubrication accesa ere ete dh ente o fe ete ee 3 10 Garburetor a Mu 3 11 Idie Speed lnspeclion ae rn ERBE b bes 3 11 Idle a ag 3 11 Flo t Height Inspector eme eg 3 11 Carburetor Removal Are er le een el e feme fe see an LU eet 3 12 Carburetor Installation eese enm nennen nennen nrene retener nnne rns n nanan 3 13 Carburetor DISassembly 2 0 e reete ert tto Drexler ccce c 3 13 Caiburetor ASSerbly uico Dude ex dere bist eee duda o 3 14 Carburetor Cleaning iocur tn asta sh eic toe 3 16 Carburetor Inspection pp 3 16 AIPGIGarigr s octo ie hoa safest oe x aes ar ph 3 18 Air Cleaner Element mene 3 18 Air Cleaner Element Installation
8. Cylinder Head Cylinder Head Cover Removal Cylinder Head Cover Installation Camshaft Chain Tensioner Camshaft Chain Tensioner Installation Rocker Arms Shafts Rocker Arm Removal Rocker Arm Installation Rocker Arm and Shaft Inspection Stop Plate Inspection ie Camshaft Removal Camshaft Installation Cam Wear Inspection Camshaft Bearing Inspection Camshaft Chain Removal Camshaft Chain Installation Camshaft Chain Guide Wear Cylinder Head Cylinder 5 2 5 6 5 7 5 8 5 8 5 8 5 8 5 9 5 9 5 9 5 10 5 10 5 10 5 11 5 11 5 11 5 13 5 13 5 13 5 13 5 14 5 15 5 15 5 15 5 16 5 16 5 16 5 16 5 17 5 18 Cylinder Head Removal Cylinder Head Installation Cylinder Head Cleaning Cylinder Head Warp Inspection MCI RE Valve Clearance Inspection Valve Clearance Adjustment
9. vede e Mee d Ha Meets 17 10 Wiring mI m 17 12 Special Tools and Sealant niet t m RAT er a een e e REP qe Men den 17 14 Precautions ae a ee lenken onen anni 17 15 IG CU een 17 17 Wiring Inspection 17 17 cde T 17 18 Battery LETT 17 18 Battery alc P 17 18 Battery Ni oi Em 17 18 PEE 17 21 lajizire NAGS 222 IEEE 17 22 Charging Condition Inspection 17 22 Refreshing Charge anni 17 22 Charging den eta 17 24 Alternator Cover ite terit ut e tte een Mn be dax 17 24 Alternator Cover Installation 17 24 Alternator Rotor Removal ua c Eee I ue te ne red tus 17 25 Alternator Rotor Installation Hee 17 26 Alternator Stator 2 ene nnne 17 27 Alternator Stator Installation 17 27 Regulator Rectifier Output Voltage INSPECTION pp 17 28 Alternator eae eae cae 17 29 Regulator Rectifier Removal 2 ala 17 30 Regulat r Reetifier Installation a chen ee lea 17 30 Regulator Rectifier Inspection 4 17 30 Ignition Systemae nira 17 32 Spark Pl g Removal d reap Mute i 17 32
10. Clamp Hold the throttle cable Clamp Hold the main harness Clamp of Frame Hold the ignition coil lead Band Hold the main harness to the frame pipe Ignition Coil Spark Plug Cap Run the ignition coil lead under the choke cable View from A Engine Ground Terminal The ground terminal is tightened together with ignition coil mounting bolt Clamp of Frame Hold the main harness Main Harness Band Hold the battery negative cable and starter motor cable Frame Ground Terminal Fuse Box Starter Circuit Relay Battery Positive Cable Battery Battery Negative Cable Starter Motor Cable 18 12 APPENDIX Cable Wire Routing APPENDIX 18 13 Cable Wire and Hose Routing Reserve Tank Overflow Hose Reserve Tank Hose Clamps Hold the reserve tank hose Radiator Hose Radiator Cap Thermostat Clamp of Frame Hold the radiator hose Water Temperature Sensor Lead Radiator Hose Water Pump Radiator Radiator Hose Cylinder Water Pump Radiator Hose Thermostat Radiator 10 Run the reserve tank hose between the fuel tank and radiator cap bracket 11 Radiator Hose Radiator Cap Radiator 12 Run the water temperature sensor lead under the radiator cap bracket 13 View from A 18 14 APPENDIX Cable Wire Hose Routing APPENDIX 18 15 Cable Wire
11. 13 13 Front Master Cylinder Removal 13 13 Front Master Cylinder Installation 13 13 Rear Master Cylinder Lever 4 13 14 Rear Master Cylinder Lever Installation 13 14 Rear Master Cylinder Pedal 13 15 Rear Master Cylinder Pedal Installation 13 15 Master Cylinder Disassembly pp 13 15 Front Master Cylinder Assembly 13 16 Rear Master Cylinder Lever Disassembly 13 16 Rear Master Cylinder Lever Assembly 13 17 Rear Master Cylinder Pedal 1 5 5 13 17 Rear Master Cylinder Pedal PSSEMDIY iade 13 18 Master Cylinder Inspection Visual Inspectionm serie 13 18 Calipers 13 19 Front Caliper 13 19 Rear Caliper Removal 13 19 Front Caliper Installation 13 20 Rear Caliper Installation 13 20 Front Caliper Disassembly 13 21 Front Caliper Assembly 13 21 Rear Caliper Disassembly 13 22 Rear Brake Caliper Assembly 13 23 Fluid Seal Damage Inspection 13 24 Dust Seal and Friction Boot Damage Inspection 13 24 Brake Fluid Leak Inspection 13 25 Piston and Cylinder Damage
12. Hose Routing QI CN NO Front Brake Rear Brake Hose Steering Shaft Clamp Left and Rear Side Run the parking brake cable Parking Brake Cable Run the parking brake cable backward of the handlebars Handlebar Holder Center Guide Run the front brake hose rear brake hose and parking brake cable through handlebar holder center guide Parking Brake Cable Clamp Radiator Fan Motor Lead Hold the front brake hoses on both sides 18 16 APPENDIX Cable Wire Routing APPENDIX 18 17 Cable Wire Hose Routing Clamp of Frame Hold the parking brake cable Clamp of Frame Hold the rear brake hose Clamps of Frame Hold the parking brake cable and rear brake hose Rear Brake Hose To Proportioning Valve Clamp of Frame Unused Run the parking brake cable between the frame and swingarm Parking Brake Cable Clamps Hold the parking brake cable and rear brake hose Rear Brake Hose Rear Brake Master Cylinder Lever Proportioning Valve Proportioning Valve Rear Brake Hose Proportioning Valve Rear Brake Caliper Rear Brake Hose Proportioning Valve Rear Brake Master Cylinder Pedal Run the rear brake hose pedal between the frame pipe and frame pipe 18 18 APPENDIX Cable Wire Routing APPENDIX 18 19 Cable Wire Hose Routing N
13. Replace the breather hose if any fraying leak craks or bulges are noticed e Check that the hose is securely connected and clamps are installed correctly Replace the hose if it has been sharply bent or kinked Fuel Hose Replacement A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Clamps Fuel Hoses GSO5006BS1 C PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Fit the fuel hose A onto the pipe fully and install the clamps B beyond the raised rib C e Run the fuel hose correctly see Cable Wire and Hose Routing section in the Appendix chapter e Install the removed parts See appropriate chapters Start the engine and check the fuel hose for leaks Cooling System Radiator Cleaning NOTICE 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 through muddy terrains the radiator screen and the radiator should be cleaned immediately e Remove Front Fender see Front Fender Remo
14. Torque Converter Cover Assembly Press in the bearing with the bearing driver Special Tool Bearing Driver Set 57001 1129 e Install the bearing retainer as shown in the figure Apply a non permanent locking agent to the threads of the driven shaft bearing retainer bolt and tighten it Torque Driven Shaft Bearing Retainer Bolt 9 8 N m 1 0 kgf m 87 in Ib CONVERTER SYSTEM 6 7 Torque Converter Cover Bearing Inspection NOTE ODo not remove the bearing for inspection If the bearing is removed it will need to be replaced with a new one Turn the bearing back and forth A while checking for plays roughness or binding x If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage 8008002881 6 x If the seal is torn or is leaking replace the bearing 6 8 CONVERTER SYSTEM Drive Belt Drive Belt Removal Remove the drive pulley see Drive Pulley Removal Remove the clutch outer see Clutch Driven Pulley Re moval NOTE OBefore removing observe the direction the belt s printed information A such as manufacturer s name is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed Remove the clutch driven pulley B and drive belt C Drive Belt Installation NOTE OBe sure the printed information faces the same direc tion so the belt rotates in the same direct
15. Valve Valve Installation Valve to Guide Clearance Cylinder and Piston Cylinder Piston Cylinder Piston Installation Cylinder Wear Inspection Piston Wear Inspection Piston Cylinder Clearance Piston Ring Piston Ring Groove Wear Inspection Piston Ring End Gap Inspection Piston Piston Pin Connecting Rod Inspection Carburetor Carburetor Holder Removal Carburetor Holder Installation Exhaust System Spark Arrester Cleaning Muffler Removal Muffler Installation Exhaust Pipe Removal Exhaust Pipe Installation Exhaust System Inspection 5 18 5 19 5 19 5 19 5 20 5 20 5 20 5 20 5 20 5 20 5 21 5 21 5 21 5 22 5 23 5 24 5 24 5 24 5 24 5 25 5 26 5 26 5 26 5 27 5 27 5 27 5 27 5 27 5 28 5 28 5 2 END Exploded View ENGINE END 5 3 Exploded View No Fasten
16. 2 15 Radiator replace Every 3 years 2 19 Fuel hose replace Every 5 years 2 14 CHASSIS Final gear case oil inspect Final gear case oil change Brake operation inspect Brake fluid level inspect Brake pad wear inspect Parking brake inspect Wheeltire damage inspect Rim runout inspect Wheel bearings damage inspect 2 4 PERIODIC Periodic Maintenance Chart FREQUENCY First Regular Service Service Eve Every 2 After 150 E 1500 200 km 100 mi or6 mi or 1 months month of of use or year See of use page whichever use whicheve comes first OPERATION first Steering inspect 2 35 inspect e 2 27 2 37 Nut bolt and fastener tightness inspect 2 39 Brake hose replace Every 4 years 2 30 Brake fluid change Every year 2 32 Joint boots ispect 2 36 Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping e Clean adjust lubricate torque or replace parts as necessary PERIODIC MAINTENANCE 2 5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners and the parts requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean EO Apple engine oil L Apply a non permanen
17. Install the pads A e Apply a non permanent locking agent to the rear brake pad pin bolts B Tighten the rear brake pad pin bolts Fluid Seal Damage Inspection 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 Maintenance 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 x If the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed Dust Seal and Friction Boot Damage Inspection 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 x If they show any damage replace them BRAKES 13 25 Calipers Brake Fluid Leak Inspection Inspect the brake fluid leak A from the rear caliper f the brake fluid is leaked replace the rear caliper Piston and Cylinder Damage Inspection e Visually inspect the pistons A and cylinder surfaces B Replace the caliper if the cylinder and piston are badly scored or rusty Calipe
18. e Remove the right side cover see Right Side Cover Re moval in the Frame chapter e Disconnect the gear position switch connectors A e Setthe hand tester A and connect itto the each terminals in the gear position switch lead connector and ground B G Lead Neutral R Lead Low BK Lead Reverse Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance Standard about 0 x If the tester reading is not as specified replace the gear position switch with a new one Switch Inspection e Using the hand tester check to see that only the connec tions shown in the table have continuity about 0 Q Special Tool Hand Tester 57001 1394 OFor the handlebar switches ignition switch refer to tables in the Wiring Diagram x If the switch has an open or short repair or replace it with a new one HP14081BS1 C ELECTRICAL SYSTEM 17 59 Relay Relay Inspection e Remove Seat see Seat Removal in the Frame chapter Starter Circuit Relay A Connect the hand tester A and a 12 V battery B to the starter circuit relay C as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Q Criteria When battery is connected 0 Q When battery is disconnected gt Q HP27002BS1 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 17 60 ELECTRICAL SYSTE
19. Installation is the reverse of removal Note the following sure to install the dampers A and collars B ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Torque Front Carrier Bolts M8 C 26 N m 2 7 kgf m 19 ft Ib Rear Carrier Removal e Remove Rear Carrier Bolts M6 A Both Sides Collars Both Sides Rear Carrier Bolts M8 B Both Sides Rear Carrier C 16 10 FRAME Carriers Rear Carrier Installation Installation is the reverse of removal Note the following sure to install the dampers A and collars Torque Rear Carrier Bolts 8 C 26 N m 2 7 kgf m 19 ft lb H007029BS1 FRAME 16 11 Fenders Front Fender Removal e Remove Front Carrier see Front Carrier Removal Front Guard see Front Guard Removal Side Covers see Left Right Side Cover Removal e Disconnect Headlight Lead Connectors A Both Sides Loosen the clamp screw A and remove the torque con verter intake duct B e Remove Clamp A and Hose B Front Fender C Front Fender Installation Installation is the reverse of removal Note the following ORun the leads and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter Rear Fender Removal Remove Tail Brake Light Cover see Tail Brake Light Cover Re moval Rear Carrier see Rear Carrier Removal Side Covers s
20. Band Hold the main harness to the frame pipe Alternator Crankshaft Sensor Lead Connectors Gear Position Switch Lead Regulator Rectifier Lead Connectors Band Hold the brake light switch lead to the frame pipe Brake Light Switch Band Hold the main harness and gear position switch lead to the frame pipe View from A Regulator Rectifier Clamp Hold the tail brake light switch lead Tail Brake Light Switch Lead Band Hold the tail brake light switch lead to the frame pipe 18 8 APPENDIX Cable Wire and Hose Routing APPENDIX 18 9 Cable Wire Hose Routing N Choke Cable Clamp Hold the speedometer cable Clamp of Frame Hold the choke cable Breather Hose Run the breather hose between the air duct and frame pipe Run the breather hose under the battery negative cable starter relay lead and gear position switch lead Run the speedometer cable under the carburetor Clamp Hold the battery negative cable starter motor cable gear position switch lead and alternator crankshaft sensor lead View from A Band Hold the main harness to the frame pipe Gear Position Switch Lead Engine Ground Terminal Starter Motor Cable Alternator Crankshaft Sensor Lead 18 10 APPENDIX Cable Wire Hose Routing APPENDIX 18 11 Cable Wire Hose Routing
21. EN 4 BRUTE FORCE 300 Kawasaki KVF300 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 Periodic Maintenance Fuel System Cooling System Engine Top End Converter System Recoil Starter Engine Lubrication System Removal lnstallation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Electrical System I N o A Appendix 300 Kawasaki KVF300 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 Division Motorcycle amp Engine Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserv
22. Front Master Cylinder A see Front Master Cylinder moval e Remove the reservoir cap B and diaphragm C and pour the brake fluid into a container e Remove Brake Lever Pivot Bolt Locknut A Brake Lever Pivot Bolt B Brake Lever C Front Master Cylinder Assembly Before assembly clean all parts including the master cylinder with brake fluid or alcohol 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 Apply brake fluid to the removed parts and to the inner wall of the cylinder Tighten the brake lever pivot bolt and locknut Rear Master Cylinder Lever Disassembly e Remove Rear Master Cylinder Lever A see Rear Master Cylin der Lever Removal e Remove the reservoir cap B and diaphragm C and pour the brake fluid into a container Master Cylinder BRAKES 13 17 Remove Brake Lever Pivot Bolt Locknut A Brake Lever Pivot Bolt B Brake Lever Screw D Rear Brake Light Switch E Remove Screws A Plate Parking Brake Lever Rear Master Cylinder Lever Assembly B
23. Install the output driven shaft housing Align the mark A on the output driven shaft housing with the mark C on the transmission case D Tighten Torque Output Driven Shaft Housing Bolts 9 8 N m 1 0 kgf m 87 in Ib Install the boot and then tighten the boot clamp screw e Tighten Torque Speedometer Cable Holder 9 8 N m 1 0 kgf m 87 in Ib e Install the output drive bevel gear cover e Tighten Torque Output Drive Bevel Gear Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters Transmission Case Disassembly Remove Transmission Case Cover see Transmission Case Re moval Shift Drum Stopper Plug A Washer Spring and Ball Shift Fork Rod B Shift Fork C Remove Shift Fork A Drive Shaft B Driven Shaft C Shift Drum D CRANKSHAFT TRANSMISSION 10 17 Transmission e Remove Washer 20 x 33 x 1 0 A Reverse Gear B e Remove Washer 20 x 33 x 3 0 A Shifter B e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Toothed Washer B Low Gear C e Remove Washer 22 x 30 x 1 0 A e Remove Washer 17 x 26 x 1 0 A Shifter B 10 18 CRANKSHAFT TRANSMISSION Transmission e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove Toothed Washer B High Gear C Washer 25 x 637 x 3 0 D Transmission Case Assembly e A
24. Insufficient oil Bevel gears maladjusted Coolant incorrect Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Cooling system component incorrect Water temperature sensor trouble Thermostat trouble Radiator fan switch trouble 18 22 APPENDIX Troubleshooting Guide Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn 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 bushing worn Drive pulley weight roller worn Shifting too quickly 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 Driven pulley movable sheave doesn t move smoothly Clutch Operation Faulty Clutch slipping Clutch housing or shoe linings overworn or worn unevenly Clutch spring broken or weak Clutch outer overworn or worn unevenly Clutch not disengaging properly
25. Main Fuse 15 A Ignition Switch Gear Position Switch Rear Brake Pedal Light Switch Clutch Diode Starter Circuit Relay Starter Relay Battery 12 V 10 Ah Starter Motor Engine Ground Rear Brake Lever Light Switch Starter Button Engine Stop Switch 17 40 ELECTRICAL SYSTEM Electric Starter System Starter Motor Clutch Removal e Remove the alternator rotor see Alternator Rotor Re moval Hold the rotor with the flywheel holder A and take out the starter motor clutch bolts B 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 to the starter motor clutch bolts Tighten Torque Starter Motor Clutch Bolts 20 N m 2 0 kgf m 15 ft Ib Starter Motor Clutch Inspection Remove Alternator Rotor see Alternator Rotor Removal e Fit the starter clutch gear into the starter motor clutch x If the alternator rotor turns clockwise A freely from the starter clutch gear but not counterclockwise B the clutch is operating correctly x lf the clutch does not operate correctly or if it makes noise disassemble it and examine each part visually Re place any worn or damaged parts NOTE the starter clutch gear A Replace it if it is worn or damaged
26. NOTICE 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 A of the inspection bolt opening B xIf is insufficient first check the final gear case for oil leakage remedy it if necessary and add oil through the inspection bolt opening Use the same type and brand of oil that is already in the final gear case Replace the gasket C with a new and tighten the inspection bolt Torque Final Gear Case Oil Level Inspection Bolt 20 N m 2 0 kgf m 15 ft Ib 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 front to rear 0008 5 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Remove Rear Guard Bolts A Rear Guard B e Place an oil pan beneath the final gear case and remove the oil drain bolt A e Remove Final Gear Case Oil Drain Bolt Oil Filler Cap B A WARNING Oil on tires can cause loss of traction and an ac cident resulting in serious injury or death When draining or filling the final gear case do not spill oil the tire or rim Clean any oil that may spill with a high flash point solvent e After the oil has completely drained out install the oil drain
27. Spark Plug Wrench Hex 18 57001 1024 e Fit the spark plug caps securely e Pull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Spark Plug Cleaning Inspection Refer to the Spark Plug Cleaning Inspection in the Peri odic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter Ignition System ELECTRICAL SYSTEM 17 33 Ignition Coil Removal e Remove Left Side Cover see Left Side Cover Removal in the Frame chapter Spark Plug Cap see Spark Plug Removal Primary Lead Connectors A Ignition Coil Mounting Bolts B Ignition Coil C Ignition Coil Installation e Install Ignition Coil Tighten the ignition coil mounting bolts securely Connect the primary leads to the ignition coil terminals as shown G GY Lead Green Terminal A BK W Lead Black Terminal B Hold the ignition coil lead with a clamp A Ignition Coil Inspection Measure the primary winding resistance A as follows OConnect the tester between the coil terminals OSet the tester to the x 1 range e Measure the secondary winding resistance B as follows OConnect the tester between the spark plug lead and ter minal OSet the tester to the x 1 range ORemove the plug cap by turning it counterclockwise OMeasure the secondary winding resistance with the plug cap removed Ignition Coil Winding Resistanc
28. e Remove Bolts A Bearing Stopper Plate B 14 16 SUSPENSION Swingarm e Remove Rear Axle Bearings A Special Tools Steering Stem Bearing Driver 42 5 57001 1344 Steering Stem Bearing Driver Adapter 041 5 C 57001 1345 Swingarm Assembly Install the new outer race A by using special tool B both sides Special Tool Bearing Driver Set 57001 1129 e Apply grease to the tapered roller bearing A and install it both sides e Apply grease to the dust seal B and install it both sides e Install the rear axle bearings A by using special tool B Special Tool Bearing Driver Set 57001 1129 Swingarm SUSPENSION 14 17 Replace the O ring A with a new one apply grease Install O ring A Bearing Stopper Plate B Bolts C Swingarm Bearing Inspection e Remove the rear final gear case see Final Gear Case Removal in the Final Drive chapter Move the swingarm up and down to check for abnormal friction and push and pull it back and forth to check for bearing play If abnormal friction is felt the bearings are damaged Re place the oil seals and both left and right bearings The play developed during use may indicate bearing dam age In this case remove the swingarm and inspect the bearings Replace both left and right bearings if either of the bearings is damaged Swingarm Bearing Lubrication Remove the swingarm see Swingarm
29. ment or blow it dry the element can be damaged Inspect the element for damage x lf it is torn punctured or hardened replace it e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess oil then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the element HC07010381 2 14 PERIODIC Periodic Maintenance Procedures Air Cleaner Draining e If any water or oil accumulates in the plug drain it by taking off the plug A After draining be sure to install the plug and clamp B firmly Fuel Hose Inspection fuel leak damage installation condition e Turn the fuel tap to the OFF position e Check the fuel hoses and fittings for deterioration cracks and signs of leakage Replace the fuel hose if any fraying leak A cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are installed correctly e When installing run the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e 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 Engine Breather Hose Inspection e Check the breather hose A for deterioration craks and signs of leakage
30. 4 0 8 0 in and make a temporary knot B at that point Pull out the rope end from the starter grip and untie the knot D at the rope end to remove the starter grip Holding the reel E with hand untie the temporary knot Pull the rope in through the rope hole in the housing and hold it in the notch A in the reel NOTE ODo not let the rope wedge between the reel and the housing Slowly allow recoil spring tension to unwind the reel e Remove Bolt A Friction Plate B A WARNING The recoil spring is under great tension and can travel at high speed if it comes loose and cause injury To prevent the spring from coming loose during disassembly turn the reel one quarter turn counterclockwise past the rest position where no tension can be felt then slowly lift the friction plate straight up out of the housing RECOIL STARTER 7 5 Recoil Starter Other than EUR Model e Remove Recoil Guide A Friction Plate Spring B Pawls Remove the reel A noting the following A WARNING The recoil spring B is still under great tension and can travel at high speed if it comes loose and cause injury To prevent the spring from coming loose during disassembly turn the reel one quarter turn counterclockwise past the rest position where no tension can be felt then slowly lift the reel straight up out of the housing NOTE OThere should be no spring tensio
31. A into the holes B both sides ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Tail Brake Light Cover Removal Free the lead from the clamp A e Disconnect the connector B Remove Nuts A and Screws Bolt B e Clear the projections C from the holes and remove the tail brake light assy FRAME 16 17 Covers Remove Screws A Tail Brake Light Tail Light C Tail Brake Light Cover Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B OReplace the nuts with new ones ORun the leads correctly see Cable Wire and Hose Rout ing section in the Appendix chapter 16 18 FRAME Guards Front Guard Removal Remove Bolts A and Screws B Front Guard Cover C e Remove Front Carrier Bolts M8 A e Remove Front Guard Bolts M6 A Both Sides Front Guard Bolts M8 B Both Sides Front Guard C Front Guard Installation Installation is the reverse of removal Note the following OBe sure to install the plugs A Torque Front Guard Bolts 26 N m 2 7 kgf m 19 ft Ib Front Bottom Guard Removal Remove Bolts A Front Bottom Guard B FRAME 16 19 Guards Front Bottom Guard Installation Installation is the reverse of removal Note the following Olnsert the projection A into the space B 16 20 FRA
32. Anti rattle Spring Using compressed air remove the piston OCover the caliper opening with a clean rubber mat A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston NOTE Olf compressed air is not available do as follows with the brake hose connected to the caliper OPrepare a container for brake fluid ORemove the pads see Front Brake Pad Removal and anti rattle spring OPump the brake lever to remove the caliper piston Remove Bleed Valve A and Rubber Cap B Caliper Holder C e Remove Boots A Dust Seal B Fluid Seal C Front Caliper Assembly Replace the fluid seal A with a new one OApply silicone grease 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 OApply brake fluid to the dust seal and install it into the cylinder by hand 6105040251 13 22 BRAKES Calipers e Apply silicone grease to the outside of the pistons A and push them into the cylinder by hand Take care that neither the cylinder nor the piston skirt gets scratched Replace the rubber boots B if they are damaged e Install the ani rattle spring C in the caliper as shown e Apply a grease to the caliper holder shafts A e Inst
33. Clutch spring tension uneven Clutch shoe spring broken or weak Gear Shifting Faulty Doesn t go into gear Clutch not disengaging Shift fork s bent or seized Gear s stuck on the shaft Shift return spring weak or broken Shift mechanism gear broken Shift drum damaged Jumps out of gear Shift fork s worn Gear groove s worn Gear dogs dog recesses and or dog holes worn Shift drum groove s worn Shift fork guide pin s worn Drive shaft output shaft and or gear splines worn Overshifts Shift mechanism gear broken Abnormal Engine Noise Knocking Igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guides worn Balancer bearing worn Balancer gear worn or shipped Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley s
34. D Install the rear wheel see Wheel installation Clean and wipe dry the threads of the rear axle Replace the rear wheel hub nut with a new one Torque Rear Wheel Hub Nut 147 15 0 kgf m 108 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole HJ08012BS1 11 16 WHEELS TIRES Hub Bend the cotter pin A over the nut e Install the cap HJO8013BS1 C FINAL DRIVE 12 1 Final Drive Table of Contents ubdolere oi 12 2 EE 12 4 Special M M H 12 5 Propeller Shattered tie 12 6 Propeller Shaft 12 6 Propeller Shaft InstallatiOr uie itte a ti etae tede tn 12 6 Propeller Shaft 12 7 Propeller Shaft Joint Boot Inspection pp 12 7 aii ii EET 12 8 Rear Axle REMOVAL is use teet b on i eer e eg 12 8 Rear Axle 12 8 Rear Axle Runout 12
35. D 9 8 1 0 kgf m 87 in Ib e Install Spring A Joint Pin B Washer C e Replace the cotter pin D with a new one e Install Shift Bracket A e Tighten Torque Shift Bracket Nuts B 20 N m 2 0 kgf m 15 ft Ib e Install Shift Lever C Shift Lever Bolt D and Nut e Install the removed parts see appropriate chapters Shift Lever Adjustment e Set the shift lever in the neutral position e Loosen the tie rod locknuts A e Shift the gear to neutral by moving the shift lever and or turn the rod B e Insert a screwdriver A through the shift shaft lever B into the index hole C at the transmission case 10 14 CRANKSHAFT TRANSMISSION Transmission e Turn the rod A clockwise or counterclockwise and adjust the neutral position of shift lever Tighten the locknuts B C and then pull out the screw driver D NOTE OThe locknut C near the L mark E on the tie rod left hand threads Turn the locknut clockwise for loosen ing e After adjustment start the engine and test to ride the ATV to be sure the shift lever is operating properly Transmission Case Removal Remove Engine see Engine Removal in the Engine Removal In stallation chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Screen see Oil Screen Removal in the Engine Lu brication System chapter Piston see Piston Removal in the Engine Top End chap ter Dri
36. HP22014BW2 Meter Unit Charge Fuse 30 A Main Fuse 15 Headlight Tail Light Fuse 10 A Ignition Switch Fuel Level Sensor Battery 12 V 10 Ah Engine Ground ELECTRICAL SYSTEM 17 51 Meter Meter Unit Removal Installation e Remove Meter Cover Screws A e While pulling up the meter cover loosen the speedometer cable nut A fully e Remove the speedometer cable B from the meter unit e Disconnect the ignition switch connector A e Slide the dust cover A and disconnect the meter unit connector B e Remove Meter Unit Mounting Screws A Meter Unit B Do not drop the meter unit 17 52 ELECTRICAL SYSTEM Meter Installation is the reverse of removal OFit the projection A on the meter cover to the damper B Meter Operation Inspection Turn the ignition switch to ON Check that when the Right button A is pushed for more than two seconds and held continuously the display B cycles through the two modes ODO TRIP ODO x If this display function does not work replace the meter unit Cycle the meter to ODO mode e Check that when the Left and Right buttons A are pushed for more than 2 seconds the meter display turns to the clock set mode OThe hour display start blinking NOTE OThe display will stop blinking automatically and the ad justment will be cancelled if the button i
37. High quality foam air filter oil FUEL SYSTEM 3 7 Throttle Lever and Cable Throttle Lever Free Play Inspection e Refer to the Throttle Lever Free Play Inspection in the Periodic Maintenance chapter Throttle Lever Free Play Adjustment e Refer to the Throttle Lever Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Lubrication e Refer to the Lubrication in the Periodic Maintenance chapter Throttle Cable Removal Remove the throttle cable lower end from the carburetor see Carburetor Removal Slide the rubber cover A at the throttle case Remove Screws B Throttle Case Cover C and Gasket Clear the cable upper end A from the throttle lever B Loosen the locknut and remove the throttle cable Free the throttle cable from the clamp A and remove it out of the vehicle Throttle Cable Installation Install the throttle cable in accordance with Cable Wire and Hose Routing section in the Appendix chapter e Install the lower end of the throttle cable in the throttle pulley on the carburetor after installing the upper end of the throttle cable in the lever e After installation adjust the cable properly A WARNING Operation with incorrectly routed or improperly ad justed cable could result in an unsafe riding condi tion Be sure the cable is routed correctly and prop erly adjusted 3 8 FUEL SYSTEM Throttle Lever and Cable Th
38. Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or the piston and or the piston rings piston ring grooves Cylinder Head Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Carburetor see Carburetor Removal in the Fuel System chapter Exhaust Pipe see Exhaust Pipe Removal Spark Plug Cap Camshaft see Camshaft Removal END 5 19 Cylinder Head Remove Cylinder Head Bolts A Washers Cylinder Head B and Gasket Cylinder Head Installation Replace the cylinder head gasket with a new Install Dowel Pins A New Cylinder Head Gasket B Cylinder Head Camshaft see Camshaft Installation Tighten the cylinder head bolts Torque Cylinder Head Bolts 9 8 N m 1 0 kgf m 87 in Ib Cylinder Head Cleaning Remove the cylinder head see Cylinder Head Removal e Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool e Wash the head with a high flash point solvent Cylinder Head Warp Inspection e Clean the cylinder head see Cylinder Head Cleaning Lay a straightedge across the lower surface of the cylinder head e Use a thickness gauge A to measure the space between the straightedge B and the head at
39. Water Pump Impeller see Water Pump Impeller Re moval in the Cooling System chapter Right Footboard see Right Footboard Removal in the Frame chapter Right Side Cover see Right Side Cover Removal in the Frame chapter e Disconnect Alternator Stator Connector A Crankshaft Sensor Connector B e Cut the band C Open the clamp D Loosen the clamp screw A fully and remove the coolant hose Remove Alternator Cover Bolts C Alternator Cover D Alternator Cover Installation e 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 B on the crankcase ELECTRICAL SYSTEM 17 25 Charging System e Using a high flash point solvent clean off oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the circumference of the alterna tor lead grommet and fit the grommet A into the notch of the alternator cover securely Sealant Liquid Gasket TB1216 92104 1063 e Fit the slot A on the water pump shaft to the projection B on the oil pump shaft Tighten Torque Alternator Cover Bolts 9 8 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters e Pour Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Chan
40. zo 2 Frame Ground G BK 1 G G Y a Y BR BK BR BK ELT AIL G Y G Y BR BK BR BK G GR Ignition x Coil 3 BL Y G W BK W SE BL Y G W L 6 8 x SEENS S2o 6 a m Spark Crankshaft 8 Alternator Sensor Regulator Igniter Rectifier Engine Ground Tail Light Right 12V5W Tail Brake Light Right 12V5 21W Tail Brake Light Left 12V5 21W Tail Light Left 12V5W Color Code BK Black BL Blue BR Brown amp Green 9 Orange P Pink PU Purple IR Red wW White HPOSO20BWS C 17 14 ELECTRICAL SYSTEM Special Tools and Sealant Spark Plug Wrench Hex 18 57001 1024 875710245 6 Rotor Puller 16 18 20 22 1 5 57001 1216 875712165 C Flywheel Holder 57001 1313 Needle Adapter Set 57001 1457 O ST571313ST C Hand Tester 57001 1394 7571394ST C Flywheel Puller M28 x 1 0 57001 1471 Q 5157145751 C 875714715 C Liquid Gasket 1216 92104 1063 7 879210635 6 Precautions ELECTRICAL SYSTEM 17 15 There are a number of important precautions that should be taken when servicing electrical systems Learn and ob serve all the rules below ODo not reverse the battery cable connections This will bu
41. 0 039 in 152 1 152 2 mm 5 988 5 992 in 0 3 mm 0 012 in 152 6 mm 6 008 in CONVERTER SYSTEM 6 5 Special Tools Inside Circlip Pliers Flywheel amp Pulley Holder 57001 143 57001 1605 7570143ST C 5157160551 C Bearing Driver Set Clutch Spring Compressor 57001 1129 57001 Y006 amp 7571129ST C ST57K006ST 6 6 SYSTEM Torque Converter Torque Converter Cover Removal e Remove Left Side Cover see Left Side Cover Removal in the Frame chapter Recoil Starter Other than EUR Model see Recoil Starter Removal in the Recoil Starter chapter Clamp Screws A Loosen Torque Converter Intake Duct B and Exhaust Duct C Torque Converter Cover Bolts D Torque Converter Cover E and Gasket Torque Converter Cover Installation e Replace the torque converter cover gasket with a new one e Install Dowel Pins A New Torque Converter Cover Gasket B Torque Converter Cover Tighten Torque Torque Converter Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Install the torque converter intake duct and exhaust duct OFit the projections A to the slits Tighten the clamp screws securely Install the removed parts see appropriate chapters Torque Converter Cover Disassembly Remove Torque Converter Cover see Torque Converter Cover Removal Bolt A Bearing Retainer B Remove the bearing C with a suitable tool
42. 1 or MA2 SAE 10W 40 1 6 L 1 7 US qt 1 8 L 1 9 US qt When engine is completely dry Crankshaft Transmission Transmission Oil Type Viscosity Oil Level Capacity 2 SP AUTOMATIC REV 5 90 Inspection bolt opening bottom 0 6 L 0 63 US qt Wheels Tires Tire Tread Depth Front Rear Standard tire Front Rear Rim Runout with tire installed Axial Radial Toe in AT 22 x 7 10 MAXXIS M937 Tubeless AT 22 x 10 10 MAXXIS M938 Tubeless 2 5 17 5 mm 0 098 0 689 in at 1 G 3 mm 0 12 in 3 mm 0 12 in TIR 2 mm 0 08 in TIR 2 mm 0 08 in 2 10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Final Gear Case Gear Case Oil Viscosity Oil Level Capacity SAE 80 Inspection bolt opening bottom 0 15 L 0 16 US qt Brakes Brake Fluid Type Disc Brake Pad Lining Thickness DOT4 5 5 mm 0 22 in 1 mm 0 04 in Electrical System Spark Plug Type Spark Plug Gap NGK DPR7EA 9 0 8 0 9 mm 0 032 0 036 in 1 G The tires are grounded without the person and load PERIODIC MAINTENANCE 2 11 Special Tool Valve Adjusting Screw Holder 57001 1217 T5712178T C 2 12 PERIODIC 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 qui
43. A Collar B Remove the A Special Tool Inside Circlip Pliers 57001 143 Remove the bearing B Special Tool Bearing Driver Set 57001 1129 15 12 STEERING Steering Maintenance Steering Shaft Bearing Installation Replace the circlip A with a new and install it Special Tool Inside Circlip Pliers 57001 143 e Replace the bearing B with a new one e Press in the bearing until the circlip Special Tool Bearing Driver Set 57001 1129 e Install Collar A Dust Seal B Install Dust Seal A Collar B Tie rod End Inspection e Inspect each spherical bearing A If roughness excessive play or seizure is found replace the tie rod end e Inspect each boot B If damage wear or deterioration is found replace the tie rod end STEERING 15 13 Handlebar Handlebar Removal e Remove Multifunction Meter Unit see Meter Unit Removal in the Electrical System chapter Throttle Case A Front Master Cylinder B see Front Master Cylinder Re moval in the Brakes chapter Bands C Left hand Switch Housing D Rear Master Cylinder Lever E see Rear Master Cylin der Lever Removal in the Brakes chapter Handlebar Holder Bolts F and Bracket G Handlebar Holders H Handlebars I Handlebar Installation e The handlebar holders A must be installed with the punch mark B forward Align the punch mark on the handlebar wi
44. AND AREA CODES AU Australia US United States EUR Europe EMISSION CONTROL INFORMATION US Model Only To protect the environment in which we all live Kawasaki has incorporated crankcase emis sion 1 exhaust emission 2 and evaporative emission 3 control systems in compliance with applicable regulations of the United States Environmental Protection Agency and 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 This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this vehicle The fuel ignition and exhaust systems of this vehicle have been carefully designed and con structed to ensure an efficient engine with low exhaust pollutant levels A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere 3 Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fue
45. Bearing Retainer Bolt 9 8 1 0 87 in lb Torque Converter Cover Bolts 9 8 1 0 87 in Ib 2 6 PERIODIC Torque and Locking Agent Torque Fastener kgf m Fb Remarks Torque Converter Outer Cover Bolts EU Model 9 8 1 0 87 in Ib Recoil Starter Recoil Starter Mounting Bolts AU US Models 9 8 1 0 87 in Ib Engine Lubrication System Engine Oil Drain Plug 25 2 5 18 Engine Oil Level Inspection Window Retainer Bolt 9 8 1 0 87 in Ib Engine Oil Screen Plug 15 1 5 11 Oil Pump Chain Cover Bolts 9 8 1 0 87 in Ib Oil Pump Cover Screw 2 0 0 20 18 in Ib Oil Pump Mounting Bolts 9 8 1 0 87 Engine Removal Installation Engine Bracket Mounting Bolts 26 2 7 19 Front Engine Mounting Nut 39 4 0 29 R Lower Engine Mounting Nut 39 4 0 29 R Upper Engine Mounting Nut 39 4 0 29 R Crankshaft Transmission Crankcase Bolts 9 8 1 0 87 L Driven Pulley Bearing Retainer Bolt 9 8 1 0 87 in Ib L Output Drive Bevel Gear Cover Bolts 9 8 1 0 87 in Ib Output Drive Bevel Gear Nut 98 10 72 St Output Driven Bevel Gear Nut 98 10 72 St Output Driven Shaft Housing Bolts 9 8 1 0 87 Shift Bracket Nuts 20 2 0 15 Shift Drum Stopper Plug 47 4 8 35 Shift Lever Clamp Bolt 9 8 1 0 87 Speedometer Cable Holder 9 8 1 0 87 in Ib Tie Rod End Nuts 26 2 7 19 Transmission Case Cover Bolts 26 2 7 19 Transmission Oil Drain Plug 9 8 1 0 87 Transmission Oil Filler Bolt 20 2 0 15 Transmission Oil Level I
46. C Springs D Retainer E Split Keepers F Closed Coil End G Valve to Guide Clearance Measurement e Measure each valve stem outside diameter and each valve guide inside diameter e Subtract each valve stem outside diameter from the cor responding guide inside diameter to obtain the valve to guide clearance x If the clearance exceeds service limit replace the cylinder head Valve Valve Guide Clearance Standard Exhaust 0 025 0 052 mm 0 0010 0 0020 in Intake 0 01 0 037 mm 0 0004 0 0015 in Service Limit Exhaust 0 08 mm 0 0031 in Intake 0 06 mm 0 0024 in 128018 P HE13017BS2 C Cylinder Piston ENGINE TOP END 5 21 Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Clamp Screw A Loosen Water Hose B e Remove Front Camshaft Chain Guide A Cylinder B NOTE OWhile removing the front camshaft chain guide and cylinder pull the camshaft chain upward and keep it taut after the removal The camshaft chain will drop off from the crankshaft sprocket without the front camshaft chain guide 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 Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Using the piston pin puller assembly A special tool re move th
47. Choke Lever Lubrication Whenever the choke cable is removed lubricate the choke lever as follows e Apply a thin coating of multi purpose grease to the wave washer A 3 10 FUEL SYSTEM Choke Lever and Cable Choke Cable Removal e Remove Choke Cable Upper End see Choke Lever Removal Fuel Tank see Fuel Tank Removal Loosen the locknut A and remove the choke cable lower end e Free the choke cable from the clamp A and remove it out of the vehicle Choke Cable Installation Installation is the reverse of removal e Install the choke cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After installation adjust the cable properly A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions e Adjust the choke lever operation as the following proce dures OSlide the rubber cover A OLoosen the locknut B OTurn the adjuster C to adjust the hardness of the lever operation Choke Cable Lubrication Whenever the choke cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cable see Lubrication in the Periodic Maintenance chap ter FUEL SYSTEM 3 11 Carburetor Idle Speed Inspection e Refer to the Idle Speed Inspection in the Peri
48. Discs Brake 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 AWARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Front Brake Disc Removal Remove Front Hub see Front Hub Removal in the Wheels Tires chapter Brake Disc Mounting Bolts A Brake Disc B Front Brake Disc Installation The front brake disc must be installed with the marked side A facing toward inside Tighten Torque Brake Disc Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e After installing the discs check the disc runout Com pletely clean off any grease that has gotten on either side of the disc with a high flash point solvent Do not use one which will leave an oily residue Rear Brake Disc Removal e Remove Rear Hub see Rear Hub Removal in the Wheels Tires chapter Set the plate A of the rotor puller and disc hub puller B Special Tools Rotor Puller 57001 1623 Disc Hub Puller 57001 1781 Tighten the bolt of special tools and remove the disc hub Brake Disc Mounting Bolts Brake Disc B BRAKES 13 29 Discs Rear Brake Disc Installation The rear brake disc must be installed with the marked side A facing toward inside Tighten Torq
49. Engine Removal Installation Engine Removal e Remove Engine Oil Drain see Engine Oil Change in the Periodic Maintenance chapter Coolant Drain see Coolant Change in the Periodic Maintenance chapter Footboards see Left Right Footboard Removal in the Frame chapter Front Fender see Front Fender Removal in the Frame chapter Torque Converter Exhaust Duct see Torque Converter Cover Removal in the Converter System chapter Exhaust Pipe see Exhaust Pipe Removal in the Engine Top End chapter Ignition Coil see Ignition Coil Removal in the Electrical System chapter Carburetor see Carburetor Removal in the Fuel System chapter Vacuum Switch Valve see Vacuum Switch Valve Re moval in the Engine Top End chapter Air Cleaner Intake Duct and Breather Hose see Air Cleaner Housing Removal in the Fuel System chapter e Remove Clamp A Engine Ground Terminal B Starter Motor Cable Nut C Disconnect Alternator Lead Connector A Crankshaft Sensor Lead Connector B Gear Position Switch Lead Connectors C e Remove Water Temperature Sensor Connectors A Clamps B Water Hoses C REMOVAL INSTALLATION 9 5 Engine Removal Installation e Remove Shift Shaft Lever A see Shift Lever Removal in the Crankshaft Transmission chapter Brake Pedal B see Brake Pedal Removal in the Brakes chapter Speedometer Cable C Clamp D Loosen Water Hose E e Remove Clamp Screw A Loosen Engine Moun
50. Fill the reservoir with new brake fluid Change the brake fluid as follows OOpen the bleed valve A OApply the front brake lever and hold it B OClose the bleed valve C ORelease the brake lever D Check the fluid level the reservoir often replenishing it as necessary NOTE Olf the fluid in the reservoir runs completely out any time during fluid changing air will enter the line and the sys tem must be bled PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid changes A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified Tighten Torque Bleed Valves 6 0 N m 0 61 kgf m 53 in Ib e Apply the front brake lever forcefully for a few seconds and check for fluid leakage around the fittings x If necessary bleed the air from the brake line see Brake Line Air Bleeding in the Brakes chapter A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever has a soft or spong
51. Guard Front Brake Disc Guard Bolts Install the removed parts see appropriate chapters Proportioning Valve BRAKES 13 31 Rear Brake Proportioning Valve Removal Drain the brake fluid see Brake Fluid Change in the Pe riodic Maintenance chapter Loosen the banjo bolts A at the brake hose lower end and tighten it loosely Unscrew the rear brake proportioning valve mounting bolts B Unscrew the banjo bolts and remove the brake hoses from the rear brake proportioning valve D Rear Brake Proportioning Valve Installation Install the rear brake proportioning valve and brake hoses lower end OReplace the washers that are on each side of hose fitting with new ones Tighten Torque Rear Brake Proportioning Valve Mounting Bolts 12 1 2 kgf m 106 in Ib Check the fluid level the brake reservoir Bleed the brake line see Brake Line Air Bleeding e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Brake Proportioning Valve Inspection Remove the rear brake proportioning valve A see R
52. Kaim x 8680 kg x 2 205 Ib g x 0 03527 OZ Units of Pressure kPa x 0 01020 kgf cm Units of Volume kPa x 0 1450 psi L x 0 2642 gal US kPa x 0 7501 cmHg L 0 2200 kgf cm x 98 07 kPa L x 1 057 qt US kgf cm x 14 22 psi L 2 113 05 L 1 816 pint IMP mL 0 03381 oz US Units of Speed mL x 002816 oz IMP 29 0 06102 cu in Units of Power Units of Force d E d 2 5 x 07355 kW PS x 0 9863 HP kg x 9 807 N kg x 2 205 Ib Units of Temperature E 5 9 4 32 68 104 176 212 248 284 40 20 0 20 40 60 i 80 100 120 140 160 180 200 1220 240 260 280 300 320 40 20 20 407 60 80 100 120 1140 160 ic 17 8 44 26 7 48 9 71 1 93 3 116 138 PERIODIC 2 1 Periodic Maintenance Table of Contents Periodic Maintenance 2 3 Torque and Locking deems E cave tach 2 5 Specifications Y RE EXE EX 2 9 Jerem LC 2 11 Periodic Maintenance 2 2 12 F el Syste m QN 2 12 Throttle Lever Free Play Inspection pp 2 12 Throttle Lever Free Play Adjustment pp 2 12 Idle Speed Inspection 2 12 Idle Speed AdjUslTieni i las edes neonate tenes 2 13 Air Cleaner Elem
53. N m 2 0 kgf m 15 ft Ib Exhaust Pipe Cover Mounting Bolts 11 N m 1 1 kgf m 97 in Ib Exhaust Pipe Removal e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Exhaust Pipe Cover see Muffler Removal Muffler Body Clamp Bolt A Loosen 5 28 END Exhaust System Remove Exhaust Pipe Nuts A Exhaust Pipe B Exhaust Pipe Installation Installation is the reverse of removal Note the following OReplace the exhaust pipe gasket and muffler body gasket with new ones 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 x 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 Ex haust Pipe Removal Inspect the gasket for damage and signs of leakage x If the gasket is damaged or has been leaking replace it e Check the exhaust pipe and muffler for dents cracks rust and holes x 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 Converter System Table of Contents EXPloded sie ET 6 2 ETE 6 4 Special LOGS o tede e e ed eve ane e
54. OThe backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash related parts be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth con tact by replacing shims 10 26 CRANKSHAFT TRANSMISSION Transmission Output Drive Bevel Case Backlash related Parts Hinoxe 5 1 Driven Bevel Gear 2 Driven Bevel Gear Shim s 3 Drive Bevel Gear 4 Drive Bevel Gear Shim s 2 Driven Bevel Gear Shim s Thickness 0 60 mm 0 024 in 0 65 mm 0 026 in 0 70 mm 0 028 in 0 75 mm 0 030 in 0 80 mm 0 031 in 0 85 mm 0 033 in 0 90 mm 0 035 in 0 95 mm 0 037 in 1 00 mm 0 039 in 1 05 mm 0 041 in 1 10 mm 0 043 in 1 15 mm 0 045 in 2 x x x ees es nn Part Number 92180 Y013 92180 Y014 92180 Y015 92180 Y016 92180 Y017 92180 Y018 92180 Y019 92180 Y020 92180 Y021 92180 Y022 92180 Y023 92180 Y024 CRANKSHAFT TRANSMISSION 10 27 Transmission 4 Drive Bevel Gear Shim s Thickness Part Number 0 60 mm 0 024 in 92180 Y001 0 65 mm 0 026 in 92180 002 0 70 mm 0 028 92180 003 0 75 mm 0 030 92180 004 0 80 mm 0 031 92180 005 0 85 0 033 92180 006 0 90 0 035 92180 007 0 95 mm 0 037 92180 008 1 00 0 039 92180 009 1 05 0 041 92
55. PERIODIC Periodic Maintenance Procedures e With the cable disconnected at the both ends the cable should move freely A within the cable housing x 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 Upper End A Choke Cable Lower End Parking Brake Cable Ends Slide Points Lubricate with Grease Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft Steering Stem Bushings Steering Stem Holders 6004020152 6004040351 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures 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 x lf there are loose fasteners retorque them to the speci fied torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not listed in the appropriate chapter see the Basic Torque Table see Torque and Locking Agent For each fastener first loosen it by 1 2 turn then tighten it x 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 W
56. Removal Left Side Inner Cover see Side Inner Cover Removal Left Footboard see Left Footboard Removal Quick Rivet A e Remove Screws A and Bolt B e Clear the projections C from the holes and remove the left side cover D Left Side Cover Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B Right Side Cover Removal Remove Middle Cover see Middle Cover Removal Right Side Inner Cover see Side Inner Cover Removal Right Footboard see Right Footboard Removal Storage Case see Storage Case Removal FRAME 16 15 Covers e Remove Screws A and Bolts B e Clear the projections C from the holes and remove the right side cover D Right Side Cover Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B Side Inner Cover Removal e Remove Bolts A Nut B and Screw Side Inner Cover C Side Inner Cover Installation Installation is the reverse of removal 16 16 FRAME Covers Headlight Cover Removal e Remove Front Fender see Front Fender Removal Clamps A Both Sides Bolts B Both Sides Headlights C Both Sides e Remove Bolts A Clear the projections from the holes and remove the head light cover B Headlight Cover Installation Installation is the reverse of removal Note the following Olnsert the projections
57. Spark getesteten in 17 32 Spark Plug Cleaning INSpe Cton eek 17 32 Spark Plug Inspection Ignition Goil Removals Ignition Coil InstallatiDPi nisse I Ignition Coil INS pe 34 laden une Crankshaft Sensor Removal 8 17 34 Crankshaft Sensor 17 34 Crankshaft Sensor Inspectigom 9 17 34 Alternator ierat ee Reagan 17 35 Electric Starter System ee langen 17 37 hin 17 37 Starter Motor 17 37 Starter Relay Inspeelion s geteilt 17 37 Starter Motor Clutch 8 17 40 Starter Motor Clutch Installatiom 17 40 Starter Motor Clutch Inspection 8 nere 17 40 Reduction Gears 17 41 Lighting SY UE EORR Tuta teca i o Ea ird 17 42 Headlight Beam Vertical Adjustment esee eene ntes 17 42 17 2 ELECTRICAL SYSTEM Headlight Removal ccs eo Reb 17 42 Headlight Ins
58. an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents T Model IdentifICatiOn oi ep e e EE rte ren hin Gt er i agr ef e a General Specifications Unit Conversion Table 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 preventthe engine from S accidentally turning over Disconnect the ground wire ES RE SE first and then the positive When completed with the TFA er 75 service first connect the positive wire to the positive 2 A L terminal of the battery then the negative wire to the negative terminal DISASSEMBLY ASSE
59. cable lower end into the throttle pulley Insert the hook A of the throttle pulley cover to the hole B of the carburetor Tighten the throttle pulley cover screw Install the removed parts see appropriate chapters Adjust Throttle Lever Free Play see Throttle Lever Free Play Inspection in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Carburetor Disassembly Remove Carburetor see Carburetor Removal Float Bowl Screws A Float Bowl B and O ring 3 14 FUEL SYSTEM Carburetor Slide out the float pivot pin A remove the float and drop out the float valve needle with its hanger e Remove Float Valve Needle C Main Jet D Needle Jet Holder and Needle Jet Pilot Jet E Starter Jet F e Remove Screws A Chamber Cover B Spring C and Spring Seat D Vacuum Piston E Diaphragm F and Jet Needle G During carburetor disassembly be careful not to damage the diaphragm Never use a sharp edge to remove the diaphragm Carburetor Assembly Turn the carburetor body upside down and install the needle jet A into the carburetor Do not force the needle jet holder B and main jet C or overtighten them The needle jet or the car buretor body could be damaged requiring replace ment 9008125 FUEL SYSTEM 3 15 Carburetor eDrop the float valve needle into the valve
60. ends of the ring with a thickness gauge Piston Ring End Gap Standard Top 0 15 0 3 mm 0 0059 0 012 in Second 0 3 0 45 mm 0 012 0 0177 in Cil 0 2 0 7 mm 0 008 0 028 in Service Limit Top 0 5 mm 0 020 in Second 0 65 mm 0 0256 in Cil 0 9 mm 0 0354 in xIf the end gap of either ring is greater than the service limit replace all the rings GE16020881 C SY SIIISSISS N EN N IAES SSS IIISSI N SSISIIIS NS ENN SSSSS KSE HE14005BS1 Cylinder Piston ENGINE TOP END 5 25 Piston Piston Pin Connecting Rod Inspection Measure the inside diameter A of both piston pin holes in the piston Piston Pin Hole Inside Diameter Standard 17 002 17 008 mm 0 6694 0 6696 in Service Limit 17 04 mm 0 671 in x If either piston pin hole diameter exceeds the service limit replace the piston Measure the diameter of the piston pin Piston Pin Outside Diameter Standard 16 994 17 mm 0 6691 0 67 in Service Limit 16 96 mm 0 668 in x If the piston pin diameter is less than the service limit at any point replace the piston pin e Measure the inside diameter A of the connecting rod small end Connecting Rod Small End Inside Diameter Standard 17 016 17 034 mm 0 6699 0 6706 in Service Limit 17 06 mm 0 672 in x If the diameter exceeds the service limit replace the con necting
61. hardened or otherwise damaged WHEELS TIRES 11 1 Wheels Tires Table of Contents Exploded MI 11 2 Specifications RE SIR RIM 11 4 MR ES 11 5 Whee l Alignment 11 6 Steering Centering INSPSCHON en eure 11 6 Steering Centering Adjustment u 11 6 To8 in INSpection c icto aceto ital Toe in Adjustiment ee a ande Te Wheels RIMS esse Hr iii Wheel Removal M E MUR CERE een Wheel Installation en un be RENTEN nis TESNE albo Front Hub Removal n Fr nt Hub Inst llationss teet eet deer te eee teet e eter ee Front Hub Disassembly Front Hub Assemblyads e sica ei Hub Bearing Inspection Rear iub Removal Rear H b Installation 2 2 22 11 2 WHEELS TIRES Exploded View if 2 7 NN f 3X8 Q 4 ds qv 2 2 Exploded View WHEELS
62. impeller by hand until the seat bottoms out Tighten the water pump impeller by turning it counter clockwise Torque Water Pump Impeller 12 N m 1 2 kgf m 106 in Ib 4 10 COOLING SYSTEM Radiator Radiator Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Front Fender see Front Fender Removal in the Frame chapter Loosen the hose clamp screw A fully e Remove Radiator Hose B Radiator Mounting Bolts C Remove Radiator Upper Cover Bolts A Radiator Upper Cover B e Remove Radiator Cover Bolts A Remove the radiator cover B together with the radiator screen C Loosen the hose clamp screws A fully Remove the radiator hoses B e Disconnect the radiator fan motor lead connectors C COOLING SYSTEM 4 11 Radiator Open the brake hose clamp Move the radiator forward e Pull up the radiator to remove it Do not touch the radiator core This could damage the radiator fins resulting in loss of cooling effi ciency Radiator Installation Be sure to install the dampers A Insert the projections of the radiator in the dampers e Fit the dampers A to the projections B of the frame Hold the brake hose with the clamp A 4 12 COOLING SYSTEM Radiator e Connect Radiator Fan Motor Lead Connectors A e Install the radiator hoses Tighten the clamp screws C
63. 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 Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Troubleshooting Guide Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other Carburetor throttle valve doesn t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Final gear case oil level too high 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 Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Main air jet clogged 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 obs
64. permanent locking agent R Replacement Parts 14 6 SUSPENSION Specifications Standard Service Limit Shock Absorbers Usable Range Spring Preload Setting Position Front 2nd Step 1 5 Rear 2nd Step 1 5 SUSPENSION 14 7 Special Tools Oil Seal amp Bearing Remover Steering Stem Bearing Driver 642 5 57001 1058 57001 1344 7571058ST C 7571344ST C Steering Stem Nut Wrench Steering Stem Bearing Driver Adapter 641 5 57001 1100 57001 1345 D SS ST571100ST C ST571345ST C Bearing Driver Set Swingarm Pivot Nut Wrench 57001 1129 57001 1597 7571129ST C 875715975 C Jack 57001 1238 7571238ST C 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 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 Setting Load Terrain Speed Force 1 Weak Soft Light Smooth Low 2 STD 1 1 1 3 4 5 e 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 T
65. seat and hold the float in place with the tang A hooked into the needle hanger e Slip the float pivot pin B through the pivot posts and the float C as shown in the figure A WARNING Fuel is flammable and can damage the environ ment If the float is not properly installed the specified fuel level cannot be maintained and fuel may spill from the carburetor Be sure the float is properly installed and the float level set according to specifications Set the float height as specified see Float Height Inspec tion Replace the float bowl O ring A with a new one Install the following parts Pilot Jet Starter Jet New Float Bowl O ring Float Bowl and Screws Slip the jet needle through the hole in the center of the vacuum piston and put the spring seat A on the top of the jet needle Turn the seat so that it does not block the hole B at the bottom of the vacuum piston Install the chamber cover and tighten the screws After installing the chamber cover check that the vacuum piston slides up and down smoothly without binding in the carburetor bore HC06010951 3 16 FUEL SYSTEM Carburetor Carburetor Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the carburetor in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any applianc
66. securely Install the radiator cover A Tighten the radiator cover bolts B securely Install the radiator upper cover A Tighten the radiator upper cover bolts B securely Install the radiator hose A Tighten the clamp screw B securely Tighten Torque Radiator Mounting Bolts C 12 N m 1 2 kgf m 106 in Ib Radiator Fan Removal Installation Remove Radiator see Radiator Removal Radiator Fan Assembly Bolts A Fan Assembly B Install Radiator Fan Assembly Tighten the radiator fan assembly bolts Radiator COOLING SYSTEM 4 13 Radiator Inspection Check the radiator core x If there are obstructions to air flow remove the radiator and remove obstructions the corrugated fins A are deformed carefully straighten them x 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 x If any one of them shows visible damage replace the cap Top and Bottom Valve Seals A Valve Spring B e Install the cap A on a cooling system pressure tester NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leakage e Wa
67. see Front Fender Removal in the Frame chapter Handlebar see Handlebar Removal Front Bottom Guard see Front Bottom Guard Removal in the Frame chapter Bolts A Cable Holder B Steering Shaft Holder C e Remove Cotter Pins A Tie rod End Nuts B NOTICE 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 e Remove Cotter Pin A Steering Shaft Bottom End Nut B e Pull the steering shaft assembly upward to remove it from the frame Steering Shaft Installation e Assemble the steering shaft and bracket in reverse order of disassembly e Apply grease to the collar A dust seal B and bearing Apply grease to the steering shaft bushing A on the steering shaft B Install Steering Shaft Clamps C Cable Holder D Tighten Torque Steering Shaft Holder Bolts E 26 N m 2 7 kgf m 19 ft Ib STEERING 15 7 Steering e Replace the steering shaft bottom end nut A with a new Tighten Torque Steering Shaft Bottom End Nut 69 N m 7 0 kgf m 51 ft lb Install a new cotter e Install Tie rod Ends A Tighten Torque Tie rod End Nuts B 25 Nm 2 5 kgf m 18 ft lb e Install the new cotter pins C e Install the removed parts Steering Knuckle Removal e Remove Front Hub see Front Hub Removal in the Wheels Tires chapter Front Brake Disc Guard
68. the driven pulley bearing retainer bolt Tighten Torque Driven Pulley Bearing Retainer Bolt 9 8 N m 1 0 kgf m 87 in Ib Shift Shaft Inspection e Visually inspect the shift shaft A circlips B spring C for conditions x lf the shift shaft is bent or damaged excessively replace it with a new one x If the circlips spring are damaged or worn excessively replace them Shift Fork Rod Inspection Visually inspect the shift fork x If the shift fork rod is bent replace the shift fork rod with a new one CRANKSHAFT TRANSMISSION 10 23 Transmission Output Driven Shaft Housing Disassembly Remove Transmission Case A see Transmission Case Re moval Loosen the screw of the boot clamp Remove the boot with boot clamp Remove Bolts A Output Driven Shaft Housing B e Flatten out the bended threaded portion of the bevel gear nut e Install the universal joint A to the output driven shaft housing B Hold the universal joint in a vise Loosen the bevel gear nut Remove the A Special Tool Inside Circlip Pliers 57001 143 Remove the driven gear shaft Remove the bearing A Special Tools Oil Seal amp Bearing Remover B 57001 1058 Oil Seal amp Bearing Remover Adapter A C 57001 1061 10 24 CRANKSHAFT TRANSMISSION Transmission Remove the oil seal Remove the circ
69. the holder C Clear the parking cable upper end D from the lever Parking Brake Cable Installation e Lubricate the parking brake cable before installation see General Lubrication in the Periodic Maintenance chapter e Install the parking brake cable in accordance with Cable Wire and Hose Routing section in the Appendix chapter Install the return spring so that the spring ends A faces inside e Adjust the parking brake see Parking Brake Cable Ad justment in the Periodic Maintenance chapter Parking Brake Adjustment Refer to the Parking Brake Cable Adjustment in the odic Maintenance chapter Parking Brake Cable Lubrication Refer to the General Lubrication in the Periodic Mainte nance chapter SUSPENSION 14 1 Suspension Table of Contents Exploded VIew seinen er een 14 2 SPEEINCAUONS o oat eb RI Vid eh M 14 6 Special 100 S u eine ie ale iin Rn De xg hen 14 7 Shock Abs rberszh sen aan anni re N ea 14 8 Front Shock Absorber Preload Adjustment 14 8 Front Shock Absorber 14 8 Front Shock Absorber 14 8 Front Shock Absorber 14 8 Rear Shock Absorber Preload 14 9 Rear Shock Absorber 14 9 Rear Shock Absorber 14 9 Rear Shock Absorber
70. the measurement exceed the service limit replace the oil pump body and rotors as a set Outer Rotor Pump Body Clearance Standard 0 05 0 10 mm 0 002 0 004 Service Limit 0 10 mm 0 004 in or more ENGINE LUBRICATION SYSTEM 8 11 Oil Pump OCheck the clearance A between rotor end and pump body with a thickness gauge x If the measurement exceed the service limit replace the oil pump body and rotors as a set Rotor End Pump Body Clearance Standard 0 05 0 10 mm 0 002 0 004 in Service Limit 0 10 mm 0 004 in or more ENGINE REMOVAL INSTALLATION 9 1 Engine Removal Installation Table of Contents ahaa a Oe AND hee 9 2 Engine Removal llnstallation aan meets 9 4 Engine Removal 9 4 Engine Installation 9 5 9 2 ENGINE REMOVAL INSTALLATION Exploded View REMOVAL INSTALLATION 9 3 Exploded View Fastener Torque fib Engine Bracket Mounting Bolts 2 7 19 EN Front Engine Mounting Nut 4 0 29 R Lower Engine Mounting Nut 4 0 29 R Upper Engine Mounting Nut 39 4 0 29 R 5 Front R Replacement Parts 9 4 ENGINE REMOVAL INSTALLATION
71. while turning the wheel With the front wheels on the ground set the handlebar straight ahead e At the level of the axle height measure the distance be tween the scribed or painted lines for both front and rear of the front tires e Subtract the measurement of the front from the measure ment of the rear to get the toe in x If the toe in is not in the specified range adjust the toe in see Toe in Adjustment 118010 P Toe in of Front Wheels Standard 2 5 17 5 mm 0 098 0 689 in at 1G 2 28 PERIODIC Periodic Maintenance Procedures Toe in Adjustment e 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 OThe locknut B near the steering shaft on the tie rod has left hand threads Turn the locknut clockwise for loosening NOTE OThe toe in will be near the specified value if the tie rod length A is 334 5 mm 13 17 in on each tie rod 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 Locknuts 25 N m 2 5 kgf m 18 16 e Test ride the vehicle Final Drive Final Gear Case Level Inspection e Park the vehicle so that it is level both side to side and front to rear Remove Final Gear Case Oil Level Inspection Bolt A
72. 0035 in 0 5 mm 0 020 in 0 65 mm 0 0256 in 0 9 mm 0 0354 in 16 96 mm 0 668 in 17 04 mm 0 671 in 0 02 mm 0 0008 in 17 06 mm 0 672 in 0 06 mm 0 0024 in Special Tools Compression Gauge 20 kgf cm 57001 221 Valve Spring Compressor Assembly 57001 241 7570221ST C 7570241ST C Piston Pin Puller Assembly 57001 910 7570910ST C ENGINE TOP END 5 7 Compression Gauge Adapter M12 x 1 25 57001 1183 875711835 6 Valve Spring Compressor Adapter 22 57001 1202 875712025 C 5 8 END Clean Air System Air Suction Valve Removal e Remove Vacuum Switch Valve see Vacuum Switch Valve Re moval Air Suction Valve Cover Bolts A Air Suction Valve Cover B e Remove the air suction valve A Air Suction Valve Installation Installation is the reverse of removal Torque Air Suction Valve Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Air Suction Valve Inspection e Remove the air suction valve see Air Suction Valve Re moval e Visually inspect the reed A for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reed replace the air suction valve as an assembly e Check the reed contact area B of the valve holder for grooves scratches any signs of separation from the holder or heat damage If there is any doubt as to the condition of the reed contact a
73. 180 010 1 10 mm 0 043 92180 011 1 15 mm 0 045 92180 012 Backlash Adjustment Remove the output drive bevel gear cover see Transmis sion Case Removal Clean dirt and oil off the output drive bevel gear teeth Set a dial gauge A on the driven bevel gear B as shown Measure the backlash by turning the driven bevel gear shaft A in each direction reading the total backlash on the dial gauge Driven Bevel Gear Backlash Standard 0 03 0 15 mm 0 0012 0 0059 in If the backlash is not within specification the shim must be changed and the backlash should be rechecked until correct see Tooth Contact Adjustment xIf the backlash is too small under 0 03 mm 0 001 replace the driven bevel gear side spacer with a thinner shim x lf the backlash is too great over 0 15 mm 0 006 in replace the driven bevel gear side spacer with a thicker shim 10 28 CRANKSHAFT TRANSMISSION Transmission Tooth Contact Adjustment After backlash adjustment is carried out the tooth con tact must be checked Pay attention to the following proce dures Remove the driven bevel gear Clean and degrease several teeth of the drive and driven bevel gears Apply a coating of machinist s layout dye or paste to several teeth of the driven bevel gear e Install the driven bevel gear Rotate the driven bevel gear several turns in both direc tions e Remove t
74. 2 92 23 08 mm 0 902 0 909 in Service Limit 22 8 mm 0 90 in Drive Pulley Installation Installation is the reverse of removal Note the following OClean the following portions with an oil less cleaning fluid and dry them with a clean cloth Fixed Sheave Tapered Portion Crankshaft Drive Belt A WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings CONVERTER SYSTEM 6 11 Drive Pulley OWhen installing the fixed drive sheave A compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened OMake sure the ratchet B into the splines C on the crankshaft when the ratchet is installed Other than EUR model OApply engine oil to the drive pulley nut A OUsing the flywheel amp pulley holder B tighten the drive pulley nut Special Tool Flywheel amp Pulley Holder 57001 1605 Torque Drive Pulley Nut 93 N m 9 5 kgf m 69 ft lb 6 12 CONVERTER SYSTEM Clutch Driven Pulley Clutch Driven Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Removal Drive Pulley see Drive Pulley Removal e Using the flywheel amp pulley holder A remove the driven pulley nut B Special Tool Flywheel amp Pulley Holder 57001 1605 Remove the collar C and clutch outer D e Remove Clutch Driven Pulley A
75. 2 mm 0 15 0 17 in 3 mm 0 12 in Disc Runout 0 3 mm 0 012 in Brake Lever Brake Pedal Brake Lever Position Brake Lever Free Play Brake Pedal Free Play Non adjustable Non adjustable Non adjustable BRAKES 13 7 Special Tools Rotor Puller Hub Driver Set 57001 1623 57001 1782 Disc Hub Puller 57001 1781 E CF 5157178151 6 7571623ST C 5157178251 13 8 BRAKES Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning 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 rio
76. 57001 1377 875713775 Je 75717828T 6 Hub Driver Set 57001 1782 11 6 WHEELS TIRES Wheel Alignment is the difference between the distance of front the one of rear at the axle height position in the front wheels When there is toe in the distance A Rear is greater than B Front as shown The purpose of toe in is to prevent the front wheels from getting out of parallel at any time and to prevent any slip ping or scuffing action between the tires and the ground If toe in is incorrect the front wheels will be dragged along the ground scuffing and wearing the tread knobs Caster and camber are build in and require no adjust ment A Rear B Front Amount of Toe in Distance A and B are measured at axle height with the vehicle sitting on the ground or at 1G Steering Centering Inspection e Test ride the vehicle xIf the handlebars is straight when the vehicle is traveling in a straight line check the toe in see Toe in Inspection in the Periodic Maintenance chapter Otherwise adjust the steering centering see Steering Centering Adjustment Steering Centering Adjustment Hold a straightedge A against the rear wheel rim side at axle height e With the handlebars 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 OThe locknut B near the steering shaft
77. 6 LUBRICATION SYSTEM Engine Oil Flow HG04010B 5 1 Rocker Arm Shaft 2 Crankshaft 3 Oil Screen 4 Oil Pump LUBRICATION SYSTEM 8 7 Engine Oil Oil Filter A WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Check the oil level before each use and change the oil and filter according to the periodic maintenance chart Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear Check that the engine oil level is between the H mark line A and L mark line B lines in the oil level inspection window C NOTE Olf the oil has just been changed start the engine and run it for several minutes at idle speed Stop the engine then wait several minutes until the oil settles NOTICE Racing the engine before the oil reaches every part can cause engine seizure x If the level is too high suck the excess oil out the filler hole with a syringe or other suitable device x 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 NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level in preference to running the engine with the oil level low Then at your earliest convenience c
78. 8 8 PUIMND tm 8 9 Oil Purp FermoVall conce 8 9 8 9 8 2 ENGINE LUBRICATION SYSTEM Exploded View J LUBRICATION SYSTEM 8 3 Exploded View No Fastener Toraug Remarks N m kgf m ft Ib 2 Oil Pump Cover Screw 2 0 0 20 18 in Ib 3 Oil Pump Mounting Bolts 9 8 1 0 87 4 Engine Oil Drain Plug 25 2 5 18 5 Oil Level Inspection Window Retainer 98 10 87 in lb 6 Engine Oil Screen Plug 15 1 5 11 7 Front EO Apply engine oil R Replacement Parts 8 4 LUBRICATION SYSTEM Specifications Item Standard Service Limit Engine Oil Type Viscosity Capacity SG SH SJ SL or SM with JASO MA MA1 MA2 SAE 10W 40 1 6 L 1 7 US qt 1 8 L 1 9 US qt when engine is completely dry Oil Level after warm up or driving Between upper and lower level lines Oil Pump Inner Rotor Outer Rotor Clearance 0 05 0 15 mm 0 002 0 006 Outer Rotor Pump Body Clearance 0 05 0 10 mm 0 002 0 004 in Rotor End Pump Body Clearance 0 05 0 10 mm 0 002 0 004 in 0 15 mm 0 006 in or more 0 10 mm 0 004 in or more 0 10 mm 0 004 in or more LUBRICATION SYSTEM 8 5 Special Tool Outside Circlip Pliers 57001 144 7570144ST C 8
79. 88 5 992 in Service Limit 152 6 mm 6 008 in RECOIL STARTER 7 1 Recoll Starter Table of Contents Exploded View Other than EUR Model 7 2 Recoil Starter Other than EUR Model een 7 4 Recoil Starter Removal CES 7 4 Ree ll starter Installation eee qao teens 7 4 RECHI Starter Disassembiy u 7 4 gt 7 5 RECOM Starter Cleanihg hielten 7 7 Recoil Starter 7 7 7 2 RECOIL STARTER Exploded View Other than EUR Model HT020068W5 C RECOIL STARTER 7 3 Exploded View Other than EUR Model P ne Dem Recoil Starter Mounting Bolts 2 Front Apply R Replacement Parts 7 4 RECOIL STARTER Recoil Starter Other than EUR Model Recoil Starter Removal e Remove Left Footboard see Left Footboard Removal in the Frame chapter Recoil Starter Mounting Bolts A Recoil Starter B Recoil Starter Installation Tighten the recoil starter mounting bolts Torque Recoil Starter Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Recoil Starter Disassembly Remove the recoil starter see Recoil Starter Removal e Remove the starter grip plug A Pull out the rope end about 100 200 mm
80. 9 Final GamCase T 12 10 Final Gear Case Oil Level Inspection 12 10 Final Gear Final Gear Case 2 2 Final Gear Case Final Gear Case Disassembly pp Final Gear Case Assembly sr eek pute teca tato Final Bevel Gear Adjustment 1 Pinion Gear Disassembly gatio ee epe ee Pinion GearASsembly TT Bevel Gear ai EE E a R a AE EAER Be ng and Oil o EA AA piena ee Ball or Needle Bearing Inspection EI EN 12 2 FINAL DRIVE Exploded View Exploded View FINAL DRIVE 12 3 No Fastener N m Torque kgf m ft lb Remarks Final Gear Case Cover Bolts M8 26 2 7 2 Final Gear Case Cover Bolts M10 39 4 0 29 L 3 Gear Case Oil Level Inspection Bolt 20 2 0 15 4 Final Gear Case Mounting Bolts 54 5 5 40 5 Gear Case Oil Filler Cap 15 1 5 11 6 Final Gear Case Oil Drain Bolt 20 2 0 15 7 Pinion Gear Bearing Holder Nut 98 10 72 8 Gear Case Guard Bolts 31 3 2 23 9 Front G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 12 4 FINAL DRIVE Specifica
81. Be sure the following parts are in place in the left crankcase half Crankshaft A Balancer B Dowel Pins C New Gasket D 10 10 CRANKSHAFT TRANSMISSION e Align the mark on the balancer with the mark on the crankshaft Install the right crankcase half e Apply a non permanent locking agent to the crankcase bolts Tighten Torque Crankcase Bolts 9 8 N m 1 0 kgf m 87 in Ib CRANKSHAFT TRANSMISSION 10 11 Crankshaft Connection Rod Crankshaft Inspection Remove the crankshaft see Crankcase Disassembly e Measure the diameter A of connecting rod small end x If the measurement exceeds the service limit replace the crankshaft with a new one Connecting Rod Small End Diameter A Service Limit 17 06 mm 0 672 in Measure the crankshaft runout A x If the measurement exceeds the service limit replace the crankshaft with a new one Crankshaft Runout A Service Limit TIR 0 1 mm 0 004 in e Measure the connecting rod small end free play B x If the measurement exceeds the standard replace the crankshaft a new one Connecting Rod Small End Free Play B Standard 0 8 1 0 mm 0 03 0 04 in Measure the connecting rod big end side clearance C x If the measurement exceeds the service limit replace the crankshaft a new one Connecting Rod Big End Side Clearance C Service Limit 0 6 mm 0 024 in e Measure the crank width D x I
82. Clamps B for Brake Hose C and Parking Brake Cable D Loosen Boot Clamp Screw A e Remove Boot B e Remove Cap A Remove Swingarm Adjusting Locknut A Special Tool Swingarm Pivot Nut Wrench B 57001 1597 e Remove Swingarm Pivot Bolt Left Shaft C 14 14 SUSPENSION Swingarm e Remove Swingarm Pivot Right Shaft B e Remove Swingarm together with the Final Gear Case and Rear Axle Final Gear Case see Final Gear Case Removal in the Final Drive chapter Swingarm Installation e Apply grease Dust Seals A Install the final gear case see Final Gear Case Installa tion in the Final Drive chapter e Apply molybdenum disulfide grease to the spline of the output shaft A e Fit the propeller shaft B on the output shaft Tighten Torque Swingarm Pivot Right Shaft 116 N m 11 8 kgf m 85 6 ft lb Tighten Torque Swingarm Pivot Bolt Left Shaft A 11 N m 1 1 kgf m 97 in Ib Swingarm Pivot Locknut B 116 N m 11 8 kgf m 85 6 ft Ib Special Tool Swingarm Pivot Nut Wrench C 57001 1597 e Fitthe boot on the swingarm and tighten the clamp screw e Install the removed parts see appropriate chapters SUSPENSION 14 15 Swingarm Swingarm Disassembly Remove Dust Seals A e Remove Tapered Roller Bearings A e Remove Outer Races A Both Sides Special Tool Oil Seal amp Bearing Remover B 57001 1058
83. Clutch Driven Pulley Disassembly NOTE OBe sure to use a clutch spring compressor to avoid spring damage Set the holes A of the clutch driven pulley assembly B to the pins C of the clutch spring compressor D Hold the clutch driven pulley assembly with the clutch spring compressor securely Special Tool Clutch Spring Compressor 57001 Y006 Set the clutch spring compressor A in a vise e Using the hex nut wrench 39 mm 57001 Y006 B re move the clutch driven plate nut Special Tool Clutch Spring Compressor 57001 Y006 e Loosen the clutch spring compressor and remove the clutch driven pulley assembly CONVERTER SYSTEM 6 13 Clutch Driven Pulley Remove the clutch A Remove Spring Seat A Spring B Remove the seal collar A e Wipe off the grease Remove the guide roller pins A with guide rollers Remove the movable driven sheave from the fixed driven sheave C Remove Oil Seal A 6 14 SYSTEM Clutch Driven Pulley Remove the inner needle bearing A e Remove the snap ring B and outer bearing C Special Tool Inside Circlip Pliers 57001 143 Driven Pulley Inspection x lf the sheave surfaces A appear damaged replace the fixed driven sheave and or movable driven sheave x lf the movable driven sheave bushing is damaged or worn replace the movable driven sheave Movable Driven Sheave Bushing Ins
84. Disassembly Assembly in the Suspension chapter PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Wheel Inspection e Raise the front rear wheel off the ground see Wheel Re moval in the Wheels Tires chapter Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings see Hub Bearing Removal Installation Inspect the wheel for small cracks dents bending or warp x If there is any damage to the wheel replace the wheel Remove the wheel and support it with the tire by the axle Measure the rim runout axial A and radial with a dial gauge If rim runout exceeds the service limit check the hub bear ings see Wheel Bearing Damage Inspection x lf the problem is not due to the bearings replace the wheel Rim Runout with tire installed Service Limit Axial TIR 2 mm 0 08 in Radial TIR 2 mm 0 08 in A WARNING Damaged wheel parts may fail and cause an acci dent resulting in serious injury or death Never at tempt to repair a damaged wheel part If the wheel part is damaged it must be replaced with a new one Toe in Inspection e Raise the front wheels off the ground with the jack see Wheel Removal in the Wheels Tires chapter Apply a heavy coat of chalk or a paint line near the center of the front tires e Using a needle nose scriber make a thin mark near the center of the chalk coating
85. Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Crankshaft Sensor trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface 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 Idle adjusting screw maladjusted Pilot jet
86. M Fuses Fuse Removal e Remove Seat see Seat Removal in the Frame chapter Fuse Box Lid A e Pull the fuses A straight out of the fuse box with needle nose pliers Fuse Installation x 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 e Install the fuses on the original position as specified on the fuse box lids A Fuse Inspection e Inspect the fuse element x 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 8 19040151 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 Appendix Table of Contents Cable Wire and Hose ru 18 2 Troubleshooting UIQ 18 20 18 2 APPENDIX Cable Wire Routing APPENDIX 18 3 Cable Wire and Hose Routing Band Hold the front brake light switch lead Band Hold the left switch housing lead and rear brake light switch lead Throttle Cable Front Brake Hose Front Br
87. MBLY 68020248 5 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts 6 020048 5 Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer 6 020058 5 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 68020088 5 Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol SN oration or other damage Refer to the appropriate sections N of this manual for service limits on individual parts Replace AN the parts if any damage has been found or if the part is be yond its s
88. ME Footboards Left Footboard Removal e Remove Screws A and Nuts Screws B Bolts C Clear the projections D from the holes and remove the left footboard E Left Footboard Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B OReplace the nuts with new ones Torque Footboard Bolts 26 2 7 kgf m 19 ft Ib Right Footboard Removal Remove Screws A and Nuts Screws B Bolts C e Clear the projections D from the holes and remove the right footboard E FRAME 16 21 Footboards Right Footboard Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B OReplace the nuts with new ones Torque Footboard Bolts 26 N m 2 7 kgf m 19 ft Ib Footboard Bracket Removal e Remove Footboard see Left Right Footboard Removal Nut A Footboard Bracket Bolts B Footboard Bracket C Footboard Bracket Installation Installation is the reverse of removal Note the following Torque Footboard Bracket Bolts 26 2 7 kgf m 19 ft Ib ELECTRICAL SYSTEM 17 1 Electrical System Table of Contents Parts Locations era S erede E ee herr per reete 17 3 Exploded VIEW shore en e e He Dedi Rei EI Doria vides eoo PER eae oes 17 6
89. OOR WD Carburetor Overflow Hose Radiator Hose Radiator Cap Radiator To CVT Air Intake Duct Clamp Hold the carburetor overflow hose Carburetor Fuel Drain Hose Clamp Hold the carburetor fuel drain hose Run the hose of vacuum switch valve to the back side of cylinder head and connect the hose to the carburetor holder Vacuum Switch Valve Vacuum Switch Valve Hose To Air Suction Valve Cover 18 20 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Gear position 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 Balancer bearing seizure No fuel flow Fuel tank air vent obstructed Fuel tap clogged
90. Removal e Using a high flash point solvent wash the bearings clean of grease and dry them Inspect the bearings and dust seals for abrasion color change or other damage e Apply grease to the outer races A and pack the tapered roller bearings B with the same grease Apply grease to the inside of the oil seals e Install the swingarm see Swingarm Installation STEERING 15 1 Steering Table of Contents View ET 15 2 ETT 15 4 Special He t rec Da a ede Devas 15 5 I e 15 6 Steering Shall 15 6 Steering Shaft Installation sen 15 6 Steering Knuckle REMOVALS trennen 15 7 Steering Knuckle Installation rr te ttr so re 15 8 M Gegr ggMC 15 9 Tie rod Installation stetit eti taedet ode into 15 10 Tie rod End Removal o rrr iode efi sein 15 10 Tierod End InstallaliOl i tepido RERO eene fueris 15 10 steering Maintenance deae Dr e et Gs n ead 15 11 Steering NSPE iO PE 15 11 Steering Shaft Straightness 15 11 Steering Shaf
91. TIRES 11 3 Fastener Torque Nm kgfm fb 54 Rear Wheel Nuts Rear Wheel Hub Nuts 147 55 150 4 Front wheel Huo nus 6 70 9 5 Front G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease 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 2 5 17 5 mm 0 098 0 689 in at 1G Wheels Rims Rim Size Front 10 x 5 5 AT SSS Rear 10 x 8 0 AT Tires Standard Tire Front AT 22 x 7 10 MAXXIS M937 Tubeless Rear AT 22 x 10 10 Tire Air Pressure when cold Front Rear Maximum Tire Air Pressure to seat beads when cold Tire Tread Depth Front Rear MAXXIS M938 Tubeless 32 kPa 0 33 kgf cm 4 6 psi 24 kPa 0 24 kgf cm 3 5 psi 250 kPa 2 5 kgf cm 36 psi 3 mm 0 12 in 3 mm 0 12 in 1G The tires are grounded without the person and load Special Tools Bearing Driver Set 57001 1129 7571129ST C Jack 57001 1238 7571238ST C Bearing Remover Shaft 9 57001 1265 875712655 C Bearing Remover Head 15 x 17 57001 1267 5157126751 C WHEELS TIRES 11 5 Bearing Remover Head 20 x 22 57001 1293 7571293ST C Bearing Remover Shaft 13
92. Time h NOTICE If possible do not quick charge If the quick charge 9 1 1 1 1 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 0 Battery Terminal Voltage V GPO8021BS1 is done due to unavoidable circumstances do the standard charge later on Terminal Voltage less than 11 5 V Charging Method 1 2 A x 20h NOTE Olncrease the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current If the battery will accept current D decrease the voltage and charge by the standard charging method described on the battery case If the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C 8 08011351 C e Determine battery condition after refreshing charge ODetermine 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 8 V or lower Charge insufficient Recharge 12 0 V or lower Unserviceable Replace 17 24 ELECTRICAL SYSTEM Charging System Alternator Cover Removal Drain Coolant see Coolant Change in the Periodic Mainte nance chapter Engine Oil see Engine Oil Change in the Periodic Main tenance chapter e Remove
93. ables and wires will have some effect on the steer ing action which must be taken into account 2 36 PERIODIC Periodic Maintenance Procedures Check the steering action again x If the lubrication does not remedy the problem inspect the steering shaft for straightness steering stem holders and tie rod bearings x 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 x lf the steering action does not change by tightening the bolts and nuts inspect the steering stem bearings tie rod bearings and steering knuckle joints Electrical System Spark Plug Cleaning Inspection Remove the spark plug See Spark Plug Removal in the 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 Use the standard spark plug or its equivalent Spark Plug Gap Inspection Measure the gap A with a wire type thickness gauge x If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 8 0 9 mm 0 032 0 036 in Join
94. acing out Press the bearing into place by putting RSs pressure on the correct bearing race as shown 2 B Bh B Pressing the incorrect race can cause pressure between 5 A the inner and outer race and result in bearing damage 77 orem 68020188 5 Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed H L new oil seals with manufacture size marks facing out Make sure the seal is aligned properly when installing N N V 2 68020198 5 specified grease to the lip of seal before installing the seal Grease GBO2046BS1 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 68020268 5 1 6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to wear during Lubri AH p TN cation points are called out throughout this manual apply A VAT a the specific oil or grease as specified S e A x 68020218 5 Direction of Engine Rotation When rotating the crankshaft by hand the free play MN amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction c
95. add oil through the inpection bolt opening Use the same type and brand of oil that is already in the transmission case Replace the gasket C with a new one and tighten the inspection bolt Torque Transmission Oil Level Inspection Bolt 9 8 N m 1 0 kgf m 87 in Ib Transmission Oil Change e Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily Then stop the vehicle e Remove the transmission oil filler bolt A e Place an oil pan beneath the transmission case Remove the transmission oil drain plug A and let the oil drain completely Replace the gasket with a new one e After the oil has completely drained out install the drain plug with the gasket Torque Transmission Oil Drain Plug 20 N m 2 0 kgf m 15 ft lb e Fill the transmission case with a good quality oil as spec ified in the table Transmission Oil Type 2 SP AUTOMATIC REV Viscosity SAE 90 Capacity 0 6 L 0 63 US qt Check the oil level see Transmission Oil Level Inspec tion Replace the O ring on the oil filler bolt with a new one and apply grease to the O ring Torque Transmission Oil Filler Bolt 20 N m 2 0 kgf m 15 ft Ib 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels Tires Tire Inspection e Examine the tire for damage and wear x If the tire is cut or cracked replace it OLumps or high spots on the tread or sidewalls indic
96. ake Light Switch Lead Steering Shaft Clamp Right Side Left Switch Housing Lead Rear Brake Light Switch Lead Rear Brake Hose Choke Cable Steering Shaft Clamp Front and Left Side Steering Shaft Clamp Rear and Left Side Parking Brake Cable Ignition Switch Lead Speedometer Cable Meter Unit Lead Handlebar Holder Bracket Run the ignition switch lead speedometer cable and meter unit lead through inside the handlebar holder bracket Fuel Level Sensor Lead Main Harness Clamp Hold the fuel level sensor lead and main harness To Ignition Switch Handlebar Holder Center Guide 18 4 APPENDIX Cable Wire and Hose Routing APPENDIX 18 5 Cable Wire Hose Routing Run the right headlight lead to outside the radiator guard Run the left headlight lead to outside the radiator guard Main Harness Power Outlet Lead Run the power outlet lead under the torque converter exhaust duct View form A Band Hold the headlight lead on both sides Headlight Lead Clamps Hold the headlight leads on both sides Hold the headlight connector on both sides Run the right headlight lead to torque converter exhaust duct 18 6 APPENDIX Cable Wire Routing HB095002 G APPENDIX 18 7 Cable Wire Hose Routing Igniter Main Harness
97. aling surface may allow oil to leak Check Oil Seal see Oil Seal Inspection Ball Bearings see Ball or Needle Bearing Inspection e Visually check the bevel gears for scoring chipping or other damage Replace the bevel gears as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact OBe sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash related parts are replaced see Final Bevel Gear Adjustment Install the new needle bearing and new circlip Special Tool Inside Circlip Pliers 57001 143 Install Pinion Gear Assembly Pinion Gear Bearing Holder Locknut Special Tool Pinion Bearing Lock Nut Wrench 52 5 mm 57001 Y019 Torque Pinion Gear Bearing Holder Locknut 98 N m 10 kgf m 72 ft lb New Oil Seal 12 12 FINAL DRIVE Final Gear Case Final Bevel Gear Adjustment OThe backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged e After replacing any of the backlash related parts be sure to check and adjust the backlash and tooth contact of the bevel gears First adjust backlash and then tooth con tact by replacing shims OThe amount of backlash is influenced by the ring gear position more than by the pinion gear position OTooth contact location is influenced by pinion gear posi tion more than by ring gear position Final Ge
98. all Caliper Holder B Bleed Valve C and Rubber Cap D Torque Bleed Valve 6 0 0 61 kgf m 53 in Ib e Install the pads see Front Brake Pad Installation Rear Caliper Disassembly e Remove the rear caliper see Rear Caliper Removal e Remove Pad Bolts A Brake Pads B Pull out the caliper holder C e Remove Spring A Bolts B Parking Brake Bracket C Push out the piston A BRAKES 13 23 Calipers Remove Dust Seal A Fluid Seal B Anti rattle Spring C Remove Boots A Bleed Valve B and Rubber Cap C Rear Brake Caliper Assembly Replace the fluid seal A with a new one OApply silicone grease to the fluid seal and install it into the cylinder by hand e Replace the dust seal B with a new one brake fluid to the dust seal and install it into the cylinder by hand 8105040251 C Install the anti rattle spring A in the caliper as shown e Apply silicone grease to the outside of the piston A and push it into the cylinder by hand Take care that neither e the cylinder nor the piston skirt gets scratched Replace the rubber boots B if they are damaged e Install Caliper Holder C Bleed Valve D and Rubber Cap E Torque Rear Caliper Bleed Valve 6 0 N m 0 61 kgf m 53 in Ib HL060378 5 13 24 BRAKES Calipers e Install Parking Brake Bracket A Bolts B Spring C
99. and possibly engine damage will occur e Remove Screw A Holder B Element C Air Cleaner Element Installation e Install the following parts on the element frame A Metal Net B Element C Holder D Screw E FUEL SYSTEM 3 19 Air Cleaner e Fit the tangs A of the housing cap into the holes B of the housing Install the clips securely Air Cleaner Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Air Cleaner Draining Refer to the Air Cleaner Draining in the Periodic Mainte nance chapter Air Cleaner Housing Removal Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Loosen the screw A and remove the rivet Loosen the clamp screw A Remove Air Intake Duct Outside B Air Intake Duct Inside C Remove Clamp A and Breather Hose B Loosen the clamp screw 3 20 FUEL SYSTEM Air Cleaner Remove Air Cleaner Housing Mounting Bolts A Air Cleaner Housing B Air Cleaner Housing Installation Installation is the reverse of removal Note the following ORun the leads and hose correctly see Cable Wire and Hose Routing section in the Appendix chapter OFit the hole A and slits B of the air intake duct outside to the projections C of the air intake duct inside FUEL 5 5 3 21 Fuel Tank Fu
100. ansmission chapter x If the shift lever condition is good replace the meter unit Blue High Beam Indicator Light LED Check e Turn the ignition switch to ON e Set the dimmer switch to the high beam position OThe blue high beam indicator light A goes on x If the display function does not work check the wiring see Meter Circuit x If the wiring is good replace the meter unit Meter ELECTRICAL SYSTEM 17 55 Meter Circuit HP20134BW3 C Meter Unit Water Temperature Sensor Charge Fuse 30 A Main Fuse 15 A Headlight Tail Light Fuse 10 A Ignition Switch Gear Position Switch Fuel Level Sensor Battery 12 V 10 Ah Engine Ground Light Dimmer Switch 17 56 ELECTRICAL SYSTEM Switches and Sensor Rear Brake Pedal Light Timing Adjustment e Remove the right footboard see Right Footboard Re moval in the Frame chapter e Adjust the brake light switch A up or down To change the switch position turn the adjusting nut B Light sooner as the body rises C Light later as the body lowers D To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment Water Temperature Sensor Inspection Remove the water temperature sensor see Water Tem perature Sensor Removal in the Cooling System chapter Suspend the sensor A in a contain
101. ar Case Backlash related Parts HK180048 5 1 Gear Ball Bearing 4 Ring Gear Shim s Right 7 Ring Gear Ball Bearing 2 Pinion Gear Shim s 5 Pinion Gear Left 3 Ring Gear Ball Bearing 6 Ring Gear Shim s Left 8 Ring Gear Right 4 Ring Gear Shims Right Thickness Part Number 1 53 mm 0 060 in 92180 Y029 1 50 mm 0 059 in 92180 Y030 1 47 mm 0 058 in 92180 Y031 6 Ring Gear Shims Left Thickness Part Number 1 53 mm 0 060 in 92180 Y029 1 50 mm 0 059 in 92180 Y030 1 47 mm 0 058 in 92180 Y031 Final Gear Case FINAL DRIVE 12 13 Backlash Adjustment Clean any dirt and oil off the bevel gear teeth e Install the pinion puller set A and screw the bolt B until it stops Hold securely the nut of the pinion puller set with a wrench D Special Tool Pinion Puller Set A 57001 Y020 Remove the oil filler cap Set up a dial gauge A against a ring gear tooth to check gear backlash To measure the backlash move the ring gear back and forth B while holding the pinion gear steady with the pin ion puller set The difference between the highest and the lowest gauge reading is the amount of backlash Bevel Gear Backlash Rear Standard 0 05 0 25 mm 0 0020 0 0098 in at ring gear tooth Service Limit 0 4 mm 0 016 in xIf the backlash is too small replace the ring gear shim right with a thicker one Backl
102. are made to extremely close tol erances the clearance can not normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones Turn each bearing in the hub back and forth A while checking for plays roughness or binding If bearing play roughness or binding is found replace the bearing e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing HJ07022BS1 6J06030581 WHEELSI TIRES 11 15 Hub Rear Hub Removal e Remove Cap A Cotter Pin B Loosen the axle nut while applying the brake Remove Rear Wheel see Wheel Removal Axle Nut e Using a suitable puller A remove the rear hub B while holding it with the pullers hooks Make sure that the hooks are positioned C on the rear hub as shown in the figure NOTE Olf the puller s hooks are not positioned correctly on the rear hub the rear hub could be damaged and distorted Rear Hub Installation Clean any dirt and molybdenum disulfide grease off the splines of rear hub and rear axle e Apply molybdenum disulfide grease to the splines of the axle so the spline grove is filled with grease Install the rear hub A onto the rear axle Special Tool Hub Driver Set B 57001 1782 Tighten the nut C of the special tool and install the rear hub until it is the disc hub
103. ash is changed by about 0 03 mm 0 0012 in when thickness of the shim is changed by 0 06 mm 0 0024 in NOTE OThree shims are available in thickness increments of 0 03 mm 0 0012 in Backlash Difference Remove the dial gauge Turn the ring gear 120 and mea sure backlash e Repeat this procedure once more Compare the differ ence of the three measurements Service Limit 0 2 mm 0 008 in x If the difference in measurements exceeds the service limit it indicates that the bearing is not installed squarely or the case is deformed e Inspect the bearings and case Tooth Contact Adjustment e Remove the oil filler cap e Rotate ring gear several turns in each direction 180058 5 12 14 FINAL DRIVE Final Gear Case Check the gear tooth contact pattern through the oil filler hole This will provide a contact pattern on the coated teeth of the gear Compare the coated teeth to the exam ples shown in A B and C Contact is normal if the machinist s layout dye to the ap proximate center of each tooth example B f tooth contact is found to be incorrect example A and C the shim between the pinion gear bearing and pinion gear must be changed and the tooth contact re checked until correct Tooth Contact Shim Adjustment Contact at tooth top A Decrease shim thickness Contact at tooth root C Increase shim thickness NOTE OMake sure to check the backlash and shim thic
104. ate internal damage requiring tire replacement ORemove any foreign objects from the tread After re moval check for leaks with a soap and water solution e Measure the tread depth at the center of the tread with a depth gauge A Since the tire may wear unevenly take measurements at several places 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 3 mm 0 12 in Standard Tire Front AT 22 x 7 10 MAXXIS M937 Tubeless Rear AT 22 x 10 10 MAXXIS M938 Tubeless Wheel Bearing Damage Inspection e Raise the front wheels off the ground with the jack see Wheel Removal in the Wheels Tires chapter Turn the handlebar all the way to the right or left Inspect the roughness of the front wheel bearing by push ing and pulling A the wheel Spin B the front wheel lightly and check for smoothly turn roughness binding or noise If roughness binding or noise is found replace the wheel bearing see Front Hub Disassembly Assembly in the Wheels Tires chapter e Raise the rear wheels off the ground with the stand see Wheel Removal in the Wheels Tires chapter Inspect the roughness of the rear wheel bearing by push ing and pulling A the wheel Spin B the rear wheel lightly and check for smoothly turn roughness binding or noise x If roughness binding or noise is found replace the rear axle bearing see Swinarm
105. ath Do not operate the vehicle until any water or soap solution applied to the bead has com pletely dried Tire Inspection e Refer to the Tire Inspection in the Periodic Maintenance chapter HJ06023BS1 11 12 WHEELS TIRES Front Hub Front Hub Removal Remove Cap A Cotter Pin B Loosen the axle nut Remove the front wheel see Wheel Removal e Remove the caliper by taking off the mounting bolts A and let the caliper B hang free Remove the axle nut A and pull off the front hub together with the brake disc Separate the brake disc from the front hub see Front Brake Disc Removal in the Brakes chapter Front Hub Installation e Install the front brake disc see Front Brake Disc Installa tion in the Brakes chapter Wipe dry the surface of the hub and threads of the axle shaft e Wipe dry the threads and seating surface of the nuts Tighten Torque Front Wheel Hub Nuts 69 7 0 kgf m 51 ft Ib Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole 2 HJ07023BS1 Front Hub WHEELS TIRES 11 13 eBend the cotter pin A over the nut e Install the cap Fr
106. bearing in or out NOTICE Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new ball bearing until it stops at the bottom of its housing OThree new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole Special Tool Bearing Driver Set 57001 1129 6114060551 Ball and Needle Bearing Wear Inspection Do not remove the bearings for inspection Re moval may damage them Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it Check the needle bearings OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is any doubt as to the condition of a needle bear ing replace it 6114010151 C Oil Seal Inspection Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated
107. bolt with a new gasket and tighten it Torque Final Gear Case Oil Drain Bolt 20 N m 2 0 kgf m 15 ft lb e Fill the gear case up to the bottom of inspection bolt open ing with the oil specified below Final Gear Case Oil Viscosity SAE 80 Capacity 0 15 L 0 16 US qt Replace the O ring A with a new one and tighten the filler cap B OApply grease to the O ring Torque Final Gear Case Oil Filler Cap 15 N m 1 5 kgf m 11 ft lb Brakes Brake Operation Inspection Inspect the operation of the front and rear brake by run ning the vehicle on the dry road xIf the brake operation is insufficiency inspect the brake system A WARNING When test riding the vehicle be aware of surround ing traffic for your safety 2 30 PERIODIC Maintenance Procedures Brake Pad Wear Inspection Check the lining thickness A of the pads in each caliper x If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Then adjust the parking brake see Parking Brake Cable Ad justment Pad Lining Thickness Standard 5 5 mm 0 22 in Service Limit 4 0 04 in Brake Hoses and Connections Inspection Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if
108. brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever or pedal has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately Front Brake Remove the front brake reservoir and diaphragm e Fill the reservoir with fresh brake fluid to the upper level line A Slowly pump the front brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the front master cylinder by this operation Remove the rubber cap A on the front caliper e Attach a clear plastic hose B to the bleed valve C and run the other end of the hose into a container 13 10 BRAKES Fluid the brake line the front caliper ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the front brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve of front caliper while holding the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time durin
109. by referring to the coolant manufacturer s directions Bleed the air from the cooling system as follows OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the radiator hoses to force any air bubbles caught inside OStop the engine and add coolant up to the radiator filler neck e Install the radiator cap Remove the reserve tank cap A e Fill the reserve tank up to the F mark line B 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 x If the coolant level is lower than the L mark line C add coolant to the F mark line Do not add more coolant above the F mark line PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Radiator Hose and O ring Replacement e Drain the coolant see Coolant Change e Remove Front Fender see Front Fender Removal in the Frame chapter Replace the following hoses with new one A Radiator Cap to Radiator B Radiator to Water Pump Cover C Radiator to Thermostat Housing D Alternator Cover to Cylinder E Radiator Cap to Reserve Tank F Overflow Hose e Remove Thermostat Housing see Thermostat Removal in the Cooling System chapter Replace the O ring A with a new one e Apply grease to the O rings and i
110. ce chapter Final Gear Case Oil Change Refer to the Final Gear Oil Change in the Periodic Main tenance chapter Final Gear Case Removal e Remove Rear Axle see Rear Axle Removal Final Gear Case Mounting Bolts A Remove the final gear case backward Final Gear Case Installation Installation is the reverse of removal note the following Install the final gear case Tighten Torque Final Gear Case Mounting Bolts A 54 N m 5 5 kgf m 40 16 Install the removed parts see appropriate chapters Fill the final gear case with the specified oil see Final Gear Case Oil Change in the Periodic Maintenance chap ter Final Gear Case Disassembly e Remove Final Gear Case see Final Gear Case Removal Oil Seal A 100 P FINAL DRIVE 12 11 Final Gear Case e Fit the projection of the pinion bearing lock nut wrench B in grooves C of the pinion gear bearing lock nut wrench Special Tool Pinion Bearing Lock Nut Wrench 52 5 mm B 57001 Y019 Remove the pinion gear bearing holder locknut D Remove the pinion gear assembly E Remove the A Special Tool Inside Circlip Pliers 57001 143 Remove the needle bearing Final Gear Case Assembly NOTICE Be careful not to scratch the sealing surfaces A of the final gear case and case cover during the bear ing removal and installation A scratched se
111. cified replace the crank shaft sensor ELECTRICAL SYSTEM 17 35 Ignition System Alternator Rotor Inspection Check the timing projection A for damage such as ping or grooving x lf the timing projection on the rotor is visibly damaged replace the alternator rotor Ignition System Circuit HP10083BW3 C Charge Fuse 30 A Main Fuse 15 A Ignition Switch Gear Position Switch Battery 12 V 10 Ah Engine Ground Crankshaft Sensor Spark Plug Ignition Coil 10 Igniter 11 Reverse Power Assist Switch Override 12 Engine Stop Switch 17 36 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting Faulty ignition Malfunctioned engine Battery voltage inspection Ignition system wiring and connector inspection Charge or replace battery Repair or replace Replace Spark plug inspection Plug cap inspection Replace Ignition coil winding resistance inspection Replace Crankshaft sensor resistance inspection 1 Adapter connection is incorrect or adapter is defective 2 Ignition switch and engine stop switch No good Good Replace bad parts Igniter is defective Replace the igniter HP10084B F ELECTRICAL SYSTEM 17 37 Electric Starter System Starter Motor Removal Slide the rubber boots A e Remove Starter Motor Cable Mounting Nut B Starter Motor Cable C Starter Motor M
112. ckly and com pletely in all steering positions by the return spring x If the throttle lever does not return properly check the throttle cable routing lever free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x 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 x If the free play is not within the specified range adjust the cable Throttle Lever Free Play Standard 1 4mm 0 04 0 16 in Throttle Lever Free Play Adjustment Slide the rubber cover off the adjuster at the throttle case Loosen the locknut A and turn the throttle cable adjuster B until the cable has proper amount of play Tighten the locknut and reinstall the rubber cover Idle Speed Inspection Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides to check for any changes in the idle speed If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted incorrectly routed or damaged Be sure to correct any of these conditions before riding A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to co
113. d d ede Dee ads 6 5 Torque Converter Cover 6 6 Torque Converter Cover Removal 1002000 2 000 00000000000000000000000000000000 2 6 6 Torque Converter Cover Installation 6 6 Torque Converter Cover Disassembly caret sits 2 alien 6 6 Torque Converter Cover Assembly pp 6 6 Bearing amp b D ches META MEC Drive Belt Rem Wal lat Drive Belt installation an a 6 8 Drive Belt InSpections cc isa refe eee HAN Hep a 6 8 Drive Pullgy eee desc e ete ta Si 6 9 Drive Pulley renta Cop e hn t M een 6 9 Drive Pulley Inspection areas elek 6 9 Drive Pulley Installatien ee ae 6 10 Cluteh Driven Pulley ciel een 6 12 Clutch Driven Pulley Removal 6 12 Clutch Driven Pulley Disassembly pp 6 12 Driver Pulley BIETER 6 14 Clutch Driven Pulley Assembly lan 6 15 Clutch Driven Pulley Installation 1 22222 2 1141 1 1 nnne 6 16 Disassemblya ea ie 6 16 Iere 6 16 Gl tch Inspection RER CR PO HEY e
114. drum B as shown CRANKSHAFT TRANSMISSION 10 21 Transmission e Install the shift fork A as shown and then the shift fork rod e Align the punch mark A of the shift shaft gear to between the punches B mark of the shift drum gear Install Ball A Spring B Washer C Tighten Torque Shift Drum Stopper Plug D 47 N m 4 8 kgf m 35 in Ib e Install the transmission case cover see Transmission Case Installation e Install the removed parts see appropriate chapters Shift Fork Rod Runout e Measure the shift fork rod runout x If the measurement exceeds the service limit replace the shift fork rod with a new one Shift Fork Rod Runout Service Limit Less than 0 03 mm 0 012 in Clutch Driven Pulley Shaft Disassembly e Remove Transmission see Transmission Case Disassembly Bolt A Driven Pulley Bearing Retainer B Clutch Driven Pulley Shaft C 10 22 CRANKSHAFT TRANSMISSION Transmission e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Using a suitable puller remove the ball bearing B Clutch Driven Pulley Shaft Assembly e Install Clutch Driven Pulley Shaft Bearing A Special Tool Bearing Driver 32 B 57001 382 Replace the with a new Special Tool Outside Circlip Pliers 57001 144 Install Clutch Driven Pulley Shaft Driven Pulley Bearing Retainer Apply a non permanent locking agent to
115. e Primary Windings 3 4 4 1 O at 20 C 68 F Secondary Windings 18 9 with plug cap at 20 C 68 F 14 45 without plug cap at 20 C 68 F x If the hand tester does not read as specified replace the coil OTo install the plug cap turn it clockwise HP10081BS1 C 17 34 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Removal Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Mounting Screws A Crankshaft Sensor B Crankshaft Sensor Installation Install Stator Coil Leads A Crankshaft Sensor B Tighten Torque Crankshaft Sensor Mounting Screws C 7 4 N m 0 75 kgf m 65 in Ib e Using a high flash point solvent clean off any oil or dirt that may be on the silicone sealant coating area Dry them with a clean cloth e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the lead grommet A into the notch of the alternator cover securely Sealant Liquid Gasket TB1216 92104 1063 Crankshaft Sensor Inspection Remove the right side cover see Right Side Cover moval in the Frame chapter Disconnect the crankshaft sensor lead connector A Measure the crankshaft sensor resistance OConnect a hand tester between the BL Y lead and the G W lead OSet the tester to the x 10 range Crankshaft Sensor Resistance Standard 105 110 at 20 C 68 F x If the tester does not read as spe
116. e Stator Coil Resistance Three phase AC 13 5 15 5 V 110 V at 4 000 r min rpm 0 1 1 5 Q at 20 C 68 F Ignition System Spark Plug Type Spark Plug Gap Spark Plug Cap Resistance Ignition Coil Primary Winding Resistance Secondary Winding Resistance NGK DPR7EA 9 0 8 0 9 mm 0 032 0 036 in 4 2 5 2 at 20 C 68 F 34 410 18 9 with plug cap at 20 C 68 F 14 45 with out plug cap at 20 C 68 F Crankshaft Sensor Resistance Switches and Sensors Fuel Level Sensor Resistance Full Level Position Empty Level Position Brake Light Switch Timing Front Rear Lever Rear Pedal Water Temperature Sensor Resistance Radiator Fan Switch Resistance Rising Temperature Falling Temperature 105 110 at 20 C 68 F Less than 60 Over than 820 Pulled ON Pulled ON ON after 10 mm 0 4 in of pedal travel in the text From OFF to ON at over than 85 90 C 185 194 F From ON to OFF at less than 85 90 C 185 194 F ON about 0 O OFF Q ELECTRICAL SYSTEM 17 11 Specifications This page intentionally left blank 17 12 ELECTRICAL SYSTEM Wiring Diagram W BK BL BK AAO v zu lt oma on as gt er Sm o a 0 5 o BR BK Meter Unit R W BR BL BR BK 1 Power Outlet Fuse 15 2 Charge Fuse 30 3 Main Fuse 15 4 Headlight Water ene Temperature Tail light Fu
117. e engine oil or any other petroleum distillate will cause de terioration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake Take care not to scratch the piston or the inner wall of the cylinder Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders Check that there are no scratches rust or pitting on the inner wall of each master cylinder and on the outside of each piston If a master cylinder or piston shows any damage replace them Check the dust covers for damage x If they are damaged replace the master cylinder e Check that the relief A and supply B ports are not plugged x If the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with com pressed air Calipers BRAKES 13 19 Front Caliper Removal e Remove the front wheel see Wheel Removal in the Wheels Tires chapter Loosen the banjo bolt A at the brake hose lower and tighten it loosely Unscrew the caliper mounting bolts and detach the caliper C from the disc Unscrew the banjo bolt and remove the brake hose D from the caliper Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the b
118. e or no reading infinity for any two leads the stator has an open and must be replaced Much less resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the yellow leads and chassis ground Any reading less than infinity indicates a short neces sitating stator replacement x 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 17 30 ELECTRICAL SYSTEM Charging System Regulator Rectifier Removal e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter e Disconnect the connectors A e Cut the bands A e Remove Regulator Rectifier Mounting Nuts A Regulator Rectifier B Regulator Rectifier Installation Installation is reverse of removal Regulator Rectifier Inspection e Remove i Regulator Rectifier see Regulator Rectifier Removal Mr Set the hand tester to the x 1 range and make the measurements shown in the table az Special Tool Hand Tester 57001 1394 Connect the hand tester to the regulator rectifier x lf the tester readings are not as specified replace the Y3 regulator rectifier 9042881 Use only Kawasaki Hand Tester 57001 1394 for this test A tester oth
119. e Cable Removal 13 34 Parking Brake Cable Installation 13 34 Parking Brake Adjustment 13 34 Parking Brake Cable Lubrication 13 34 13 2 BRAKES Exploded View HL020388W5 C BRAKES 13 3 Exploded View 1 Brake Hose BanjoBos 3 38 25 73 Rear Master Cylinder Clamp Bots 12 12 eme 4 Brake Caliper Mounting Bolts 28 27 19 5 os S3mb 6 e 18 77 Brake Disc Mounting Bos a 38 25 Rear Brake Proportioning Valve Mounting Bolts 12 1 2 106imb 9 Front L Apply a non permanent locking agent R Replacement Parts S Follow the specified tightening sequence Si Apply silicone grease Co NS NIO 13 4 BRAKES Exploded View HL020398W5 C BRAKES 13 5 Exploded View No Fastener Torque kgf m ft Ib i i 12 Rear Master Cylinder Mounting Bolts 1 2 106 in Ib 35 Brake Disc Mounting Bolts 6 Front G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts Si Apply silicone grease Remarks 13 6 BRAKES Specifications ltem Standard Service Limit Brake Fluid Grade DOT 4 Disc Brake Pad Lining Thickness Front 5 5 mm 0 22 1mm 0 04 5 5 mm 0 22 1 mm 0 04 in Disc Thickness 3 8 4
120. e Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire e Remove the tire from the rim using a suitable commer cially available tire changer NOTE OThe 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 NOTICE 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 the Periodic Maintenance chapter e Lubricate the tire beads and rim flanges with a soap and water solution or water A WARNING Lubricants other than water or a water and soap so lution can cause the bead to separate from the rim and cause an accident resulting in serious injury or death Use only water or a water and soap solution to lubricate the bead when installing the tire HJO6005BS1 C Tires WHEELS TIRES 11 11 Check the tire rotation mark A on the tire and install the tire on the rim accordingly B Tire Rotation Direction Install the tire on the rim using a suitable commercially available tire changer e Lubricate the tire beads again and center the ti
121. e While compressing the push rod A turn it clockwise with a suitable screwdriver until the rod stopped NOTICE Do not turn the rod counterclockwise before in stalling the tensioner This could detach the rod and the tensioner cannot be reinstalled Replace the chain tensioner gasket with a new one e While holding the rod in position with a suitable push rod holder plate A install the tensioner on the cylinder block 5 12 END Camshaft Chain Tensioner Tighten Torque Camshaft Chain Tensioner Mounting Bolts A 12 N m 1 2 kgf m 106 in Ib e Take out the holder plate B Replace the O ring with a new one Apply engine oil to a new O ring e Install the O ring and tighten the cap bolt Torque Camshaft Chain Tensioner Cap Bolt 4 2 N m 0 43 kgf m 37 in Ib e Install the removed parts see appropriate chapters END 5 13 Rocker Arms and Shafts Rocker Arm Removal e Remove Camshaft Cap see Camshaft Removal Rocker Shaft Intake Side A Rocker Arm B OThe rocker shaft intake side has a threads C e Using a suitable tool A remove the rocker shaft exhaust side B Remove Rocker Arm C Stop Plate D OMark and record the rocker arm location so it can be in stalled in the original position OThe rocker arms come off with the rocker shafts Rocker Arm Installation Apply engine oil to the following parts Rocker Shaf
122. e battery E Battery Installation Connect the positive cable A with the red cap to the positive terminal first and then the negative cable to the negative terminal Cover the positive terminal with the red Install the battery holder Tighten the battery holder bolts E securely 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 KVF300C YTX12 BS Each battery comes with its own specific elec trolyte container using the wrong container may overfill the battery with incorrect electrolyte which can shorten battery life and deteriorate battery per formance Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type GP08135BS1 C Battery ELECTRICAL SYSTEM 17 19 Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to the dedicated electrolyte container for correct electrolyte volume DANGER Sulfuric acid in battery electrolyte can cause severe burns To prevent burns wear protective clothing and safety glasses when handling electrolyte If the electrolyte comes in contact with your skin or eyes wash the area with liberal am
123. e by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations Removal of the muffler or any internal portion of the muffler Removal of the air cleaner housing or air cleaner housing cover Modifications to the muffler or air intake system by cutting drilling or other means if such modifications result in increased noise levels Modification to the air cleaner element 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 ca
124. e careful not to bend or damage the fuel level sensor float arm Fuel Level Sensor Installation Replace the fuel level sensor gasket A with a new one e Install Fuel Level Sensor e When installing the fuel level sensor align the triangular mark A on the fuel tank with the projection B on the fuel level sensor Tighten the fuel level sensor mounting bolts Fuel Level Sensor Inspection e 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 x If the float does not move smoothly replace the fuel pump assembly 17 50 ELECTRICAL SYSTEM Fuel Level Sensor e Using hand tester A measure the resistance across the terminals Special Tool Hand Tester 57001 1394 NOTE contrast to the normal measuring method the current 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 x If the readings are not as specified replace the fuel pump assembly Fuel Level Sensor Resistance Standard Full Level Position B Less than 60 O Empty Level Position C Over than 820 Fuel Level Sensor Circuit D v w BL
125. e 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 sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a 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 68020128 5 GB020138 5 68020148 5 J 2 68020158 5 68020188 5 GENERAL INFORMATION 1 5 Before Servicing Press For items such as bearings or oil seals that must be r pressed into place apply small amount of oil to the con D uua tact area Be sure to maintain proper alignment and use dai d smooth movements when installing gt GB020178 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is 2 N absolutely necessary Replace with new ones whenever m removed Press bearings with the manufacturer and size MI marks f
126. e piston pin Special Tool Piston Pin Puller Assembly 57001 910 e Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it Remove the 3 piece oil ring with your thumbs the same manner HE14007BS1 C 8 16011351 C 5 22 END Cylinder and Piston Cylinder Piston Installation NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance Inspec tion and use new piston rings NOTE OThe oil ring rails have no top or bottom e Apply engine oil to the oil ring expander and oil ring steel rails 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 one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove e engine oil to the piston rings e Do not mix up the top ring and second ring e Install the top ring A so that the mark faces up e Install the second ring so that the RN mark faces to the piston Install the piston with its IN mark A facing intake side Install the piston pin e Fit a new piston pin snap ring int
127. e the reduction gears and starter clutch gear When the rotor does not install easily it installs while turn ing the rotor a little ELECTRICAL SYSTEM 17 27 Charging System Hold the alternator rotor with the flywheel holder Special Tool Flywheel Holder 57001 1313 Tighten Torque Alternator Rotor Nut B 59 N m 6 0 kgf m 44 ft Ib Install the spring A and oil guide Alternator Stator Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor A see Crankshaft Sensor Re moval Alternator Stator Bolts B Alternator Stator C Alternator Stator Installation Tighten Torque Alternator Stator Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install Crankshaft Sensor see Crankshaft Sensor Installation e Using a high flash point solvent clean off any or dirt that may be on the silicone sealant coating area Dry LS them with a clean cloth e Apply silicone sealant to the circumference of the alter nator lead grommet and fit the lead grommet A into the notch of the alternator cover securely Sealant Liquid Gasket TB1216 92104 1063 ORun the alternator leads under the crankshaft sensor leads 17 28 ELECTRICAL SYSTEM Charging System Regulator Rectifier Output Voltage Inspection e Remove Seat see Seat Removal in the Frame chapter Check the battery condition see Battery section e Warm up the engine to obtain ac
128. e the valve with a new Thermostat COOLING SYSTEM 4 15 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 OThe 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 78 82 172 180 F 6009020252 C 4 16 COOLING SYSTEM Radiator Fan Switch Radiator Fan Switch Removal The fan switch should never be allowed to fall ona hard surface Such a shock to the part can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Front Fender see Front Fender Removal in the Frame chapter e Disconnect the fan switch lead connectors A Remove the radiator fan switch Radiator Fan Switch Installation e Apply silicone sealant to the threads of the radiator fan switch Sealant Liquid Gasket TB1211 56019 120 Tighten Torque Radiator Fan Switch 22 N m 2 2 kgf m 16 ft lb Fill the coolant see Coolant Change in the Periodic Main tenance chapter Radiator Fan Switch Inspection Refer to t
129. e with a pilot light Do not use gasoline or a low flash point solvent to clean the carburetor e Disassemble the carburetor see Carburetor Disassem bly Do not use compressed air on an assembled carbu retor the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the car buretor with cleaning solution This will prevent damage or deterioration of the parts Do not use strong carburetor cleaning solution which could attack the plastic parts instead use mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Immerse all the metal parts in carburetor cleaning solu tion e Rinse the parts in water e After the parts are cleaned dry them with compressed air e Blow through the air and fuel passages with compressed air e Assemble the carburetor see Carburetor Assembly Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Disassemble the carburetor see Carburetor Disassem bly Clean the carburetor see Carburetor Cleaning Check the carburetor holder start
130. eal 10 29 Ball and Needle Bearing Replacement pp 10 29 Ball and Needle Bearing Wear Inspection pp 10 29 Oil Seal Inspection Eme oe Pes eee OE MER Dr age ER 10 29 10 2 CRANKSHAFT TRANSMISSION Exploded View x WM i iy OS 9 A vj A S 3 De 9 gt gt e lt CRANKSHAFT TRANSMISSION 10 3 Exploded View ESL een rm GrankeaseBols 98 L 2 Front R Replacement Parts 10 4 CRANKSHAFT TRANSMISSION Exploded View CRANKSHAFT TRANSMISSION 10 5 Exploded View No Fastener Remarks 1 Output Driven Bevel Gear Nut St 2 Output Driven Shaft Housing Bolts 9 8 1 0 87 in lb 3 Oil Level Inspection Bolt 9 8 1 0 87 4 Output Drive Bevel Gear Cover Bolts 9 8 1 0 87 in lb 5 Speedometer Cable Holder 9 8 1 0 87 in lb 6 Transmission Oil Filler Bolt 20 2 0 15 7 Transmission Case Cover Bolts 26 2 7 19 8 Transmission Oil Drain Plug 9 8 1 0 87 in lb 9 Output Drive Bevel Gear Nut 98 10 72 St 10 Driven Pulley Bearing Retainer Bolt 9 8 1 0 87 in lb L 11 Shift Drum Stopper Plug 47 4 8 35 12 Tie Rod End Nuts 26 2 7 19 13 Shift Bracket Nuts 20 2 0 15 14 Shift Lever Clamp Bolt 9 8 1 0 87 in Ib 15 Front G Apply grease L Apply a non permanent locking agent Lh Left hand Threads R Replacement Part St Stake the fasteners to pr
131. ear Brake Proportioning Valve Removal e Visually inspect the rear brake proportioning valve x If the rear brake proportioning valve are cracked leaked or otherwise damaged replace it 13 32 5 Brake Hose Inspection e Refer to the Brake Hose and Connections Inspection in the Periodic Maintenance chapter Brake Hose Replacement e Refer to the Brake Hose Replacement in the Periodic Maintenance chapter BRAKES 13 33 Lever Pedal Brake Pedal Removal e Remove Right Footboard see Right Footboard Removal in the Frame chapter Brake Pedal Return Spring A Brake Light Switch Spring B Cotter Pin and Joint Pin C Brake Pedal Pivot Cotter Pin D and Washers Brake Pedal E Brake Pedal Installation e Install Brake Pedal Return Spring A Brake Light Switch Spring B e Apply grease the brake pedal pivot C Replace the cotter pin with new one Install Joint Pin D Cotter Pin E Brake Pedal Pivot Cotter Pin F and Washers Bend the cotter pin ends 13 34 BRAKES Parking Parking Brake Cable Removal ar Release the parking brake Remove the parking brake spring A Loosen the parking brake adjusting bolt locknut and turn out the bolt C several turns Clear the parking cable lower end D Remove the master cylinder mounting bolts A Pull the parking cable to clear the it from
132. ed 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 2011 Kawasaki Heavy Industries Ltd First Edition 2 Aug 31 2011 LIST 5 ampere s L liter s ABDC after bottom dead center Ib pound s AC alternating current LCD liquid crystal display Ah ampere hour LED light emitting diode ATDC after top dead center m meter s BBDC before bottom dead center min minute s BDC bottom dead center mmHg millimeters of mercury BTDC before top dead center mph miles per hour C degree s celsius N newton s cmHg centimeters of mercury OZ ounce S cu in cubic inch s Pa pascal s DC direct current PS horsepower F farad s psi pound s per square inch F degree s fahrenheit qt quart s ft foot feet r revolution g gram s rpm revolution s per minute gal gallon s 5 second s h hour s TDC top dead center HP horsepower s TIR total indicator reading IC integrated circuit V volt s in inch s watt s km h kilometers per hour Q ohm s COUNTRY
133. ee Left Right Side Cover Removal Battery A see Battery Removal in the Electrical System chapter Fuse Box B Starter Relay C see Starter Relay Inspection in the Electrical System chapter Starter Circuit Relay D 16 12 FRAME Fenders Loosen the clamp screw remove the torque con verter exhaust duct B e Remove Bolts A Rear Fender B Rear Fender Installation Installation is the reverse of removal Note the following ORun the leads and cables correctly see Cable Wire and Hose Routing section in the Appendix chapter FRAME 16 13 Covers Middle Cover Removal Remove Seat see Seat Removal Fuel Tank Cover see Fuel Tank Removal in the Fuel System chapter Middle Cover Screws A e Clear the projections B from the holes and remove the middle cover C e Disconnect Power Outlet Lead Connectors A Middle Cover Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B Storage Case Removal Remove Bolt A and Shift Knob B Screws C Screws D and Nuts e Clear the projections E from the holes and remove the storage case F Storage Case Installation Installation is the reverse of removal Note the following Olnsert the projections A into the holes B OReplace the nuts with new ones 16 14 FRAME Covers Left Side Cover Removal e Remove Middle Cover see Middle Cover
134. efore assembly clean all parts including the master cylinder with brake fluid or alcohol NOTICE 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 Apply brake fluid to the removed parts and to the inner wall of the cylinder Apply grease to the brake lever pivot bolt and dust cover Tighten the brake lever pivot bolt and locknut Rear Master Cylinder Pedal Disassembly Remove the rear master cylinder pedal see Rear Mas ter Cylinder Pedal Removal Remove the reservoir cap A and diaphragm B pour the brake fluid into a container Slide the clamps e Remove Rear Master Cylinder Hose D Screw E Rear Master Cylinder Joint F 9 078017 P 13 18 BRAKES Master Cylinder Rear Master Cylinder Pedal Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning of these parts Gasolin
135. efully for a few seconds and check for fluid leakage around the fittings x If necessary bleed the air from the brake line see Brake Line Air Bleeding in the Brakes chapter Remove the reserve tank cover see Coolant Change Fill the reservoir with new brake fluid Change the brake fluid as follows OOpen the bleed valve A OApply the brake pedal and hold it B OClose the bleed valve C ORelease the brake pedal D Check the fluid level the reservoir often replenishing it as necessary NOTE Olf the fluid in the reservoir runs completely out any time during fluid changing air will enter the line and the sys tem must be bled e Repeatthis operation until fresh brake fluid comes out into the plastic hose or the color of the fluid changes e Tighten Torque Bleed Valve 6 0 0 61 kgf m 53 in Ib e Apply the brake pedal forcefully for a few seconds and check for fluid leakage around the fittings x If necessary bleed the air from the brake line see Brake Line Air Bleeding in the Brakes chapter A WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death If the brake lever or pedal has a soft or spongy feeling mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake system immediately PERIODIC MAINTENANCE 2 35 Peri
136. el Tank Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Seat see Seat Removal in the Frame chapter Fuel Tank Cap A Screws B e Clear the projections C from the holes and remove the fuel tank cover D e Remove Middle Cover see Middle Cover Removal in the Frame chapter e Turn the fuel tap to the OFF position e Remove Screw A and Knob B Bolts C e Remove Clamp A Fuel Hose B e Remove Connectors A Nuts B and Collars Bolts C and Collars Fuel Tank D 3 22 FUEL SYSTEM Fuel Tank Fuel Tank Installation A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn the ignition switch OFF Do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Check the rubber dampers A on the frame top tubes as shown in the figure x If the dampers are damaged or deteriorated replace them Installation is the reverse of removal Note the following ORun the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter Torque Fuel Tank Bolts and Nuts 12 N m 1 2 k
137. emoved Igniter A Rear Brake Pedal Light Switch B ELECTRICAL SYSTEM 17 5 Parts Location Regulator Rectifier A X RUE 17 6 ELECTRICAL SYSTEM Exploded View HP021008W5 C Exploded View ELECTRICAL SYSTEM 17 7 Fastener Alternator Cover Bolts Alternator Rotor Nut Alternator Rotor Nut Cap Bolts Alternator Stator Bolts Torque S m arin a ra ern 5 Sensor Mounting Screws 65 in Ib 6 Starter Motor Clutch Bolts 20 2 0 15 L 7 Starter Motor Mounting Bolts 9 8 1 0 87 in Ib 8 Spark Plug 18 1 8 13 9 Gear Position Switch Mounting Bolt 9 8 1 0 87 in lb 10 Regulator Rectifier Starter Circuit Relay Starter Relay Igniter Power Outlet Connector Front Apply grease Apply a non permanent locking agent Apply molybdenum disulfide grease Replacement Parts Apply silicone sealant 17 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 17 9 Exploded View 1 Rear Brake Pedal Light Switch 2 Front Brake Light Switch 3 Rear Brake Lever Light Switch 4 Front 17 10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Model Name Capacity Voltage Sealed Battery YTX12 BS 12 V 10 Ah 12 8 V or more Charging System Alternator Type Charging Voltage Regulator Rectifier Output Voltage Alternator Output Voltag
138. ent Cleaning and 2 13 Air Cleaner Draining 2 20er ale 2 14 Fuel Hose Inspection fuel leak damage installation condition 2 14 Engine Breather Hose Inspection cte rete ea 2 14 Fuel Hose 2 14 Cooling Sy Ste Mr 2 15 Radiator Cleaning Merten LS T T 2 15 Water Hoses and Connections Inspection 6 2 15 Coolant Level InspectioTi ee enun 2 16 esr Neque EEEn E 2 16 Radiator Hose and O ring 2 19 UR BM 2 20 Valve Clearance 2 20 Valve Clearance Adjustment ich denne ee tene nien bene p 2 21 Spark Atrester Cleaning enn 2 21 Exhaust Pipe and Muffler 2 22 Converter nee Dee Mh 2 22 Converter Drive Belt Wear 2 22 Engine Lubrication System ee na 2 23 Engine Ol Change ie Ir 2 23 Oil Screen Cleanihg eek 2 24 Mr i pete rdg tan neo 2 24 Transmissi
139. er Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing Intake Open Close Duration Exhaust Open Close Duration Lubrication System 2 8 m 9 2 ft 4 stroke SOHC Single cylinder Liquid cooled 72 7 x 65 2 mm 2 86 x 2 57 in 271 cm 16 5 cu in 11 0 1 AU EUR 16 kW 22 PS 7 500 r min rpm 05 AU 22 Nm 2 2 kgf m 16 ft lb 6 500 r min rpm EUR 22 3 N m 2 3 kgfm 16 16 96 500 r min rpm US Carburetor Keihin CVK32 US AU Electric starter amp Recoil Starter EUR Electric Starter Full transistor digital ignition Electronically advanced digital 10 BTDC 1 500 r min rpm DPR7EA 9 9 BTDC 40 ABDC 229 42 BBDC 7 ATDC 229 Forced lubrication wet sump 1 10 GENERAL General Specifications ltems KVF300CC Engine Oil Type API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 1 8L 1 9 US qt Coolant Capacity 1 3 L 1 4 US qt Drive Train Primary Reduction System Type Belt drive torque converter CVT Reduction Ratio 2 200 0 830 Clutch Type Dry Centrifugal Transmission Type 2 speed and reverse Automatic Gear Ratios Forward High 2 926 Low 4 147 Reverse 4 128 Final Drive System Type Shaft 2WD Reduction Ratio 4 273 Overall Drive Ratio Top Gear 10 377 Transmission Gear Case Oil Visco
140. er Torque Remarks kgf m ft Ib 2 Air Suction Valve Cover Bolts 9 8 1 0 87 3 Clean Air System Pipe Mounting Bolt 9 8 1 0 87 in Ib 4 Clean Air System Pipe Mounting Nuts 9 8 1 0 87 in lb 5 Valve Adjusting Screw Locknuts 8 8 0 90 78 in lb EO 6 Camshaft Cap Nuts 25 2 5 18 EO 7 Cylinder Head Bolts 9 8 1 0 87 8 Plug 21 2 1 15 9 Cylinder Head Stud Bolts 9 0 0 92 80 in Ib 10 Carburetor Holder Nuts 9 8 1 0 87 11 Spark Plug 18 1 8 13 12 Camshaft Chain Tensioner Mounting Bolts 12 1 2 106 in Ib 13 Camshaft Chain Tensioner Cap Bolt 4 2 0 43 37 14 Rear Camshaft Chain Guide Bolt 9 8 1 0 87 15 Stud Bolts for Cylinder Cylinder Head 9 0 0 92 80 in Ib 16 Front EO Apply engine oil Replacement Parts 5 4 END Exploded View HE02064885 C ENGINE END 5 5 Exploded View Torque Fastener Nm Fib Remarks 2 Muffler Body Mounting Nut 20 2 0 15 3 Muffler Body Mounting Bolt 20 2 0 15 4 Spark Arrester Mounting Bolt 11 1 1 97 in Ib 5 Front R Replacement Parts 5 6 END Specifications Item Standard Service Limit Rocker Case Rocker Arm Shaft Clearance 0 034 0 09 mm 0 0013 0 0035 in 0 1 mm 0 004 in Camshafts Cam Height Exhaust Intake 34 172 mm 1 3454 in 34 287 mm 1 3499 in 34 05 mm 1 341 in 34 15 mm 1 344 in Cylinder Head Cylinder Compres
141. er of machine oil so that the heat sensitive portion and threaded portion are submerged Suspend an accurate thermometer with heat sensitive portions C located in almost the same depth NOTE OThe sensor and thermometer must not touch the con tainer side or bottom e Place the container over a source of heat and gradually raise the temperature of the oil while stirring the oil gently for even temperature e Using the hand tester measure the internal resistance of the sensor across the terminal and the body at the tem peratures shown in the table Special Tool Hand Tester 57001 1394 If the measurement is out of the range replace the sensor Water Temperature Sensor Resistance Temperature Resistance Q 50 C 122 F 154 80 C 176 F 52 100 C 212 F 27 120 C 248 F 16 GP18624BS2 C ELECTRICAL SYSTEM 17 57 Switches and Sensor Radiator Fan Switch Inspection e Remove Radiator Fan Switch see Radiator Fan Switch Removal in the Cooling System chapter Suspend the fan switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant NOTE OThe switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand
142. er plunger plunger idle adjusting screw and vacuum piston diaphragm are in good condition x If any of the parts is not in good condition replace it Carburetor FUEL SYSTEM 3 17 Check the plastic tip A of the float valve needle B It should be smooth without any grooves scratches or tears x If the plastic tip is damaged C replace the needle e Push the rod D in the other end of the float valve needle and then release it E x If it does not spring out replace the float valve needle Check that the vacuum piston moves smoothly in the car buretor body The surface of the piston must not be ex cessively worn xIf 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 6606014351 C 3 18 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal e Remove Seat see Seat Removal in the Frame chapter Clips A Air Cleaner Housing Cap B e Remove Element Clamp Screw A Element B e After removing the element stuff pieces of lint free clean cloth into the air cleaner duct to keep dirt out of the car buretor and engine A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets through into the engine excessive en gine wear
143. er than the Kawasaki Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator rectifier will be damaged System ELECTRICAL SYSTEM 17 31 Regulator Rectifier Resistance Unit kQ Tester Lead Connection Tester Lead Connection Charging System Circuit HP090418W2 C 1 Charge Fuse 30 A 2 Ignition Switch 3 Battery 12 V 10 Ah 4 Engine Ground 5 Alternator 6 Regulator Rectifier 7 Load 17 32 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock Do not disconnect the battery cables 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 Remove Spark Plug Cap A e Using a spark plug wrench remove the spark plug A Special Tool Spark Plug Wrench Hex 18 57001 1024 Spark Plug Installation Tighten Torque Spark Plug 18 N m 1 8 kgf m 13 ft lb Special Tool
144. ere burns Clean the starter in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the starter Do not clean any non metallic parts in the solvent as they may be damaged OUse compressed air to dry the cleaned components Recoil Starter Inspection Clean the recoil starter e Examine the starter pawl for chips or excessive wear Check the starter rope for excessive wear or fraying Check the condition of the recoil spring and friction plate spring Olnspect the springs for breaks rust distortion or weak ened condition LUBRICATION SYSTEM 8 1 Engine Lubrication System Table of Contents EXPloded View vedas sg meets 8 2 Specifications ETE 8 4 Special Harrislee ee bleu Be 8 5 Engine Oll Flow Chart u a kei 8 6 8 7 Oil Level 1 0 202 01000000000000000000000990 0 8 7 Engine Oil Change moo rie 8 7 Oil Screen REMOVAL 8 8 Oil Screen 8 8 Oil CISAMING MEET RM
145. ervice limit 680200968 5 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings Oil seals Grease seals circlips cotter pins or self locking nuts must be replaced with new ones whenever disassembled 68020108 5 Assembly Order 2 In most cases assembly order is the reverse of disassem TE od bly however if assembly order is provided in this Service zn i Manual follow the procedures given x S DE 5 gt SS WX 2 4 68020118 S 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 caus
146. event loosening 10 6 CRANKSHAFT TRANSMISSION Specifications Standard Service Limit Crankshaft Crankshaft Runout Connecting Rod Small End Diameter Connecting Rod Small End Free Play Connecting Rod Big End Side Clearance Crank Width 55 15 55 20 mm 2 171 2 173 in Crankshaft Bearing Play Axial Redial Transmission Oil Viscosity SAE 90 Oil Level Inspection Bolt Opening Bottom Capacity 0 6 L 0 63 US qt Transmission Shift Fork Rod Runout ees Driven Bevel Gear Backlash 0 03 0 15 mm 0 0012 0 059 in 0 1 mm 0 004 in 17 06 mm 0 672 in 0 6 mm 0 024 in 0 2 mm 0 008 in 0 05 mm 0 002 in Less than 0 03 mm 0 0012 in Special Tools Inside Circlip Pliers 57001 143 Outside Circlip Pliers 57001 144 7570143ST C 7570144ST C Bearing Driver 32 57001 382 5157038251 C Oil Seal amp Bearing Remover 57001 1058 7571058ST C CRANKSHAFT TRANSMISSION 10 7 Oil Seal amp Bearing Remover Adapter A 57001 1061 ST571061ST Bearing Driver Set 57001 1129 875711295 C Stem Bearing Driver Adapter 42 57001 1510 SZ 5157151051 C Flywheel amp Pulley Holder 57001 1605 5157160551 C 10 8 CRANKSHAFT TRANSMISSION Crankcase Disassembly e Remove Engine see Engine Removal in the Engine Removal In stal
147. ew ones Insert the cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the knuckle joint tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole Bend the cotter pin A over the nut B Tie rod Removal e Remove Front Wheels see Wheel Removal in the Wheels Tires chapter Front Brake Disc Guard see Front Brake Disc Guard Removal in the Brakes chapter Cotter Pins A Remove the tie rod end joint and remove the tie rod nuts B and washers see Steering Knuckle Removal e Remove Tie rod C NOTICE When removing the tie rod be careful not to bend it Do not loosen the locknuts D at the end of the tie rod adjusting sleeve or the toe in of the front wheels will be changed HNO4051B 5 HJ07007BS1 15 10 STEERING Steering Tie rod Installation The right and left tie rods are identical Tighten Torque Tie rod End Nuts 35 N m 3 6 kgf m 26 ft Ib e Install the cotter pins Inspect the toe in see Toe in Inspection in the Periodic Maintenance 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 OThe locknut distant the tie rod flattened area has left
148. f the measurement exceeds the service limit replace the crankshaft a new one Crank Width D Standard 55 15 55 20 mm 2 171 2 173 e Install the crankshaft see Crankcase Assembly Crankshaft Main Bearing Wear Inspection Turn the crankshaft bearings and check for excessive play e Measure the crankshaft bearing free play A x If the measurement exceeds the service limit replace the crankshaft with a new one Crankshaft Bearing Free Play A Service Limit Axial B 0 2 mm 0 008 in Radial C 0 05 mm 0 0002 in 1040398 5 10404068 5 10 12 CRANKSHAFT TRANSMISSION Transmission Shift Lever Removal Set the shift lever in the neutral position Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Shift Lever Bolt A and Locknut Shift Lever B Shift Bracket Nut C Shift Bracket D e Remove Cotter Pin A Washer B Joint Pin C Spring D Remove Shift Lever Clamp Bolt A Shift Shaft Lever B Remove Tie Rod End Nuts A Shift Lever Installation e Install the shift shaft lever A to the L mark B side of tie rod end Tighten Torque Tie Rod End Nuts C 26 N m 2 7 kgf m 19 ft lb CRANKSHAFT TRANSMISSION 10 13 Transmission Install Shift Shaft Lever A eAlign the punch mark B on the shift shaft lever with the mark on the shift shaft Tighten Torque Shift Lever Clamp Bolt
149. f the reservoir OBleed the air completely from the rear master cylinder pedal by this operation Remove the rubber cap A on the proportioning valve e Attach a clear plastic hose B to the bleed valve C and run the other end of the hose into a container 13 12 BRAKES Fluid Bleed the brake line and the proportioning valve ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the rear brake pedal until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve of propor tioning valve while holding the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding e Remove the clear plastic hose e Install the rear brake pedal diaphragm and reservoir Install the reserve tank cover and bolts Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 6 0 N m 0 61 kgf m 53 in lb Check the fluid level in the rear brake pedal reservoirs see Brake Fluid Level Inspection in the Periodic Mainte
150. g bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding OFirst bleeding the right caliper then repeat the above steps for the left caliper Remove the clear plastic hose Install the front brake diaphragm and reservoir Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 6 0 N m 0 61 kgf m 53 in lb Check the fluid level in the front brake reservoirs see Brake Fluid Level Inspection in the Periodic Maintenance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage Rear Brake Lever e Remove the rear brake lever reservoir cap and di aphragm e Fill the reservoir with fresh brake fluid to the upper level line A Slowly pump the rear brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir OBleed the air completely from the rear master cylinder lever by this operation Remove the rubber cap A on the rear caliper e Attach a clear plastic hose B to the bleed valve C and run the other end of the hose into a container Fluid BRAKES 13 11 Bleed the brake line and the rear caliper ORepeat this operation until no more air can be seen com ing out in
151. ge in the Periodic Main tenance chapter Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal e Remove the oil guide A and spring e Holding the alternator rotor A with the flywheel holder B loosen the alternator rotor nut C Special Tool Flywheel Holder 57001 1313 e Remove Alternator Rotor Nut 17 26 ELECTRICAL SYSTEM Charging System Screw the flywheel puller A and rotor puller onto the alternator rotor Special Tools Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 Flywheel Puller M28 x 1 0 57001 1471 Holding the flywheel puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft 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 e Remove Reduction Gears A Starter Clutch Gear B Alternator Rotor Installation e Apply molybdenum disulfide grease to the shaft of the reduction gears Install the reduction gears e Assemble the alternator rotor A and starter clutch gear Clean the inside of the rotor tapered portion of the crankshaft e Fit the rotor onto the crankshaft so that woodruff key C fits in the groove D of the rotor Install the alternator rotor OWhile assembling the alternator rotor and starter clutch gear engag
152. gf m 106 in Ib Olnsert the projections A into the holes B Fuel Tap Removal e Drain the fuel from the tank e Remove Screw A Knob B e Remove Clamps A and Hoses B Fuel Tap Mounting Screws C Fuel Tap D Fuel Tank FUEL SYSTEM 3 23 Fuel Tap Installation e Be sure the fuel hoses are clamped to the fuel tap to pre vent leakage A WARNING Fuel Spilled from the fuel tap is hazardous Set the knob A the shaft securely Fuel Tank and Fuel Tap Cleaning Remove the fuel tank with fuel tap and drain it see Fuel Tank Removal e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the tank e Pour the solvent out the tank Remove the fuel filter e Pour high flash point solvent through the tap in both ON and RES positions e Dry the tank with compressed air Install the fuel filter e Install the fuel tank see Fuel Tank Installation Fuel Filter Removal Remove the fuel tank bolts and nuts see Fuel Tank Re moval Remove Clamps A and Hoses B Fuel Fi
153. h 17 57 Gear Position Switch Installation 17 58 Gear Position Switch Inspection 4 17 58 linet 17 58 a 17 59 Relay isis 17 59 USCS PH 17 60 FUSE 17 60 FUSE Installation Hr ae 17 60 Fuse Inspection dt d d e ede iin 17 60 ELECTRICAL SYSTEM 17 3 Parts Location Light Dimmer Switch Starter Button B Meter Unit C Ignition Switch D Fuel Level Sensor E Rear Brake Lever Light Switch F Reverse Power Assist Switch Override G Engine Stop Switch H Front Brake Light Switch A Power Outlet Connector A Radiator Fan Switch A Radiator Fan B Battery A Starter Relay B Fuse Box C Starter Circuit Relay D 17 4 ELECTRICAL SYSTEM Parts Location Ignition Coil A Spark Plug B Gear Position Switch A Oln the photo the torque converter cover has been re moved Starter Motor A Water Temperature Sensor B Crankshaft Sensor A Alternator Stator Coil B Oln the photo the alternator cover has been r
154. h 6 17 6 2 CONVERTER SYSTEM Exploded View 0 HS02022B 5 C CONVERTER SYSTEM 6 3 Exploded View T No Fastener SIUS Remarks ft Ib 40 Driven Plate Nm 2 DivenPuleyNut 54 98 Driven Shaft Bearing Retainer Bolt Drive Pulley Nut 87 in lb Torque Converter Cover Bolts Torque Converter Outer Cover Bolts EUR 98 10 87 in lb Model only 7 Ratchet Other than EUR Model 8 Front EO Apply engine oil G Apply grease L Apply a non permanent locking agent R Replacement Parts 6 4 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt Belt Width Drive Pulley Movable Drive Sheave Bushing Inside Diameter Drive Pulley Collar Outside Diameter Weight Roller Outside Diameter 23 6 24 4 0 929 0 961 in 22 mm 0 87 in 26 989 27 052 mm 1 0626 1 0650 in 27 06 mm 1 0654 in 26 94 mm 1 0606 in 22 8 mm 0 90 in 26 96 26 974 mm 1 061 1 0620 in 22 92 23 08 mm 0 902 0 909 in Clutch Driven Pulley Movable Driven Sheave Bushing Inside Diameter Fixed Driven Sheave Outside Diameter Driven Pulley Spring Free Length Clutch Lining Thickness Clutch Outer Inside Diameter 40 40 025 mm 1 57 1 5758 in 40 06 mm 1 577 in 39 965 39 985 mm 1 5734 1 5742 in 39 94 mm 1 572 in 131 mm 5 16 in 0 8 1 0 mm 0 031
155. haft Connection ee tte oe polo Foi orabat 10 11 Crankshaft Inspection 10 11 Crankshaft Main Bearing Wear Inspection 10 11 Br cur Shift Lever REMOVAL Shift Lever Installation Shift Lever Adj stment iet ese er Transmission Case Removal nucis Transmission Case Installation een Transmission Case Disassembly 4 Transmission Case Assembly todos trees Re E Pee uen d 252500 P UPRR Clutch Driven Pulley Shaft Cluten Driven Pulley Shaft Assembly 22 42 ersehen Shift Shaft Inspections ere ine bee ei een nero het teas cones Shift Fork Rod Inspection erede e lan da Output Driven Shaft Housing 10 23 Output Driven Shaft Housing 222 1 1 00601 666 anna 10 24 Output Drive Bevel Gears Adjustment 10 25 Backlash Adjustment ea a er ane te 10 27 Tooth C ntactAdj sStMeEnt 10 28 Ball Bearing Needle Bearing and Oil S
156. hand threads Turn the wrench clockwise for loosen ing 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 e Install the tie rod ends so that the tie rod has the correct length A and both visible thread lengths B are approx imately equal Tie rod Length Standard 334 0 335 0 mm 13 15 13 19 in e Install the tie rod ends so that the thread portions A of the tie rod ends are opposite direction 180 B as shown HNO4052B 5 HNO4053B 5 HNO4054B 5 HNO4055B 5 STEERING 15 11 Steering Maintenance Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Shaft Straightness Inspection Remove the steering shaft see Steering Shaft Removal Check the steering shaft for straightness 5 a straightedge along the stem xIf the steering shaft is bent replace the steering shaft Steering Shaft Bearing Inspection 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 for tears or leakage x If the seal is torn or is leaking replace the bearing 6J06002BS1 Steering Shaft Bearing Removal e Remove Steering Shaft see Steering Shaft Removal Collar A Dust Seal B Remove Dust Seal
157. hange the oil completely Engine Oil Change Refer to the Engine Oil Change in the Periodic Mainte nance chapter 8 8 LUBRICATION SYSTEM Engine Oil Oil Filter Oil Screen Removal Drain the engine oil see Engine Oil Change in the odic Maintenance chapter e Remove Engine Oil Screen Plug A and O ring B Spring C Oil Screen D Oil Screen Installation Installation is the reverse of removal Note the following OReplace the O ring with a new one Torque Engine Oil Screen Plug 15 1 5 kgf m 11 ft Ib Oil Screen Cleaning e Refer to the Oil Screen Cleaning in the Periodic Mainte nance chapter LUBRICATION SYSTEM 8 9 Oil Oil Pump Removal Remove Alternator Rotor see Alternator Rotor Removal in the Electrical System chapter Starter Motor Clutch Gear Oil Pump Chain Cover Bolts A Oil Pump Chain Cover B Remove Circlip A Oil Pump Chain B together with Oil Pump Gear C Special Tool Outside Circlip Pliers 57001 144 Remove Oil Pump Mounting Bolts A Oil Pump Assembly B Oil Pump Shaft C e Remove Oil Pump Cover Screw A Oil Pump Cover B Inner Rotor C Outer Rotor D Oil Pump Installation e Apply engine oil to the following parts Oil Pump Shaft Inner A and Outer B Rotors Install Inner Rotor Outer Rotor Check to see that the dowel pin C is in place e Install the pump cover b
158. he Radiator Fan Switch Inspection in the Elec trical System chapter Water Temperature Sensor COOLING SYSTEM 4 17 Water Temperature Sensor Removal The water temperature sensor should never be al lowed to fall on a hard surface Such a shock to the part can damage it e Drain the coolant see Coolant Change in the Periodic Maintenance chapter Remove the right side cover see Right Side Cover Re moval in the Frame chapter e Disconnect the sensor lead connectors A Remove the water temperature sensor B Water Temperature Sensor Installation e Apply silicone sealant to the threads of the sensor and tighten it Sealant Liquid Gasket 1211 56019 120 Tighten the water temperature sensor securely Fill the coolant see Coolant Change in the Periodic Main tenance chapter Water Temperature Sensor Inspection e Refer to the Water Temperature Sensor Inspection in the Electrical System chapter END 5 1 Engine Top End Table of Contents Exploded Specifications Special 15 200222 22 Clean Air System Air Suction Valve Removal Air Suction Valve Installation Air Suction Valve Inspection Vacuum Switch Valve Removal Vacuum Switch Valve Installation Clean Air System Hose
159. he driven bevel gear and inspect the coated teeth of the drive bevel gear The tooth contact pattern should be as shown in A B and C x If tooth contact is found to be correct example B then to complete installation x If tooth contact is found to be incorrect examples A C the shim thickness between the drive bevel gear and driven bevel gear must be changed and the tooth contact rechecked until correct NOTE Obacklash until they are both within specification If the correct tooth contact cannot be maintained when ad justing the backlash replace the drive and driven bevel gears Driven Bevel Gear Shim Adjustment Increase shim thickness Drive Bevel Gear Tooth Contact Shim Adjustment Contact at tooth top Increase shim thickness Contact at tooth root Decrease shim C thickness Decrease shim thickness Incorrect Contact at tooth top Correct Incorrect Contact at tooth root 11001 5 CRANKSHAFT TRANSMISSION 10 29 Ball Bearing Needle Bearing and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary Removal may damage them e Using a press or puller remove the ball bearing and or the needle bearing NOTE 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
160. he holder B on the reserve tank cover Remove Reserve Tank Bolts A Reserve Tank B with Hose e Remove the reserve tank cap C and pour the coolant into a container e Place a container under the drain bolt A at the bottom of the water pump cover B then remove the drain bolt Remove the radiator cap A in two steps First turn the cap counterclockwise to the first step Then push and turn it further in the same direction and remove the cap e Place a container under the drain screw A at the bottom of the radiator then remove the drain bolt The coolant will drain from the radiator and engine 2 18 PERIODIC Periodic Maintenance Procedures Tighten the coolant drain bolts securely Support the vehicle on a stand or the jack so that the front wheels are off the ground This makes air bleeding easier e Fill the radiator up to the radiator filler neck A with coolant NOTE OPour in the coolant slowly so that the air in the engine and radiator can escape 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 70 Coolant 30 Freezing Point 15 5 F Total Amount 1 3 L 1 4 US qt NOTE OChoose a suitable mixture ratio
161. he reel Install Friction Plate A Recoil Guide B Pawls C Friction Plate Spring D OApply grease to the tabs of the pawls e Install the pawls A to the reel B as shown for proper starter operation e Install the spring C to the recoil guide D Set the tabs E of the pawl to fit the grooves F of the recoil guide e Install Friction Plate Bolt e Turn the reel A 1 1 4 turns clockwise to preload the spring Recoil Starter Other than EUR Model RECOIL STARTER 7 7 e While holding the reel to keep it from unwinding pull the end of the through the hole in the starter e Pull out the rope about 100 200 4 0 8 0 in make a temporary knot A at that point Wind back the reel slowly until the temporary knot returns to rope guide B e Install the starter grip and washer and secure it with a knot E Install the starter grip plug F Holding the starter housing untie the temporary knot Check that the rope is wound smoothly by pulling the starter grip Check that the real operates smoothly by pulling the starter grip Install the recoil starter see Recoil Starter Installation Recoil Starter Cleaning Disassemble the recoil starter Immerse only the metal parts a bath of high flash point solvent A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause sev
162. heave worn Drive or driven pulley movable sheave bushing worn Drive or driven pulley mount loose Drive pulley weight roller worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Drive train noise Insufficient lubricant Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Propeller shaft bearing worn Abnormal Frame Noise Shock absorber noise Shock absorber damaged Brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble APPENDIX 18 23 Troubleshooting Guide Brake not properly adjusted Other noise Bracket nut bolt etc mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level to 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 Handlebars hard to turn Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Damage tie rod end Handlebars shakes or excessively vibrates Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing w
163. heel Nuts Brakes Front Brake Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Caliper Mounting Bolts Brake Pedal Cotter Pin Steering Suspension Handlebar Holder Bolts Steering Shaft Holder Nuts Swingarm Mounting Nut Tie rod End Nuts and Cotter Pins Tie rod Locknuts Shock Absorber Mounting Nuts Front Suspension Arm Pivot Nuts Engine Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffler Mounting Nuts Others Footboard Mounting Bolts Throttle Case Screws Carrier Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents EET 3 2 Specifications inss ET 3 6 Thirotte Lever and Capena daa ites aa 3 7 Throttle Lever Free Play 2 2 201 1 2 1 4 1 44 nnn nnne 3 7 Throttle Lever Free Play Adjustment 444 0 012 0 1 10 3 7 Throttle Cable Lubrication 3 7 ThirottleeCable ROO V Eti nn 3 7 Throttle Cable nennen 3 7 Throttle Case Removal ee 3 8 Throttle Case Installations aide 3 8 Throttle Case Inspection nene rre nnne 3 8 Choke Lever and Cable
164. ide Diameter A Standard 40 40 025 mm 1 57 1 5758 in Service Limit 40 06 mm 1 577 in x If the fixed driven sheave is damaged or worn replace the fixed driven sheave Fixed Driven Sheave Outside Diameter A Standard 39 965 39 985 mm 1 5734 1 5742 in Service Limit 39 94 mm 1 572 in x If the spring is damaged or worn replace the spring Spring Free Length A Service Limit 131 mm 5 16 in x lf the spring coils are distorted replace the spring Clutch Driven CONVERTER SYSTEM 6 15 Clutch Driven Pulley Assembly e Apply grease to the outer bearing A e Press a new outer bearing into the fixed driven sheave with the sealed end facing up Replace the snap ring with a new one e Insert a new snap ring B in its groove Special Tool Inside Circlip Pliers 57001 143 e Apply grease to the fixed driven sheave bore areas C NOTE OPack all bearing cavities with proper grease Specified Grease Heat resistance 230 C 446 F e Press a new inner needle bearing D into the fixed driven sheave Special Tool Bearing Driver Set 57001 1129 Clean off any grease or dirt on the movable driven and fixed driven sheaves and dry them with a clean cloth Replace the O rings A with new ones Apply grease to a new O rings and install them e Apply grease to the oil seal lips e Press the oil seal B in the movable driven sheave so that the oil seal surface i
165. ide of the vehicle Wipe dry the threads of the hub bolts and the seating surface of the rim Wipe dry the nuts Tighten Torque Wheel Nuts 54 5 5 40 ft lb Wheel Rim Inspection e Examine both sides of the rim for dents A If the rim is dented replace it HJ05042BS1 WHEELS TIRES 11 9 Wheels Rims x 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 Remove the tire from the see Tire Removal ORemove the air valve and discard it Replace the air valve whenever the tire is replaced Do not reuse the air valve Install a new air valve in the new rim ORemove the valve cap lubricate the stem with a soap and water solution and pull A the stem through the rim from the inside out until it snaps into place Do not use engine oil or petroleum distillates to lu bricate the stem because they will deteriorate the rubber Install the tire on the new rim see Tire Installation e Install the wheel see Wheel Installation e Install the air valve cap HJ05022BS1 C p HJ05043BS1 11 10 WHEELS TIRES Tires Tire Removal Remove the wheel e Unscrew the valve core to deflate the tire OUse a proper valve core tool A
166. ie rod Locknuts Frame Footboard Bracket Bolts Front Carrier Bolts M8 Front Carrier Bracket Bolts Front Guard Bolts Rear Carrier Bolts M8 Footboard Bolts Electrical System Alternator Cover Bolts 9 8 1 0 87 in Ib Alternator Rotor Nut 59 6 0 44 Alternator Rotor Nut Cap Bolts 9 8 1 0 87 in lb Alternator Stator Bolts 9 8 1 0 87 in lb Crankshaft Sensor Mounting Screws 7 4 0 75 65 in Ib Gear Position Switch Mounting Bolt 9 8 1 0 87 in lb 2 8 PERIODIC Torque and Locking Agent Fastener Torque Remarks kgf m ft Ib Spark Plug 18 1 8 13 Starter Motor Clutch Bolts 20 2 0 15 L Starter Motor Mounting Bolts 9 8 1 0 87 in Ib Specifications PERIODIC MAINTENANCE 2 9 Standard Service Limit Fuel System Throttle Lever Free Play Idle Speed Air Cleaner Element Oil 1 4 0 04 0 16 in 1 500 100 r min rpm High quality foam air filter oil Cooling System Coolant Type Recommended Color Mixed Ratio Freezing Point Total Amount Permanent type antifreeze Green Soft water 70 Coolant 30 15 5 F 1 3 L 1 4 US qt Engine Top End Valve Clearance Exhaust Intake Converter System Belt Width Engine Lubrication System Engine Oil Type Viscosity Capacity 0 08 0 12 mm 0 0032 0 0048 in 0 08 0 12 mm 0 0032 0 0048 in 23 6 24 4 mm 0 929 0 961 in API SG SH SJ SL or SM with JASO MA
167. ill 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 ORemove the right side cover see Right Side Cover Re moval in the Frame chapter ODisconnect the alternator connector A OConnect a hand tester B as shown in the table Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 OStart the engine ORun it at the rpm given in the table ONote the voltage readings total 3 measurements Alternator Output Voltage Reading Tester Range Tester to Tester to at 4 000 rpm 250 VAC One yellow Another yellow 410 V lead lead x If the output voltage is within the values in the table the alternator is operating correctly and the regulator rectifier is damaged A much lower reading indicates that the al ternator is defective e Check the stator coil resistance as follows OStop the engine ODisconnect the alternator connector OConnect a hand tester as shown in the table ONote the readings total 3 measurement Stator Coil Resistance at 20 C 68 F Connections Tester Reading Tester to Tester to One yellow Another yellow lead lead x10 0 1 1 50 x If there is more resistance than shown in the tabl
168. in Camshaft Bearing Inspection Check each bearing A which is press fitted on the camshaft OSince the ball bearing is made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean the bearing in a high flash point solvent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has rough stops replace camshaft Camshaft Chain Removal e Remove Cylinder Head see Cylinder Head Removal Starter Clutch Gear see Alternator Rotor Removal in the Electrical System chapter Rear Camshaft Chain Guide Bolt A Rear Camshaft Chain Guide B Front Camshaft Chain Guide C Remove the camshaft chain from the crankshaft sprocket Camshaft Chain Installation Hang the camshaft chain A to the crankshaft sprocket Install Front Camshaft Chain Guide B Rear Camshaft Chain Guide C Tighten Torque Rear Camshaft Chain Guide Bolt D 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters 8 11012251 6 END 5 17 Camshaft Camshaft Chain Guide Wear Inspection e Visually inspect the rubber on the guides x If the rubber is damaged cut or is missing pieces replace the guide 5 18 END Cylinder Head Cylinder Compression Measu
169. ing Bots 12 12 home 7 Front G Apply grease Lh Left Hand Threads R Replacement Parts SS Apply silicone sealant 4 4 COOLING SYSTEM Specifications Item Standard Service Limit Coolant Provided when Shipping Type Color Mixed Ratio Freezing Point Total Amount Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiator Green Soft water 70 coolant 30 15 5 F 1 3 L 1 4 US qt reserve tank full level including radiator and engine Radiator Cap Relief Pressure About 108 kPa 1 1 kgf cm 16 psi Thermostat Valve Opening Temperature Valve Full Opening Lift 78 82 C 172 180 F 3 5 4 5 mm 0 14 0 18 in or more 90 C 194 F COOLING SYSTEM 4 5 Special Tools and Sealant Inside Circlip Pliers Valve Guide Driver 57001 143 57001 1564 7570143ST C 7571564ST C Bearing Remover Shaft 9 Liquid Gasket TB1211 57001 1265 56019 120 bw 875712655 C 875601205 Bearing Remover Head 10 x 012 57001 1266 5157126651 C 4 6 COOLING SYSTEM Coolant Coolant Deterioration Inspection e Remove Reserve Tank Cover Bolts A Reserve Tank Cover B e Clear the over flow hose A from the holder B on the reserve tank cover e Visually inspect the coolant in the reserve tank If whitish cotton like
170. ion as origi nally installed When installing a new belt install it so the printed information A can be read from beside the vehicle e Installation is the reverse of removal Drive Belt Inspection e Refer to the Converter Drive Belt Wear Inspection in the Periodic Maintenance chapter CONVERTER SYSTEM 6 9 Drive Pulley Drive Pulley Removal e Remove Torque Converter Cover see Torque Converter Cover Removal e Using the flywheel amp pulley holder A remove the drive pulley nut B Special Tool Flywheel amp Pulley Holder 57001 1605 e Remove Ratchet C Other than EUR Model Fixed Drive Sheave D Remove Collar A Movable Drive Sheave Assembly B Remove Ramp Plate A with Dampers B Remove Weight Rollers A Drive Pulley Inspection x If the sheave surfaces A appear damaged replace the fixed drive sheave and or movable drive sheave 6 10 CONVERTER SYSTEM Drive Pulley x If the movable drive sheave bushing is damaged or worn replace it Movable Drive Sheave Bushing Inside Diameter A Standard 26 989 27 052 mm 1 0626 1 0650 in Service Limit 27 06 mm 1 0654 in x If the drive pulley collar is damaged or worn replace it Drive Pulley Collar Outside Diameter A Standard 26 96 26 974 mm 1 061 1 0620 in Service Limit 26 94 mm 1 0606 in x If the weight rollers are damaged or worn replace them Weight Roller Outside Diameter A Standard 2
171. is obtained by pumping the lever until the pads are against the disc Rear Brake Pad Removal e Remove the left rear wheel see Wheel Removal in the Wheels Tires chapter e Release the parking brake Loosen the adjusting locknut A and adjusting bolt B on the rear brake caliper e Remove the rear caliper mounting bolts C and detach the caliper D form the disc Pads BRAKES 13 27 Remove Brake Bolts Brake Pads Rear Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Be sure that the anti rattle spring is in place e Install the brake pads Apply a non permanent locking agent to the threads of the brake pad bolts Tighten the brake pad bolts securely Install the rear caliper see Rear Caliper Installation A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Adjust the parking brake see Parking Brake Adjustment in the Periodic Maintenance chapter Brake Pad Wear Inspection Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 13 28 BRAKES
172. ity Light Right 12 V 5 W 17 48 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection e Remove the front fender see Front Fender Removal in the Frame chapter e Disconnect the connectors A from the radiator fan switch e Using an auxiliary wire connect the radiator fan switch terminals of the main harness e Turn the ignition switch to ON x If the fan rotates inspect the fan switch x If the fan does not rotate inspect the following Leads and Connectors Main Fuse Fan Motor Radiator Fan Motor Inspection Remove the front fender see Front Fender Removal in the Frame chapter e Disconnect the connector A in the fan lead e Using two auxiliary wires supply battery voltage to the fan motor Radiator Fan Motor Lead Connections BK Battery BL Battery If the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Circuit HPi130168W2 C Charge Fuse 30 A Main Fuse 15 A lgnition Switch Battery 12 V 10 Ah Engine Ground Radiator Fan Switch Radiator Fan ELECTRICAL SYSTEM 17 49 Fuel Level Sensor Fuel Level Sensor Removal e Remove Meter Cover see Meter Unit Removal Installation Fuel Tank Cover see Fuel Tank Removal in the Fuel System chapter Fuel Level Sensor Connectors A Open the clamp B Remove Fuel Level Sensor Mounting Bolts A Fuel Level Sensor B NOTE OB
173. kness after the tooth contact has been adjusted since it may have changed Adjust the tooth contact and backlash until they are both within specification If the correct tooth contact cannot be maintained when adjusting the backlash replace the pinion gear and ring gear as a set Pinion Gear Shims Part Number 92180 Y026 92180 027 92180 028 Thickness 2 03 mm 0 0799 in 2 00 mm 0 0787 in 1 97 mm 0 0776 in Pinion Gear Disassembly e Remove the final gear case see Final Gear Case Re moval Remove the pinion gear assembly see Final Gear Case Disassembly e Using a suitable puller A remove the ball bearing B and shim s C Pinion Gear Assembly The pinion gear and ring gear are lapped as set by the factory to get the best tooth contact They must be re placed as a set Install the shim s A and ball bearing using the bear ing driver set Special Tool Bearing Driver Set C 57001 1129 e Install the pinion gear see Final Gear Assembly Be sure to check and adjust the bevel gear backlash and tooth contact when any of the parts which influence these items are replaced see Final Bevel Gear Adjustment Incorrect OMA Correct Incorrect Contact at tooth top Contact at tooth root 180068 5 Final Gear Case FINAL DRIVE 12 15 Bevel Gear Inspection e Visually check the bevel gears A for scoring chipping
174. knuts 8 8 N m 0 90 kgf m 78 in Ib Special Tool Valve Adjusting Screw Holder 57001 1217 Recheck the clearance x If the clearance is incorrect repeat the adjustment proce dure x If the clearance is correct perform the adjustment proce dure on the other valve Spark Arrester Cleaning A WARNING The muffler can become extremely hot during nor mal operation and cause severe burns Since the engine must be running during this procedure wear heat resistant gloves while cleaning the spark ar rester Remove Spark Arrester Mounting Bolt A Spark Arrester B Clean the spark arrester A in a bath of high flash point solvent and if necessary use a fine wire brush to gently remove any particles in the screen on the spark arrester Inspect the screen for damage and replace the spark ar rester if necessary an open area away from combustible materials start the engine with the transmission in neutral e Raise and lower engine speed while tapping on the muf fler with a rubber mallet until carbon particles are purged from the muffler 2 22 PERIODIC Periodic Maintenance Procedures A DANGER Exhaust gas contains carbon monoxide a color less odorless poisonous gas Inhaling carbon monoxide can cause serious brain injury or death DO NOT run the engine in enclosed areas Operate only in a well ventilated area Stop the engine Ins
175. l hoses and a fuel tank The Clean Air Act which is the Federal law covering motor vehicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any 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 ina motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe 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 a
176. lation chapter Starter Motor see Starter Motor Removal in the Electri cal System chapter Oil Screen see Oil Screen Removal in the Engine Lu brication System chapter Piston see Piston Removal in the Engine Top End chap ter Drive Pulley see Drive Pulley Removal in the Converter System chapter Clutch Driven Pulley see Clutch Driven Pulley Removal in the Converter System chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter e Remove Crankcase Bolts A Right Crankcase Half B e Remove Dowel Pins Crankshaft A Balancer B CRANKSHAFT TRANSMISSION 10 9 Crankcase Crankcase Assembly 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 OBe certain that all parts are cleaned thoroughly before assembly OBlow through all oil passages with compressed air to clear any blockage in the crankcase halves and crank shaft A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the engine parts in a well ventilated area and take care that there is no spark or flame anywhere near the working areas Do not use gasoline or low flash point solvents to clean parts e Press and insert the new ball bearings A until they are bottomed Special Tool Bearing Driver Set 57001 1129 Apply engine oil to the bearings e
177. lip A Special Tool Inside Circlip Pliers 57001 143 Remove the bearing A Special Tools Oil Seal amp Bearing Remover B 57001 1058 Oil Seal amp Bearing Remover Adapter A C 57001 1061 Output Driven Shaft Housing Assembly Replace the bearing A with a new one Press in the bearing until it bottomed Special Tool Bearing Driver Set B 57001 1129 Replace the circlip with a new e Install the new circlip Special Tool Inside Circlip Pliers 57001 143 Replace the oil seal A with a new one Press in the oil seal until it bottomed Special Tool Bearing Driver Set B 57001 1129 CRANKSHAFT TRANSMISSION 10 25 Transmission Replace the bearing A with a new one Press the bearing until it bottomed Special Tool Bearing Driver Set B 57001 1129 e Replace the circlip with a new one Install the circlip Special Tool Inside Circlip Pliers 57001 143 Install the driven gear shaft Install the universal joint A to the output driven shaft housing B Hold the universal joint in a vise Tighten Torque Output Driven Bevel Gear Nut C 98 N m 10 kgf m 72 ft lb Bend a point of the nut Align the mark A on the output driven shaft housing with the mark C on the transmission case D Tighten Torque Output Driven Shaft Housing Bolts 9 8 N m 1 0 kgf m 87 in Ib Output Drive Bevel Gears Adjustment
178. ller shaft assembly A into the swingarm and then secure propeller shaft spring C onto the pinion gear shaft in the final gear case D FINAL DRIVE 12 7 Propeller Shaft Apply molybdenum disulfide grease Splines at Front End A of Propeller Shaft Splines at Rear End B of Driven Gear Shaft e Fit the propeller shaft to the driven gear shaft Install the swingarm assembly Install the removed parts see appropriate chapters Propeller Shaft Inspection e Remove the propeller shaft see Propeller Shaft Re moval e Check that the universal joint A works smoothly without rattling or sticking x lf it does rattle or stick the universal joint is damaged Replace the propeller shaft with a new one e Visually inspect the splines B the universal joint and pro peller shaft is damaged x If they are badly worn chipped or loose replace the pro peller shaft and universal joint Propeller Shaft Joint Boot Inspection Refer to the Propeller Shaft Joint Boot Inspection in the Periodic Maintenance chapter 12 8 FINAL DRIVE Rear Axle Rear Axle Removal Remove Swingarm Assembly see Swingarm Removal in the Suspension chapter Boot A Final Gear Case Bolts B Final Gear Case Cover C e Put the swingarm assembly A on the wooden blocks Strike the rear axle with a copper hammer remove the rear axle and ring gear Hold the ring gear A and then tap the rear axle B wi
179. lockwise viewed r from output side UM 68020228 5 Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R wires must be connected to those of the same color e oar e GB020238 5 Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the meter Incorrect values may lead to improper adjustments GB02082BS1 C GENERAL INFORMATION 1 7 Model Identification KVF300CC United States Left Side View KVF300CC United States Right Side View 1 8 GENERAL INFORMATION Model Identification Frame Number Engine Number A Frame Number A Engine Number Oln this photo the left side inner cover has been removed General Specifications GENERAL INFORMATION 1 9 Items KVF300CC Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance Seat Height Curb Mass Front Rear Fuel Tank Capacity 1 915 mm 75 39 in 1 080 mm 42 52 in 1 170 mm 46 06 in 1 165 mm 45 87 in 155 mm 6 10 in 845 mm 33 3 in US AU 243 kg 536 Ib EUR 242 kg 534 Ib US AU 127 kg 280 Ib EUR 126 kg 278 Ib 116 kg 256 Ib 12 L 3 2 US gal Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepow
180. lt A Crack B Broken C Peeling D NOTE OWhenever the belt is replaced inspect the drive and the driven pulleys Engine Lubrication System Engine Oil Change e Support the vehicle so that it is level both side to side and front to rear after warming up the engine Remove the engine oil drain plug A to drain the oil Replace the oil drain plug gasket with a new one Tighten Torque Engine Oil Drain Plug 25 N m 2 5 kgf m 18 ft Ib e Pour in the specified type and amount of oil Engine Oil Type API SG SH SJ SL or SM with JASO MA 1 or MA2 Viscosity SAE 10W 40 Amount 1 6L 1 7 US qt 1 8 L 1 9 US qt When engine is completely dry NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 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 e Check the engine oil level see Oil Level Inspection in the Periodic Maintenance chapter HUOSOO5BS1 C 1 1 1 1 SAE 20W 50 gt 2084 40 40 C 104 F 09002 51 2 24 PERIODIC Periodic Maintenance Procedures Oil Screen Cleaning e Drain the engine oil see Engine Oil Change Remove the oil screen plug A and
181. lter C Fuel Filter Installation e Install the fuel filter so that the arrow mark A faces car buretor side 3 24 FUEL SYSTEM Fuel Tank Fuel Filter Inspection e Visually inspect the fuel filter A x lf the filter is clear with no signs of dirt or other contami nation it is OK and need not be replaced x If the filter is dark or looks dirty replace it with a new one Also check the rest of the fuel system for contamination COOLING SYSTEM 4 1 Cooling System Table of Contents Tr Get 4 2 asian En BR EEE sinn nie 4 4 Special Tools and Sealant naar a RR 4 5 eur 4 6 Coolant Deterioration 9 nnns 4 6 Coolant Level Inspection nere nnne nnne 4 6 Coolant Dalida he ttes kiss 4 6 eraat 4 6 ccm 4 6 Water Pumps a ner tesa T I prre cM 4 7 Water Pump Cover Removal esses ener nnne 4 7 Water Pump Cover Installation pp 4 7 Water Pump Impeller Removal pp 4 7 Water Pump Impeller Installation pp 4 7 Water Pump Impeller Inspection sees nennen 4 8 Water Pump Leakage Inspection pp 4 8 Mechanical Seal Replacement 4 8 at on 4 10 Radiator 2 ener nennen en nnne nnne nennen e
182. m Therefore replace a sealed battery only on a vehicle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment the sealed battery s life will be shortened Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage Remove the battery see Battery Removal sure to disconnect the negative cable first e Measure the battery terminal voltage NOTE OMeasure 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 Terminal Voltage V A Battery Charge Rate B Good C Refresh charge is required D Refreshing Charge e Remove the battery A see Battery Removal Refresh charge by following method according to the bat tery terminal voltage A WARNING This battery is sealed type Never remove seal sheet B even at charging Never add water Charge with current and time as stated below 8 08010851 C 8 09001251 ELECTRICAL SYSTEM 17 23 Battery Terminal Voltage 11 5 less than 12 8 V 11 Standard Charge 1 2A x 5 10 h see following chart Quick Charge 5 0Ax1 0h Charge
183. mpeller Re moval Alternator Cover see Alternator Cover Removal in the Electrical System chapter Circlip A Special Tool Inside Circrip Pliers 57001 143 e Remove Water Pump Shaft B Inner Bearing C Remove the outer bearing with the bearing remover Special Tools Bearing Remover Shaft 9 A 57001 1265 Bearing Remover Head 10 x 912 57001 1266 COOLING SYSTEM 4 9 Water Pump Press out the mechanical seal and oil seal from the inside of the alternator cover Special Tool Bearing Remover Head 10 x 012 A 57001 1266 Replace the mechanical seal and oil seal with a new one Press in the oil seal A until it bottoms out Special Tool Valve Guide Driver B 57001 1564 2 P e Using a suitable socket A press and insert a new me chanical seal B until its flange C stops at the step of the hole From inside the alternator cover press the outer bear ing A until it bottoms out Special Tool Valve Guide Driver B 57001 1564 e Install Inner Bearing Water Pump Shaft New Circlip Special Tool Inside Circlip Pliers 57001 143 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 surfaces of the rubber seal and seal ing seat A and press the rubber seal B and sealing seat into the
184. mshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Nuts A and Washers Camshaft Cap B Remove the camshaft A Support the chain using a suitable tool Camshaft Installation Apply engine oil to all cam parts e Install the dowel pins A Engage the camshaft chain with the camshaft sprocket Keep the round hole A on the camshaft sprocket facing up and align the holes B on the camshaft sprocket with the cylinder head upper surface C The position of the intake and exhaust cam lobes is down e Install the camshaft cap so that the EX mark D faces exhaust side Apply engine oil to the threads of the camshaft cap nuts e Install the washers and camshaft cap nuts Tighten Torque Camshaft Cap Nuts 25 N m 2 5 18 ft lb 5 16 END Camshaft Install Camshaft Chain Tensioner see Camshaft Chain Ten sioner Installation e Turn the crankshaft 2 turns clockwise to allow the ten sioner to expand and recheck the camshaft chain timing Install the removed parts see appropriate chapters Cam Wear Inspection Remove the camshaft see Camshaft Removal 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 34 172 mm 1 3454 in Intake 34 287 mm 1 3499 in Service Limit Exhaust 34 05 mm 1 341 in Intake 34 15 mm 1 344
185. n on the reel when removing the reel Lift the reel slightly If tension is felt push the reel back into place and gently wiggle it until the reel may be easily removed f necessary remove the recoil spring A as follows OPlace the starter housing facing down on a bench OStrike the starter housing with a rubber mallet so safely remove the spring Recoil Starter Assembly If the recoil spring was removed install it as shown If itis not installed correctly the starter will not operate properly A WARNING The recoil spring is under great tension and can travel at high speed if it comes loose and cause in jury or pinch fingers Wear gloves during reassem bly to avoid injury Hook the outer ends A of the recoil spring onto the dents Reel the recoil spring clockwise into the housing from out side to inside NOTE OPush the recoil spring against the housing securely to prevent the spring from slipping off during installation Lightly grease the spring 7 6 RECOIL STARTER Recoil Starter Other than EUR Model e f the rope was unwound from the reel it must be wound clockwise for correct starter operation e Wind the rope around the smaller diameter of the reel NOTE the reel counterclockwise A to wind the clockwise This prevents the rope from twisting e Set the reel into the place so that the grooves A on the spring catch on the tabs B in t
186. n reduce bulb life or cause the bulb to explode NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution Replace the headlight bulb Fit the projections A of the bulb in the hollows of the headlight e Install the hooks e Fit the dust cover onto the headlight body firmly 17 44 ELECTRICAL SYSTEM Lighting System Pull out the city light socket A with the bulb Remove the city light bulb A Replace the city light bulb and install it to the socket B Install the socket into the headlight body Install the headlight body A into the headlight cover Tighten the screws C securely Tighten the bolts A securely e Install the headlight see Headlight Installation e After installation adjust the headlight aim see Headlight Beam Vertical Adjustment 28127 Tail Brake Light Bulb Replacement Unscrew the socket A counterclockwise B ELECTRICAL SYSTEM 17 45 Lighting System e Push the bulb A in turn it counterclockwise and pull it out e Be sure the socket is clean wim Insert the new bulb by aligning the pins A with the grooves B in the walls of the socket e Push the bulb in turn it clockwise and release it It should lock in position P Tail Brake Light Removal Remove the socket see Tail Brake Light Bulb Replace ment Rem
187. nance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage Master Cylinder BRAKES 13 13 Front Master Cylinder Removal Slide the rubber A e Remove Brake Hose Banjo Bolt B Master Cylinder Clamp Bolts C Front Master Cylinder D NOTICE Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Front Master Cylinder Installation e Fit the projection A of the master cylinder clamp into the hole B of the handlebar 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 Front Master Cylinder Clamp Bolts 12 N m 1 2 kgf m 106 in lb e Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib e Install the rubber cap e Bleed the brake line after master cylinder installation see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt t
188. nk ing flatting or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Fill the brake line after installing the brake hose see Brake Fluid Change 2 32 PERIODIC Periodic Maintenance Procedures Brake Fluid Level Inspection e Position the reservoir horizontal and check that the fluid level in the reservoir is higher than the lower level line A If the fluid level is lower than the lower level line check for fluid leakage of the brake line and add the fluid as follows ORemove 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 Recommended Brake Fluid Type DOT4 AWARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified Tighten the reservoir cap screws Brake Fluid Change Front Brake Remove the reservoir cap and the rubber cap on the bleed valve e Attach a clear plastic hose to the bleed valve on the front caliper and run the other end of the hose into a container e
189. nne 4 10 Radi tor Installation nassen e eka ERE E e re etas 4 11 Radiator Fan 4 12 erre fe te per ed wed i bre nca R 4 13 4 13 Radiator Cap Inspection 2 rtr eie te oret ere ite hee i eee uh D 4 13 3TiHertiostab s seo MM 4 14 Thermostat Removal eee sie ai ited eed eti Ll cv ve Ped vg 4 14 Thermostat Iristallation irit rto tte o oa Hr M dus Maa de ag o ge usa 4 14 Thermostat Inspection pp 4 14 Radiator Fan Switch oot RR u IE lila 4 16 Radiator Fan Switch 92 emnes 4 16 Radiator Fan Switch 4 16 Radiator Fan Switch 4 16 Water Temperature Sensor 8 nnns nnns 4 17 Water Temperature Sensor 1 0 1 eene 4 17 Water Temperature Sensor 4 17 Water Temperature Sensor Inspection 4 17 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View Torque No Fastener kgf m fb 1 Water Pump Cover Bots 98 4 ThermostatHousing Mounting Bot 10 ermbl 5 Radiator Mount
190. nspection Bolt 9 8 1 0 87 in Ib Wheel Tires Front Wheel Hub Nuts 69 7 0 51 Front Wheel Nuts 54 5 5 40 5 Wheel Hub Nuts 147 15 0 108 R L Rear Wheel Nuts 54 5 5 40 S Final Drive Final Gear Case Cover Bolts M10 39 4 0 29 L Final Gear Case Cover Bolts M8 26 2 7 19 Final Gear Case Guard Bolts 31 3 2 23 Final Gear Case Mounting Bolts 54 5 5 40 Final Gear Case Oil Drain Bolt 20 2 0 15 Final Gear Case Oil Filler Cap 15 1 5 11 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Remarks Final Gear Case Oil Level Inspection Bolt Pinion Gear Bearing Holder Nut Brakes Bleed Valves Brake Caliper Mounting Bolts 19 Disc Mounting Bolts 25 Brake Hose Banjo Bolts 25 Front Pad Pin Bolts E 13 Front Master Cylinder Clamp Bolts 106 in Ib Parking Brake Adjusting Locknut 12 Rear Brake Proportioning Valve Mounting Bolts 87 in lb Rear Master Cylinder Mounting Bolts f 106 in Ib Rear Master Cylinder Clamp Bolts 106 in Ib Suspension Front Shock Absorber Mounting Nuts 39 4 0 29 R Rear Shock Absorber Mounting Nuts 39 4 0 29 R Steering Knuckle Pivot Nuts 30 3 1 22 Suspension Arm Mounting Nuts 44 4 5 32 R Swingarm Pivot Bolt Left Shaft 11 1 1 97 in Ib Swingarm Pivot Locknut 116 11 8 85 6 Swingarm Pivot Right Shaft 116 11 8 85 6 Steering Handle Holder Nuts Handlebar Holder Bolts Steering Shaft Bottom End Nut Steering Shaft Holder Bolts Suspension Arm Joint Nuts Tie rod End Nuts T
191. nstall it Install the hoses and tighten the clamps securely e Fill the coolant see Coolant Change Check the cooling system for leaks 2 20 PERIODIC Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE OCheck the valve clearance only when the engine is cold at room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Alternator Rotor Nut Cap Bolts A Alternator Rotor Nut Cap B Timing Inspection Plug C e Remove Oil Through Guide A Spring e Turn the crankshaft clockwise with a wrench on the alter nator rotor bolt until T F mark A on the alternator rotor aligns with the notch B as shown the end of the com pression stroke in the cylinder head Measure the clearance for 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 08 0 12 mm 0 0032 0 0048 in Intake 0 08 0 12 mm 0 0032 0 0048 in x If the valve clearance is not correct adjust it see Valve Clearance Adjustment PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Valve Clearance Adjustment Loosen the locknut and turn the adjusting screw until the clearance is correct Holding the adjusting screw A with the holder B tighten the locknut C Torque Valve Adjusting Screw Loc
192. o ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc 13 14 BRAKES Master Cylinder Rear Master Cylinder Lever Removal e Slide the rubber cap A e Remove Brake Hose Banjo Bolt B Rear Master Cylinder Clamp Bolts C Rear Master Cylinder D Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Rear Master Cylinder Lever Installation e Fit the projection A of the master cylinder mounting into the hole B of the handlebar The rear master cylinder clamp must be installed with the PARKING mark A upwards Tighten Torque Rear Master Cylinder Clamp Bolts B 12 N m 1 2 kgf m 106 in Ib e Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib e Install the rubber cap e Bleed the brake line after master cylinder installation see Brake Line Air Bleeding e Check the brake for good braking power no brake drag and no fluid leakage e Adjust the parking brake see Parking Brake Cable Ad justment in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt
193. o the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more GE16044BS1 GE16060481 C HE14032BS1 Cylinder Piston ENGINE TOP END 5 23 eApply engine oil to the cylinder bore and piston skirt The piston ring openings must be positioned as shown in the figure Top Ring A Second Ring B Oil Ring Steel Rail Upper C Oil Ring Expander D Oil Ring Steel Rail Lower E Replace the cylinder base gasket with a new one e Install Dowel Pins A New Cylinder Base Gasket B Install Cylinder A Front Camshaft Chain Guide B Cylinder Wear Inspection 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 xIf 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 72 705 72 715 mm 2 8624 2 8628 in Service Limit 72 8 mm 2 866 in 100238 S HE14029BS1 5 24 END Cylinder Piston Piston Wear Inspection e Measure the outside diameter A
194. odic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Float Height Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Remove the carburetor see Carburetor Removal e Drain the fuel of the carburetor Remove the screws A and take off the float bowl Measure the height A between the float bowl mating sur face B with the gasket removed and the float upper sur face C NOTE OMeasure the height with the carburetor upside down ODo not push the needle rod in during the float height measurement Float Height Standard 17 0 2 mm 0 669 0 08 in x lf the float level is incorrect adjust the float level as fol lows Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level x lf the float level cannot be adjusted by this method the float or the float valve is damaged Install the removed parts see appropriate chapters 3 12 FUEL SYSTEM Carburetor Carburetor Removal A WARNING Gasoline is extremely flammable and can be explo sive under certain conditi
195. odic Maintenance Procedures Parking Brake Cable Adjustment Release the parking brake lever Loosen the adjusting locknut A on the rear brake caliper and turn out the adjusting bolt B a few turns Loosen the locknut A at the upper part of the parking brake cable B Adjusting Nut Turn the adjusting nut on the parking brake cable until the specified length A between center of the cable lower end and cable holder bracket obtained Parking Brake Cable Lower End Length Standard 52 55 mm 2 0 2 2 in e While holding the adjusting nut on the cable tighten the locknut Turn in the adjusting bolt A on the caliper until resistance is felt then turn out the adjusting bolt by 1 8 turn e While holding the adjusting bolt tighten the adjusting lock nut B Torque Parking Brake Adjusting Locknut 16 N m 1 6 kgf m 12 ft lb Check the parking brake for good braking power and no brake drag x If parking brake power is weak or brake is drag readjust the parking brake 7 ms Steering Steering Inspection e Support the vehicle on a stand or a jack so that the front wheels are off the ground e Turn the handlebars left and right and check the steering action x If the steering action is not smooth or if the steering binds or catches before the stop lubricate the steering stem bearing steering shaft grease seals steering stem hold ers NOTE OThe c
196. of the piston 10 mm 0 4 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 72 67 72 69 mm 2 8610 2 8618 in Service Limit 72 6 mm 2 858 in Piston Cylinder Clearance Inspection e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 025 0 055 mm 0 0010 0 0022 in x If the clearance exceeds service limit inspect the piston and cylinder Piston Ring Piston Ring Groove Wear Inspection Check for uneven groove wear by inspecting the ring seat ing x The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance HE14034BS1 Standard Top 0 015 0 055 mm 0 0006 0 0022 in Second 0 015 0 055 mm 0 0006 0 0022 in Service Limit Top Second 0 09 mm 0 0035 in 0 09 mm 0 0035 in Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap B between the
197. off the ground Special Tool Jack 57001 1238 While holding the rear wheels remove the lower and up per shock absorber mounting bolts A and nuts B Remove the rear shock absorber Rear Shock Absorber Installation Replace the rear shock absorber mounting bolts and nuts with new ones Check the bush A in the rear shock absorber x If bushings are worm crack hardened or otherwise dam age replace the rear shock absorber Apply a non permanent locking agent on the thread of the rear shock absorber mounting bolts Tighten Torque Rear Shock Absorber Mounting Nuts 39 N m 4 0 kgf m 29 ft lb HM04040BS1 14 10 SUSPENSION Shock Absorbers Rear Shock Absorber Inspection Remove the rear shock absorber see Rear Shock Ab sorber Removal Visually inspect the following items Smooth Stroke Oil Leakage Crack Dent or Bend x If there is any damage to the rear shock absorber replace it Suspension Arms SUSPENSION 14 11 Suspension Arm Removal e Remove Front Hub see Front Hub Removal in the Wheels Tires chapter Steering Knuckle see Steering Knuckle in the Steering chapter Front Shock Absorber see Front Shock Absorber Re moval Suspension Arm Mounting Bolts A Suspension Arms B Suspension Arm Installation e Replace the suspension arm mounting nuts with new ones Tighten Torque Suspension Arm Mounting Nuts 44 N m 4 5 kgf m 32 ft lb e In
198. olant level is lower than the L mark line remove the seat see Seat Removal in the Frame chapter and reserve tank cap A then add coolant to the F mark line B 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 attack the aluminum engine parts In an emergency soft water can be added But the diluted coolant must be returned to the cor rect mixture ratio 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 Change A WARNING Coolant can be extremely hot and cause severe burns is toxic and very slippery Do not remove the radiator cap or attempt to change the coolant when the engine is hot allow it cool completely Immediately wipe any spilled coolant from tires frame engine or other painted parts Do not ingest coolant e Remove Middle Cover see Middle Cover Removal in the Frame chapter Right Footboard see Right Footboard Removal in the Frame chapter Right Side Inner Cover see Side Inner Cover Removal in the Frame chapter Front Bottom Guard see Front Bottom Guard Removal in the Frame chapter Reserve Tank Cover Bolts A Reserve Tank Cover B PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Clear the over flow hose A from t
199. on Oil Level Inspection nn 2 24 Transmission OI Charge se eee 2 25 MINI I mET 2 26 Mire Inspections iue ctr rore erg e en 2 26 Wheel Bearing Damage Inspection pp 2 26 Wheel Inspection oder a Rare t Dae eoe ate 2 27 Toesin InSpection i temp HER Rd CR e e e eU er 2 27 Toe in Adjusiment 2 28 m 2 28 Final Gear Case Level 2 28 Final Gear Case Oil Change idR ote He 2 28 EE 2 29 Brake Operation Inspection pp 2 29 Brake Pad Wear 8 9 2 30 Brake Hoses and Connections Inspection 2 30 Brake Hose 2 30 Brake Fluid Level Inspection pp 2 32 Brake Fluid Change a 2 32 2 2 PERIODIC Parking Brake Cable Adjustment 41 2 SISELING nein M m Steering Inspection Electrical System Spark Plug Cleaning l Inspectlonzsicn has ira Spark Plug Gap Inspection pp Joint Boots Inspection Tie rod End B
200. on the tie rod has left hand threads Turn the locknut clockwise for loosening HJ04011BS1 C Wheel Alignment WHEELS TIRES 11 7 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 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 Check the toe in see Toe in Inspection in the Periodic Maintenance chapter Toe in Inspection e Refer to the Toe in Inspection in the Periodic Maintenance chapter Toe in Adjustment Refer to the Toe in Adjustment in the Periodic Mainte nance chapter 9040268 S HJ04016BS1 C 11 8 WHEELS TIRES Wheels Rims Wheel Removal Squeeze the brake lever securely and hold it with a band Loosen the wheel nuts Support the vehicle on a stand ora jack so that the wheels are off the ground Special Tool Jack 57001 1238 Remove Wheel Nuts Wheel Wheel Installation Check the wheel runout see Wheel Inspection in the Pe riodic Maintenance chapter Check the tire rotation mark A on the tire and install the wheel accordingly B Tire Rotation Direction Position the wheel so that the air valve A is toward the outs
201. ons creating the potential for serious burns Make sure the area is well venti lated 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 Be prepared for fuel spillage any spilled fuel must be completely wiped up immediately e Turn the fuel tap to the OFF position Remove Fuel Tank see Fuel Tank Removal Choke Cable see Choke Cable Removal Screw A e Clear the hook B from the hole and remove the throttle pulley cover C Remove the throttle cable lower end A from the throttle pulley Loosen the clamp screws A Pull off the carburetor e After removing the carburetor stuff pieces of lint free clean cloths into the carburetor holder NOTICE If dirt gets into the engine excessive engine wear and possible engine damage will occur Carburetor FUEL SYSTEM 3 13 Carburetor Installation e Turn the throttle pulley A to check that the throttle valve B move smoothly and return by spring force x lf the throttle valve do not move smoothly replace the carburetor e Run the leads cables and hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Fit the projection A of the carburetor into the slit B on the carburetor holder Tighten the clamp screws securely Apply thin coating of grease to the throttle cable lower end e Fit the throttle
202. ont Hub Disassembly e Remove Collars A Dust Seals B Brake Disc see Front Brake Disc Removal in the Brakes chapter Take the bearings A out of the hub using the bearing remover Special Tools Bearing Remover Shaft 59 57001 1265 B Bearing Remover Head 15 x 17 57001 1267 C For Outside Bearing Bearing Remover Head 20 x 22 57001 1293 For Inside Bearing Front Hub Assembly e Before installing the hub bearings blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings e Replace the bearings with new ones NOTE Olnstall the bearings so that the marked side faces out e Press in the one side bearing A until it is bottomed Special Tool Bearing Driver Set 57001 1129 e Insert the collar B in the hub C as shown e Press in the other side bearing D until it is bottomed Special Tool Bearing Driver Set 57001 1129 HJ07024BS1 HJ07020BS1 HJ07021BS1 11 14 WHEELS TIRES Front Hub e Replace the dust seals with new ones e Press in the dust seal A until it is bottomed e Apply grease to the dust seal lips Special Tool Bearing Driver Set 57001 1129 B e Press the hub bolts using a press if removed Install the brake disc see Front Brake Disc Installation in the Brakes chapter Install the removed parts see appropriate chapters Hub Bearing Inspection OSince the hub bearings
203. ool Jack 57001 1238 Remove Bolts A and Nuts B Front Shock Absorber C Front Shock Absorber Installation Replace the front shock absorber mounting nuts with new ones Check the bushings A in the front shock absorber x If bushings are worm crack hardened or otherwise dam age replace the front shock absorber Tighten Torque Front Shock Absorber Mounting Nuts 39 N m 4 0 kgf m 29 ft lb Front Shock Absorber Inspection Remove the front shock absorber see Front Shock Ab sorber Removal e Visually inspect the following items Smooth Stroke Oil Leakage Crake Dent or Bend If one unit is damaged replace both shock absorbers as a set If only one unit is replaced and the two are not balanced vehicle instability at high speed may result HM04038BS1 SUSPENSION 14 9 Shock Absorbers 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 Spring Force Position 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
204. oots In Propeller Shaft Joint General Lubrication Lubrication SPOCTON nmm Boots Inspection oiii eee tee eee ER nn Bolis and Nuts Tighterlitig oreet eee te ht de rehome Tightness Inspection 2 35 2 35 2 35 2 36 2 36 2 36 2 36 2 36 2 37 2 37 2 37 2 39 2 39 Periodic Maintenance Chart PERIODIC MAINTENANCE 2 3 The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected Pirat Regular Service Service Every 1 000 After 150 km 600 km 100 mi or 6 FREQUENCY OPERATION Engine oil change Oil screen clean 2 000 km 1 200 mi or year of use whichever comes mi or 1 months month of Transmission oil inspect Transmission oil change Air cleaner element clean and inspect Idle speed inspect e Throttle lever play inspect Every 20 40 hours 150 300 km 100 200 mi Breather hose and connections inspect Converter drive belt wear inspect Spark plug clean and gap Fuel hose and connections inspect Valve clearance inspect Spark arrester clean Coolant leak water hose and pipe inspect Coolant change Exhaust gas leak inspect Radiator clean and inspect
205. or other damage Replace the bevel gears as a set if either gear is dam aged 12 16 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close toler ances the clearance cannot normally be measured 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 e Check the needle bearing A OThe rollers in the needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If the bearing is damaged replace the bearing Oil Seal Inspection Inspect the oil seal A Replace it if the lips are misshapen discolored indicat ing that the rubber had deteriorated hardened or been otherwise damaged BRAKES 13 1 Table of Contents Exploded 13 2 Specifications 13 6 Special Tools pp 13 7 Brake Fluid 22 2 22 13 8 Brake Fluid Recommendation 13 8 Brake Fluid Level Inspection 13 8 Brake Fluid Change 13 8 Brake Line Air Bleeding 13 9 Master Cylinder
206. orn Handlebar clamp loose Steering stem clamp bolt loose Handlebars pulls to one side Frame bent not properly Wheel maladjustment Suspension arm bent or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Brake Doesn t Hold 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 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 MODEL APPLICATION Year Model Beginning Frame No RGSWM22ADCB100201 2012 KVF300CC RGSWM22A0CB120101 This digit in the frame number changes from one machine to another RGSVF300CCB110101 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Motorcycle amp Engine Company Part No 99924 1455 01 Printed in Japan
207. ounting Bolts D Starter Motor E NOTICE 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 legs A and crankcase B where the starter motor is grounded Replace the O ring A with a new e Apply grease to the O ring Install Starter Motor A Tighten Torque Starter Motor Mounting Bolts B 9 8 Nm 1 0 kgf m 87 in Ib Tighten the starter motor cable mounting nut C securely Slide back the rubber cap D to the original position Starter Relay Inspection Remove Seat see Seat Removal in the Frame chapter e Disconnect Starter Motor Cable A Battery Positive Cable B Connector C Remove Starter Relay D 17 38 ELECTRICAL SYSTEM Electric Starter System e Connect the hand tester Al and a 12 V battery B to the starter relay as shown x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range 1 range Criteria When battery is connected 0 Q When battery is disconnected HP11035BS1 Electric Starter System ELECTRICAL SYSTEM 17 39 Electric Starter Circuit BR BL BK W BK W AR ar BR BL BK N 8K W _ GE HP11036BW3 C Front Brake Light Switch Charge Fuse 30 A
208. ounts of water and seek medical attention for more severe burns e Place the battery on a level surface e Check to see that the sealing sheet has no peeling tears or holes in it Remove the sealing sheet NOTE OThe 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 e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells e 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 ODo not tilt the electrolyte container ME02112BS1 GP08139BS1 C ffe L 8 09000751 C 17 20 ELECTRICAL SYSTEM Battery 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 NOTE OBe careful not to have the battery fall down e Keep the container in place Don t remove the container from the battery the battery requires all the electrolyte from the container for pro
209. ove chargers are not available use equivalent one Let battery sit 30 minutes after initial charge then check voltage using a voltmeter Voltage immediately after charging becomes temporarily high For accurate mea suring let the battery sit for given time NOTE OCharging rates will vary depending on how long the battery has been stored temperature and the type of charger used If voltage is not at least 12 8 V repeat charging cycle OTo 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 V repeat the charging cycle and load test If still below 12 8 V 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 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 NOTICE This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above H
210. ove the tail brake light mounting screws A Remove the tail brake light body Tail Brake Light Installation e Installation is the reverse of removal Tail Light Bulb Replacement e Disconnect the connectors A e Remove Tail Light Mounting Screws B Tail Light Unit C 17 46 ELECTRICAL SYSTEM Lighting System eRemove the bracket nut A and bracket e Remove Tail Light Socket Screws A Tail Light Socket B e Push and turn the bulb A counterclockwise B and re move it Replace the bulb with a new one e Insert the new bulb A by aligning its pins B with the grooves C in the socket and turn the bulb clockwise e Install the removed parts Wi28140 28141 P Lighting System ELECTRICAL SYSTEM 17 47 Lighting System Circuit HP12030BW3 C OOANODOABRWDN gt Front Brake Light Switch Charge Fuse 30 A Main Fuse 15 A Headlight Tail Light Fuse 10 A Ignition Switch Rear Brake Pedal Light Switch Battery 12 V 10 Ah Engine Ground Tail Light Right 12 V 5 W Tail Brake Light Right 12 V 5 21 W 11 12 13 14 15 16 17 18 Headlight Right 12 V 35 W 35 W 20 Tail Brake Light Left 12 V 5 21 W Tail Light Left 12 V 5 W Igniter Rear Brake Lever Light Switch Light Dimmer Switch City Light Left 12 V 5 W Headlight Left 12 V 35 W 35 W Meter Unit C
211. owever the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal caps during refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 3 When you do not use the vehicle for months Give a refresh charge before you store the vehicle and store it with the negative lead removed 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 17 22 ELECTRICAL SYSTEM Battery A DANGER tention for more severe burns Interchange Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri ous injury and burns if ignited Keep the battery away from sparks and open flames during charging 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 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 and seek medial at A sealed battery can fully display its performance only when combined with a proper vehicle electri cal syste
212. per operation Removal of the container before it is completely empty can shorten the service life of the battery Do not remove the container until it is completely empty e After filling let the battery sit for 20 60 minutes with the electrolyte container kept in place which is required for the electrolyte to fully permeate into the plates e Make sure that the container cells have emptied com pletely and remove the container from the battery e Place the strip of caps A loosely over the filler ports press down firmly with both hands to seat the strip of caps into the battery don t pound or hammer When properly installed the strip of caps will be level with the top of the battery NOTICE Once the strip of caps is installed onto the battery never remove the caps nor add water or electrolyte to the battery NOTE OCharging the battery immediately after filling can shorten service life ME02114BS1 e Hm LJ LJ LJ L3 GPO8012BS1 C 8 08010851 C ELECTRICAL SYSTEM 17 21 Battery Initial Charge eNewly activated sealed batteries require an initial charge Standard Charge 1 2 A x 5 10 hours x lf using a recommended battery charger follow the charger s instructions for newly activated sealed battery Kawasaki recommended chargers Battery Mate 150 9 OptiMate PRO 4 S PRO S PRO2 Yuasa MB 2040 2060 Christie C10122S xIf the ab
213. peration OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black G Green P Pink BL Blue Gray Purple Brown LB Light blue R Red CH Chocolate LG Lightgreen W White DG Darkgreen Orange Y Yellow 17 16 ELECTRICAL SYSTEM Precautions OElectrical Connectors Connectors A Connectors B 8 06010251 Electrical Wiring ELECTRICAL SYSTEM 17 17 Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x1 O range x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary lp97001BS1 17 18 ELECTRICAL SYSTEM Battery Battery Removal e Turn the ignition switch to OFF e Remove Seat see Seat Removal in the Frame chapter Battery Holder Bolts A Battery Holder B e Disconnect the battery negative cable C first and then the positive cable D e Take out th
214. r ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the 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 eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Vehi cle parts Special tools gauges and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man ual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts 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 sys
215. r 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 x If the rubber friction boot is damaged replace the rubber friction boot x lf caliper holder shaft is damaged replace the caliper holder shaft and rubber friction boot as a unit 13 26 BRAKES Pads Front Brake Pad Removal Remove the front wheel see Wheel Removal in the Wheels Tires chapter Remove the front caliper mounting bolts A and detach the caliper form the disc e Remove Brake Pad Bolts B Brake Pads C Front Brake Pad Installation e Push the caliper piston in by hand as far as it will go e Be sure that the anti rattle spring is in place Install Brake Pads Brake Pad Bolt Tighten the brake pad bolts securely e Install the front brake caliper see Front Caliper Installa tion A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake lever
216. r and collar e Apply engine oil to the top of the driven shaft e Using the flywheel amp pulley holder A tighten the driven pulley nut B Special Tool Flywheel amp Pulley Holder 57001 1605 Torque Driven Pulley Nut 54 N m 5 5 kgf m 40 ft Ib Clutch Disassembly e Remove the clutch see Clutch Driven Pulley Disassem bly e Remove the circlips A and retainer plate B to disassem bly the clutch NOTE OKeep grease off the clutch linings C Clutch Assembly e Install the damper rubbers A on the drive plate pins B e Install the clutch weights shoes C and clutch springs D e Replace the circlips E with new ones e Install the retainer plate F and install the new circlips in the grooves of the drive plate pins H807016BS1 CONVERTER SYSTEM 6 17 Clutch Driven Pulley Clutch Inspection Check the clutch shoes for damage x lf there is any damaged part replace it e Measure the clutch lining thickness A x If the lining thickness is worn over the service limit re place the clutch shoe Clutch Lining Thickness Standard 0 8 1 0 mm 0 031 0 039 in Service Limit 0 3 mm 0 012 in Inspect the clutch outer for damage x If there is any damaged part replace it e Measure the clutch outer inside diameter A x If the clutch outer is worn over the service limit replace it Clutch Outer Inside Diameter Standard 152 1 152 2 mm 5 9
217. r before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Rear Caliper Installation e Install the caliper and brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Apply non parmanent locking agent to the rear caliper mounting bolts Tighten Torque Brake Caliper Mounting Bolts 26 N m 2 7 kgf m 19 ft lb Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft lb Replenish the fresh brake fluid Check the fluid level 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 e Adjust the parking brake see Parking Brake Cable Ad justment in the Periodic Maintenance chapter A WARNING After servicing it takes several applications of the brake lever before the brake pads contact the disc which could result in increased stopping distance and cause an accident resulting in injury or death Do not attempt to ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc Calipers BRAKES 13 21 Front Caliper Disassembly e Remove Caliper see Front Caliper Removal Pads see Front Brake Pad Removal
218. rake hose is removed see Front Caliper Disassembly Rear Caliper Removal Remove the left rear wheel see Wheel Removal in the Wheels Tires chapter Release the parking brake Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Loosen the parking brake adjusting locknut and turn out the bolt C several turns Clear the parking cable lower end E from the cable arm Unscrew the caliper mounting bolts F and detach the caliper G from the disc e Unscrew the banjo bolt and remove the brake hose H from the caliper Immediately wash away any brake fluid that spills NOTE Olf 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 Rear Caliper Disassembly 13 20 BRAKES Calipers Front Caliper Installation Install the caliper and brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Tighten Torque Brake Caliper Mounting Bolts 26 N m 2 7 kgf m 19 ft lb Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib Replenish the fresh brake fluid Check the fluid level 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 A WARNING After servicing it takes several applications of the brake leve
219. rate 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 DOT4 Recommended Disc Brake Fluid Grade DOT 4 Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter BRAKES 13 9 Fluid Brake Line Air Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Air in the
220. re 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 FEDERAL LAW THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 10 000 PER VIOLATION PLEASE DO TAMPER WITH NOISE CONTROL SYSTEM US Model Only TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED Federal regulations and California State law prohibit the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Do not tamper with the original emission related parts e Carburetor or internal parts Spark plug Ignition system Air cleaner element TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperativ
221. re on the rim e Support the wheel rim A on a suitable stand B to pre vent the tire from slipping off e Inflate the tire until the tire beads seat on the rim Maximum Tire Air Pressure to seat beads when cold Front and Rear 250 kPa 2 5 kgf cm 36 psi A WARNING Overinflating a tire can cause it to explode causing serious injury or death Be sure to install the valve core whenever inflating the tire and do not inflate the tire to more than maximum pressure Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B x If the rim lines and the rim flanges are not parallel deflate the tire lubricate the sealing surfaces again and reinflate the tire e After the beads are properly seated check for air leaks a soap and water solution around the tire bead and check for bubbles e Deflate the tire to the specified pressure Check the tire pressure using an air pressure gauge NOTE OKawasaki provides the air pressure gauge with the owner s tool kit Tire Air Pressure when cold Front 32 kPa 0 33 kgf cm 4 6 psi Rear 24 kPa 0 24 kgf cm 3 5 psi e Install the air valve cap e Install the wheel see Wheel Installation e Wipe off the soap and water solution on the tire and dry the tire before operation A WARNING Water or soap solution on the tire bead can cause tire separation and an accident resulting in serious injury or de
222. rea replace the air suction valve as an assembly x If any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly clean with a high flash point solvent Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly Clean Air System ENGINE TOP END 5 9 Vacuum Switch Valve Removal Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Clamps A and Hoses B Vacuum Switch Valve C Vacuum Switch Valve Installation Installation is the reverse of removal Note the following ORun the hoses correctly see Cable Wire and Hose Rout ing section in the Appendix chapter Clean Air System Hose Inspection Be certain that all the hoses are routed without being flat tened or kinked and are connected correctly to the torque converter intake duct carburetor holder vacuum switch valve and air suction valve cover xIf they are not correct them Replace them if they are damaged 5 10 END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Air Suction Valve see Air Suction Valve Removal Clean Air System Pipe Mounting Bolt A and Nuts B Clean Air System Pipe C Remove the clamp A and breather hose B Remove the cylinder head cover bolt
223. rement NOTE OUse the battery which is fully charged Warm up the engine thoroughly and stop the engine Remove the spark plug see Spark Plug Removal in the Electrical System chapter e 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 M12 x 1 25 57001 1183 e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Cylinder Compression Usable Range 1190 1900 kPa 12 1 19 4 kgf cm 173 276 psi at 400 500 r min rpm The following table should be consulted if the obtainable compression reading is not within the us able range Problem Remedy Action Cylinder Carbon accumulation on piston Remove the carbon deposits and replace compression cylinder head and in combustion damaged parts if necessary is higher than chamber possibly due to damaged usable range valve stem oil seal and or damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket Replace the gasket with a standard part thickness Cylinder Gas leakage around cylinder head Replace damaged gasket and check compression is cylinder head warp lower than usable Bad condition of valve seating Repair if necessary enge Incorrect valve clearance Adjust the valve clearance
224. rn out the diodes in the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damaging electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OBecause 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 OOnly use an illumination bulb rated for the voltage or wattage specified in the wiring diagram or the handle cover could be warped by excessive heat radiated from the bulb OTake care not to short the cables that are directly con nected to the battery positive terminal to chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc De fective leads and bad connections will affect electrical system o
225. rod GE16008BS1 GE16012781 5 26 END Carburetor Holder Carburetor Holder Removal e Remove Carburetor see Carburetor Removal in the Fuel System chapter Clamp A and Hose B Carburetor Holder Nuts C Carburetor Holder D Carburetor Holder Installation Replace the O ring with a new one e Apply engine oil to the new O ring and install it Install the carburetor holder and nuts Tighten Torque Carburetor Holder Nuts 9 8 N m 1 0 kgf m 87 in Ib Exhaust System ENGINE TOP END 5 27 This vehicle is equipped with a spark arrester approved for off road use by the United States Forest Service It must be properly maintained to ensure its efficiency In accor 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 Removal e Remove Left Side Cover see Left Side Cover Removal in the Frame chapter Exhaust Pipe Cover Mounting Bolts A Exhaust Pipe Cover B e Remove Muffler Body Clamp Bolt A Loosen Muffler Body Mounting Bolt B Muffler Body Mounting Nut C Muffler Body D Muffler Installation Installation is the reverse of removal Note the following OReplace the muffler body gasket with a new one OTighten Torque Muffler Body Mounting Bolt 20 N m 2 0 kgf m 15 ft Ib Muffler Body Mounting Nut 20
226. rottle Case Removal e Remove Throttle Cable Upper End see Throttle Cable Removal Screws A Throttle Case Clamp B Throttle Case Assembly C Throttle Case Installation Installation is the reverse of removal Note the following OSet the throttle case to match its mating surface A to the punch mark B of the handlebar Throttle Case Inspection With the throttle cable disconnected from the throttle lever A the lever should move freely and return smoothly by spring x If the lever is heavy clean and lubricate the throttle case Examine the lever and case for cracks Replace the case assembly if it is cracked Lever Cable FUEL SYSTEM 3 9 Choke Lever Removal Remove the choke lever mounting screw A and take off the plane washer and the wave washer Remove the choke lever B and free the choke cable up per end from the lever Remove the retaining ring A and free the choke cable B from the switch case Choke Lever Installation e Lubricate the choke cable before installation e Install the wave washer plane washer and screw in that order Run the choke cable according to Cable Wire and Hose Routing section in the Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to make sure to correct any of these conditions
227. rrect any of these conditions Check idle speed with a suitable tachometer x lf the idle speed is out of the specified range adjust it Idle Speed Standard 1 500 100 r min rpm PERIODIC 2 13 Maintenance Procedures Idle Speed Adjustment Start the engine and warm it up thoroughly e Turn the adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or muddy terrains the element should be cleaned immediately OAlso if there is a break in the element material or other damage to the element replace the element with a new one A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element e Remove the air cleaner elements see Air Cleaner Ele ment Removal in the Fuel System chapter Clean the elements A in a bath of high flash point sol vent Squeeze it dry in a clean towel A Do not wring the ele
228. s C and the cylinder head cover D Cylinder Head Cover Installation Replace the head cover O ring A with a new one Install the head cover Tighten Torque Cylinder Head Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Install the clean air system pipe e Tighten Torque Clean Air System Pipe Mounting Nuts 9 8 N m 1 0 kgf m 87 in Ib Clean Air System Pipe Mounting Bolt 9 8 N m 1 0 kgf m 87 in Ib e Install the removed parts see appropriate chapters Camshaft Chain Tensioner ENGINE TOP END 5 11 Camshaft Chain Tensioner Removal NOTICE This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves Remove Thermostat Housing see Thermostat Removal in the Cooling System chapter Cap Bolt A and O ring Mounting Bolts B Chain Tensioner C Camshaft Chain Tensioner Installation Remove the tensioner cap bolt and O ring
229. s flush C with the sleeve end e Install the movable driven sheave onto the fixed driven sheave Apply grease to the guide rollers A and guide roller pins B and insert them into the holes C in the fixed driven sheave Install the seal collar e Wipe off any excessive grease NOTE OBe sure to clean the fixed driven sheave off any grease Install the spring and spring seat Align the flat surface A of the clutch drive plate B with the flat surface C of the fixed driven sheave D 61134658 5 6 16 CONVERTER SYSTEM Clutch Driven Pulley NOTE OBe sure to use a clutch spring compressor to avoid spring damage Set the holes of the clutch driven pulley assembly A to the pins of the clutch spring compressor B Hold the clutch driven pulley assembly with the clutch spring compressor securely Special Tool Clutch Spring Compressor 57001 Y006 Set the clutch spring compressor in a vise Tighten the clutch driven plate nut C temporarily e Using the hex nut wrench 39 mm 57001 Y006 A tighten the clutch driven plate nut to the specified torque Special Tool Clutch Spring Compressor 57001 Y006 Torque Clutch Driven Plate Nut 54 N m 5 5 kgf m 40 ft Ib Loosen the clutch spring compressor and remove the clutch driven pulley assembly Clutch Driven Pulley Installation e Install the drive belt and clutch driven pulley e Install the clutch oute
230. s not pressed for about 10 seconds In the HOUR MINUTE setting mode press the Right but ton again to effect the HOUR setting mode OThe hour display blinks on the display e Press the Right button to set the hour the HOUR setting mode press the Left button to effect the MINUTE setting mode OThe minute display blinks on the display e Press the Right button to set the minute Meter ELECTRICAL SYSTEM 17 53 e In the HOUR MINUTE setting mode press the Left and Right buttons for more than 2 seconds to return to com plete the time setting process Check that the display changes to the mile and km display A each time by pushing the Left button B is pushed for more than 2 seconds NOTE OMile km display can alternate between mile and km modes in the digital meter Make sure that km or mile according to local regulations is correctly displayed before riding x If the display function does not work and adjust replace the meter unit Set the TRIP meter mode A in the display e Push the Left and Right buttons B for more than two seconds and check that each TRIP meter resets to 0 0 x If the display function does not change replace the meter unit NOTE OThe integrated value of the odometer cannot be reset Meter Indicator Light Inspection Green Neutral Indicator Light LED Check Turn the ignition switch to ON Set the shift lever in the neutral position OThe green neu
231. screw A fully e Remove Radiator Hose B Water Pump Cover Bolts C Water Pump Cover D Water Pump Cover Installation Install Knock Pins A New Gasket B Tighten Torque Water Pump Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Water Pump Impeller Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Water Pump Cover see Water Pump Cover Removal e Loosen the water pump impeller A and washer NOTE OThe water pump impeller has left hand threads Turn the impeller clockwise and remove it Water Pump Impeller Installation e Apply a small amount of coolant on the sliding surface A of the mechanical seal and the sealing seat e Install the washer B e Install the impeller on the water pump shaft and tighten the impeller counterclockwise Torque Water Pump Impeller 12 1 2 kgf m 106 in Ib 4 8 COOLING SYSTEM Water Pump Water Pump Impeller Inspection e Visually inspect the impeller A x If the surface is corroded or the blades are damaged re place the impeller Water Pump Leakage Inspection e Check the drainage outlet passage A at the bottom of the water pump body for coolant leakage x 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 I
232. se Light gensar Fuse Box Ignition Switch Switeh 5 Bor EE 9 5 oz 3 Gear Position Switch we TOKE BL R 6 8 G BL G W Y w BL W W R W BK Headlight BL BL BK Left G 12V35W 35 BR BK City Light 8 Left BR 12V5W Left Handlebar 1 Engine 2 Light Dimmer 3 Reverse Power Switch Overri 4 Starter Stop Switch BR BL BK W BL BR BK W G R BL R BK W Y R Switches Switch Assist Button LEFT SWITCH HOUSING CONNECTIONS BR BL G Y R BR BL BL n x2 mm Power Outlet Connector Rear Brake Radiat Lever Radiator 2 Light Switch Fan Switch IGNITION SWITCH CONNECTIONS Reverse Power Assist Switch Starter Button Engine Stop Switch u oe jepre Light Dimmer Switch 18 BATI 2 0 Free D Free a Push Push Color 6 6 Color Color BR BL Color W BL HP05019BW5 C ELECTRICAL SYSTEM 17 13 Wiring Diagram Starter Relay Rear Starter Brake Circuit Pedal mel Clutch Relay Light ews Diode Switch Sensor amp BR BL G Y Y w KE Starter Motor gt 6 G Y G 6 us e 977 o gt mo SA SS
233. see Front Brake Disc Guard Removal in the Brakes chapter Remove the cotter pin A Loosen the tie rod end nut Do not loosen the locknuts at the ends of the tie rod or the toe in of the front wheels will be changed Remove the tie rod end joint A from the steering knuckle using a suitable joint remover B Remove the tie rod end nut C 15 8 STEERING Steering Remove Cotter Pins Suspension Arm Joint e Remove the suspension arm joint A from the steering knuckle using a suitable joint remover B Steering Knuckle Installation Inspect the spherical bearings in the suspension arm joints A If roughness excessive play or seizure is found replace the suspension arm Check the joint boot A is not torn worn deteriorated is leaking grease x If it is found replace the suspension arm e Using a cleaning fluid clean off any oil or dirt on the shanks B of the knuckle joint and dry it with a clean cloth Using a cleaning fluid clean off any oil or dirt on the taper surfaces A in the steering knuckle B and dry it with a clean cloth STEERING 15 9 Steering e Install Washers A and Suspension Arm Joint Nuts B Washer A and Tie rod End Nut C Tighten Torque Suspension Arm Joint Nuts 34 3 5 kgf m 25 ft Ib Tie rod End Nuts 35 N m 3 6 kgf m 26 ft Ib Replace the cotter pins D with n
234. sert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degrees OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B HJ07007BS1 C GJ04109BS1 C 14 12 SUSPENSION Suspension Arms Suspension Arm Disassembly e Remove Suspension Arms A see Suspension Arm Removal Collars B Seals C e Using a press remove the bearings D Suspension Arm Assembly e Using a press install the new bearing A until it stops at the bottom of suspension arm housing B Replace the seals with new ones Install the seal until it stops at the bottom of suspen sion arm housing align the surface of the seal D with the outside of the suspension arm surface Install the collars E HM05042B 5 HM05041BS1 Swingarm SUSPENSION 14 13 Swingarm Removal Support the vehicle on a stand a jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 e Remove Footboards see Left and Right Footboard Removal in the Frame chapter Rear Hubs see Rear Hub Removal in the Wheels Tires chapter Rear Disc Hub see Rear Disc Removal in the Brake chapter Rear Shock Absorber Mounting Lower Bolt A and Nut
235. several locations Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 in x If the cylinder head is warped more than the service limit replace it x 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 20 END Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal Remove the cylinder head see Cylinder Head Removal OMark and record the valve location so it can be installed in the original position e Using the valve spring compressor assembly A and adapter B remove the valve Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 22 57001 1202 Valve Installation e Replace the valve stem oil seal xlf a new valve is to be used check the valve to guide clearance see Valve to Guide Clearance Measurement x If there is too little clearance replace the cylinder head x If there is too much clearance replace the cylinder head e Apply engine oil to the valve stem and install the valve and spring seat e Install the springs so that the closed coil end of each spring faces downwards Valve Stem A Oil Seal B Spring Seat
236. sion Cylinder Head Warp Valve Valve Clearance Exhaust Intake Valve Valve Guide Clearance Exhaust Intake Valve Spring Free Length Outer Inner Usable Range 1 190 1 900 kPa 12 1 19 4 kgf cm 173 276 psi at 400 500 r min rpm 0 08 0 12 mm 0 0032 0 0048 in 0 08 0 12 mm 0 0032 0 0048 in 0 025 0 052 mm 0 0010 0 0020 in 0 01 0 037 mm 0 0004 0 0015 in 41 mm 1 614 in 30 9 mm 1 217 in 0 05 mm 0 002 in 0 08 mm 0 0031 in 0 06 mm 0 0024 in 39 mm 1 535 in 29 4 mm 1 157 in Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Top Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Piston Pin Clearance Connecting Rod Small End Inside Diameter Connecting Rod Piston Pin Clearance 72 705 72 715 mm 2 8624 2 8628 in 72 67 72 69 mm 2 8610 2 8618 in 0 025 0 055 mm 0 0010 0 0022 in 0 015 0 055 mm 0 0006 0 0022 in 0 015 0 055 mm 0 0006 0 0022 in 0 15 0 3 mm 0 0059 0 012 in 0 3 0 45 mm 0 012 0 0177 in 0 2 0 7 mm 0 008 0 028 in 16 994 17 mm 0 6691 0 67 in 17 002 17 008 mm 0 6694 0 6696 in 0 002 0 014 mm 0 00008 0 00055 in 17 016 17 034 mm 0 6699 0 6706 in 72 8 mm 2 866 in 72 6 mm 2 858 in 0 09 mm 0 0035 in 0 09 mm 0
237. sity SAE 90 Capacity 0 6 L 0 63 US qt Rear Final Gear Case Oil Viscosity SAE 80 Capacity 0 15 L 0 16 US qt Frame Type Double tubelar Caster Rake Angle 3 5 Camber 1 0 King Pin Angle 12 Trail 16 mm 0 63 in Tread Front 850 mm 33 5 in Rear 830 mm 32 7 in Rim Size Front 10 x 5 5AT Rear 10 x 8 0AT Front Tire Type Tubeless Size AT22 x 7 10 General Specifications GENERAL INFORMATION 1 11 KVF300CC Rear Tire Type Size Suspension Front Type Wheel Travel Rear Type Wheel Travel Brake Front Rear Parking Brake Electrical Equipment Battery Headlight Type Bulb Tail Brake Light Bulb Alternator Type Rated Output Tubeless AT22 x 10 10 Double Wishbone 131 mm 5 16 in Swingarm 141 mm 5 55 in Disc x 2 Disc Disc Mechanical 12 V 10 Ah Semi sealed beam 12 V 35 35 W x 2 12V 5 24 W x 2 Three phase AC 14 A 14 V 5 000 r min rpm Specifications subject to change without notice and may not apply to every country 1 12 GENERAL Unit Conversion Table Prefixes for Units Units of Length km x 0 6214 mile Prefix Symbol Power m x 3 281 ft mega M x 1000 000 mm x 0 03937 in kilo k x 1000 centi C x 0 01 milli m x 0 001 Units of Torque micro u 0 000001 0 1020 kgf m 0 7376 ft Ib N m x 8 851 in Ib kgf m x 9 807 N m kgf m x 7 233 ft Ib nits Or Mass
238. spring Clean the oil screen with a high flash point solvent and remove any particles stuck A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the screen in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the screen Check the screen A carefully for any damage holes broken wires gasket pulling off x If the screen is damaged replace it Replace the O ring A with a new one Install the oil screen together with the spring OThe smaller diameter on the spring faces downward Tighten Torque Engine Oil Screen Plug 15 1 5 kgf m 11 ft Ib Crankshaft Transmission Transmission Oil Level Inspection e Park the vehicle so that it is level both side to side and front to rear e Remove Right Footboard see Right Footboard Removal in the Frame chapter Transmission Oil Level Inspection Bolt A NOTICE Be careful not to allow any dirt or foreign materials to enter the gear case PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Check the oil level The oil level should come to the bot tom A of the inspection bolt opening B x If it is insufficient first check the transmission case for oil leakage remedy it if necessary and
239. ssemble the driven shaft as shown fi 1 Driven Shaft 2 Washer 20 x 33 x 1 0 3 Reverse Gear 4 Washer 20 x 33 x 3 0 5 Shifter 6 Circlip 7 Toothed Washer 8 Low Gear 9 Washer 25 x 40 x 1 0 e Install the parts in the driven shaft A as follow e Install Low Gear B Toothed Washer C Replace the circlip with a new Special Tool Outside Circlip Pliers 57001 144 CRANKSHAFT TRANSMISSION 10 19 Transmission Install Shifter A Washer 20 x 33 x 3 0 B Install Reverse Gear A Washer 620 x 33 1 0 B Assemble the drive shaft as shown IS E zc Drive Shaft Washer 22 x 33 x 1 0 Washer 25 x 37 x 3 0 High Gear Toothed Washer t 2 0 Circlip Shifter Washer 617 x 26 x 1 0 10 20 CRANKSHAFT TRANSMISSION Transmission Install the parts in the drive shaft A as follow Install Washer 25 37 3 0 B High Gear C Toothed Washer D Replace the circlip E with a new Special Tool Outside Circlip Pliers 57001 144 e Install Shifter A Washer 617 x 26 x 1 0 B Washer 22 x 33 x 1 0 C e Assemble the drive shaft A and driven shaft B e Install the drive shaft and driven shaft assemblies A as a set into the transmission case e Install the shift fork A and shift
240. t Bearing Inspection pp 15 11 Steering Shaft Bearing Removal 1 1 11141 15 11 Steering Shaft Bearing Installatiom ne 15 12 Tie rod End nennen nne rennen rr nnne 15 12 Handlebar cotta me ue teint 15 13 rs cos ELE 15 13 Handlebar Installation emm nmn nnne 15 13 15 2 STEERING Exploded View HN020308W5 C STEERING 15 3 Exploded View pmo Faster ees katm mie Handiebar Holder Bots 26 27 5 2 Handiebar Holder 40 29 3 Steering Shaft Holder Bots 26 27 19 4 emd amp dNus 25 28 6 Steering Shaft Bottom Enant 70 s rR 7 Suspension Arm Joint Nuts 38 25 8 Front G Apply grease Lh Left hand Threads R Replacement Parts S Follow the specific tightening sequence 15 4 STEERING Specifications Standard Service Limit Tie rods Tie rod Length 334 0 335 0 mm 13 15 13 19 in STEERING 15 5 Special Tools Inside Pliers Bearing Driver Set 57001 143 57001 1129 7570143ST C 7571129ST C 15 6 STEERING Steering Steering Shaft Removal e Remove Front Fender
241. t Boots Inspection Tie rod End Boots Inspection e Visually inspect the tie rod end boots A of the tie rods lf the boot is torn worn deteriorated or leaks grease replace the tie rod end see Tie Rod End Removal in the Steering chapter 9 0 0 0 9 0 9 0 9 N lt gt oS eee ese ean KK III KK witli 8 10010851 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Propeller Shaft Joint Boots Inspection e Visually inspect the boots A of the propeller shaft x If the joint boot is torn worn or deteriorated replace the joint boot and check the propeller shaft see Propeller Shaft section in the Final Drive chapter General Lubrication Lubrication Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure spray water perform the general lubri cation Cables Lubricate with Cable Lubricant Parking Brake Inner Cable Throttle Inner Cable Choke Inner Cable Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant P 6004011481 C 2 38
242. t locking agent Lh Left hand Threads R Replacement Parts S Follow the specific tightening sequence SS Apply silicone sealant Liquid Gasket TB1211 56019 120 St Stake the fasteners to prevent loosening Fastener Torque Remarks kgf m ft Ib Fuel System Fuel Tank Bolts and Nuts 1 2 Cooling System Radiator Mounting Bolts 106 in Ib Radiator Fan Switch 16 Thermostat Housing Mounting Bolt 87 in lb Water Pump Cover Bolts 87 in lb Water Impeller 106 in Ib Water Temperature Sensor 11 Engine Top End Air Suction Valve Cover Bolts 9 8 1 0 87 in lb Camshaft Cap Nuts 25 2 5 18 Camshaft Chain Tensioner Bolt 4 2 0 43 37 in Ib Camshaft Chain Tensioner Mounting Bolts 12 1 2 106 in Ib Carburetor Holder Nuts 9 8 1 0 87 in lb Clean Air System Pipe Mounting Bolt 9 8 1 0 87 in Ib Clean Air System Pipe Mounting Nuts 9 8 1 0 87 in lb Cylinder Head Bolts 9 8 1 0 87 Cylinder Head Cover Bolts 9 8 1 0 87 Cylinder Head Stud Bolts 9 0 0 92 80 in Ib Exhaust Pipe Cover Mounting Bolts 11 1 1 97 in Ib Muffler Body Mounting Bolt 20 2 0 15 Muffler Body Mounting Nut 20 2 0 15 Plug 21 2 1 15 Rear Camshaft Chain Guide Bolt 9 8 1 0 87 in lb Spark Arrester Mounting Bolt 11 1 1 97 in Ib Stud Bolts for Cylinder Cylinder Head 9 0 0 92 80 in Ib Valve Adjusting Screw Locknuts 8 8 0 90 78 in Ib EO Converter System Clutch Driven Plate Nut 54 5 5 40 Drive Pulley Nut 93 9 5 69 EO Driven Pulley Nut 54 5 5 40 Driven Shaft
243. tall the spark arrester A Tighten Torque Spark Arrester Mounting Bolt B 11 N m 1 1 kgf m 97 in lb Exhaust Pipe and Muffler Inspection Check for signs of leakage at the exhaust pipe gasket in the cylinder head x If there are signs of leakage around the exhaust pipe gas ket it should be replaced Check the exhaust pipe and muffler for dents cracks rust and holes If the exhaust pipe or muffler is damaged it should be replaced for best performance and least noise Converter System Converter Drive Belt Wear Inspection A WARNING Neglect abuse or failure to maintain the transmis sion can result in 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 Maintain ac cording to periodic maintenance chart e Remove the torque converter cover see Torque Con verter Cover Removal in the Converter System chapter e 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 23 6 24 4 mm 0 929 0 961 in Service Limit 22 mm 0 87 in HUO8004BS1 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Check the belt for cracks breaks or peeling x If necessary replace the belt with a new Be
244. tallaliQlt ue tere deter gene eer Latin o me eee ont 17 42 Headlight Bulb and City Light Bulb 17 42 Tail Brake Light Bulb 141 24 7 7 1 441414 17 44 Tall Brake sight Removal 17 45 Tail Brake Light Installation e eed er Pte ep tet 17 45 Tau Light Bulb Replacements re een 17 45 Radiator e eire een nannten ae 17 48 Radiator Fan Circuit 17 48 Radiator Fan Motor Inspectigom eee nnn 17 48 gU NELUTEIIOQ C 17 49 Fuel Level Sensor 17 49 Fuel Level Sensor Installation sss 17 49 Fuel Level Sensor 17 49 EE E A E AA T A 17 51 Meter Unit 17 51 Meter Operation 17 52 Meter Indicator Light ER 17 53 SWITCHES ANd Sensor rnit en le XX ERE Xa 17 56 Rear Brake Pedal Light Timing Adjustment usen 17 56 Water Temperature Sensor Inspection 21 1 0 7 00000 99 17 56 Radiator Fan Switch Inspection pp 17 57 Gear Position Switc
245. tching the pressure gauge slowly pump the pressure tester to build up the pressure The relief valve opens indicated by the gauge hand flicks downward OThe 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 seconds Radiator Cap Relief Pressure Standard About 108 kPa 1 1 kgf cm 16 psi x If the cap cannot hold the specified pressure or if it holds too much pressure replace it with a new one 6007010451 C GD07001BS1 C 4 14 COOLING SYSTEM Thermostat Thermostat Removal e Drain the coolant see Coolant Change in the Periodic Maintenance chapter e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Water Temperature Sensor Connectors A Hose Clamps B Air Vent Hose C Radiator Hose D Thermostat Housing Bolt E e Remove Thermostat Housing Cover Screws A Thermostat Housing Cover B Thermostat Thermostat Installation e Install the thermostat Tighten the thermostat housing cover screws securely Replace the O ring A with a new one Install the O ring on the housing Apply grease to the O ring Tighten the thermostat housing bolt Fill the coolant see Coolant Change in the Periodic Main tenance chapter Thermostat Inspection Remove the thermostat and inspect the thermostat valve A at room temperature x If the valve is open replac
246. tems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices A DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury NOTICE is used to address practices not related to personal injury This manual contains four more symbols which will help you distinguish different types of information NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x 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
247. tester measure the internal resistance of the switch across the terminals at the temperatures shown the table Special Tool Hand Tester 57001 1394 x If the hand tester does not show the specified values re place the switch HP14012BS2 C Radiator Fan Switch Resistance ORising Temperature From OFF to ON at over than 85 90 C 185 194 F OFalling Temperature From ON to OFF at less than 85 90 C 185 194 F ON about 0 OFF Install Radiator Fan Switch see Radiator Fan Switch Installa tion in the Cooling System chapter Gear Position Switch Removal e Remove Right Side Cover see Right Side Cover Removal in the Frame chapter Drive Belt see Drive Belt Removal in the Converter Sys tem chapter e Disconnect the gear position switch lead connectors A A 74 5784 17 58 ELECTRICAL SYSTEM Switches and Sensor Remove Lead Holder Mounting Bolt A Lead Holder B Gear Position Switch Bolt C Gear Position Switch D Gear Position Switch Installation e Apply grease to the O ring A on the gear position switch e Install the gear position switch so that the fits the groove D on the shift drum Tighten Torque Gear Position Switch Mounting Bolt 9 8 N m 1 0 kgf m 87 in Ib e Tighten the lead holder mounting bolt securely Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition
248. th a copper hammer C and then remove the ring gear Rear Axle Installation e Apply molybdenum disulfide grease to the center spline A of the rear axle Press the ring gear A into the rear axle B so that its surface is flush with the end C of rear axle center spline FINAL DRIVE 12 9 Rear Axle e Install the ring gear and rear axle A and shims to the final gear case e Install the final gear case cover B Tighten Torque Final Gear Case Bolts 8 C 26 N m 2 7 kgf m 19 ft Ib Apply a non permanent locking agent to the final gear case bolts M10 D Tighten Torque Final Gear Case Bolts M10 39 N m 4 0 kgf m 29 ft lb e Install the boot E e Install the removed parts see appropriate chapters Rear Axle Runout Inspection e Remove the rear axle see Rear Axle Removal e Visually inspect the rear axle A for damage xIf the rear axle is damaged or bent replace it e Set the rear axle in an alignment jig or on V blocks B and place a dial gauge C against the middle point e Turn the rear axle slowly The difference between the highest and lowest dial gauge readings is the axle runout TIR xIf the runout exceeds the service limit replace the rear axle Rear Axle Shaft Runout Service Limit TIR 3 mm 0 12 in 12 10 FINAL DRIVE Final Gear Case Final Gear Case Level Inspection e Refer to the Final Gear Oil Level Inspection in the Periodic Maintenan
249. th the top of the mating surface D of the steering holder 15 14 STEERING Handlebar Install the bracket Tighten the holder front bolts B first and then the rear bolts C Torque Handlebar Holder Bolts 26 N m 2 7 kgf m 19 ft Ib Olf the holder is correctly installed there will be no gap D at the front and an even gap E at the rear after tightening Install the left switch housing A OFit the projection B into a hole C in the handlebars Install the throttle case A e Align the punch mark B on the handlebar with the sur face C of throttle case e Install Front Master Cylinder see Front Master Cylinder Instal lation in the Brakes chapter Rear Master Cylinder Lever see Rear Master Cylinder Lever Installation in the Brakes chapter 16 1 Table of Contents et ir EE oeat Removals ge Seats alatom eric Front Carrier Removal eode Front Carrier Installation Nt Rear Garrier Removal tait ente Meise checa nada fite Rear Carrier Installation eeeseesseeseeeneee n ene nenne nnne Front Fender Removal
250. the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings Brake Hose Replacement Pump the brake fluid out of the line as explained in the Brake Fluid Change e Remove Front Fender see Front Fender Removal in the Frame chapter Slide the rubber cover A and remove the brake hose banjo bolts B at the handlebars Remove Brake Hose Banjo Bolts A Brake Hose Fitting Bolt B GL10020181 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures e Remove Brake Hose Clamp Bolt A Both Sides Brake Hose Banjo Bolt B Both Sides Brake Hose C Both Sides Remove Brake Hose Banjo Bolt A Brake Hoses B e Clear the brake hose from the clamps A Remove Brake Hose Banjo Bolt B Brake Hose C Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e Replace the new flat washers for each side of the hose fittings e Install the new brake hose in its place and tighten the banjo bolts OFit the projection of the brake hose end to the calipers and master cylinder and tighten the brake hose banjo bolts Torque Brake Hose Banjo Bolts 35 3 6 kgf m 26 ft lb e When installing the hoses avoid sharp bending ki
251. ting Nuts and Bolts B Engine Mounting Bracket Bolts C Both Sides Engine Mounting Brackets D Both Sides e Free the engine A from the propeller shaft and remove the engine as shown in the figure Engine Installation e Apply molybdenum disulfide grease the splines at the driven gear shaft and front end of the propeller shaft e Support the vehicle so that the rear wheels are off the ground e Fit the driven gear shaft to the propeller shaft while rotat ing one rear wheel slowly e Replace the engine mounting nuts with new ones e Install Engine Brackets A and Bolts B Both Sides Engine Mounting Bolts C and Nuts e Tighten Torque Engine Bracket Mounting Bolts 26 N m 2 7 kgf m 19 ft lb Engine Mounting Nuts 39 N m 4 0 kgf m 29 ft Ib e Slide the boot on the swingarm securely and tighten the clamp screw e Run the hoses cables and leads correctly see Cable Wire and Hose Routing section in the Appendix chapter Install the removed parts see appropriate chapters CRANKSHAFT TRANSMISSION 10 1 Crankshaft Transmission Table of Contents Exploded LEM 10 2 LEE 10 6 T OE 10 7 Ce 10 8 Grankcase DISSssetnply 10 8 Grankease Assembly ide e 10 9 Cranks
252. tions Standard Service Limit Rear Axle Shaft Rear Axle Shaft Runout 3 mm 0 12 Bevel Gear Final 0 05 0 25 0 0020 0 0098 at ring gear tooth 0 4 mm 0 016 in Final Gear Case Oil Viscosity Capacity SAE 80 0 15 L 0 16 US qt Special Tools Inside Circlip Pliers 57001 143 7570143ST C Oil Seal amp Bearing Remover 57001 1058 7571058ST C Bearing Driver Set 57001 1129 7571129ST C FINAL DRIVE 12 5 Jack 57001 1238 7571238ST C Pinion Bearing Lock Nut Wrench 52 5 mm 57001 Y019 ST57YO19ST Pinion Puller Set 57001 Y020 8757 0205 12 6 FINAL DRIVE Propeller Shaft Propeller Shaft Removal e Support the vehicle on a stand or the jack so that the rear wheels are off the ground Special Tool Jack 57001 1238 Remove Swingarm Assembly see Swingarm Removal in the Suspension chapter Support the final gear case on a stand or jack Remove Universal Joint A Propeller Shaft B Spring C Propeller Shaft Installation e Wipe the old grease off the end splines A of the propeller shaft and the universal joint B Apply molybdenum disulfide grease in those Install the spring A to the rear end of propeller shaft Install the universal joint to the front end of propeller shaft Set the prope
253. to ride the vehicle until a firm brake lever is obtained by pumping the lever until the pads are against the disc BRAKES 13 15 Master Cylinder Rear Master Cylinder Pedal Removal e Remove Right Footboard see Right Footboard Removal in the Frame chapter Bolts A Reserve Tank Cover B Remove the cotter pin A Pull off the joint pin with washer NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the brake hose banjo bolt C e Unscrew the master cylinder mounting bolts D and re move the master cylinder E e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Rear Master Cylinder Pedal Installation Replace the cotter pin with a new one Replace the washers on each side of hose fitting with new ones Tighten the following Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib Rear Master Cylinder Mounting Bolts 12 N m 1 2 kgf m 106 in lb Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid leakage e Install the removed parts See appropriate chapters Front Master Cylinder Disassembly e Push the front brake light switch hook in the hole A by the screwdriver B and pull out the front brake light switch C 13 16 BRAKES Master Cylinder
254. to the plastic hose 1 Pump the rear brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed valve of rear caliper while holding the brake applied 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding e Remove the clear plastic hose e Install the rear brake lever diaphragm and reservoir cap Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 6 0 N m 0 61 kgf m 53 in Ib Check the fluid level in the rear brake lever reservoirs see Brake Fluid Level Inspection in the Periodic Mainte nance chapter e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage Rear Brake Pedal Remove the reserve tank cover bolt A and reserve tank cover B Remove the rear brake pedal reservoir cap and di aphragm e Fill the reservoir with fresh brake fluid to the upper level line C Slowly pump the rear brake pedal several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom o
255. tral indicator light A goes on xIf the display function does not work check the gear po sition switch see Switch Inspection x If the gear position switch is normal check the wiring see Meter Circuit x If the wiring is good check the shift lever condition see Shift Lever Installation in the Crankshaft Transmission chapter x If the shift lever condition is good replace the meter unit 17 54 ELECTRICAL SYSTEM Meter Red Reverse Indicator Light LED Check e Turn the ignition switch to ON Set the shift lever in the reverse position OThe red reverse indicator light A goes on x If the display function does not work check the gear po sition switch see Switch Inspection If the gear position switch is normal check the wiring see Meter Circuit x If the wiring is good check the shift lever condition see Shift Lever Installation in the Crankshaft Transmission chapter x If the shift lever condition is good replace the meter unit Yellow Low Gear Indicator Light LED Check e Turn the ignition switch to ON e Set the shift lever in the low gear position OThe yellow low gear indicator light A goes on x If the display function does not work check the gear po sition switch see Switch Inspection x If the gear position switch is normal check the wiring see Meter Circuit x If the wiring is good check the shift lever condition see Shift Lever Installation in the Crankshaft Tr
256. tructed 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 Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble APPENDIX 18 21 Miscellaneous Throttle valve won t fully open Carburetor throttle valve doesn t slide smoothly Brake dragging Clutch slipping Overheating Engine oil level too high Engine oil viscosity too high Balancer mechanism malfunctioning Final gear case oil level too high Final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Igniter trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Final gear case overheating
257. ts Hole in Rocker Arms Install the following parts as shown in the figure Stop Plate A Rocker Arms B Rocker Shafts Rocker Arm and Shaft Inspection Inspect the area A on the rocker arm where the cam rubs x 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 screw where it contacts the valve stem x 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 Insert the rocker shaft into the arm measure the clear ance x If the clearance exceeds the service limit replace them as a set Rocker Arm Shaft Clearance Standard 0 034 0 09 mm 0 0013 0 0035 in Service Limit 0 1 mm 0 004 in 5 14 END Rocker Shafts Stop Plate Inspection e Inspect the stop plate spring A for damage x If the spring is damaged in any way replace the stop plate assembly Check that stop plate lever B moves smoothly and spect it for damage x If the lever is damaged any way replace the stop plate assembly END 5 15 Camshaft Camshaft Removal e Position the piston TDC see Valve Clearance Inspection in the Periodic Maintenance chapter e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Ca
258. tual alternator operating conditions Check that the ignition switch is turned to OFF and con nect a hand tester to the battery terminals Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off The readings should show nearly battery voltage when the engine speed is low and as the engine speed in creases the readings should also increase Regulator Rectifier Output Voltage Connections Tester Range Reading Tester to Tester to 25 V DC Battery Battery 13 5 15 5 V e Turn the ignition switch to OFF and disconnect the hand tester x If the regulator rectifier output voltage is between the val ues given in the table the charging system is working nor mally x 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 x 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 System ELECTRICAL SYSTEM 17 29 Alternator Inspection There are three types of alternator failures short open or loss in rotor magnetism A short or open in one of the coil wires w
259. ue Brake Disc Mounting Bolts 34 N m 3 5 kgf m 25 ft lb e After installing the discs check the disc runout Com pletely clean off any grease that has gotten on either side of the disc with a high flash point solvent Do not use one which will leave an oily residue Apply molybdenum disulfide grease to rear hub spline so the spline grove is filled with grease e Install the rear disc hub assembly A onto the rear axle Special Tool Hub Driver Set B 57001 1782 e Tighten the nut of special tool and install the disc hub assembly Install the removed parts see appropriate chapters 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 8 4 2 mm 0 15 0 17 in Service Limit 3 mm 0 12 in Disc Runout e Jack up the vehicle so that the wheels are off the ground e For front brake disc inspection 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 x If the runout exceeds the service limit replace the disc Disc Runout Service Limit TIR 0 3 mm 0 012 in Front Brake Disc Guard Removal Remove Front Brake Disc see Front Brake Disc Removal Bolts A Front Brake Disc Guard B 13 30 BRAKES Discs Front Brake Disc Guard Installation Install Front Brake Disc
260. val in the Frame chapter Radiator Screen Mounting Screws A Radiator Screen Mounting Bolts B Radiator Screen C Clean the radiator screen a bath of tap water and then dry it with compressed air or by shaking it Clean the radiator When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 20 in B from the radiator core Hold the steam gun perpendicular C not oblique D to the core surface Run the steam gun following the core fin direction Water Hoses and Connections Inspection OThe high pressure inside the water 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 or bulges are noticed e Check that the hoses are securely connected and clamps are tightened correctly HU05000BS1 HUOG006BS1 2 16 PERIODIC Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature Check the coolant level in the reserve tank with the vehi cle on the level ground Reserve Tank A F Full Mark Line B L Low Mark Line C x If the co
261. ve Pulley see Drive Pulley Removal in the Converter System chapter Clutch Driven Pulley see Clutch Driven Pulley Removal in the Converter System chapter Oil Pump see Oil Pump Removal in the Engine Lubri cation System chapter e Remove Output Drive Bevel Gear Cover Bolts A Output Drive Bevel Gear Cover B Speedometer Cable Holder C e Loosen the boot clamp screw A e Remove the boot B CRANKSHAFT TRANSMISSION 10 15 Transmission e Remove Output Drive Shaft Housing Bolts A Output Drive Shaft Housing B e Remove Speedometer Gear Shaft A Washer B e Flatten out the bended threaded portion A of the nut e While holding the clutch outer B with the flywheel amp pul ley holder C and remove the output drive bevel gear nut D Special Tool Flywheel amp Pulley Holder 57001 1605 e Remove Transmission Case Cover Bolts A Transmission Case Cover B Transmission Case Installation Install Transmission Case Cover Tighten Torque Transmission Case Cover Bolts 26 N m 2 7 kgf m 19 ft lb 10 16 CRANKSHAFT TRANSMISSION Transmission e Install the shim and output drive bevel gear Tighten the output drive bevel gear nut A while holding the clutch outer B with the flywheel amp pulley holder C Torque Output Drive Bevel Gear Nut 98 N m 10 kgf m 72 ft lb Bend a point of the nut e Install Washer Speedometer Gear Shaft
262. wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system x If the coolant gives off an abnormal smell check for cool ing system leak It may be caused by exhaust gas leaking into the cooling system Coolant Level Inspection Refer to the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Draining Refer to the Coolant Change in the Periodic Maintenance chapter Coolant Filling Refer to the Coolant Change in the Periodic Maintenance chapter Pressure Testing e Remove Middle Cover see Middle Cover Removal in the Frame chapter e Remove the radiator cap and install a cooling system pressure tester A on the radiator filler neck NOTE OWet the cap sealing surfaces with water or coolant to prevent pressure leakage Build up pressure in the system carefully until the pres sure reaches 105 kPa 1 07 kgf cm 15 psi NOTICE During pressure testing do not exceed the pres sure for which the system is designed The maxi mum pressure is 105 kPa 1 07 kgf cm 15 psi e Watch the gauge for at least 6 seconds x If the pressure holds steady the system is alright x If the pressure drops soon check for leaks COOLING SYSTEM 4 7 Water Pump Water Pump Cover Removal Drain the coolant see Coolant Change the Periodic Maintenance chapter Loosen the clamp
263. y feel ing mushy when it is applied there might be air in the brake lines or the brake may be defective Do not operate the vehicle and service the brake sys tem immediately Rear Brake Remove the reservoir cap and the rubber cap on the bleed valve e Attach a clear plastic hose to the bleed valve on the rear caliper and run the other end of the hose into a container e Fill the reservoir with new brake fluid Change the brake fluid as follows the bleed valve A the rear brake lever and hold it B OClose the bleed valve C ORelease the brake lever D Check the fluid level in the reservoir often replenishing it as necessary NOTE Olf the fluid in the reservoir runs completely out any time during fluid changing air will enter the line and the sys tem must be bled 2 34 PERIODIC Maintenance Procedures eRepeatthis operation untilfresh brake fluid comes out into the plastic hose or the color of the fluid changes A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified e Apply the rear brake lever forc
264. y aligning the hole D in the cover with the dowel pin e Tighten the screw Torque Oil Pump Cover Screw 2 0 0 20 kgf m 18 in Ib e Install the oil pump shaft 8 10 LUBRICATION SYSTEM Oil Pump Fill the oil pump with engine oil e Install the oil pump assembly so that the arrow mark A faces upward Tighten the mounting bolts Torque Oil Pump Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib e Check that the oil pump shaft turn freely e Replace the circlip with a new one e Install Oil Pump Chain A and Oil Pump Gear B New Circlip C Special Tool Outside Circlip Pliers 57001 144 e Install the oil pump chain cover and tighten the cover bolts Torque Oil Pump Chain Cover Bolts 9 8 1 0 kgf m 87 in Ib Oil Pump Inspection e Remove the oil pump see Oil Pump Removal e Visually inspect the pump gear outer and inner rotor and pump cover x If there is any damage or uneven wear replace them OCheck the clearance A between the inner and outer rotor with a thickness gauge Measure the clearance between the high point of the inner rotor and the high point of the outer rotor x If the measurement exceed the service limit replace the rotors as a set Inner Rotor Outer Rotor Clearance Standard 0 05 0 15 mm 0 002 0 006 in Service Limit 0 15 mm 0 006 in or more OCheck the clearance A between the outer rotor and pump body with a thickness gauge x If

When inserting the cotter pin, if the slots in the nut do

Contents

Download Pdf Manuals

Related Search

Related Contents