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1. louie dedelase encase 17 7 17 2 APPENDIX Cable Wire and Hose Routing 1 Throttle Cables 2 Marked AAA cable is accelerator side 3 Band Hold the engine stop switch lead 4 Engine Stop Switch Lead 5 Hot Starter Cable 6B09849BW4 C 6 Clutch Cable 7 Clamp Run the clutch and hot starter ca ble 8 Clamp Run the throttle cables 9 Clamp Run the throttle cables Cable Wire and Hose Routing APPENDIX 17 3 10 11 GECKEGE CERN Clutch Cable Engine Stop Switch Lead Hot Starter Cable C D I Unit Clamps Run the clutch cable Main Harness Gear Position Switch Lead Flywheel Lead Clamp Run the gear position switch lead and flywheel lead Clamp Run the main harness gear posi tion switch lead and flywheel lead Ignition Coil 6B09850BW4 C Ground Lead Ignition Coil Ground Lead Clamp Hold the hot starter cable engine stop switch lead and main harness Clamp Run the hot starter cable and main harness Clamp Run the hot starter cable main harness and fuel hose Fuel Hose Throttle Cables Run the hot starter cable engine stop switch lead and main harness above the radiator hose 17 4 APPENDIX Cable Wire and Hose Routing GB0938518W4 C 1 Spark Plug Cap 6 Breather Hose 2 Clamp Run the carburetor vent hoses 7 Flywheel Lead 3 Clamp Run the gear position switch 8 Align the
2. 0 16 Piston Weal coussin oca 5 34 Camshaft Chain Removal 5 18 Piston Cylinder Clearance 5 34 Camshaft Chain Installation 0 18 Piston Ring Ring Groove Camshaft and Camshaft Cap Llearance 5 34 WV COP E 0 19 Piston Ring Groove Width 0 35 Camshaft Runout 0 19 Piston Ring Thickness 5 35 cam VV CAN nn tas pues 0 19 Piston Ring End Gap Cylinder Head 0 20 Measurement 5 35 Cylinder Compression Piston Piston Pin Connecting Measurement 5 20 Rod Wear Inspection 5 36 Cylinder Head Removal 9 21 Carburetor Holder 5 37 Cylinder Head Installation 0 22 Carburetor Holder Installation 5 37 Cylinder Head Cleaning 9 23 MUME eet 0 38 Cylinder Head Warp 0 23 Muffler Remowval 5 38 WE 5 24 Muffler Installation 5 38 Valve Clearance Inspection 0 24 Muffler Baffle Replacement 5 38 9 2 ENGINE TOP END Exploded View GE021938W5 C ENGINE TOP END 5 3 Exploded View mem es Dim pe O Nm mb Cylinder Head Cover Bolts 2 Cylinder Head Bolts M10 4 1 1 LA i M10 A 7 Carburetor Holder Clamp Screws Pg 22 16 Closed coil end faces down O Apply eng
3. 2 25 SIN estes diaria 2 58 Friction and Steel Plates Steering Inspection 2 58 InSpectlOD oie ce eine 2 25 Steering Adjustment 2 58 Engine Lubrication System 2 26 Stem Bearing Lubrication 2 60 Engine Oil Change 2 26 Frame ab dd das 2 60 Oil Filter Change 2 21 Frame Inspection 2 60 Breather Hose Inspection 2 21 Electrical System 2 61 2 2 PERIODIC MAINTENANCE Spark Plug Cleaning and Nut Bolt and Fastener Tightness INS DECHOM is sie ete eiae eR TUE 2 61 Jet et el tn DE IER Cable Inspection 2 61 Tightness Inspection L briCatlOH nava oie a 2 61 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition FREQUENCY Each Every Every Every 3 races 12 See race orl or7 5 Mieres races or Page OPERATION ERE be Ee pe clean el LL 129 ep l Clutch cable adjust Pe 225 Clutch and friction plates inspect T e 225 Throttle cable adjust wellt 2 12 pe Air cleaner element replace If damaged 2 14 Carburetor inspect and adjust 2 13 Engine Oil change 2 26 Piston and piston ring replace 2 23 Cyli inspect 2 22 2 23 2 27 e hel e do
4. T570144ST ST571557ST Clutch Holder 57001 1243 4 ST571243ST 6 8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use the clutch must be adjusted in accor dance with the Periodic Maintenance Chart A WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment Clutch Lever Free Play Inspection e Refer to the Clutch Lever Free Play Check in the Periodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Clutch Lever Installation e Install the clutch lever A so that it incline 20 5 B more than the horizontal line C and position it from the edge of the grip to 170 mm 6 69 in D Clutch Cable Removal e Turn in the adjuster fully A e Slide the dust cover A out of place e Screw the adjuster B at the clutch lever fully e Line up the slots C in the clutch lever and adjuster and then free the cable from the lever Clutch Lever and Cable e oosen the adjusting nuts A fully e Free the clutch inner cable tip B from the clutch release lever C CAUTION Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one e Pull the clutch cable out of the frame Clutch Cable Ins
5. e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B e Clamp the axle holder with a vise OProtect the axle holder with a rag when using a vise A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom and locknut Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING Be careful of reaction force in spring and fix surely so that special tool should not come off Do not place the fingers etc while serving e Insert the push rod A into the piston rod 2 52 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Replace the O ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O ring e Slowly turn the adjuster assembly A clockwise until re sistance is felt and check the clearance between the lock nut B and adjuster assembly to provide more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 0 kgf m 22 ft Ib e With the outer tube compressed by hands remove the top plug wrench
6. Kawasaki KX450F Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes Suspension Steering Electrical System sch sch NIO AIIIN O 0 No A AON A Appendix KX450F Kawasaki Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Division Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation
7. Support the crankcase bearing boss when the bear ing is pressed or the crankcase could be damaged CRANKSHAFT TRANSMISSION 9 9 Crankcase e Press the new transmission shaft bearing A in the left crankcase half so that the sealed side B faces outside of the engine Special Tool Bearing Driver Set 57001 1129 G104194BS1 e Press the new drive shaft bearing A in the right crankcase B half so that the stepped side C faces inside of the engine Special Tool Bearing Driver Set 57001 1129 G104195BS1 e Press the new crankshaft bearings A in the left and right crankcase half B so that the stepped side C faces in side of the engine Special Tool Bearing Driver Set 57001 1129 G104196BS1 e Press the shift drum needle bearing A and shift shaft needle B bearing in the left crankcase half so that bear ing surface flush with the crankcase surface C Special Tool Bearing driver Set 57001 1129 G104197BS1 e First press the inside release shaft needle bearing A until it bottom out with the bearing driver set B Special Tool Bearing driver Set 57001 1129 G104198BS1 9 10 CRANKSHAFT TRANSMISSION Crankcase e Next press the outside release shaft needle bearing A until the surface of the bearing is even with the crankcase surface B Special Tool Bearing driver Set 57001 1129 G104199BS1 e Replace the oil seals if removed e Press the output
8. WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first application of the lever if this is not done Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tool Jack 57001 1238 e Remove the clip A from the master link using pliers and free the drive chain B from the rear sprocket WHEELS TIRES 10 7 2 0 DY ESO Or PEN 6J04006B31 10 8 WHEELS TIRES Wheels Rims e Remove Cotter Pin A Axle Nut B e Pull out the axle C e Move the rear wheel back with the rear caliper installed e ake off the collar and cap from the each side of the rear hub CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wood wedge between the brake pads This pre vents them from being moved out of their proper position should the brake pedal be squeezed accidentally Rear Wheel Installation e Fit the brake holder stop A with the stop grooves B against the swingarm stop space C with the stop pro jection D e Fit the projection on the cap to the groove on the collar e Install the collars A on the left and right side of the hub OThe oollars are identical e Install the drive
9. The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft lb however when you use the top plug wrench special tool A reduce the torque to 9096 of the specified value 27 N m 2 8 kgf m 20 ft Ib due to the distance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 27 N m 2 8 kgf m 20 ft Ib is appli cable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point to the center of the coupling square Adjuster Assembly Inspection e Inspect the adjuster assembly A and push rod B for damage x If they are damaged replace them with new ones e Replace the gasket C and O ring D on the adjuster as sembly with new ones Base Valve Assembly Inspection e Inspect the threads portion A bushing B and spring C of base valve assembly D for damage x If they are damaged replace base valve assembly with new one e Replace the O rings E with new ones Cylinder Unit Inspection e Inspect the piston rod B of cylinder unit A for scratches or bending Alf it has scratches or is bent replace cylinder unit with a new one GM04254B31 Front Fork Inner Tube Inspection e Visually inspect the inner tube A repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal
10. 17 ft lb NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again x If the steering is too tight or too loose repeat the adjust ment as mentioned above 2 60 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the handlebar B on the handlebar holder so that the protruded scales of the both side adjust to the same width A e Apply 2 stroke oil to the threads of the handlebar clamp bolts e Install the handlebar clamp so that center D of the han dlebar clamp C and handlebar bridge E align Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Front F e After tighten make sure space A B of the ahead and back are same width e Install the handlebar pad and number plate Stem Bearing Lubrication e Remove the steering stem see Steering Stem Stem Bearing Removal in the Steering chapter e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the rollers Replace the bearing assemblies if they show wear or damage e Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e nstall the steering stem and adjust the steering see Steering Adju
11. C Clamps D Float Bowl E Leak Jet F O ring G Pin H Float I Main Jet J Needle Jet K Starter Jet L Pilot Jet M Pilot Air Jet e Pull out the push rod A of the acceleration pump 3 20 FUEL SYSTEM Carburetor e Unscrew the leak jet A e Remove E clip A Washer B e Pull out the acceleration pump lever assembly C as a set e Remove the throttle sensor mounting bolt A e Before removing the throttle sensor B mark C the car buretor body and sensor so that it can be installed later in the same position Carburetor Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the carburetor e Make sure the fuel tap is in the OFF position e Remove the carburetor see Carburetor Removal e Drain the fuel in the carburetor e Disassemble the carburetor see Carburetor Disassem bly CAUTION Do not use compressed air on an assembled carbu retor the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage or deterioration of the parts Do not use a strong carburetor cleaning solution w
12. Carburetor Make Type KEIHIN FCR40 Starter Jet 12 Leak Jet 70 Main Jet 175 Throttle Valve Cutaway CA1 5 Jet Needle NCVR Jet Needle Clip Position 4th groove from the top Slow Jet 42 EUR 40 Slow Air Jet 100 Pilot Air Screw turns out 2 EUR 1 Service Fuel Level 6 5 1 mm 0 256 0 039 in below the bottom edge of the carb body Float Height 8 1 mm 0 315 0 039 in Air Cleaner Air Cleaner Element Oil High quality form air filter oil EUR Europe Model FUEL SYSTEM 3 7 Special Tool Fuel Level Gauge M18 x 1 0 57001 122 ST5701228T 3 8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hand if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Wire and Hose Routing Section in the Appendix chapter Free Play Inspection e Refer to the Throttle Grip Free Play Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Replacement e Remove the front master c
13. Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereafter 6513044B51 YA 2 A ES 2 CH CF 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed 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 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning
14. Oil Filter Cover Bolts A Oil Filter Cover B e Remove the Oil Filter A e Install the spring A to the right engine cover e Apply grease to the grommet B e Be sure to install the filter with the grommet facing outside as shown CAUTION Inside out installation stop oil flow causing engine seizure e Replace the oil filter cover O ring A with a new one e Replace the oil filter with a new one e Apply grease to the O rings e Install the oil filter cover Torque Oil Filter Cover Bolt 9 8 N m 1 0 kgf m 87 in Ib e Pour in the specified type and amount of oil see Engine Oil Change Breather Hose Inspection e Be certain that the breather hose are routed without being flattened or kinked and is connected correctly x If it is not correct it e Inspect the breather hose A for damage or sings of de terioration OThis hose should not be hard and brittle nor should be soft swollen Replace it if any cracks or swelling is noticed 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Crankshaft Transmission Crankshaft Inspection Connecting Rod Big End Side Clearance e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Remove the cylinder see Cylinder Removal in the Engine Top End chapter e Remove the piston see Piston Removal in the Engine Top End chapter e Measure the connecting rod big end side clearance at right side of big end us
15. Replace the malfunctioned no good parts All good Repair Replace Replace No good Voltage is less than the specified value Inspection 1 Speed of cranking engine is slow Increase force of kicking engine Lower resistance in the tester Use KAWASAKI Hand Tester Lacking of sampling Sampling few times Crankshaft sensor peak voltage All good C D I Unit is defective No good Replace the malfunctioned parts or inspect in proper way GP10286B F Ignition System Crankshaft Sensor Peak Voltage Check e To check the peak voltage do the following procedures ODisconnect the connector of the magneto lead connector from the main harness NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OSet the hand tester to DC 2 5 V range OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive Green White Lead C Adapter Negative White Yellow Lead D OCrank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Peak Voltage 1 1 V or above A WARNING
16. Spark Plug Wrench Hex 16 Pilot Screw Adjust D 57001 1262 57001 1588 5757126257 ST571588ST Pilot Screw Adjuster C Top Plug Wrench 49 mm 57001 1292 57001 1653 ST5712928T T5716538T 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the inside the fuel line can cause fuel to leak A or the hose to burst e Check the fuel hose Replace the fuel hose if any fraying cracks B bulges C or ozonic cranks D are noticed e Check that the hose A are securely connected and clamps B are tightened correctly e When installing route the hose according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoid sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Throttle Grip Free Play Inspection e Check throttle grip free play B by lightly turning the throt tle grip A back and forth x If the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from full open to close and the th
17. e oosen the upper A and lower B fork clamp bolts e Remove the front fork OWith a twisting motion A work the fork leg B down and out Front Fork Installation e Install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension A 7 mm 0 28 in e Route the cables and hose according to the Cable Har ness Hose Routing section in the Appendix chapter e Install the front wheel see Front Wheel Installation in the Wheels Tires chapter e Tighten the fork clamp bolts Torque Front Fork Clamp Bolts Upper 23 N m 2 3 kgf m 17 ft Ib Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft Ib NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e Check the front brake operation after installation Front Fork Front Fork Disassembly each fork leg e oosen the front fork upper clamp bolts A e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove the front fork see Front Fork Removal NOTE OSet rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging Record the setting before turning the adjuster e Thoroughly clean the fork before dis
18. e Apply a non permanent locking agent to the threads of a adjuster assembly e Torque the adjuster assembly A Torque Adjuster Assembly 58 N m 5 9 kgf m 43 ft Ib e oosen and remove the fork top plug subtank form the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 345 mL 11 7 US oz EUR 350 mL 11 8 US oz e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 B e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 PERIODIC MAINTENANCE 2 53 Periodic Maintenance Procedures The torque of fork top plug is specified to 30 N m 3 1 kgf m 22 ft 1b however when you use the top plug wrench special tool A reduce the torque to 90 of the spec ified value 27 N m 2 8 kgf m 20 ft Ib due to the dis tance B between the center of the square hole where the torque wrench is fitted and that of the octagonal hole of the wrench This torque value 27 N m 2 8 kgf m 20 ft Ib is appli cable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point ee to the center of the coupling square Rear Shock Absorber Inspection e Bounce A the rear
19. e Install the pads see Brake Pad Installation in the Brakes chapter e Install the caliper see Caliper Installation in the Brakes chapter e Wipe up any spilled brake fluid on the caliper with wet cloth PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures Brake Hose and Connection Check e nspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings PE Brake Hose Replacement CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Immediately wash away any brake fluid that spills e Remove each banjo bolts A and washers B e Replace the washers with new ones For Front Brake e Remove Bolts A Brake Hose Clamps B 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures For Rear Brake e Remove Master Cylinder A Hose Clamps B Caliper Cover C e When installing the hoses avoid sharp b
20. ground surface OAlter grinding with 45 cutter apply thin coat of machin ists dye to 45 A seating surface This makes seating surface distinct and 32 and 55 grinding operation eas ier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact x If the outside diameter A of the seating surface is too large make the 32 grind described below If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat O D is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat O D mea surement step above e o measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x If the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat O D measurement step above x If the seat width is too wide make the 55 A grind de scribed below If the seat width is within the specified range
21. A between throttle sensor lead connector B and main harness con nector C Special Tools Hand Tester 57001 1394 Throttle Sensor Setting Adapter 1 57001 1400 e Set the Hand tester D to the DC 10 V range and connect it to the adapter leads Hand Tester Yellow White Lead Hand Tester Black Blue Lead e Temporary install the fuel tank e Start the engine e Check the sensor input voltage with the engine running Throttle Sensor Input Voltage Standard around 5 V x If it is not within the specified voltage range check the magneto output voltage If it has normal functions re place the C D I Unit GP10287BS1 GP10289BS1 Ignition System e To check the output voltage do the following procedures OConnect the digital voltmeter A as follows Tester Blue Lead Tester Black Blue Lead OStart the engine OMeasure the throttle sensor output voltage with the engine idling speed and with the idle throttle valve opening Throttle Sensor Output Voltage Standard 0 68 10 1 V when engine is idle speed x If it is not within the specified voltage range adjust the throttle sensor position see Throttle Sensor Position Ad justment Engine Stop Switch Electric Current Check e Remove the fuel tank transiently see Fuel Tank Removal in the Fuel System chapter e Disconnect the engine stop switch lead connector A e Temporary install the fuel tank e Start the engi
22. A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING Be careful of reaction force in spring and fix surely so that the special tool should not come off Do not place the finger etc while servicing e Hold the locknut A with a wrench B and remove the adjuster assembly C PERIODIC MAINTENANCE 2 47 Periodic Maintenance Procedures e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spring Seat B Spacer C Washer D Fork Spring E CAUTION Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Holding the top plug wrench A with a vise loosen the base valve assembly B on the subtank C Special Tool Top Plug Wrench 49 mm 57001 1653 2 48 PERIODIC MAINTENANCE Periodic
23. Apply engine oil G Apply grease Lh Left hand threads M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil R Replacement Parts 6 4 ENGINE RIGHT SIDE Exploded View ENGINE RIGHT SIDE 6 5 Exploded View LE MILL Dk e Pom us T asm RR 1 Ratchet Guide Bot 88 090 T8imb 3 anren ze J 08 10 erme 4 Ratchet Plate Mounting Bot 98 10 S87mb S Ls 6 GerSelewrNu In 090 78mb 8 Kick Pedal 9 Kickshaft Idle Gear 10 Ratchet Gear 11 Kick Gear 12 Shift Pedal 13 Ratchet Plate 14 Ratchet Assembly 15 Gear Set Lever 16 Shift Drum Cam 17 Shift Shaft G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts St Stake the fasteners 6 6 ENGINE RIGHT SIDE Specifications tem Standard Clutch Lever Clutch Lever Free Play 8 13 mm 0 3 0 5 in Clutch Friction Plate Thickness Friction Plate Warp Steel Plate Warp Clutch Spring Free Length Friction Plate Clutch Housing Clearance Clutch Plate Assembly Length 2 92 3 08 mm 0 115 0 121 in 0 15 mm 0 0059 in or less 0 2 mm 0 008 in or less 49 2 mm 1 94 in 0 20 0 60 mm 0 0079 0 024 in 34 9 35 5 mm 1 37 1 40 in 2 6 mm 0 10 in 0 3 mm 0 01 in 0 3 mm 0 01 in 46 7 mm 1 84 in 0 8 mm 0 03 in ENGINE RIGHT SIDE 6 7 Special Tools Outside Circlip Pliers Gear Holder m2 0 57001 144 57001 1557
24. Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock x If the voltage is less than the specified check the crank shaft sensor ELECTRICAL SYSTEM 16 19 GP10275B81 16 20 ELECTRICAL SYSTEM Ignition System Charge Coil Peak Voltage Check e Disconnect the connector of the magneto lead connector from the main harness e To check the peak voltage do the following procedures NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OConnect the peak voltage adapter A to the tester and the terminals of the magneto lead connector B Special Tools Hand Tester 5701 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive White Lead C Adapter Negative Red Lead D OCrank the engine by kicking the pedal several time to measure the peak voltage of the charge coil Peak Voltage 20 V or Above x If the voltage is less than the specified check the charge coil Throttle Sensor Output Input Voltage Check e Remove the carburetor transiently see Carburetor Re moval in the Fuel System chapter e Remove the throttle sensor lead connector A e Connect the throttle sensor setting adapter
25. Engine Oil see Engine Cil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Adjust Throttle Cable see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Clutch Cable see Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Drive Chain see Drive Chain Slack Adjustment in the Periodic Maintenance chapter e Adjust the idling see Idle Speed Adjustment in the Peri odic Maintenance chapter e Check the operation of the clutch lever e Check the brake effectiveness A WARNING Do no attempt to drive the motorcycle until you pump the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done CRANKSHAFT TRANSMISSION 9 1 Crankshaft Transmission Table of Contents mele il M 9 2 SDS CIM CAUONS TM T c di ad ede 9 4 Sigi EUR Kee Ee e EE 9 5 AIK GAS mo aaa 9 6 Crank Case DISASSEMDIY E SD EE 9 6 C rahnkcadase Eer a a a UA cc p EE 9 8 rank cial ME ERNEUT EET 9 14 BE Ellen GE en Ve E WEE 9 14 Crankshalt Installatiolisbatta sequi con ile ue UT 9 14 Crankshaft Disassembly EE 9 14 Cranikshialt En le rc TT EN 9 14 Cr nKSha gl Tee de WEE 9 15 CONMECUNG ROG Bend mec T 9 16 CONMECUNGIROG cider 9 17 Trans MISSION se SL ITE 9 18 Tr
26. Firing incorrect opark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Flywheel damage Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Starter plunger stuck open Hot start stuck open Main jet clogged or wrong size Jet needle or needle jet worn Air jet clogged Fuel level in carburetor float bowl too high or too low Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Water or foreign matter in fuel Carburetor holder loose Fuel tank cap air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent de formed worn carbon accumulation on the seating surface Decompression trouble Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat valve Faulty CDI unit Other Throttle valve won t fully open Brake dragging Air cleaner clogged Water or foreign matter in fuel Clutch slipping Overheating
27. If rim runout exceeds the service limit check the wheel bearings first Replace them if they are damaged If the problem is not due to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recentering the rim Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim If the rim is badly bent however it must be replaced Rim Runout with tire installed Standard Axial under 1 0 mm 0 039 in Radial under 1 0 mm 0 039 in Service Limit Axial 2 mm 0 08 in Radial 2 mm 0 08 in Wheel Bearing Inspection e Raise the front rear wheel off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness binding or noise If roughness binding abnormal noise is found replace the hub bearing e urn the handlebar until the handlebar doesn t move to either side e he wheel edge is moved to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked x If the play is found replace the bearing 6J04061031 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Check the wheel alignment see Wheel Alignment Inspec tion in the Final Drive chapter
28. Removal e Remove the valve cap A and release the nitrogen gas completely from the gas reservoir e Remove the valve A WARNING Since the high pressure gas is dangerous do not point the valve toward your face or body GMOS185BS1 GMOSOSSBS1 C SUSPENSION 13 27 Swingarm Swingarm Removal e Place the jack A under the frame so that the rear wheel is off the ground Special Tool Jack 57001 1238 e Remove Rear Wheel see Rear Wheel Removal in the Wheels Tires chapter Clamps B Brake Pedal C see Brake Pedal Removal in the Brakes chapter Disc Protector D e Remove Bolts A and Nuts B Chain Guide Plate C Chain Guide D e Unscrew the rocker arm mounting nut A and pull out the rocker arm bolt B CAUTION When pulling out the mounting bolts lift the swingarm wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Unscrew the nut A e Pull out the swingarm pivot shaft B and remove the swingarm C 13 28 SUSPENSION Swingarm e Unscrew the screws A e Separate the chain slipper B from the swingarm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and oil seals e Tighten the following Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft Ib Rocker Arm Pivot Nut 83 N m 8 5 kgf m 61 ft Ib e Refer to the Wheels Tires Final Drive and Brakes chap ters for wheel i
29. Top 0 6 mm 0 02 in Oil 0 8 mm 0 03 in ENGINE TOP END 5 35 6E16055B51 5 36 ENGINE TOP END Cylinder and Piston Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap ring A still fitted in place xlf the ring shows weakness or deformation replace the ring Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin B with a microm eter x If the piston pin diameter is less than the service limit at any point replace the piston pin e Using a cylinder gauge measure the diameter of both of piston pin holes C in the piston and the inside diameter of the connecting rod small end D x If either piston pin hole diameter exceeds the service limit replace the piston x If the connecting rod small end inside diameter exceeds the service limit replace the connecting rod Piston Pin Diameter Standard 18 991 19 000 mm 0 74768 0 74803 in Service Limit 18 95 mm 0 7461 in Piston Pin Hole Diameter Standard 19 004 19 010 mm 0 74819 0 74842 in Service Limit 19 08 mm 0 7512 in Connecting Rod Small End Inside Diameter Standard 19 019 19 030 mm 0 74878 0 74921 in Service Limit 19 07 mm 0 7508 in GE16139BS2 C Carburetor Holder Carburetor Holder Installation e Install the carburetor holder A with the marked B side facing toward the cylinder head outside Olnstall the holder clamp C with
30. bolt e Install the ratchet guide A Torque Ratchet Guide Bolt 8 8 N m 0 90 kgf m 78 in lb e Apply molybdenum disulfide grease to the end of the kick shaft e Insert the kick shaft assembly B into the crankcase OSecurely engage the stopper portion C of the ratchet gear with the guide e Insert the spring end D into the hole E e Install Idle Gear see Idle Gear Installation Clutch Housing see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion ENGINE RIGHT SIDE 6 23 Kickstarter Kick Shaft Assembly Disassembly Assembly e The kick shaft assembly consists of the following parts A Kick Gear E Ratchet Gear B Circlip F Kick Shaft C Washer G Kick Spring D Spring H Spring Guide e Check the kick shaft assembly parts for damage x Any damaged parts should be replaced with new ones e Apply molybdenum disulfide grease to the inside of the kick gear and ratchet gear e Apply grease to the inside of the spring guide e When assembling the ratchet gear A onto the kick shaft B align the punch mark C on the ratchet gear with the punch mark C on the kick shaft e Replace the circlips that were removed with new ones Special Tool Outside Circlip Pliers 57001 144 ENGINE LUBRICATION SYSTEM 7 1 Engine Lubrication System Table of Contents ty 6 018 210 VIEW AEN PT 1 2 Beie ler System a GRISE REEL E PEN TREO thie 7 4 SEELEN ee 7 6 pedal WO
31. clutch lever has 8 13 mm 0 3 0 5 in of play e After the adjustment is made tighten the locknut and start the engine and check that the clutch does not slip and that it release properly Friction and Steel Plates Inspection e Remove the clutch plates see Clutch Removal in the En gine Right Side chapter e Visually inspect the friction and steel plates to see if they show any signs of seizure or uneven wear xlf any plates show signs of damage replace the friction A plates and steel plates as a set e Measure the thickness A of the friction plates with vernier calipers x If they have worn past the service limit replace them with new ones GF08060231 Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 6 mm 0 10 in 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate is warped over the service limit replace it with a new one Friction and Steel Plates Warp Standard Friction Plate Not more than 0 15 mm 0 0059 in 8F13010781 Steel Plate Not more than 0 2 mm 0 008 in Service Limit Friction Plate 0 3 mm 0 01 in Steel Plate 0 3 mm 0 01 in Engine Lubrication System Engine Oil Change
32. e Install Flywheel see Flywheel Installation in the Electrical Sys tem chapter Camshaft see Camshaft Installation Camshaft Camshaft and Camshaft Cap Wear e Measure each clearance between the camshaft journal and camshaft cap using plastigauge press gauge A e Install the camshaft caps see Camshaft Installation NOTE ODo not turn the camshaft when the plastigauge is be tween the journal and camshaft cap xlf any clearance exceeds the service limit measure the diameter of each camshaft journal with a micrometer Camshaft Bearing Clearance Standard 0 020 0 062 mm 0 00079 0 0024 in Service Limit 0 15 mm 0 0059 in If the camshaft journal diameter is less than the service limit replace the camshaft with a new one and measure the clearance again Camshaft Journal Diameter Standard 22 959 22 980 mm 0 90390 0 90472 in Service Limit 22 93 mm 0 9027 in x If the clearance still remains out of the service limit re place the cylinder head unit Camshaft Runout e Remove the camshaft see Camshaft Removal e Set the camshaft in a camshaft alignment jig or on V blocks e Measure the runout with a dial gauge at the specified place as shown xlf the runout exceeds the service limit replace the camshaft Camshaft Runout Standard TIR 0 02 mm 0 0008 in or less Service Limit TIR 0 1 mm 0 004 in Cam Wear e Remove the camshaft see Camshaft Removal e Measure the heig
33. e Install the clutch housing A e Do not forget to install the toothed washer B before in stalling the clutch hub C i EN V e vd dams P Clutch e Install the washer so that stamp mark A facing the out side e Tighten the clutch hub nut A with the clutch holder B Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 98 N m 10 kgf m 72 ft lb e Install the friction plates and steel plates starting with a friction plate A and alternating them Finishing with a friction plate Olnstall the friction plates so that the lining blocks B at the plates of the both ends are many than the other plates OApply engine oil to the new friction plates when it shall be installed CAUTION If dry steel plates and friction plates are installed apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Apply molybdenum disulfide grease to the rubbing portion A of the push rod holder e Install the push rod B and push rod holder e Apply molybdenum disulfide grease to the needle bearing C and washer D and install them ENGINE RIGHT SIDE 6 13 6 14 ENGINE RIGHT SIDE Clutch e Tighten Torque Clutch Spring Bolts A 8 8 N m 0 90 kgf m 78 in lb e Install the clutch cover see Clutch Cover Installation e Check the release shaft lever positions A OPushing B the release shaft lever C lightly frontward measure the distance between the lever
34. e Remove the spacer D e Remove the ball bearing E and oil seal F from the right engine cover in the same way as ball bearing removal e Insert a bar A into the water pump shaft hole from the inside of the right engine cover and remove the oil seal B by tapping C evenly around the seal lips Oil Seal Installation CAUTION If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Be sure to replace the oil seals e Apply plenty of high temperature grease to the oil seal lips e Press in the new oil seal A using a bearing driver set from the outside of the right engine cover so that the seal bottom surface is flush with the end face B of the right engine cover e Press in the new oil seal C using a bearing driver set from the outside of the right engine cover so that the oil seal surface is flush D with the surface of the right engine COVer Special Tool Bearing Driver Set 57001 1129 e Press the ball bearing A together with the spacer B into the hole until the face of the bearing is even C with the end of the hole Special Tool Bearing Driver Set 57001 1129 COOLING SYSTEM 4 11 GD06060BS1 C GD06061BS1 C GD06062BS1 C 4 12 COOLING SYSTEM Radiator Radiator Removal e Drain the coolant see Coolant Draining e Remove Radiator Shrouds e oosen Clamp Screws A Clamp B e Remove Radiator Hoses C Bolts D Left Radiator
35. it counterclockwise to align the TDC mark A with the center of the groove B of the inspection hole e Remove Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Camshaft Cap Bolts 1 8 sequence numbers Camshaft Caps A together with the oil pipe B OPlug the oil passage and camshaft chain tunnel with a clean cloth for prevent the oil pipe from dropping into the crankcase OWhile keeping parallel remove the camshaft caps and oil pipes e Remove Positioning Rings A e Disengage the Camshafts B from camshaft chain C e Staff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase CAUTION The crankshaft may be turned while the camshafts are removed Always pull the chain taut while turning the crank shaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could dam age both the chain and the sprocket ENGINE TOP END 5 15 5 16 ENGINE TOP END Camshaft e Remove Bolt A Auto Decompressor B with the sprocket e Remove Circlips A Camshaft Installation e Assemble the auto decompressor weights A and spring B to install it to the sprocket C e Replace the circlips D with new ones and install them e Apply a non permanent locking agent to camshaft sprocket bolts e Fit the recess E of the weight and projection F of the camshaft and install it Torque Camshaft Sprocket Bolt G 12 N
36. to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2005 Kawasaki Heavy Industries Ltd First Edition 1 Aug 4 2005 M LIST OF ABBREVIATIONS ampere s pound s after bottom dead center meter s alternating current minute s after top dead center newton s before bottom dead center pascal s bottom dead center horsepower before top dead center i pound s per square inch degree s Celsius revolution direct current revolution s per minute farad s top dead center degree s Fahrenheit total indicator reading foot feet volt s gram s mass watt s hour s ohm s mass force liter s Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient exper
37. 0098 0 014 in Crankshaft Runout TIR 0 03 mm 0 0012 in or less TIR 0 08 mm 0 0031 in Connecting Rod Bend TIR 0 2 mm 0 08 in 100 mm 3 94 in Connecting Rod Twist TIR 0 2 mm 0 08 in 100 mm 3 94 in Transmission Shift Fork Ear Thickness 4 9 5 0 mm 0 193 0 197 in 4 8 mm 0 19 in Gear Shift Fork Groove Width 5 05 5 15 mm 0 199 0 203 in 5 25 mm 0 207 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 0 232 0 236 in 5 8 mm 0 228 in Shift Drum Groove Width 6 05 6 20 mm 0 238 0 244 in 6 3 mm 0 25 in TIR Total Indicator Readings CRANKSHAFT TRANSMISSION 9 5 Special Tools and Sealant Outside Circlip Pliers Crankcase Splitting Tool Assembly 57001 144 57001 1362 T570144ST C E 8157136281 Bearing Driver Set Kawasaki Bond Liquid Gasket Gray 57001 1129 92104 1063 75711298T Crankshaft Jig 57001 1174 ST5711748T 9 6 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e Remove the engine from the frame see Engine Removal in the Engine Removal Installation chapter e Set the engine on clean surface while parts are being re moved e Remove Magneto Cover see Magneto Cover Removal in the Electrical System chapter Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Cylinder Head see Cylinder Head Removal in the En gine Top End chapter Cylinder see Cylinder Removal in the Engine Top end chapter Pisto
38. 03 0 04 in e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 115 in Ib Sr 2222 DS gt ci 817051BS81 e Fit the plug cap securely OPull the spark plug cap A to make sure the installation of the spark plug cap Cable Inspection Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation 2 62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Hot Start Inner Cable Upper End Throttle Inner Cable Upper End Cables Lubricate with Rust Inhibitor Throttle Cables Clutch Cable Hot Starter Cable 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 Nut Bolt and Fastener Tightness Inspection Tightness Inspection e Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fast
39. 15 4 GEET 15 5 Seat Removal m 15 5 Seat a ESS LES de EE 15 5 O NC 15 6 Side COVE ue EE 15 6 side Cover Instala Nana oia 15 6 A PETRO RM 15 7 Front Fender Remo Validado in a Red d eU 15 7 Rear Fender Removal raras date Led ain 15 7 Rear Fab Removal do 15 7 15 2 FRAME Exploded View 6002154BW5 C FRAME 15 3 Exploded View 1 Rear Frame Mounting Bot a 38 25 G Apply grease L Apply a non permanent locking agent R Replacement Parts 15 4 FRAME Frame Frame Inspection e Refer to the Frame Inspection in the Periodic Mainte nance chapter Rear Frame Removal e Remove Seat see Seat Removal Right amp Left Side Cover see Side Cover Removal Muffler see Muffler Removal in the Engine Top End chapter Rear Fender see Rear Fender Removal e Loosen the air cleaner duct clamp screw see Air Cleaner Housing Removal in the Fuel System chapter e Unscrew the rear frame mounting bolts A e Remove the rear frame B with air cleaner housing C e Remove Bolts A Air Cleaner Housing B Rear Frame Installation e Install the air cleaner housing e Tighten Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib e Install the removal parts Engine Guard Installation e Install the engine guard as shown Right Engine Guard A Collar B Bolt C Engine Guard D Bolts E G009021BS2 C FRAME 15 5 Seat Seat Removal e Remove the bolts A e Pull the seat B out fro
40. 1b e Insert the radiator hose C into the water pump cover e Tighten Torque Radiator Hose Clamp Screw D 1 5 N m 0 15 kgf m 13 in Ib e Fill the cooling system see Coolant Filling e Bleed the air from the cooling system e Check the engine oil level and add the engine oil COOLING SYSTEM 4 9 4 10 COOLING SYSTEM Water Pump Impeller Removal e Drain Coolant see Coolant Draining e Remove Water Pump Cover see Water Pump Cover Removal Impeller Bolt A Impeller B Impeller Installation e Install Impeller A e lighten Torque Water Pump Impeller Bolt B 9 8 N m 1 0 kgf m 87 in lb e Install Water Pump Cover see Water Pump Cover Installation Water Pump Inspection e Visually check the impeller A x If the surface is corroded or if the blades B are dam aged replace the impeller e Check the drainage outlet passage A at the bottom of the right engine cover for coolant leaks x If the oil seal is damaged the coolant leaks through the seal and drains through the passage Replace the oil seals Oil Seal and Bearing Removal e Remove Impeller see Impeller Removal Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Circlip A Water Pump Shaft B Water Pump e Insert a bar A into the water pump shaft hole from the outside of the right engine cover and remove the ball bearing B by tapping C evenly around the bearing in ner race
41. 48 in 34 2 mm 1 35 in 37 8 mm 1 49 in 35 7 mm 1 40 in ENGINE TOP END 5 7 Specifications Wem Standard Cylinder and Pistons Cylinder Inside Diameter 96 000 96 012 mm 3 7795 3 7800 in 96 10 mm 3 783 in Piston Diameter 95 970 95 980 mm 3 7783 3 7787 in 95 82 mm 3 772 in Piston Cylinder Clearance 0 020 0 042 mm 0 00079 0 0016 in Piston Ring Ring Groove Clearance Top 0 04 0 07 mm 0 002 0 003 in 0 17 mm 0 0067 in Piston Ring Groove Width Top 1 03 1 05 mm 0 0406 0 0413 in 1 1 mm 0 043 in Piston Ring Thickness Top 0 970 0 990 mm 0 0381 0 0390 in 0 90 mm 0 035 in Piston Ring End Gap Top 0 25 0 35 mm 0 0098 0 014 in 0 6 mm 0 02 in Oil 0 15 0 50 mm 0 0059 0 020 in 0 8 mm 0 03 in Piston Pin Diameter 18 991 19 000 mm 0 74768 0 74803 in 18 95 mm 0 7461 in Piston Pin Hole Diameter 19 004 19 010 mm 0 74819 0 74842 in 19 08 mm 0 7512 in Connecting Rod Small End 19 019 19 030 mm 0 74878 0 74921 in 19 07 mm 0 7508 in Inside Diameter TIR Total Indicator Readings 5 8 ENGINE TOP END Specifications Cam Height Camshaft Runout GE11012281 C 6E11077BS1 C Cam Height A Valve Stem Diameter Valve Stem Bend GE15048BS1 C GE15011281 C Valve Stem Diameter A Dial Gauge A 45 B ENGINE TOP END 5 9 Special Tools and Sealant Compression Gauge 20 kgf cm Valve Seat Cutter 45 5
42. 8 1 0 87 in lb S MO Camsfaft Sprocket Bolts 12 1 2 106 in Ib L Decompressor Plug Plate Bolt 9 8 1 0 87 in lb Radiator Hose Fitting Bolts 9 8 1 0 87 in lb Oil Line Plug 3 0 0 31 27 in lb L Carburetor Holder Clamp Screws 2 0 0 20 18 in lb Plug 20 2 0 15 L Lower Camshaft Chain Guide Bolt 9 8 1 0 87 in lb Rear Camshaft Chain Guide Bolt 15 1 5 11 Chain Tensioner Mounting Bolts 9 8 1 0 87 in lb Chain Tensioner Cap 5 0 0 51 44 in lb Cylinder Bolt 12 1 2 106 in Ib S Exhaust Pipe Cover Screws 12 1 2 106 in Ib 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Engine Right Side Primary Gear Nut Shift Drum Cam Bolt Clutch Spring Bolts Clutch Hub Nut Gear Set Lever Nut Ratchet Plate Mounting Bolt Ratchet Plate Mounting Screw Ratchet Guide Bolt Kick Pedal Bolt Shift Pedal Bolt Clutch Cover Bolts Right Engine Cover Bolts Engine Lubrication System Engine Oil Drain Bolt M10 for crank room oil sump Engine Oil Drain Bolt M6 for transmission room oil sump Oil Pump Scavenge Cover Bolts Oil Pump Feed Cover Bolts Oil Filter Cover Bolt Oil Screen Feed Mounting Bolts Oil Pressure Relief Valve Piston Oil Nozzle Breather Fitting Engine Removal Installation Engine Mounting Bolt Nuts Engine Bracket Bolt Nuts owingarm Pivot Shaft Nut Crankshaft Transmission Piston Oil Nozzle Crankcase Bolts M6 Crankcase Bolts M7 Engine Oil Drain Bolt M10 for crank room oil sump Engine Oil Drain Bolt M6 for transmission room
43. A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it e Remove the float valve needle e Check the plastic tip A of the float valve needle B for wear x If the needle is worn as shown right C replace the valve needle e Push the rod D in the valve needle then release it x If the rod does not come out fully by spring tension re place the valve needle Push and release E e Remove the starter jet e Check the slow jet for any damage x If the slow jet is damaged replace it with a new one e Remove the throttle valve and jet needle e Inspect the outside of the throttle valve and plate for scratches and abnormal wear x If it is badly scratched or worn replace the throttle valve or plate e Inspect the inside of the carburetor body for these same faults x If it is badly scratched or worn replace the entire carbu retor e Check the jet needle for wear e For the throttle sensor inspection see the Electrical Sys tem chapter A worn jet needle should be replaced e Clean the fuel and air passages with a high flash point solvent and compressed air GC06014481 GC06014381 FUEL SYSTEM 3 23 Carburetor Carburetor Assembly e Clean the disassembly parts before assembling OClean the fuel and air passages with a high flash point solvent and compressed air A e
44. B Replace any damaged gears or gears with excessively worn dogs or dog holes e Visually inspect the gear teeth C on the transmission gears x Replace lightly damaged gear teeth with an oilstone The gear must be replaced if the teeth are badly damaged x When gearis repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary 6113238BS1 9 22 CRANKSHAFT TRANSMISSION Balancer Balancer Removal e Remove Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Magneto Cover see Magneto Cover Removal in the Electrical System chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter Balancer Weight Mounting Nut A Balancer Weight B Balancer Gear C e Pull out the balancer shaft from the right crankcase Balancer Installation e Insert the balancer shaft from the right crankcase e Install the balancer gear so that the stepped portion A on the balancer shaft and punch mark B on the balancer gear align e Align the punch mark A on the balancer drive gear and punch mark B on the balancer gear e Install the balancer weight so that the punch mark A on the balancer and punch mark B on the balancer gear e Tighten Torque Balancer Weight Mounting Nut 52 N m 5 3 kgf m 38 ft lb CRANKSHAFT TRANSMISSION 9 23 Bearings Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it
45. Camshaft Removal Carburetor see Carburetor Removal in the Fuel System chapter Exhaust Pipe A see Muffler Removal Clamp Screw B Radiator Hose C Engine Bracket Bolts D Engine Bracket E e Remove the 6 mm cylinder head bolts A and loosen the cylinder bolt B OThis prevents the 6 mm bolts from becoming damaged 5 22 ENGINE TOP END Cylinder Head e Remove the 10 mm cylinder head bolts following the tight ening sequence as shown e ap lightly up with a plastic mallet A to separate the cylin der head B from the cylinder e Remove the cylinder head gasket Cylinder Head Installation e Fit the projection A of the front camshaft chain guide B in the groove C of the cylinder Olnsert the guide end D into the recess E of the crankcase securely e Install Dowel Pins A New Cylinder Head Gasket B e Install the cylinder head OThe camshaft caps are machined with the cylinder head therefore if a new cylinder head is installed use the caps that are supplied with the new head e Replace all the 10 mm cylinder head bolt washers with new ones OThe 10 mm cylinder head bolt washers are copper plated and they could leak oil if reused e Apply molybdenum disulfide oil to the both sides A of the 10 mm cylinder head bolt washer and thread B of the 10 mm cylinder head bolts GE14072BS81 Cylinder Head e Tighten the 10 mm cylinder head bolts in the numbered sequenc
46. Coil A Upper Engine Bracket Bolts Left and Right B Upper Engine Mounting Bolt and Nut Left and Right C Upper Engine Brackets Left and Right D Engine Guard E Middle Engine Bracket Bolts and Nuts F Middle Engine Mounting Bolt and Nut G Middle Engine Brackets Left and Right H Lower Engine Mounting Bolts and Nuts I e Remove the swingarm pivot shaft nut A to pull out the swingarm pivot shaft B OPull out the swingarm pivot shaft half way from right side to free the engine e Remove the engine from the vehicle to right side OClear the engine rear portion from the swingarm and then remove the engine Engine Installation e Install the engine OFirst insert the front portion of the engine and then install the rear portion e Install the swingarm pivot shaft all engine bracket and mounting bolts temporarily OSwingarm pivot shaft insert from the right side Olnsert the middle and lower engine mounting bolts from the left side e Tighten the pivot shaft engine mounting bolts and engine bracket bolts Torque Swingarm Pivot Shaft Nut 98 N m 10 kgf m 72 ft Ib Engine Mounting Bolts 49 N m 5 0 kgf m 36 ft Ib Engine Bracket Bolt 29 N m 3 0 kgf m 21 ft lb 8 8 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Install the removed parts see Appropriate chapter e Run the cables hoses and leads according to the Cable Wire and Hose Routing section in the Appendix chapter e Fill
47. Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this is not done Brake Pad Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wiped up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the upper brake hose B from the master cylinder C e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Unscrew the clamp bolts A and take off the master cylin der B as an assembly with the reservoir and brake lever Front Master Cylinder Installation e Install the master cylinder so that the reservoir cap B is horizontally and position it from edge of the grip to 185 mm 7 28 in A e he master cylinder clamp must be installed with the ar row mark A upward OTighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Replace the washers that are on each side of hose fitting with new ones e Tighten t
48. Engine oil level too high Engine oil viscosity too high Drive train trouble Crankshaft bearing worn or damage Engine Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Faulty CDI unit Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner clogged poorly sealed or miss Ing Air cleaner duct loose Hot start stuck open Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brake dragging Drive train trouble Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted APPENDIX 17 9 Troubleshooting Guide Clutch inner cable sticking Valve noise Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release function trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever play excessive Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing seized Clutch release function trouble Clut
49. Green White lead Yellow lead 180 280 Q x If there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each leads and chas sis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x If the stator coils have normal resistance but the voltage check showed the magneto to be defective then the fly wheel have probably weakened and the flywheel must be replaced ELECTRICAL SYSTEM 16 13 Ignition Timing Ignition Timing Inspection e Remove the timing inspection cap A Special Tool Filler Cap Driver 57001 1454 e Attach the timing light A to the ignition coil lead in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the ignition timing mark B on the flywheel e Run the engine at the speeds specified and note the align ment of the ignition timing marks OCheck the engine speed using the engine revolution tester A for high accuracy Ignition Timing Engine speed ne r min rpm Hole groove aligns with 1 800 Line mark on flywheel If the ignition timing is incorrect check the crankshaft sen sor see Crankshaft Sens
50. Install the master link A from the frame side e Install the link plate B so that the mark faces out Clip C FINAL DRIVE 11 5 11 6 FINAL DRIVE Drive Chain e Install the clip A so that the closed end of the U B pointed in the direction of chain rotation C e Adjust the drive chain slack see Drive Chain Slack Ad justment e Check the rear brake GK04002B31 Sprockets Engine Sprocket Removal e Remove Engine Sprocket Cover Bolts A Engine Sprocket Cover B Drive Chain Guide C e Remove Drive Chain B free of engine sprocket e Flatten the bended sprocket washer A e Remove the engine sprocket nut C and sprocket washer and pull off the engine sprocket D Engine Sprocket Installation e Install the engine sprocket so that the flatten side faces A inside e Replace the sprocket washer with a new one e Install the sprocket washer and sprocket nut Torque Engine Sprocket Nut 127 N m 13 0 kgf m 93 7 ft Ib e Bend the one side of the sprocket washer on the nut e Install the engine sprocket cover Torque Engine Sprocket Cover Bolts 9 8 N m 1 0 kgf m 87 ft lb Rear Sprocket Removal e Remove the rear wheel see Rear wheel Removal in the Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Unscrew the rear sp
51. Maintenance Procedures e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily CAUTION Disassembling the base valve assembly can lead to trouble Do not disassemble the base valve assembly e Drain the fork oil A from the cylinder unit B by pumping the piston rod several times e Hold the front fork inverted position for more than 20 min utes to allow the fork oil to fully drain Z GM04251BS31 e Clean the threads A of subtank and base valve assem bly e With the piston rod in fully compressed position pour the specified amount of fork oil A Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 170 ml 5 75 US oz NOTE OPlug the two oil holes on the subtank B with fingers PERIODIC MAINTENANCE 2 49 Periodic Maintenance Procedures e Pump A the piston rod B slowly several times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly e With the piston rod held immorable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve assembly in the subtank when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a
52. N N CH Q Piston pin replace alve clearance inspect T mz gazrir O lt O gt ON 0o z E 2 5 o ES Q O O NIN 2 D gt o Q 3 D E 5 D Q D Q D O o d D c O D lt D oO 7 5 D lo Q D D LL D a d Hot starter cable adjust Oil filter replace Muffler clean and inspectf Muffler Baffle change Kick pedal and shift pedal clean 2 33 2 18 2 19 2 28 2 27 2 34 2 38 Engine sprocket inspect T Radiator hoses and connections inspect T Crankshaft inspect Breather hose inspect Brake adjustment inspect T Brake pad wear inspect T Brake fluid level inspect T Brake fluid change 2 36 Brake master cylinder cup and dust seal replace 2 38 Brake caliper piston seal and dust seal replace 2 40 Brake hoses and pipe replace 2 43 Brake hoses connections inspect T 2 43 2 29 D 00 PO opoke tightness and rim runout inspect T N LA O AAA MS pp 2 Frame inspect and clean E i 2 60 LL 232 LL 2 31 Drive chain wear inspect T Dg D D o D C 2 m 5 o D D O r Drive chain inspect and adjust 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Each Ee 12 Ecol races or OPERATION 25hr pr 30 hr oee Page Ex Le Es Every 4 years 212 Chassis pansi T Replace add adjust clean or torque if necessary NINI IN N IER CR o amp PERIODIC MAINTENANCE 2 5 Torque and Lockin
53. Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors A Female Connectors B Male Connectors Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you could receive a severe electrical shock ELECTRICAL SYSTEM 16 7 6P06010151 6P06010251 16 8 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect an ohmmeter between the ends of the leads OSet the meter to the x 1 O range and lead the meter x I
54. Race Press Shaft Jack 57001 1075 57001 1238 Head Pipe Outer Race Driver 451 5 Bearing Puller 57001 1076 57001 1575 8T5710768T STS715758T Steering Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter Steering Stem Stem Bearing Removal e Remove Front Wheel see Front Wheel Removal in the Wheels Tires chapter Front Fender Bolts A Front Fender B e Remove Handlebar Pad A Number Plate B Breather Hose C Pull out e Remove the bolts A to remove the brake hose C from the holder B e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C see Handlebar Removal e Remove the front fork upper clamp bolts D e Remove the steering stem head nut E and washer e Remove the steering stem head F STEERING 14 5 14 6 STEERING Steering e Remove Front Fork Lower Clamp Bolts A Front Fork B e Pushing up on the stem base A and remove the steering stem nut B with the steering stem nut wrench C then remove the steering stem D and stem base Special Tool Steering Stem Nut Wrench 57001 1100 e Take off the upper stem bearing inner race tapered roller bearing A e Drive out the bearing outer races from the head pipe ORemove the outer races pressed into the head pipe using the head pipe outer race remover A and h
55. Screen E e Unscrew the bolts A e Remove the left radiator B e oosen Clamp Screws A e Remove Radiator Hoses B Bolt C Right Radiator Screen D e Remove Bolts A Right Radiator B Radiator Radiator Installation e Fit the projections A of the screen in the holes B of the radiator Torque Radiator Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Radiator Mounting Bolts 9 8 N m 1 0 kgf m 87 in 1b Radiator Screen Bolts 9 8 N m 1 0 kgf m 87 in Ib Radiator Shroud Bolts 9 8 N m 1 0 kgf m 87 in 1b e Route the radiator and breather hoses correctly see Cable Wire and Hose Routing section in the Appendix chapter e Fill the cooling system with a permanent type coolant Radiator Inspection e Check the radiator core If there are obstructions to air flow remove them x If the corrugated fins are deformed carefully straighten them with the thin blade of a screwdriver A CAUTION Do not tear the radiator tubes while straightening the fins 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 CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun A away more than 0 5 m 1 64 ft B from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun
56. Set up the acceleration pump lever assembly as shown Acceleration pump lever A Spring B Push Rod Holder C Adjusting Screw with Spring D OFit the spring end on the stopper E of the push rod holder e Install the return spring A to the acceleration pump lever B e Install the acceleration pump lever assembly to the car buretor body OFit the end B of the return spring into the recess A on the carburetor body e Install Washer A E clip B 3 24 FUEL SYSTEM Carburetor e Apply thin coat silicone grease to the shaft e Fit the hook A of the return spring onto the stopper B e of the throttle cable pulley A _ ae a ge L V d Re e d le e Insert the throttle cable pulley shaft A and install the steel washer B nylon washer C and valve link D OFit the end A of the return spring into the recess B of the carburetor body e Turn the pulley counterclockwise A while holding down the acceleration pump lever B and clear the stopper C of the pulley from the throttle stop screw head D e Install the push rod A into the push rod holder B FUEL SYSTEM 3 25 Carburetor e Assembly Throttle Valve A Jet Needle B Circlip C Retainer D Spring E Jet Needle Holder F O ring G Throttle Valve Plate H OAssemble the valve plate so that the hole side down ward 6008089881 1 e Apply a non permanent locking agent to t
57. WL Apply soap and water solution or rubber lubricant 10 4 WHEELS TIRES Specifications Wem Standard Wheels Rims Rim Runout Axial 1 0 mm 0 039 in or less 2 mm 0 08 in Radial 1 0 mm 0 039 in or less 2 mm 0 08 in Axle Runout 100 mm 3 94 in 0 1 mm 0 004 in 0 2 mm 0 008 in Rim Size Front 21 x 1 60 Rear 19 x 2 15 Tires Air Pressure Front and Rear 100 kPa 1 0 kgf cm 14 psi Tires Standard Tire Front Size 90 100 21 57M Make DUNLOP Type D742F Tube Rear Size 120 80 19 63M Make DUNLOP Type D756 Tube Special Tools Inside Circlip Pliers 57001 143 Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 WHEELS TIRES 10 5 Bearing Driver Set 57001 1129 T570143ST 75711298T 57001 1238 ST571063ST C DTS ST571238ST C ST5 10728T 10 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Using the jack A under the frame and stabilize the mo torcycle Special Tool Jack 57001 1238 e Apply the rear brake to rear wheel does not turn e Unscrew the axle nut A e Loosen the left and right axle clamp bolts B e Place a commercially available jack under the engine to raise the front wheel off the ground e Remove the axle C and pull out the wheel Take off the collars and caps D from each side of the front hub CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place block
58. any doubt as to the condition of a needle bear ing replace it Oil Seal Inspection e Inspect the oil seal Replace the oil seal if the lips are deformed discolored indicating that the rubber has deteriorated hardened or otherwise damaged WHEELS TIRES 10 1 Wheels Tires Table of Contents weh Mm 911011107 LORS ER PR eee ee eee ee ee DISC al OO EE Wheels RIMS IA A q Front Wheel REMO alli ita nina Front Wheel Installation BEEN Rear IWne el R MOVAlES RS SE D Band ete Ce de re todo ta Rear VWneeltInstalatlON unica a M tutu A a ee tse telis one dcc bes WINCC IAS CN TD SPOKE hanthess Ee et a ss edat rea rats oce eects tue P E Ee es A MR MS Insta IET ET Ee Air Pressure Inspection Adjustment ss A PID IB CANING ROMOV eem FN BSarina TSUN ALOU isos ea tees eda a adie dp use MUD Bearing Inspeccion atu aus eos ne alada 10 2 WHEELS TIRES Exploded View 6J020688W5 C WHEELS TIRES 10 3 Exploded View e ES EE Spoke Nipples Not less than NE less than a less than e 2 2 0 22 19 in lb 2 Front Axe Nut 7 80 8 3 Front xe Clamp Bolts a Rear Axle Nut wo 2 83 5 Spokes 6 Front Tire T Rims 8 Front Axle 9 10 11 Swingarm Rear Tire Rear Axle AL Tighten the two clamp bolts alternately two times to ensure even tightening torque HG Apply high temperature grease
59. any of the parts of the element are damaged replace them GSO5026BS1 e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean towel and squeeze it as dry as possible OBe careful not to tear the sponge filter e Assemble the element e Remove the towel from the carburetor 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Install the element onto its frame and coat the element lip and lip seat with a thick layer of all purpose grease to assure a complete seal e Install the air cleaner element so that its tab faces A upward and its projections B align with the holes C in the housing e Tighten the wing bolt D e Install the seat see Seat Installation in the Frame chap ter Fuel Inspection AA WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove the carburetor see Carburetor Removal in the Fuel System chapter e Place a suitable container beneath the carburetor e Remove the drain plug A from the bottom of the float bowl and check for water or dirt in the fuel If
60. any water or dirt comes out clean the carburetor fuel filter fuel tap and fuel tank e Install the drain plug on the float bowl and tighten it se curely e Install the carburetor see Carburetor Installation in the Fuel System chapter 6505027B31 GS05078BS1 PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Fuel Tank Filter and Tap Cleaning WARNING Clean the fuel tank in a well ventilated area and take care that there is no sparks or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank e Remove the fuel tank and drain it see Fuel Tank Removal in the Fuel System chapter e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Remove the fuel filter from the tank by taking out the bolts e Clean the fuel filter screen in a high flash point solvent After cleaning install the fuel filter e Pour high flash point solvent through the tap in all lever positions e Dry the tank filter and tap with compressed air e Install the filter in the fuel tank e Install the tap and fuel tank Fuel Tap and Filter Inspection e Remove the fuel filter from the fuel tank e Check the fuel filter screen A for any breaks or deterio ration x If the fuel filter screen have any breaks or is deteriorated it
61. brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake When handing the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures NOTE OThe procedure to change the front brake fluid Chang ing the rear brake fluid is the same as forthe front brake e evel the brake fluid reservoir e Remove the screws A reservoir cap B and diaphragm C e Remove the rubber cap A on the bleed valve B G813119BS1 e Attach a clear plastic hose A to the bleed valve on the caliper and run the other end of the hose into a container B e Change the brake fluid as follows ORepeat thi
62. by pushing the inner pipe into the muffler body with aligning the inner pipe with the exhaust hole e Install the end A of the inner pipe B to the baffle C e Apply a non permanent locking agent to the pipe mount ing bolts e Install the muffler body GS07068BS1 e Apply silicone sealant to the circumference A of the inner pipe e Install the muffler see Muffler Installation in the Engine Top End chapter Gummi P Engine Right Side A WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures Clutch Lever Free Play Check e Slide the clutch lever dust covers A out of place e Check that the clutch cable upper end is fully seated in the adjusting bolt B e Check that the clutch lever C has 8 13 mm 0 3 0 5 in of play D x If it does not adjust the lever play Gsm P Clutch Lever Free Play Adjustment e Slide the clutch lever dust cover out of place e Turn the adjuster A so that the clutch lever will have 8 13 mm 0 3 0 5 in of play NOTE OBe sure that the outer cable end at the clutch lever is fully seated in the adjusting bolt at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement e f it cannot be done loosen the locknut A at the middle of the clutch cable and turn the adjusting nut B so that
63. clamp claw and white mark on lead the breather hose 4 Gear Position Switch Lead 9 Align the white mark on the breather hose 5 Clamp Run the gear position switch and embossed mark lead radiator overflow hose and breather 10 Radiator Overflow Hose hose APPENDIX 17 5 Cable Wire and Hose Routing E 1 Left Radiator 6 Joint Pipe 2 Right Radiator 7 Clamp Position the clamp claw left side 3 Radiator Hose to cylinder head 8 Clamp Position the clamp claw down 4 Radiator Hose to water pump ward 5 Radiator Overflow Hose 17 6 APPENDIX Cable Wire and Hose Routing eb Q o 9 ps ZAS oN te ALL O gt Y M AS AQ yO Je g OCH ER O k o ei z O OO 6B09853BW4 C 1 Brake Lever 10 Rear Brake Master Cylinder 2 Front Brake Master Cylinder 11 Rear Brake Hose 3 Front Brake Hose 12 Clamps 4 Clamp 13 Rear Brake Caliper 5 Viewed 14 Rear Brake Caliper Guard 6 Clamps 15 Rear Brake Disc T Front Brake Caliper 16 Rear Brake Disc Guard 8 Front Brake Disc 17 Cotter Pin 9 Brake Pedal Troubleshooting Guide This is not an exhaustive list giving every possible cause for each problem listed it is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Engine won t turn over Valve seizure Valve lifter seizure Cylinder piston seizure Crankshaft s
64. confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly GENERAL INFORMATION 1 3 Before Servicing Storage of Removed Parts After all the parts including subassembly parts have been cleaned store the parts in a clean area Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re assembly Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol oration or other damage Refer to the appropriate sections of this manual for service limits on individual parts Replace the parts if any damage has been found or if the part is be yond its service limit Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI Gaskets O rings Oil seals Grease seals circlips or cotter pins must be replaced with new ones whenever disassembled GB020108 5 Assembly Order In most cases assembly order is the reverse of disassem bly however if assembly order is provided in this Service Manual follow the procedures given 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 loose
65. cover bolts following the sequence number as shown Torque Oil Pump Scavenge Cover Bolts 9 8 N m 1 0 kgf m 87 in lb 7 14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Feed Removal e Remove Clutch Clutch Removal in the Engine Right Side chap ter Circlip A Oil Pump Driven Gear B Shaft C Oil Pump Idle Gear D e Remove Oil Pump Cover Bolts A Oil Pump Cover B e Remove Inner Rotor A Outer Rotor B Oil Pump Feed Installation e Install the dowel pins A to the crankcase e Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft e Install Outer Rotor B Inner Rotor C e While turn the oil pump shaft install the oil pump so that the left and right oil pump shaft may mesh in the crankcase e Install the oil pump cover A e While pushing the oil pump cover tighten the oil pump cover bolts following the sequence number as shown OThread length of the bolt is 16 mm 0 63 in only in the bolt installed thirdly Torque Oil Pump Feed Cover Bolts 9 8 N m 1 0 kgf m 87 in lb ENGINE LUBRICATION SYSTEM 7 15 Oil Pump e Install the oil pump idle gear A facing the stepped side B to the outside e Replace the circlip C with a new one e Install the oil pump driven gear D and circlip Oil Pump Inspection e Remove the oil pump e Visually inspect the oil pump body outer rotors and the inner rotors x If the oil pump is any damaged or
66. cycle stability Shock Absorber Spring Free Length Standard 260 mm 10 2 in Service Limit 255 mm 10 0 in GM04011831 Rear Suspension Uni Trak Rear Shock Absorber Removal e Remove Seat see Seat Removal in the Frame chapter oide Covers see Side Cover Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Frame with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the tie rod mounting bolt and nut Front and turn it downward e Remove the rear shock absorber lower mounting bolt A and nut e Remove the rear shock absorber upper mounting bolt B nut and pull out the rear shock absorber C down and out Rear Shock Absorber Installation e Pack the rocker arm needle bearings with grease e Tighten the following Torque Rear Shock Absorber Mounting Nut Upper 39 N m 4 0 kgf m 29 ft Ib Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Tie Rod Mounting Nut Front 83 N m 8 5 kgf m 61 ft lb Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purp
67. damage OApply fork oil to the piston rod sliding surface e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston rod is not extend remove the base valve assembly and perform the air bleeding pour the specified amount fork oil and discharge an excess of oil 13 18 SUSPENSION Front Fork e Make sure about 16 mm 0 63 in A of push rod thread is exposed from the locknut B e Completely wipe of the fork oil from the spring A collar B and cylinder unit C e Insert above mentioned parts into the fork e Temporarily tighten the fork top plug A subtank using the top plug wrench Special Tool Top Plug Wrench 49 mm 57001 1653 B e Clamp the axle holder with a vise OProtect the axle holder with a rag when using a vise WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom and locknut Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING Be careful of reaction force in spring and fix surely so that special tool should not come off Do not place the fingers etc while serving SUSPENSION 13 19 Front Fork e Insert the push rod A into the piston rod e Repl
68. e Pull the spark plug cap lightly to make sure the installation of the spark plug cap ENGINE TOP END 5 21 Cylinder Head Remedy Action The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression is cylinder head combustion chamber is damaged parts if necessary higher than the suspected due to damaged valve stem usable range or piston oil rings Incorrect cylinder head gasket Replace the gasket with a standard one thickness Damaged auto decompressor spring or Replace the spring or auto decompressor do not move smoothly decompressor The oylinder Exhaust gas leakage around cylinder Replace the damaged gasket and check compression is head cylinder head warp lower than the Incorrect seating surface of valve Repair seating surface if possible peana Tange Valve clearance is too narrow Adjust the valve clearance Piston cylinder clearance is too wide Replace the piston and or cylinder Piston seizure Inspect the cylinder and piston repair or replace them if necessary Bad condition of piston ring and or Replace the piston and or the piston piston ring grooves rings Auto decompressor do not move Replace the auto decompressor smoothly Cylinder Head Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Camshaft Chain Tensioner see Camshaft Chain Ten sioner Removal Cylinder Head Cover see Cylinder Head Cover Re moval Camshaft see
69. eee eee re 8 2 DOS Cla Mi Tera Meere PER EN 8 4 ENGINGIREMOV all INS Alan olla id aio adosado lie 8 5 ENGINE FSerTiO Valise tet ti lies 8 5 Stelle E Te DEE 8 7 8 2 ENGINE REMOVAL INSTALLATION Exploded View ENGINE REMOVAL INSTALLATION 8 3 Exploded View Jane e Peer gu Tam sr 1 Upper Engine Mounting Bots M0 49 so 36 2 Middle Engine Mounting Bott Nut MIO 49 50 36 3 Lower Engine Mounting Bott Nut MO 49 80 36 4 Upper Engine Bracket Bots MB 29 30 2 5 Midde Engine Bracket Bots Nuts M6 29 30 21 6 Swingarm Piot Shanu e 10 72 8 4 ENGINE REMOVAL INSTALLATION Special Tool Jack 57001 1238 T5712385T ENGINE REMOVAL INSTALLATION 8 5 Engine Removal Installation Engine Removal e Place the jack A under the frame to support the motor cycle Special Tool Jack 57001 1238 A WARNING For engine removal the swingarm pivot shaft must be pulled out causing the swingarm and rear wheel assembly to become detached To prevent the motorcycle from falling make sure to support the frame with a jack e Squeeze the brake lever slowly and hold it with a band A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury CAUTION Be sure to hold the front brake when removing the engine or the motorcycle may fall o
70. effi ciency of the cooling system e Drain the cooling system e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacture of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding Water Pump Water Pump Cover Removal e Unscrew the drain plug A and drain the coolant see Coolant Draining e Loosen the clamp screw B and remove the radiator hose C from the water pump cover e Unscrew the cover bolts D e Using the pry points A remove the pump cover B Water Pump Cover Installation e Replace the pump cover gasket A with a new one e Check to see that dowel pins B are in place in the mating surfaces of the right engine cover e Install the water pump cover OReplace the drain bolt washer with a new ones e Tighten Torque Water Pump Cover Bolts A 9 8 N m 1 0 kgf m 87 in Ib Coolant Drain Plug B 6 9 N m 0 70 kgf m 61 in
71. is neces sary Removal may damaged them e Remove the ball bearing and or needle bearing outer race using a press or puller NOTE Oln the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 C 200 F max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Install the new bearing until its outer race stops at the bottom of the case using a press and the bearing driver set A Special Tool Bearing Driver Set 57001 1129 6114060531 Bearing Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil to it OSpin A the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it 6113014951 9 24 CRANKSHAFT TRANSMISSION Bearings Oil Seals e Check the needle bearing OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing for abrasion color change or other damage x If there is
72. 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 these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE 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 an exploded view illustration of the system components follows the Table of Contents In these illustrati
73. its screw head D facing left side Torque Carburetor Holder Clamp Screw 2 0 N m 0 20 kgf m 18 in lb e Fit the recess A of the holder into the projection B of the cylinder head ENGINE TOP END 5 37 GE17012B81 GC GE17013BS1 5 38 ENGINE TOP END Muffler A WARNING To avoid a serious burn do not remove the muffler when the engine is still hot Wait until the muffler cools down Muffler Removal e oosen the muffler clamp bolt A e Remove the exhaust pip holder nut B e Remove the exhaust pipe C e Remove oeat see Seat Removal in the Frame chapter Right Side Cover see Side Cover Removal in the Frame chapter e Remove the muffler mounting bolts A e Remove the muffler B from the back Muffler Installation e Replace the holder gasket A with a new one e Check the gasket B at the clamp and replace it if it is damaged Make sure that the gasket is placed securely outside the exhaust pipe e First tighten all the bolts and nuts to a snug fit e Next tighten the exhaust pipe holder nuts evenly to avoid exhaust leaks e Lastly tighten the rest of the bolts and clamp bolt securely Torque Exhaust Pipe Holder Nuts 21 N m 2 1 kgf m 15 ft Ib Muffler Mounting Bolts 21 N m 2 1 kgf m 15 ft Ib e Thoroughly warm up the engine wait until the engine cools down and then retighten the exhaust pipe holder nuts and the clamp bolt securely Muffler Baffle Replacement e Refer to
74. lap the valve to the seat as described below e Grind the seat at a 55 angle until the seat width is within the specified range OTo make the 55 grind fit a 55 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 55 grind return to the seat width mea surement step above Correct Width B ENGINE TOP END 5 29 GE150121381 GE15012281 GE15012381 5 30 ENGINE TOP END Valves e he seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may have been refaced too much replace it e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment in the Peri odic Maintenance chapter ENGINE TOP END 5 31 Valves Valve Seat Repair Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seating Area O D Tool Venire Caliper Purpose check seat O D against spec Results 45 Grind Machinist s dye on seat Tool 45 Cutter Purpose increase O D of seat area to spec 32 Grind Tool 32 Cutter Purpose reduce O D of seat area to spec Measure Seating Width Tool Venire Caliper Purpose check seat width against spec Results Machinist s dye on seat To
75. level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic Mainte nance chapter ENGINE LUBRICATION SYSTEM 7 9 Engine Oil and Oil Filter Oil Filter Change e Refer to the Oil Filter Change in the Periodic Maintenance chapter Oil Screen Scavenge Removal e Remove the oil pump scavenge cover see Oil Pump Scavenge Cover Removal e Pull out the oil screen A from the crankcase Oil Screen Scavenge Installation e Clean the oil screens thoroughly whenever it is removed for any reason e Clean the oil screens with a high flash point solvent and remove any particles stuck to them WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screens check for any metal parti cles that might indicate internal engine damage e Check the screens A carefully for any damage holes broken wires gasket pulling off x If the screen is damaged replace it G607000BS1 C e Apply engine oil to the rubber portion A on the oil screen e Install the oil screen facing the carved line B to the out side e Install the oil pump scavenge cover G607001BS1 7 10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Scr
76. lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close the bleed valve while holding the brake applied B 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs almost out any time during bleeding operation the bleeding opera tion must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for easier bleeding e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib GLOSG34BS2 C Brake Fluid e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this in not done BRAKES 12 11 12 12 BRAKES Caliper Caliper Removal Front Brake e Loosen the banjo bolt A so as not to spill brake fluid e Remove the caliper mounting bolts B e Remove the banjo bolt and take off the brake hose from the caliper C e f the caliper is to be disassembled aft
77. locknut C and turn the adjuster D to either side e After adjustment tighten the locknut NOTE OUsually it is not necessary to adjust the pedal position but always adjust it when the master cylinder is disas sembled or pedal position is incorrect e Measure the length indicated in the figure Length A Standard 68 5 1 mm 3 09 0 04 in Alf it is not specified length the brake pedal may be de formed or incorrectly installed x If it is not within the specified length adjust the push rod in the master cylinder as follows G812024B81 GLO4004BS1 C PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures OLoosen the push rod locknut A OReplace the cotter pin with a new one ORemove Cotter Pin B Washer Joint Pin C OTurn the bracket D to obtain the specified length OTighten the locknut Torque Rear Master Cylinder Push Rod Locknut 17 N m 1 7 kgf m 13 ft lb Brake Fluid Level Inspection e Check the brake fluid level in the front or rear brake reser voir A NOTE OHold the reservoir horizontal when checking brake fluid level e he front or rear reservoir must be kept above the lower level line B Olf the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line In side the reservoir is stopped end showing the upper level line C Torque Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in 1b A WARNING
78. made during removal or the white paint mark on a new tire see Re moval e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Pry one side of the tire back onto the rim Fit the bead protector into the tire e Pry the other side of the tire onto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same manner e Check that the tube is not pinched between the tire and rim 6J05010431 GJ05064BS1 WHEELS TIRES 10 13 Tires e Tighten the bead protector nut A and valve stem nut B and put on the valve cap C e Check and adjust the air pressure after installing Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection Adjustment in the Pe riodic Maintenance chapter 10 14 WHEELS TIRES Hub Bearings Hub Bearing Removal e Remove the wheel see Wheel Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the oil seals and circlips Special Tool Inside Circlip Pliers 57001 143 e Remove the hub bearing
79. may allow dirt to reach the carburetor causing poor run ning Replace the fuel filter e Remove the fuel tap e Check the fuel tap for fuel leaks e f the fuel tap leaks or allows fuel to flow when it is at OFF position replace the fuel tap Cooling System WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wash away any coolant that spills on the wheels Since coolant is harmful to the human body do not use for drinking 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e ean the motorcycle slightly to the left until the radiator capis level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Check the coolant level The coolant level A should be at the bottom of the filler neck B x If the coolant level is low add coolant through the filler opening to the bottom of the filler neck Install the cap Recom
80. of the motorcycle up and down and check for smooth suspension stroke e Remove the rear frame see Rear Frame Removal in the Frame chapter e Check for a broken or collapsed spring e Check the shock for a bent shaft or oil leaks If the shock does not smoothly or damaged replace or repair defective parts Rear Shock Absorber Oil Change The oil should be changed in the rear shock absorber at least once per racing season The frequency for best per formance must be based upon riding conditions and rider ability e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal in the Suspension chap ter e Remove the shock absorber spring see Spring Replace ment in the Suspension chapter e Point the valve A away from you slowly release nitrogen gas pressure by pushing down the valve core with a screw driver WARNING Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure An oil mist is often released with the nitrogen Always release nitrogen gas pressure before disassem bling the rear shock absorber to prevent explosive separation of parts 2 54 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Adjust the gas reservoir damping adjusters A to the soft est position e Remove the air bleed bolt B and pump the rear shock to drain the oil out the rear shock body e Install the air bleed bolt e Using the suitable tool A and pres
81. of the oil pipes e Assemble Camshaft Caps A Oil Pipes B e While keeping parallel install them e Uniformly tighten all bolts and after the camshaft has set tled uniformly tighten all the bolts OFollowing the sequence numbers on the camshaft caps Tighten the cap bolts 1 8 after applying molybdenum disulfide oil to the thread of them Torque Camshaft Cap Bolts 9 8 N m 1 0 kgf m 87 in Ib e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation then check the camshaft chain timing CAUTION After this procedure if any resistance is felt while turning over the crankshaft stop immediately and check the camshaft chain timing Valves will be bent if the timing is not properly set e Install the cylinder head cover see Cylinder Head Cover Installation timing inspection cap and the balancer shaft cap Special Tool Filler Cap Driver 57001 1454 Camshaft Chain Removal e Remove Camshaft see Camshaft Removal Flywheel see Flywheel Removal in the Electrical Sys tem Lower Camshaft Chain Guide Bolt A Lower Chain Guide B Front Chain Guide C e Remove the camshaft chain D from the crankshaft sprocket Camshaft Chain Installation e Hang the camshaft chain A to the crankshaft sprocket e Install Front Chain Guide B Lower Chain Guide C e Tighten Torque Lower Camshaft Chain Guide Bolts D Oil Pump Scavenge Cover Bolts 9 8 N m 1 0 kgf m 87 in lb
82. out the air e Remove the valve stem nut B OWhen handling the rim be careful not to damage the rim flanges e oosen the bead protector nut A e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 6J05031B31 10 12 WHEELS TIRES Tires e Step on the side of the tire opposite valve stem pry the tire off the rim with the tire iron A of the bead breaker protecting the rim with rim protectors B Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 CAUTION Take care not to inset the tire irons so deeply that the tube gets damaged e Remove the bead protector and tube when one side of the tire is pried off e Pry the tire off the rim Tire Installation NOTE OThe Tires should be installed so that the ID serial NO A faces to left side e Inspect the rim and tire and replace them if necessary e Install the tube band and tube e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Position the front tire on the rim so that the valve A is at the tire balance mark B the chalk mark
83. possible to the cylinder head mating surface e Move the stem back and forth C to measure the valve wobble e Repeat the measurement in a direction at a 90 angle to the first measurement x If the reading exceeds the service limit replace the guide NOTE OThe reading is greater than the actual valve valve guide clearance because the measurement is taken outside of the guide Valve Valve Guide Clearance Measurement Wobble Method Standard Exhaust 0 09 0 16 mm 0 0035 0 0063 in Inlet 0 06 0 14 mm 0 0024 0 0055 in Service Limit Exhaust 0 36 mm 0 014 in Inlet 0 33 mm 0 013 in GE15010431 Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C e Measure the outside diameter D of the seating pattern on the valve seat If the outside diameter is too large or too small repair the seat see Seat Repair Valve Seating Surface Outside Diameter Exhaust 30 4 30 6 mm 1 197 1 205 in Inlet 35 4 35 6 mm 1 39 1 40 in e Check the seating surface width of the valve seat OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Valve Seating Surface Width Standard Exhaust 0 8 1 2 mm 0 03 0 047 in Inlet 0 5 1 0 mm 0 02 0 039 in x If the width is too wide G too narrow H or unev
84. raise the rear wheel off the ground Special Tool Jack 57001 1238 SUSPENSION 13 23 GMOS206BS1 c D 1615 14131211109 8 7 6 5 4 3 2 1 t GM05207B51 13 24 SUSPENSION Rear Suspension Uni Trak e Using the hook wrenches A loosen the locknut B on the rear shock absorber Special Tool Hook Wrench R37 5 R42 57001 1101 e Using the stem nut wrench A turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Special Tool Steering Stem Nut Wrench 57001 1100 Spring Preload Adjustment Adjusting nut position at the lower surface A from the center of the mounting hole Standard 127 5 mm 5 020 in 121 5 138 5 mm 4 783 5 453 in e Tighten the locknut securely e After adjusting move the spring up and down to make sure that the spring is seated e Install the parts removed e Tighten the rear frame mounting bolts Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Adjustable Range Spring Tension e Since the spring becomes shorter as it weakens check its free length A to determine its condition x If the spring of either rear shock absorber is shorter than the service limit it must be replaced If the length of re placement spring and that of the remaining spring vary greatly the remaing spring should also be replaced in or der to keep the rear shock absorbers balanced of motor
85. shaft and release shaft oil seals C so that oil seal lip A face to the engine outside and oil seal surface flush with the left crankcase surface B e Press the shift shaft oil seal until it bottom out so that oil seal lip face the engine outside e Apply high temperature grease to the oil seal lip e Install the new circlip D to the output shaft and release shaft oil seal Special Tool Bearing driver Set 57001 1129 e Apply a non permanent locking agent to the retaining screw e Tighten the bearing retaining screws A Torque Bearing Retaining Screws 15 N m 1 5 kgf m 11 ft Ib AA Piston Oil Nozzle B 2 9 N m 0 30 kgf m 26 in Ib ps gt LES P ss Cr I ah F e Apply engine oil to the transmission gears bearings shift forks shift drum and crankshaft bearing e Install the drive shaft A and output shaft B in the right crankcase C as a set CRANKSHAFT TRANSMISSION 9 11 Crankcase e Install Shift Drum A see Transmission Installation Shift Rods B see Transmission Installation Shift Forks C see Transmission Installation e Install Crankshaft A Dowel Pins B e Replace the O ring A with a new one e Install the Oil Screen Feed Torque Oil Screen Feed Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb e With the connecting rod positioned at the bottom dead center install the crankshaft jig A Special Tool Crankshaft Jig 57001 1174 e Apply liquid gasket to the m
86. the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter Master Cylinder Assembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter GLO7088BS1 BRAKES 12 17 Master Cylinder Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on the outside of each piston B x If a master cylinder or piston shows any damage replace hs EE DL e Inspect the primary C and secondary D cups A If a cup is worn damaged softened rotted or swollen the piston assembly should be replace to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup e Check the dust covers E for damage x If they are damaged replace them e Check that the relief F and supply G 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 e Check the piston return springs H for any damage If a spring is damaged replace it J Front Master Cylinder K Rear Master Cylinder i n w ei li D AH GLO7022B 12 18 BRAKES Brake Disk Brake Disc Inspection e Visually inspect the disc A x If it is scratched or damaged
87. the Muffler Baffle Change in the Periodic Main tenance chapter GE18033BS1 ENGINE RIGHT SIDE 6 1 Engine Right Side Table of Contents EXPLICO PC MEET 6 2 OSC tee EE 6 6 Specgial 1010 PRES DE m 6 7 CHIC Ver and Cableado Vena En eee Rb eer suae ERR REX FE 6 8 Clutch Lever FreedPlay InspecllODsecuse eo pe Eee ad bene e 6 8 Clutch Lever Free Play Adjustment EE 6 8 e ead Ricci e EE 6 8 Gluten Cable REMOVAL EE 6 8 CUTE ale InstallallOlissse e a ia Pa tiae esca atio atat sain 6 9 Clutch Cable Inspection and Lubrication cccccceecceeeceeeteeeteeceeeeeeeeeeeeueceeeeeeeeseeeaeeeas 6 9 Clutch Cover and Right Engine Cover 6 10 Gluten Cover RemoVal isse a a a a 6 10 Clutch cover last AO Mie rai a da E wv ia PEN e sauteuse 6 10 Fait Engine over Remate a dues dee fia Babe d mu 6 10 Right Engine Cover InstallallOII socis uibus soccer mins cr ns in nc 6 10 Release Shat Removal iuniaistee dete aee bet i pov P Db ia 6 11 Release sonal Instalar is 6 11 A A A m PC NR 6 12 Gluten Remolino 6 12 luteh Inici ATION EE IEEE 6 12 Clutch Plate Assembly Free Play Inspection Adjustment n0nnn0nnannnennennnnnnnnnnnnnnnnnnnne 6 15 Friction and Steel Plates Wear Damage Inspechon 6 15 Friction and Steel Plate Warp Inspechon 6 15 Clutch Spring Free Length Inspechon 6 15 Clutch FAousmo Finger Damage e nsc NN nl sn n sit a at 6 16 Friction Plate Clutch Housing Clearance ccccccccceecccececeeeeceeeeeececeecaucese
88. the steel plates if their teeth are damaged as well GROSOS2BS1 GRO5010581 GROSOSSBS1 ENGINE RIGHT SIDE 6 17 Primary Gear Primary Gear Removal e Remove Right Engine Cover Clutch see Clutch Removal e Temporarily install the clutch housing A e Using the gear holder B secure the primary gear Special Tool Gear Holder m2 0 57001 1557 e Remove the clutch housing e Remove the primary gear nut C washer primary gear D and oil pump drive gear OPrimary gear nut is left hand threads Primary Gear Installation e Apply high temperature grease to the oil seal lip e Insert the oil pump drive gear A and primary gear B to the crankshaft e Install the washer C as shown GROG007BS1 e Using the gear holder A secure the clutch gear and the bottom of the primary gear then tighten the primary gear nut B OPrimary gear nut is left hand threads Torque Primary Gear Nut 98 N m 10 kgf m 72 ft Ib Special Tool Gear Holder m2 0 57001 1557 e Install Clutch see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion 6 18 ENGINE RIGHT SIDE External Shift Mechanism External Shift Mechanism Removal e Remove Shift Pedal Bolt A Shift Pedal B e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal Circlip A Oil Pump Driven Gear B e Pull out the shift shaft C e Remove the bolt D and scre
89. too high Brown smoke Main jet too small Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable hose wire routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn owingarm pivot bearings worn Rim warped or not balanced Spokes loose Wheel bearing worn Handlebar clamp bolt loose Steering stem head bolt loose Front rear axle runout excessive Handlebar pulls to one side Frame bent Rear wheel misalignment owingarm bent or twisted owingarm pivot shaft bent Steering maladjusted Steering stem bent Front fork bent Right and left front fork oil level uneven Suspension operation trouble Too hard Tire air pressure too high Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Front fork bent Front fork air pressure too high Too soft Front fork oil insufficient or leaking Front fork oil viscosity too low Rear shock absorber adjusted too soft Front fork rear shock absorber spring weak Rear shock absorber oil or gas leaking Tire air pressure too low Brake Doesn t Hold Air in brake system Pad disc worn Brake fluid leakage Contaminated pad Brake fluid deteriorated Brake master cylinder cups damag
90. using the grinding compound lt will come off oxide film treated surface of the valve e Visually inspect the valve surface x If the surface is damaged replace it e Replace the oil seal C with a new part e Apply a thin coat of molybdenum disulfide grease to the valve stem A before installing the valve e Check to make sure that the valve moves up and down smoothly e Check to make sure that the valve and the valve seat are making proper contact e Install the inner valve spring D and outer valve spring E so that the closed coil end faces the spring seat B e Compress the valve spring to install the split keepers G in order to secure the spring retainer F in place Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 24 57001 1586 e The shim H must be installed with its thickness indication facing up towards the retainer OApply high temperature grease to the shim or to the retainer to prevent the shim from falling off when the camshaft is being installed e Apply engine oil to the valve lifter I surface then install the lifter GE15113BS2 C ENGINE TOP END 5 25 Valves Valve Guide Removal e Remove Valve see Valve Removal Oil Seal opring Seat e Heat the area around the valve guide up to 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the o
91. 10 i 5 Radiator Hose Clamp Sorews 15 0 16 13mb 6 Radiator Mounting Bots Lag 10 S 7 Radiator Shroud Bols Lag 10 ermm 8 Redator Seren Bote aiser 9 Water Pump Cover 10 Impeller 11 Right Engine Cover 12 Right Radiator 13 Left Radiator 14 Radiator Cap 15 Coolant Overflow Hose G Apply grease R Replacement Parts 4 4 COOLING SYSTEM Specifications Mem Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 antifreeze 50 Freezing Point 35 C 31 F Total Amount 1 05 L 1 11 US qt Radiator Cap Relief Pressure 112 142 kPa 1 14 1 45 kgf cm 16 2 20 6 psi COOLING SYSTEM 4 5 Special Tool Bearing Driver Set 57001 1129 75711298T 4 6 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor cycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter A WARNING To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down Coolant Level Inspection e Referto the Coolant Level Inspection in the Periodic Main tenance chapter Coolant Deterioration Inspection e Refer to the Coolant Deterioration Inspection in the Peri odic Maintenance cha
92. 165 20 225 325 23 33 165 240 Specifications PERIODIC MAINTENANCE 2 9 Wem Standard Fuel System Throttle Grip Free Play Hot Starter Lever Free Play Air Cleaner Element Oil Cooling System Coolant Type recommended Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance Exhaust Inlet Cylinder Head Warp Cylinder Inside Diameter see text Piston cylinder Clearance Engine Right Side Clutch Lever Free Play Friction Plate Thickness Friction Plate Warp Steel Plate Warp Engine Lubrication System Engine oil Type Viscosity Capacity Crankshaft Transmission Connecting Rod Big End Side Clearance Wheels Tires Rim Runout Axial Radial Front and Rear Tires Air Pressure Standard Tire Front Size Make Type 2 3 mm 0 08 0 12 in 0 5 1 0 mm 0 02 0 04 in High quality foam air filter oil Permanent type antifreeze Green Soft water 50 and coolant 50 35 C 31 F 1 05 L 1 11 US qt 0 17 0 22 mm 0 0067 0 0087 in 0 10 0 15 mm 0 0039 0 0059 in E 0 05 mm 0 002 in 96 000 96 012 mm 3 7795 3 7800 in 96 10 mm 3 783 in 0 020 0 042 mm 0 00079 0 0016 in 8 13 mm 0 3 0 5 in 2 92 3 08 mm 0 115 0 121 in 2 6 mm 0 10 in Not more than 0 15 mm 0 0059 in 0 3 mm 0 01 in Not more than 0 2 mm 0 008 in 0 3 mm 0 01 in Castrol R4 superbike 5W 40 or API SG SH SJ or SL wi
93. 2 10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake whenever brake lever or pedal action feels soft or spongy af ter the brake fluid is changed or whenever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap and check that there is plenty of fluid in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Install the reservoir cap e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake
94. 34 N m 3 5 kgf m 25 ft Ib Element Removal e Remove Seat see Seat Removal in the Frame chapter Wing Bolt A Element B e Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract eomm P Air Cleaner Element Installation e When installing the element coat the lip of the element with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Also coat the base where the lip of the element fits e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Take out the towel from the carburetor securely e Install the element so that its tab A faces upward and fit the frame projections B to the holes of the holder C e Tighten the wing bolt D e Install the seat see Seat Installation in the Frame chap ter Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 29 GCO7O33BS1 GC07034BS81 3 30 FUEL SYSTEM Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammable and can be
95. 35 57001 221 57001 1116 5757022157 ST5711168T Valve Spring Compressor Assembly Valve Seat Cutter 32 535 57001 241 57001 1121 T570241ST 75711218T Valve Guide Arbor 55 5 Valve Seat Cutter 32 538 5 57001 1021 57001 1122 T5710218T 8T5711228T Valve Guide Reamer 65 5 Valve Seat Cutter Holder 45 5 57001 1079 57001 1125 ST571079ST ST571125ST Piston Ring Compressor Grip Valve Seat Cutter Holder Bar 57001 1095 97001 1128 ST571095S8T 75711288T 5 10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter 55 535 Valve Seat Cutter 45 540 57001 1247 57001 1496 ST5712478T ST5 14968T Spark Plug Wrench Hex 16 Valve Seat Cutter 55 538 5 57001 1262 57001 1497 5757126257 ST5714978T Compression Gauge Adapter M10 x 1 0 Valve Guide Driver 57001 1317 57001 1564 ST5713178T ST5715648T Piston Ring Compressor Belt 495 4108 Piston Pin Puller 57001 1358 57001 1568 Sa p Une C Filler Cap Driver Valve Spring Compressor Adapter 524 57001 1454 57001 1586 75714545T T5715868T ENGINE TOP END 5 11 Special Tools and Sealant Valve Guide Driver Attachment D Kawasaki Bond Silicone Sealant 57001 1659 92104 0004 T5716598T ST9200048T 5 12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter Sp
96. 7 8 0 80 69 in lb Caliper Holder Bolt Rear 27 2 8 20 Brake Pad Bolt 17 1 7 13 Rear Brake Pad Bolt Plug 2 5 0 25 22 in lb Brake Pedal Mounting Bolt 25 2 5 18 L G Suspension Front Fork Clamp Bolts Upper 23 2 3 17 AL Front Fork Clamp Bolts Lower 20 2 0 15 AL Front Fork Top Plug 30 3 1 22 Adjuster Assembly 58 5 9 43 L Base Valve Assembly 28 2 9 21 Locknut Adjuster Assembly 29 3 1 21 Swingarm Pivot Shaft Nut 98 10 12 Rear Shock Absorber Mounting Nuts Upper 39 4 0 29 Lower 34 3 5 25 Air Bleed Bolt 6 4 0 65 57 in lb Tie Rod Mounting Nut Front Rear 83 8 5 61 Rocker Arm Pivot Nut 83 8 5 61 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Steering Steering Stem Head Nut Steering Stem Nut 43 in 1b Handlebar Clamp Bolts 18 Frame Rear Frame Mounting Bolts 25 Upper Footpeg Bracket Bolts 40 Electrical System Gear Position Switch Screws 26 in lb Flywheel Nut 58 Stator Bolts 35 in Ib Crankshaft Sensor Bolts 62 in lb Spark Plug 115 in 1b C D I Unit Bolts 87 mb Magneto Cover Bolts f l 87 in lb Breather Fitting 11 Ignition Coil Bolts 62 in lb Basic Torque for General Fasteners Threads dia Torque mm Mm kfm ip 5 3 4 4 9 0 35 0 50 30 43 in lb 6 9 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125
97. 71 1 93 3 116 138 SE eX PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Crankshaft Transmission 2 28 Torque and Locking Agent 2 5 Crankshaft Inspection 2 28 Specifications esses 2 9 Wheel WEE 2 28 Special TOONS sn ns 2 11 Air Pressure Inspection Adjust Periodic Maintenance Procedures 2 12 VLC E 2 28 FUEL SS Mistica 2 12 Tires Inspection 2 29 Fuel Hose and Connection Spoke Tightness Inspection 2 29 INS PS CHON EE 2 12 Rim Runout Inspection 2 30 Throttle Grip Free Play Inspection 2 12 Wheel Bearing Inspection 2 30 Throttle Grip Free Play UMA DAVE uri 2 31 Adjustment 2 12 Drive Chain Slack Inspection 2 31 Hot Starter Lever Free Play Drive Chain Slack Adjustment 2 31 Jee en EE 2 13 Drive Chain Wear Inspection 2 32 Idle Speed Inspection 2 13 Drive Chain Lubrication 2 33 Idle Speed Adjustment 2 14 Sprocket Wear Inspection 2 33 Air Cleaner Element Cleaning and Rear Sprocket Warp Inspection 2 34 Jet e In BEE 2 14 Brake Secum UEM ce uM RI 2 34 Fuel Inspection 2 16 Brake Lever and Pedal Position Fuel Tank Filter and Tap Adjustment 2 34 a RE 17 Brake Fl
98. AFT TRANSMISSION Crankcase e Remove Oil Screen Feed A see Oil Screen Feed Removal in the Engine Lubrication System chapter Shift rods B see Transmission Shaft Removal 2 shift forks C see Transmission Shaft Removal Shift dram D see Transmission Shaft Removal Transmission E see Transmission Shaft Removal e Remove the crankshaft from the right crankcase half see Crankshaft Removal CAUTION Do not remove the bearings and the oil seals unless it is necessary Removal may damage them Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state so if replaced they must be replaced as a set e Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high flash point solvent e Using compressed air blow out the oil passages in the crankcase halves A WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or ex plosions could result e Support the crankcase bearing boss with a suitable re E tainer A e Using a press and the bearing driver set C install a new B bearing B until it bottoms out Special Tool Bearing Driver Set 57001 1129 CAUTION D a D Y 6104000B51
99. BRAKES Exploded View 6L021578W5 C BRAKES 12 5 Exploded View cl ren ue man Nm kgfm mp 1 Brake Hose Barjo Bots Ia 38 25 2 Rear Master Cylinder Mounting Bots 10 10 smb 3 Rear Master Cylinder Push Rod Locknut 17 17 19 4 CaliperBleedVave 78 080 amp mb 5 ferae Paast 7 i17 19 6 Rear Brake Pad Bot Pug 25 025 2mb 7 CaperHoderSt x 28 20 8 Brake Pedal Mounting Bot 25 25 18 LG 9 Brake Disc Mounting Bots 23 23 v L 10 Brake Reservoir Cap Bots 15 015 in 1 11 Brake Hose 12 Rear Master Cylinder 13 Brake Pedal 14 Rear Caliper Cover 15 Rear Caliper 16 Piston 17 Brake Pads 18 Rear Disc BF Apply brake fluid G Apply high temperature grease L Apply a non permanent locking agent R Replacement Parts Si Apply Silicone grease 12 6 BRAKES Specifications tem Standard Brake adjustment Lever Play Adjustable to suit rider Brake Fluid Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 Brake Pads Lining thickness Front 3 8 mm 0 15 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Brake Disc Thickness Front 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 10 in Rear 3 85 4 15 mm 0 152 0 163 in 3 5 mm 0 14 in Runout Not more than 0 25 mm 0 098 in 0 3 mm 0 01 in BRAKES 12 7 Special Tools Inside Circl
100. DIC MAINTENANCE 2 57 Periodic Maintenance Procedures e Insert the piston end A of the piston rod assembly into the rear shock body C slowly Do not insert the seal assembly B yet Pump the piston rod until all the air is forced out of the rear shock body e Push the seal assembly into the rear shock body until it just clears the circlip groove e Check the circlip x If it is deformed or damaged replace it with a new one e Fit the circlip A into the groove in the rear shock body B CAUTION If the circlip is not a certain fit in the groove in the rear shock body the piston rod assembly may come out of the shock absorber when injecting the nitro gen gas or riding the motorcycle e Pull up the piston rod assembly C against the circlip e Force the stop D into the rear shock body by lightly tap ping around the edge of the stop with a mallet e Fully extend the piston rod assembly e Install the suitable oil cup A to the air bleed bolt hole and fill the specified oil into the cup e Purge the air from between the gas reservoir B and rear shock body C by slowly pumping the piston rod D in and out e Install the air bleed bolt securely Torque Air Bleed Bolt 6 4 N m 0 65 kgf m 57 in lb e Fully extend the push rod assembly e Inject nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi through the valve on the gas reservoir e Check the rear shock body and gas reservoir for oil and ga
101. G est ct tte EE 14 5 Steering Stem Stem Bearing Removal ss 14 5 Steering Stem Stem Bearing Installation ooocccocnoccnoconicccnococnncnnncannonanonannnnanonoss 14 7 Stem Bearing LUBMCAUOM BE 14 8 Stem Bearing Wear Damage ain ic dt 14 8 vizio 14 8 lio lor A RERO REUNIR 14 9 Handlebar RemoVa lus O T 14 9 Handlebar IAS ais 14 9 14 2 STEERING Exploded View AIRES H TIVHLNED GNO20718W5 C STEERING 14 3 Exploded View Al re ue en a jm Nm kgfm Ep 2 SeeingSemHeadNu Im 10 72 Handlebar Clamp Handlebar Handlebar Holder Steering Stem Head Bracket Upper Tapered Roller Bearing Head Pipe Lower Tapered Roller Bearing Steering Stem Apply adhesive cement Tighten the two clamp bolts alternately two times to ensure even tightening torque Apply grease 2T Apply 2 stroke oil T First tighten the stem locknut with 39 N m 4 0 kgf m 29 ft lb of torque then loosen it and retighten it with 4 9 N m 0 50 kgf m 43 in Ib of torque 14 4 STEERING Special Tools Bearing Puller Head Pipe Outer Race Driver 54 5 57001 135 57001 1077 ST5701358T ST5710778T Steering Stem Bearing Driver Steering Stem Nut Wrench 57001 137 57001 1100 Steering Stem Bearing Driver Adapter 34 5 Head Pipe Outer Race Remover ID gt 37 mm 57001 1074 57001 1107 ST5710748T T571107ST Head Pipe Outer
102. Install the left handlebar grip so that the arrow A on the grip face to the forward e Install the clutch lever A so that it incline 20 5 B more than the horizontal line C and position it from the edge of the grip to 170 mm 6 69 in D GR11004081 14 10 STEERING Handlebar e Apply grease to the throttle cable upper end and clutch cable upper end e Apply a 2 stroke oil to the throttle grip inner wall A e Install the throttle grip assy so that the grip A is in as far as it will go e Position the throttle grip assy so that the parting line B of the throttle case vertically and tighten the screws e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter e Install the handlebar B on the handlebar holder so that the protruded scales of the both side adjust to the same width A e Apply 2 stroke oil to the thread of the handlebar clamp bolts e Install the handlebar clamp so that center D of the han dlebar clamp C and handlebar bridge E align Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib Front F e After tighten make sure space A B of the ahead and back are same width GNOG6034BS1 GNOG036BS1 C FRAME 15 1 Frame Table of Contents EXPO Rai NETT Ex 15 2 BLES Af cae A EE 15 4 Frame FASO CUO I WEE 15 4 Rear ae laten e E EE 15 4 Rear e lant In EE ue do nex ei tu ion handle 15 4 Engine Guard Bn GET de E LI ED
103. O Sia AN 7 7 0 OA A 7 8 Engine Oil Level InSpeclOfi arado alias 7 8 ENTE CAN edi 7 8 Oil Fiter Change nn m UU UT 7 9 Oil Screen Scavenge Removal iii 7 9 Oil Screen Scavenge Installaton 7 9 Oll Screen Feed Removal cda 7 10 Oll screen Feed Installation isis ida 7 10 Oil Screen Scavenge Cleanimg iii 7 10 Ol Screen Feed Cleaning uenis noie dad o clon 7 11 OIF Pressure Relef VAIV ete 7 12 Oil Pressure Relief Valve Hemoval 7 12 Oil Pressure Relief Valve Installation 7 12 Oil Pressure Relief Valve Inspechon a a aT 7 12 SUN eme T o ode codos et lle de e sde 7 13 Oil Pump Scavenge REMOVA EE 7 13 Oil Pump Scavenge Installation 7 13 OIl P mp Feed Removal vii A once 7 14 OIMPUMp Feed Sta lla Mystara iio ed 7 14 OIL PUMPE INSPECHOM aia aiii 7 15 OIL dicic MEN RU UU T ia io os duc 7 16 Oil Pressure Measurement cnc rr rn erii 7 16 7 2 ENGINE LUBRICATION SYSTEM Exploded View NEO c f e CLA Y 60020858885 C ENGINE LUBRICATION SYSTEM 7 3 Exploded View NEN NNNM M Nm kgfm rb EN Engine Oil Drain Bolt M10 for crank room oil sump i ae ts 4 1 Fr Engine Oil Drain Bolt M6 for transmission room 62 in Ib mE oil sump MEN Oil Pump Scavenge Cover Bolts 98 10 87inlb S 4 Oil Pump Feed Cover Bolts 98 10 arnb S 5 Right Engine Cover Bols 98 10 ermm 6 PstnOlNoze 29 030 m 7 On Fiter Covers 98 10 ermm EN Oil Scr
104. Pad Removal ais Ri 12 14 Brake Pad Bee e cristo 12 14 Eilen Ee de EE 12 14 Master e Ie MERERI ED 12 15 Front Master Cylinder Removal aannannnnnnannannannonnnnnnonnrnrrnnrrnrenrnnnenerrnnennrrenronernrrerrnnrne 12 15 Front Master Gylirder Installation ss ue te A nn MM ln ni 12 15 Rear Master Cylinder Removal nennen nennen nnn sns nnns 12 16 Rear Master Cylinder In E UE e EE 12 16 Front Master Cylinder Disassembly ss 12 16 Rear Master Cylinder Disassembly ss 12 16 Master Cylinder Assembly E 12 16 Master Cylinder Inspection Visual Inspechon 12 17 Brake Pi qu TD a ld a da dd 12 18 Brake DISC INSPECCION ii a A a 12 18 EE 12 19 Brake Hose Removal Installation ss 12 19 Brake nose spec HOD cec ne ue an et ot ons 12 19 12 2 BRAKES Exploded View BRAKES 12 3 Exploded View Nm kgfm pp o9 ein S Css 25 a 59 08 ein Ces 1 06 S ib nib OOOO 0 15 Ech 1 Front Master Cylinder Clamp Bolts 2 Brake Hose Banjo Bolts Brake Pad Bolt 10 Front Brake Reservoir 11 Brake Lever 12 Brake Lever Adjuster 13 Locknut 14 Brake Hose 15 Clamps 16 Front Caliper 17 Brake Pad 18 Piston 19 Front Disc BF Apply brake fluid L Apply a non permanent locking agent R Replacement Parts Si Apply Silicone grease 060 sep 015 ep 12 4
105. Radiator Hose A Right Engine Cover Bolts B Right Engine Cover C Right Engine Cover Installation e Three dowel pins A are installed at the mating surface between the crankcase and the right engine cover e Apply grease to the O rings B and install them to the crankcase Olnstall the lower O ring so that the tapered side facing outside e Replace the engine cover gasket with a new one e Apply a high temperature grease to the kick shaft oil seal lips and kick shaft spline ENGINE RIGHT SIDE 6 11 Clutch Cover and Right Engine Cover e When installing the cover doesn t go well the cover is installed according to the following procedures OFit the water pump shaft A and groove B of the balancer shaft while turning the water pump shaft e Tighten Torque Right Engine Cover Bolts 9 8 N m 1 0 kgf m 87 in 1b e Insert the water hose A into the water pump cover B and tighten it with the clamp C e Install the kick pedal see Kick Pedal Installation in the Periodic Maintenance chapter e Install the engine oil drain plugs surely see Periodic Main tenance chapter e Pour in the specified type and amount of oil see Engine Oil Change in the Periodic Maintenance chapter e Pour in the specified type and amount of coolant see Coolant Filling in the Cooling System chapter e Check the rear brake for good braking power and no brake drag Release Shaft Removal e Remove the clutch see Clutch R
106. Viscosity Capacity Drive Train Primary Reduction System Type Reduction Ratio Clutch Type Transmission Type 2 185 mm 86 02 in 820 mm 32 3 in 1 280 mm 50 39 in 1 485 mm 58 46 in 345 mm 13 6 in 965 mm 38 0 in 99 8 kg 220 Ib 7 2 L 1 9 US gal 4 stroke single cylinder DOHC 4 valve Liquid cooled 96 0 x 62 1 mm 3 78 x 2 44 in 449 cm 27 4 cu in 12 0 1 Carburetor KEIHIN FCR40 Primary kick Digital AC CDI BTDC 10 1 800 r min rpm NGK CPR8EB 9 BTDC 32 ABDC 72 284 BBDC 62 ATDC 42 284 Forced lubrication semi dry sump API SG SH SJ or SL with JASO MA SAE 10W 40 1 2 L 1 3 US at Gear 2 727 60 22 Wet multi disc 4 speed constant mesh return shift GENERAL INFORMATION 1 9 General Specifications Mems 00 KX450D6F Gear ratios 1st 2nd 3rd Ath Final Drive System Type Reduction Ratio Overall Drive Ratio Frame Type Steering Angle Caster rake angle 1 800 27 15 1 411 24 17 1 187 19 16 1 000 19 19 Chain drive 3 4846 50 13 10 489 Top gear Tubular semi double cradle 42 to either side 27 1 Trail 117 mm 4 60 in Front tire oize 90 100 21 57M Make Type DUNLOP D742F Tube type Rear tire oize 120 80 19 63M Make Type DUNLOP D756 Tube type Rim size Front 1 60 21 Rear 2 15 19 Front suspension Type Telescopic fork up side down Wheel travel 315 mm 12 4 in Rear suspension Typ
107. ace the O ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O ring e Slowly turn the adjuster assembly A clockwise until re sistance is felt and check the clearance between the lock nut B and adjuster assembly A to provide more than 1 mm 0 04 in C e Turn the locknut A counterclockwise until it contacts with the adjuster assembly B e With the locknut held immovable using a wrench tighten the adjuster assembly to the specified torque Torque Locknut Adjuster Assembly 29 N m 3 1 kgf m 21 ft Ib e With the outer tube compressed by hands remove the top plug wrench e Apply a non permanent locking agent to the threads of adjuster assembly e Torque the adjuster assembly A Torque Adjuster Assembly 58 N m 5 9 kgf m 43 ft Ib e oosen and remove the fork top plug subtank form the outer tube and slowly slide down the outer tube Special Tool Top Plug Wrench 49 mm 57001 1653 e Pour A the specified amount of fork oil into the outer tube Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity Quantity 345 mL 11 7 US oz Europe Model 350 mL 11 8 US oz 13 20 SUSPENSION Front Fork e Raise the outer tube and temporarily tighten the fork top plug subtank Special Tool Top Plug Wrench 49 mm 57001 1653 e After installing the front fork torque the top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 B
108. ack Inspeccion caian vedete ideis 11 5 Drive Chain Slack AGUS CI teca eundum tii 11 5 VheelAlignmeht INS peo e al deis Oud aUe Rn peat erat canta 11 5 Wheel Alignment AdjastimientL cii eode ea uoo Es 11 5 Drive Chan Wear Inspection Eege 11 5 DIVE Chain LUDFICATON DEE 11 5 Drive cham FRETMOV AI sess esas edo ars ceca ueteri EE 11 5 Drive Chali E el EE 11 5 ODIOGKOLS POPE OPCION NOE ON 11 7 Engine SPrOCKEE Removal sucia tetona ETT 11 7 Selten E rel WEE 11 7 Real oprocket Removal m teur da c v d ca ata cta du ex de ES aw eet MUS be Dees 11 7 Rear oprocker INS Ee Een aaa 11 8 Sprocket Wear IHSDOCHOL easier Ee 11 8 Rear oprocket Warp ASPECTO scias eadera ime troia tet a et As 11 8 11 2 FINAL DRIVE Exploded View FINAL DRIVE 11 3 Exploded View cl en eiis Nm kgfm ftlb 1 Rear Sprocket Nuts Ca 35 2 2 Engine Sprocket Nu ax 3130 937 3 Engine Sprocket Cover Bots 98 10 smb Engine Sprocket Output Shaft Chain Slipper Swingarm Chain Guide Locknut Adjusting Bolt Chain Adjuster Drive Chain Rear Sprocket Upper Chain Guide Roller Lower Chain Guide Roller Apply grease Apply a non permanent locking agent Apply oil Replacement Parts LX uA EN RE SN 0 Or O 1 P amp ND OD zl CD OD P 11 4 FINAL DRIVE Specifications Wem Standard Drive Chain Chain Slack 92 58 mm 2 0 2 3 in Chain 20 link L
109. aligned with a spline groove C and install toothed wash ers To install a circlip without damage first fit the circlip onto the shaft expanding it just enough to install it and then use a suitable gear to push the circlip into place Special Tool Outside Circlip Pliers 57001 144 6113114BS1 e he drive shaft gears can be identified by size the small est diameter gear is 1st gear and the largest is 4th Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and the washers are properly in place e he output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is oth Be sure that all parts are put back in the correct sequence facing the proper direction and that all circlips and washers are properly in place 9 20 CRANKSHAFT TRANSMISSION Transmission 900 DOO 00 0 Y AA die Sr _ Sp AA 6113234Bwm3 C 1 Circlip small 9 Ball Bearing 17 4th Gear 19T 2 Circlip middle 10 Drive Shaft 18 1st Gear 27T 3 Circlip large 11 Collar 19 Ball Bearing 4 Ball Bearing one side 12 O rings 2 20 Output Shaft sealed 13 Oil Seal 5 2nd Gear 17T 14 Ball Bearing one side 6 3rd Gear 16T sealed 7 4th Gear 19T 15 2nd Gear 24T 8 1st Gear 15T 16 3rd Gear 19T e Check each gear spins or slides freely on the transmission shaft without binding after assembly Shift Fork B
110. ammer the head pipe outer race remover to drive it out Special Tool Head Pipe Outer Race Remover ID 37 mm 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearing includ ing outer races should be replaced with new ones e Remove the lower stem bearing inner rase tapered roller bearing A with its grease seal from the stem using bear ing puller Special Tools Bearing Puller 57001 1575 Bearing Puller 57001 135 GNO4002BS1 GNO7010831 GNO4011BS1 Steering Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones OApply grease to the outer races and drive them into the head pipe at the same time using the head pipe outer race press shaft A and the head pipe outer race drivers Special Tools Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 54 5 57001 1077 B Head Pipe Outer Race Driver 51 5 57001 1076 C e Replace the lower inner races with new ones OApply grease to the lower tapered roller bearing A and drive it onto the stem using the steering stem bearing driver B and adapter C Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 634 5 57001 1074 e Apply grease to the upper inner race and install it in the head pipe e Install the stem through the head pipe and upper bearing install the stem cap and han
111. and adjust it if necessary see Drive Chain Slack Adjustment NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest e Measure the space chain slack A between the chain and the swingarm at the rear of the chain slipper as shown x If the drive chain slack exceeds the standard adjust it Chain Slack Standard 52 58 mm 2 0 2 3 in Drive Chain Slack Adjustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the axle nut C x If the chain is too tight back out the left and right chain adjusting bolts D evenly and push the wheel forward until the chain is too loose x If the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch on the left chain adjuster should align with the same swingarm mark E as the right chain adjuster notch F x Check the wheel alignment A WARNING Misalignment of the wheel result in abnormal wear and may result in an unsafe riding condition e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 2 kgf m 81 1 ft Ib e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin A through the axle
112. and cable bracket D Release Shaft Lever Position Standard 68 6 76 4 mm 2 70 3 01 in x If the lever position is not within the standard select the correct thickness of adjusting washer s according to the tables shown Adjusting Washers Release Shaft Lever Position and Adjusting Washer Selection oe Washers Position Distance Judgment Qty 68 6 mm to 76 4 mm Standard x Remove the push rod holder assy as necessary and re install the clutch ENGINE RIGHT SIDE 6 15 Clutch Clutch Plate Assembly Free Play Inspection Adjust ment e Assemble the following parts Clutch Hub A Friction Plates B Steel Plates C Friction Plates D Spring Plate E Spring F Bolts G OFriction Plates B have many lining blocks than other plates These plates install both end of the all plates Torque Clutch Spring Bolts 8 8 N m 0 90 kgf m 78 in lb e Measure the clutch plate assembly H Clutch Plate Length Standard 34 9 35 5 mm 1 37 1 40 in If clutch plate length is not within the standard select the correct length of adjusting plates according to the table shown 1 2 mm 0 047 in 13089 1010 GRO5034BS2 C 1 6 mm 0 063 in 13089 1095 2 0 mm 0 079 in 13089 1005 ODo not use the steel plate of 1 2 mm 0 047 in and 2 0 mm 0 079 in Thickness at the same time Friction and Steel Plates Wear Damage Inspection e Refer to the Friction and Steel Plates Inspection in the Per
113. ansmission Share REMOVA pieniin pom Seoul M a 9 18 Transmission Shaft Installation 9 18 Transmission Snart DISASSEMID E 9 18 Transmission Shair ASSembly EE 9 19 inse dziijeseB E e mc 9 20 Shift Fork Gear Groove Wed ti 9 21 Shift Fork Guide Pin Shift Drum Groove Wear ocoooccccccocccocccociconcconncoccconcconconncnnnconnnos 9 21 Gear Damage nes til lo olsen 9 21 Dal Ile EE 9 22 Balancer REMOVE Ss 9 22 Balancer ln EU LUCE LE PR aa 9 22 Sg Lee a Sos 9 23 Bearig Replacement a ad 9 23 A 9 23 OIE SCAN MMS OCCU el dina mec 9 24 9 2 CRANKSHAFT TRANSMISSION Exploded View 61021378W5 C CRANKSHAFT TRANSMISSION 9 3 Exploded View wiren Nm kgFm felb 3 Gear Set Levert a 000 78mb H SE Oil Drain Bolt M10 For Transmission Room Oil 62 in Ib u Engine Oil Drain Bolt M6 For Crank Room Oil Sump eee RC T PsonOlNozde 29 030 26mb 8 Bearing Retaining Sorews 15 15 1 L 9 Balancer Weight Mounting Nut 52 ss 38 11 Copper Washer EO Apply engine oil G Apply grease L Apply a non permanent locking agent LG Apply liquid gasket R Replacement parts S Tighten the fasteners following the specified sequence 9 4 CRANKSHAFT TRANSMISSION Specifications tem Standard Connecting Rods Connecting Rod Big End Radial 0 002 0 014 mm 0 06 mm 0 002 in Clearance 0 00008 0 0006 in Connecting Rod Big End Side 0 25 0 35 mm 0 6 mm 0 02 in Clearance 0
114. ar axles for damage If the axle is damaged or bent replace it Spoke Tightness Inspection e Refer to the Spoke Tightness Inspection in the Periodic Maintenance chapter Rim Runout Inspection e Refer to the Rim Runout Inspection in the Periodic Main tenance chapter WHEELS TIRES 10 9 6K04001B51 6J04034B31 10 10 WHEELS TIRES Wheels Rims Axle Inspection e Visually inspect the front and rear axle for damages x If the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 937 in A apart and set a dial gauge on the axle at a point halfway between the blocks Turn the axle to measure the runout The difference between the highest and lowest dial read ings is the amount of runout If the runout exceeds the service limit replace the axle A Axle Runout 100 mm 3 94 in Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in J04139BS1 WHEELS TIRES 10 11 Tires Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Remove the wheel from the motorcycle see Wheels Re moval GJ05029BS1 e To maintain front wheel balance mark A the valve stem position on the tire with chalk so that the tire can be rein stalled in the same position e Remove the valve cap B e Take out the valve core A to let
115. ark Plug Cap e Remove the cylinder head cover bolts A and remove the cylinder head cover B Cylinder Head Cover Installation e Apply silicon sealant A to the cylinder head as shown Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Replace the head cover gasket e Install the head cover gasket A on the cylinder head e Install the spark plug hole gasket e Make sure that the upper chain guide A is bottomed CAUTION Unless the upper chain guide is bottomed the camshaft chain could push the cylinder head cover upward leading to an oil leak e Install the head cover from the motorcycle left side e Install the head cover bolt washers A with the metal side upwards e Tighten the cover bolt B Torque Cylinder Head Cover Bolt 9 8 N m 1 0 kgf m 87 in lb e Install the spark plug cap OPull up the spark plug cap lightly to make sure of the in stallation of the spark plug cap Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non return type camshaft chain tensioner The push rod does not return to its original position once it moves out to take up camshaft chain slack Observe all the rules listed below When removing the tensioner do not take out the mounting bolts only halfway Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as desc
116. assembly CAUTION Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Using the top plug wrench A remove the fork top plug B subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 SUSPENSION 13 11 13 12 SUSPENSION Front Fork e Place a drain pan under the front fork and drain fork oil A NOTE OPump the fork tube several times to discharge the fork oll e Raise the outer tube and temporarily install the fork top plug A subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtect the axle holder with a rag when using a vise e oosen the adjuster assembly B completely A WARNING Clamping the axle holder too tight can damage it which will affect riding stability Do not clamp the axle holder too tight e Compress the outer tube by hands and install the top plug wrench A between the axle holder bottom B and locknut C Special Tool Top Plug Wrench 49 mm 57001 1653 A WARNING Be careful of reaction force in spring and fix surely so that the special tool should not come off Do not place the finger etc while servicing e Hold the locknut A with a wrench B and r
117. ating surface A of the left crankshaft half Sealant Kawasaki Bond Liquid Gasket Gray 92104 1063 NOTE OMake the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied OMoreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket 9 12 CRANKSHAFT TRANSMISSION Crankcase e Using a plastic hammer A press B the rear portion of the crankcase and tap the area around the crankshaft of the left crankcase While maintaining the mating surfaces of the right and left crankcase halves constantly parallel mate the crankcase halves evenly NOTE OConstantly check the alignment of the two crankcase halves and the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly e Remove the crankshaft jig C e Tighten the crankcase bolts starting with the periphery of the crankshaft then outward e Replace the copper washer B with a new one OTighten it together with the clamp A and copper washer Torque Crankcase Bolts M6 12 N m 1 2 kgf m 106 in Ib Crankcase Bolts M7 15 N m 1 5 kgf m 11 ft Ib NOTE OAfter tightening the crankcase bolts wipe up the liquid gasket seeping out around the mating surface espe cially around the area e Make sure that the crankshaft driveshaft and the output shaft rotate smoothy in the neutral posit
118. be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field or just by aging will result in low output e Check the magneto output voltage do the following pro cedures ORemove the left radiator shroud OPull the stopper A to the this side and remove the mag neto lead connector B ELECTRICAL SYSTEM 16 11 A sch 4 i t A Es hs MT nes KANN rant Td E d eg e e P a 4 14 uo FA BEET 16 12 ELECTRICAL SYSTEM Flywheel Magneto OConnect the hand tester A to the connector B as shown in the table 1 using the needle adapter set C OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 2 measurements Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Table 1 Magneto Output Voltage Tester Reading Range Tester to Tester to 4 000 rpm 50V AC White lead Red lead x If the output voltage shows the value in the table the mag neto operates properly x If the output voltage shows a much lower reading than that given in the table indicates that the magneto is defective e To check the stator coil resistance as follows OStop the engine ODisconnect the auxiliary leads OConnect the hand tester as shown in the table 2 ONote the readings total 2 measurement Table 2 Stator Coil Resistance Reading Range Tester to Tester to Red lead White lead 30 600
119. between the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard 0 020 0 042 mm 0 00079 0 0016 in Piston Piston Ring and Piston Pin Replacement e Refer to the Cylinder and Piston Section in Engine Top End chapter Exhaust System Inspection e he exhaust system in particular the silencer is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss If car bon has built up inside the silencer exhaust efficiency is reduced causing engine performance to drop xlf the silencer is badly damaged dented cracked or rusted replace it Replace the silencer packing if the exhaust noise becomes too loud or engine performance drops Muffler Baffle Change e Remove the muffler see Muffler Removal in the Engine Top End chapter e Remove the muffler pipe bolts A e ap the bracket A of the muffler body with a plastic mallet B to separate from the inner pipe 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pull off the old muffler baffle A e Install the new muffler baffle A into the muffler body B NOTE OWhen replacing the muffler baffle first insert the muffler baffle into the muffler body and align the exhaust hole of the muffler end cover with the muffler baffle hole while turning the muffler baffle Then install the inner pipe
120. by tapping evenly around the bearing inner race as shown A Bar B Distance Collar C Hub Bearing Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub A with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Lubricate them and install them using the bearing driver set B so that the marked or shielded sides face out OPress in the bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 e Replace the circlips and oil seals with new ones e Press in the oil seals A so that the seal surface is flush B with the end of the hole e Apply high temperature grease to the oil seal lips Special Tool Bearing Driver set 57001 1129 C Hub Bearing Inspection NOTE Olt is not necessary to remove any bearings for inspec tion If any bearings are removed they will need to be replaced with new ones e Spin A it by hand to check its condition x If it is noisy does not spin smoothly or has any rough spots it must be replaced e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing 6J06013B51 6J06009B51 C 6J06008B51 6J06002B51 FINAL DRIVE 11 1 Final Drive Table of Contents EX DOTEA VIENS ROTEN 11 2 S D CIICATONS a TET T OTT een ee ea ee ee ene eee ee eee 11 4 Big T Nei e OS 11 5 Drive Chain Sl
121. ch hub nut loose Clutch plate warped or rough Clutch hub spline damaged Valve clearance incorrect Valve spring broken or weak Camshaft bearing or cam face worn Valve lifter worn Other noise Connecting rod big end small end clear ance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket 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 chain guide worn Gear Shifting Faulty Primary gear worn or damaged Doesn t go into gear shift pedal doesn t Decompressor spring broken return Magneto flywheel loose Clutch not disengaging Shift fork bent worn or seized Shift return spring pin loose Abnormal Drive Train Noise Clutch noise Shift return spring weak or broken Shift shaft lever broken Pawl guide plate broken Shift pawl broken Shift pawl spring tension lose Gear seized Gear set lever operation trouble Shift drum broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Pawl guide plate worn Clutch housing finger and friction plate tang worn Clutch housing gear worn Metal chips jam
122. chain Install the master link clip A so that the closed end of the U B points in the direction of chain rotation C GK04002B31 Wheels Rims e Check the drive chain slack see Drive Chain Slack In spection in the Periodic Maintenance chapter e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 2 kg m 81 1 ft Ib e Install the new cotter pin A and spread its end NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes past the nearest hole WARNING If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Install the disc cover e Check the rear brake for good braking power and no brake drag A WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done Wheels Inspection e Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding If the roughness or binding is found replace the hub bear ings e Visually inspect the front and re
123. cified amount of fork oil A Recommended Oil KHL15 10 KAYABAO1 or equivalent Recommended Quantity 170 ml 5 75 US oz NOTE OPlug the two oil holes on the subtank B with fingers e Pump A the piston rod B slowly several times to expel air e Replace the O rings A on the base valve assembly with new ones e Apply specified fork oil to the O rings A B and bushings C on the base valve assembly e With the piston rod held immorable in fully compressed position A gently install the base valve assembly B to the subtank e Screw in the base valve assembly in the subtank when the piston rod extends NOTE OWhen it is hard to screw in the base valve assembly pull down the piston rod a little SUSPENSION 13 17 Front Fork e Holding the top plug wrench A with a vise e Holding the subtank B with the top plug wrench torque the base valve assembly C Special Tool Top Plug Wrench 49 mm 57001 1653 Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft Ib e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flies out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for
124. clockwise from the fully seated position e Put the caps into the bottom of the fork tubes K 16 1514131211109 8 7 6 5 4 3 2 1 M04321BS1 SUSPENSION 13 9 Front Fork Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e o adjust compression damping turn the adjuster A on the front fork top plugs with the blade of a screwdriver until you feel a click Adjust the compression damping to suit you preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated positions adjuster turned fully clockwise A Compression Damping Adjuster Setting Standard 12 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 16 clicks or more Counterclockwise from the fully seated position 16 1514131211109 8 7 6 5 4 3 2 1 GM04322BS81 Oil Change each fork leg e Refer to Front Fork Oil Change in the Periodic Mainte nance chapter Front Fork Removal e Unscrew the bolts A and remove the front brake hose clamps B e Remove Front wheel see Front Wheel Removal in the Wheels Tires chapter Bolts A e Remove the caliper B from the fork leg to be removed and rest the caliper on some kind of stand so that it doesn t dangle e Remove Bolts C Fork Protector D 13 10 SUSPENSION Front Fork
125. correctly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Harness Hose Rout ing section in the Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the idle speed using the engine revolution tester A for high accuracy x If the idle speed is out of specified range adjust it Idle Speed Standard 1 800 50 r min rpm ldle Speed Adjustment e First turn in the air screw using the pilot screw adjuster A until it seats lightly and back it out the specified num ber of turns see Specifications Section in the Fuel Sys tem chapter Special Tools Pilot Screw Adjuster C 57001 1292 or Pilot Screw Adjuster D 57001 1588 Pilot Screw Adjuster Adapter 4 57001 1371 e Start the engine and warm it up thoroughly e urn the idle adjusting screw B until the idle speed is correct To increase idle speed C To decrease idle speed D e Open and close the throttle a few times to make sure that the idle speed is 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 recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSince
126. crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist OConnecting rod big end radial clearance OCold fitting tolerance between crankpin and flywheels OSide clearance between the connecting rod big end and one of flywheels OCrankshaft runout Se G105137BS1 G105144BS1 CRANKSHAFT TRANSMISSION 9 15 Crankshaft Crankshaft Inspection Connecting Rod Big End Radial Clearance e Set the crankshaft on V blocks and place a dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between two gauge readings is the radial clearance Connecting Rod Big End Radial Clearance Standard 0 002 mm 0 014 mm 0 00008 0 0006 in Service Limit 0 06 mm 0 002 in lf the radial clearance exceeds the service limit crank shaft should be either replaced or disassembled and crankpin needle bearing and connecting rod big end should be examined for wear 6105018B51 Connecting Rod Big End Side Clearance e Measure the connecting rod big end side clearance A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 014 in Service Limit 0 6 mm 0 02 in lf the clearance exceeds the service limit replace the crankshaft assembly G105134BS1 Crankshaft Runout e Set the crankshaft in a flywheel alignment jig or on V blocks and place a
127. d room or ambient temperature e Visually Inspect the inside of the cylinder for scratches and abnormal wear x If the cylinder is damaged or badly worn replace it with a new one e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment shown in the figure x If any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed A 10 mm 0 39 in B 30 mm 1 2 in C 50 mm 2 0 in Cylinder Inside Diameter Standard 96 000 96 012 mm 3 7795 3 7800 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 96 10 mm 3 783 in or more than 0 05 mm 0 020 in difference between any two measurements GS07067BS1 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Piston Cylinder Clearance The piston to cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston to cylinder clearance must be adhered to whenever the cylinder is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must not be less than the minimum in order to avoid piston seizure The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference
128. d compression damping turn the high speed compression damping adjuster with a 17 mm wrench If the damping feels too soft or too stiff adjust it in accor dance with the following table High Speed Compression Damping Standard 1 1 6 turns out B Softer counterclockwise C Harder clockwise D Number of turns counterclockwise usable range 2 or more Counterclockwise from the fully seated position e Adjust the low speed compression damping turn the low speed compression damping adjuster with a flat head screwdriver x If the damping feels too soft or too stiff adjust it in accor dance with the following table Low Speed Compression Damping Standard 11 clicks B Softer counterclockwise C Harder clockwise D Number of turns counterclockwise usable range 16 clicks or more Counterclockwise from the fully seated position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Spring Preload Adjustment e Remove Seat see Seat Removal in the Frame chapter oide Covers see Side Cover Removal in the Frame chapter Carburetor Holder Clamp Screw loosen Muffler see Muffler Removal in the Engine Top End chapter Rear Frame Mounting Bolts A Rear Frame B with Air Cleaner Housing e Using the jack under the frame
129. d in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system Recommended Coolant Type Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed ratio Soft water 50 Coolant 50 Freezing point 35 C 31 F Total amount 1 05 L 1 11 US qt e Install the drain plug OReplace the gasket with a new one Torque Coolant Drain Plug 6 9 N m 0 70 kgf m 61 in lb e Fill the radiator up to the bottom of the radiator filler neck B with coolant A and install the cap turning it clockwise about 1 4 turn OLean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is lo cated uppermost in order to exhaust the air accumulated in the radiator NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator The radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way e Check the cooling system for leaks Air Bleeding Before putting the motorcycle into operation any air trapped in the cooling system must be removed as follows e Start the engine warm up the engine thoroughly and then stop the engine Wait until the engine cools down e Remove the radiator cap e Check t
130. d tighten the stem nut while pushing up on the stem base e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem nut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem nut to the specified torque hook the wrench A on the stem nut and pull the wrench at the hole by 22 2 kg force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem nut a fraction of a turn until it turns lightly OTurn the stem nut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib STEERING 14 7 GNO5040281 GNO4012B81 6N050605581 14 8 STEERING Steering e Install the front fork see Front Fork Installation in the Sus pension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolt e Tighten Torque Steering Stem Head Nut 98 N m 10 kgf m 72 ft Ib Front Fork Clamp Bolts Upper 23 N m 2 3 kgf m 17 ft lb Front Fork Clamp Bolts Lower 20 N m 2 0 kgf m 15 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Install
131. damage x If the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner A and outer tubes B and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Guide Bush Inspection e Visually inspect the guide bushes A and replace them if necessary Dust Seal Oil Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary e Replace the oil seal B with a new one whenever it has been removed Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition x If the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability Fork Spring Free Length Standard 480 mm 18 9 in Service Limit 470 mm 18 5 in SUSPENSION 13 21 GMO4169BS1 C GMO4168BS1 GM04011531 GM04012031 GM04011831 13 22 SUSPENSION Rear Suspension Uni Trak Rear Shock Absorber The r
132. dial gauge as shown and turn the crankshaft slowly The maximum difference in gauge reading is the crankshaft runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0031 in x If the runout at either point exceeds the service limit re place the crankshaft assembly with a new one or align the igi e crankshaft so that the runout falls within the service limit 8 5 mm 0 33 in A e First correct the horizontal misalignment by striking the projecting crank half A with a plastic soft lead or brass hammer as shown e Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit G105136BS1 9 16 CRANKSHAFT TRANSMISSION Crankshaft e Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vice depending on the nature of the misalign ment CAUTION Do not hammer the crank half at the point B x If flywheel misalignment cannot be corrected by the above method replace the crank pin or the crankshaft itself Connecting Rod Big End Seizure xin case of serious seizure with damaged flywheels the crankshaft must be replaced xin case of less serious damage disassemble the crank shaft and replace the crankpin needle bearing and con necting rod Connecting Rod Bend e Remove the connecting rod e Select an arbor A of the same diameter as the connect ing rod big end and
133. dth as follows to decide whether to replace the rings the piston or both GE16135BS1 GE16136BS1 Cylinder and Piston Piston Ring Groove Width e Measure the groove width at several points around the piston with a vernier caliper Piston Ring Groove Width Standard Top 1 03 1 05 mm 0 0406 0 0413 in Service Limit Top 1 1 mm 0 043 in x If any of the groove widths exceeds the service limit re place the piston Piston Ring Thickness e Measure the thickness at several points around ring with a micrometer Piston Ring Thickness Standard Top 0 970 0 990 mm 0 0381 0 0390 in Service Limit Top 0 90 mm 0 035 in x If any of the measurements is less than the service limit on either of the rings replace the rings as a set NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap Measurement e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Place the piston ring close to the bottom of the cylinder where cylinder wear is minimal e Measure the gap B between the ends of the ring using a thickness gauge x If the ring end gap exceeds the service limit replace the ring Piston Ring End Gap Standard Top 0 25 0 35 mm 0 0098 0 014 in Oil 0 15 0 50 mm 0 0059 0 020 in Service Limit
134. e 1 4 Torque Cylinder Head Bolts M10 59 N m 6 0 kgf m 44 ft Ib e Tighten Torque Cylinder Bolt A 12 N m 1 2 kgf m 106 in lb Cylinder Head Bolts M6 B 12 N m 1 2 kgf m 106 in Ib e Install Camshaft see Camshaft Installation Cylinder Head Cover see Cylinder Head Cover Instal lation Engine Bracket see Engine Installation in the Engine Removal Installation chapter e Connect the radiator hose and tighten the hose clamp screw e Install Carburetor see Carburetor Installation in the Fuel Sys tem chapter Exhaust Pipe see Muffler Installation Fuel Tank see Fuel Tank Installation in the Fuel System chapter Cylinder Head Cleaning e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter Cylinder Head Warp e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter ENGINE TOP END 5 23 5 24 ENGINE TOP END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal e Remove the valve lifter and the shim from the valve NOTE OUse the valve spring compressor assembly and the adapter to press down the valve spring retainer Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 24 57001 1586 B Valve Installation CAUTION Do not lap the valve to the valve seat
135. e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Remove the engine oil drain plugs on the bottom of the engine and let the oil drain completely Drain Plug for transmissionroom oil sump A Drain Plug for crank oil sump B NOTE OHold the motorcycle upright so that the oil may drain completely e Replace the gaskets at the drain plugs with a new one e After the oil has completely drained out install the drain plugs with the gaskets and tighten them Torque Engine Oil Drain Bolts Transmission Room Oil Sump 7 0 N m 0 71 kgf m 62 in Ib Crank Room Oil Sump 15 N m 1 5 kgf m 11 ft Ib e Fill the engine with a good quality motor oil specified be low Recommended Engine Type Castrol R4 Superbike 5W 40 or SAE 10W 50 por open API SG SH SJ or SL with JASO MA Viscosity SAE 10W 30 10W 40 10W 50 Capacity 0 96 L 1 01 US qt when filter is not removed 0 98 L 1 03 US qt when filter is remove 1 2 L 1 3 US qt when engine is completely dry GS09013BS1 NOTE OThe oil viscosity may need to be changed to accommo date atmospheric conditions in your riding area SAE 10W 40 30 40 70 86 104 F e Check the oil level see Engine Oil Level Inspection in the Engine Lubrication System chapter PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Oil Filter Change e Drain Engine Oil see Engine Oil Change e Remove
136. e engine excessive en gine wear and possibly engine damage will occur Carburetor Installation e Install Throttle Cables see Throttle Cable Replacement Hot Start Plunger see Hot Starter Cable Installation e Tighten Torque Throttle Pulley Cover Bolt 3 4 N m 0 35 kgf m 30 in Ib Throttle Cable Mounting Bolts 6 9 N m 0 70 kgf m 61 in Ib e When installing the carburetor into the carburetor holder fit the projection A of the carburetor with the groove B on the holder OFit the claw A of the clamp onto the groove B of the inlet duct e Tighten the clamps securely Torque Air Cleaner Duct Clamp Screw 2 0 N m 0 20 kgf m 17 in Ib e Route the air vent and overflow hoses properly see Ca ble Wire and Hose Routing Section in the Appendix chap ter CAUTION Always keep the hoses free of obstruction and GC06124BS1 make sure they do not get pinched by the chain or shock absorber e Connect the throttle sensor connector e After installing the carburetor do the following OTurn the fuel tap to the ON position and check for fuel leakage from the carburetor A WARNING Fuel spilled from the carburetor is hazardous FUEL SYSTEM 3 17 Carburetor OAdjust the following items if necessary Throttle Cable see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Idle Speed see Idle Speed Adjustment in the Periodic Maintenance chapter Fuel Inspection e Refer
137. e off the clamp B and pull the fuel hose C off the tap e Remove the fuel tank see Fuel Tank Removal e Disconnect the throttle sensor connector A 6C06088B51 C FUEL SYSTEM 3 15 Carburetor e Loosen the clamp screws A fully e Remove Engine Mounting Bracket Bolts B Engine Mounting Bracket C e Remove oeat see Seat Removal in the Frame chapter oide Covers see Side Cover Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Frame Bolts A e Pull out the rear frame B with the air cleaner housing and remove the carburetor e Unscrew the hot start plunger cap bolt A e Remove the hot start plunger e Unscrew the throttle pulley cover bolt A e Remove the throttle pulley cover B 3 16 FUEL SYSTEM Carburetor e oosen the mounting bolts A e Pull out the end of the throttle cables B e Free the tips C e Remove the carburetor to the right side of the frame e Drain the fuel from the float bowl by removing the drain plug After draining install the drain plug securely e After removing the carburetor push a clean lint free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident GC04018BS1 CAUTION If dirt gets through into th
138. e owingarm New Uni trak Wheel travel 315 mm 12 4 in Brake type Front and Rear Single disc Effective disc diameter Front effect dia 225 mm 8 86 in Rear effect dia 215 mm 8 46 in Specifications subject to change without notice and may not apply to every country 1 10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length SE M Si x 1 000 000 m x 3 281 ft x 1000 mm x 0 03937 in x 0 01 x 0 001 x 0 000001 Units of Torque N m x 0 1020 kgf m N m x 0 3 6 ft lb Units of Mass N m x 8 851 in Ib kg x 2 205 Ib kgf m x 9 807 N m g x 0 03527 OZ kgf m x 7 283 ftlb kgf m x 86 80 in Ib Units of Volume Units of Pressure L x 0 2642 gal US E L 5 0 2200 a gal imp kPa x 0 01020 kgf cm S 1057 gt US kPa x 01450 psi L x 0 8799 at imp Ka x 07901 emHg e 22245 pint US kgf cm x 9807 kPa L S 1 816 e pint imp kgf cm x 14 22 psi mL x 003381 oz US ae sS tee om nd mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force N x 0 1020 kof N x 02248 Ib Units of Power kgf x 9 807 N kW x 1360 PS kgf x 2 205 Ib kW x 1341 HP PS x 0 7355 kW PS x 0 9863 HP Units of Temperature EE ag SE dul NN 9 9 oF oF 4 32 68 104 1 6 212 248 284 40 20 O 20 i40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 40 E 0 20 40 60 80 100 420 440 160 17 8 44 26 7 48 9
139. ear suspension system of this motorcycle is New Uni trak It consists of a rear shock absorber swing arm tie rod and rocker arm To suit to various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damping force can be adjusted easily so changing oil viscosity unnecessary Rebound Damping Adjustment e urn the rebound damping adjuster A on the rear shock absorber lower end with the blade of a screwdriver until you feel a click x If the damper setting feels too soft or too stiff adjust it in accordance with the following table Seated position adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 11 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 16 or more Counterclockwise from the fully seated position NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Compression Damping Adjustment There are two adjustments you can make to the rear shock absorber gas reservoir High Speed Compression Damping Adjuster A Low Speed Compression Damping Adjuster B 16 1514131211109 8 7 6 5 43 2 1 GMOS205BS1 Rear Suspension Uni Trak e Adjust the high spee
140. ector e Remove Shift Pedal External Shift Mechanism Removal in the Engine Right Side chapter Screws A Gear Position Switch B ELECTRICAL SYSTEM 16 25 Switches e Remove O ring A Gear Position Switch Finger B Spring C Gear Position Switch Installation e Insert the spring into the hole in the shift drum e Insert the switch finger A so that the small diameter B is toward hole side e Apply grease to the O ring e Clean the contact points on the position switch e Apply a non parmanent locking agent to the gear position switch screws e Tighten Torque Gear Position Switch Screws 2 9 N m 0 30 kgf m 26 in lb e Install the other removed parts GP18010331 Gear Position Switch Inspection NOTE OBe sure the transmission mechanism is good condition e Disconnect the gear position switch lead connector A e Set the hand tester A to the x1 kO or x100 O range and connect it to the terminals in the gear position switch lead connector B and ground C Internal Circuit D Green Red Lead E Black Lead Special Tool Hand Tester 57001 1394 Gear Position Switch Resistance SE D Terminal Ground E Terminal Ground Position Wen If the tester reading is not as specified replace the gear position switch with a new one GP18189BS2 C APPENDIX 17 1 Appendix Table of Contents Cable Wire and Hose Routing iii 17 2 Troubleshooting GUIS Es Tr
141. ed Master cylinder scratched inside Disc warped MODEL APPLICATION Beginning Frame No JKAKXGDCL16A000001 or ii ES JKAKX450DDA000001 0 This digit in the frame number changes from one machine to another E E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1355 01 Printed in Japan
142. een Feed Mounting Bolts 98 10 87imlb zeen beige is 15 m t 10 Breather Fiting 15 15 M t Oil Filter Cover B Inner Rotor feed 13 Outer Rotor feed 14 Oil Filler Cap 15 Oil Screen Feed 16 Oil Screen Scavenge 17 Oil Pump Idle Gear 18 Oil Pump Gear 19 Oil Level Gauge 20 Breather Hose 21 Inner Rotor Scavenge 22 Outer Rotor Scavenge EO Apply engine oil G Apply high temperature grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts 7 4 ENGINE LUBRICATION SYSTEM Lubrication System Chart ENGINE LUBRICATION SYSTEM 7 5 Lubrication System Chart CP A e 4 e SS A a GGO4066BWS C Oil Screen feed Oil Pump feed Oil Pressure Relief Valve Right Engine Cover Oil Passage from Feed Oil Pump to Oil filter Oil Filter Right Engine Cover Oil Passage from Oil filter to Crankshaft Crankshaft Piston Oil Nozzle Left Crankcase Oil Passage from Oil filter to Transmission Oil Passage Cylinder Oil Passage from Crankcase Oil Passage to Cylinder Head Oil Passage Oil Pipes Oil Screen scavenge Oil Pump scavenge Balancer Weight Fitting Breather Hose Crank Room Oil Transmission Room Oil Blowby Gas OO OO d OO PS ND gt X Gok Sc cb y 0X COD gt o O1 P GA 7 6 ENGINE LUBRICATION SYSTEM Specifications Wem Standard Engine Oil G
143. een Feed Removal e Split the crankcase see Crankcase Disassembly in the Crankshaft Transmission chapter e Remove Bolts A Oil Screen B Oil Screen Feed Installation e Replace the O ring A with a new one e Apply grease to the O ring and install it e Install the oil screen A and tighten the bolts B Torque Oil Screen Feed Mounting Bolts 9 8 N m 1 0 kgf m 87 in lb Oil Screen Scavenge Cleaning e Remove the oil screen see Oil Screen Scavenge Re moval e Clean the oil screens with a high flash point solvent and remove any particles stuck to them WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent ENGINE LUBRICATION SYSTEM 7 11 Engine Oil and Oil Filter e Check the screen A carefully for any damage holes broken wires gasket pulling off x If the screen is damaged replace it e Install the oil screen see Oil Screen Scavenge Installa tion G607000BS1 Oil Screen Feed Cleaning e Remove the oil screen see Oil Screen Feed Removal e Clean the oil screen with a high flash point solvent and remove the particles stuck e Blow away the particles by applying compressed air A from the inside to the outside from the clean side to the dirty side A WARNING Clean the screen in a well vent
144. eesueeseeesaneeaes 6 16 EU er le Ee Me Damage E Emm 6 16 A T IL TL 6 17 Piman Gear REMOVA aai a a a 6 17 Priman Gear installato se e ade io a 6 17 External shirt Meslhianisrise aan x quist mea ocv io AE 6 18 External Shift Mechanism Hemoval iesirea i a a 6 18 External Shift Mechanism Installation 6 18 External Shift Mechanism Inspechon 6 19 RIC RS CAINS Uh ROUTE A 6 21 NICK Pedal ASSV Removal sd ir an 6 21 KICK Fedal Assy AS AMAN ac icaadd 6 21 KICK F CGalsASSY DISASSCMOIVE EE aia 6 21 KICK PedalASSY ASSeIpPDIV se ac de edades dio ou e oce 6 21 GEAR a Sca oct aaa eee cnc opu itu Ere E 6 21 Idle Gear a UE en BEE 6 22 KICKSNATE REMOVA EE 6 22 KIGKShAIT NS AIAION EE 6 22 Kick Shaft Assembly Disassembly Assembly nnn0nnannnnnnannnnnnnnnnnnnnnnnnnennnnnnenrenrnnrnnrnnnnne 6 23 6 2 ENGINE RIGHT SIDE Exploded View GRO2018BW5 C ENGINE RIGHT SIDE 6 3 Exploded View ne mnn e Fastener us T asm RR 1 PmayGerNt e 0 72 t 2 Ctuten Cover Bots aa 10 Stmb 3 Right Engine Cover Bots 98 10 ain 4 ctutch spring Bots ss 090 mb 5 lounen 99 19 7 6 Primary Gear 7 Push Rod Holder 8 Release Lever Shaft 9 Clutch Lever 10 Clutch Cable 11 Clutch Hub 12 Clutch Housing 13 Clutch Pressure Plate 14 Friction Plates Number of the lining blocks are many 15 Friction Plates Number of the lining blocks are little 16 Steel Plates CL Apply cable lubricant EO
145. eizure Connecting rod small end big end seizure Transmission gear or bearing seizure Camshaft seizure Kick shaft return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Fuel tank cap air vent obstructed Fuel tap clogged Fuel tap turned off Fuel line clogged Carburetor float valve clogged Engine flooded Fuel level in carburetor float bowl too high Float valve worn or jammed with foreign matter Starting technique faulty When flooded crank the engine with the hot start opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Ignition coil trouble Engine stop switch shorted Neutral switch trouble Wiring shorted or open Flywheel damage Compression Low Spark plug loose APPENDIX 17 7 Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent de for
146. emoval e Remove the clutch cable upper end see Clutch Cable Removal e Remove the tips A of the clutch cable see Clutch Cable Removal e Pull the lever and shaft assembly B out of the crankcase Release Shaft Installation e Apply high temperature grease to the oil seal lips e Apply engine oil to the bearing in the hole of the crankcase e Apply grease to the part where the push rod comes in contact e Insert the release shaft straight into the upper hole of the crankcase CAUTION When inserting the release shaft be careful not to remove the spring of the oil seal e Install the clutch cable see Clutch Cable Installation 6 12 ENGINE RIGHT SIDE Clutch Clutch Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the clutch cover see Clutch Cover Removal e Remove Clutch Spring Bolts A Clutch Spring Clutch Pressure Plate B e Remove Washer A Needle Bearing B Push Rod Holder C Push Rod Friction Plates D Steel Plates E e Fix the clutch hub A with the clutch holder B Special Tool Clutch Holder 57001 1243 e Loosen the clutch hub nut C counterclockwise e Remove Washer Clutch Hub Toothed Washer A Clutch Housing B Clutch Installation e Check the clutch plate assembly free play see Clutch Plate Assembly Free Play Inspection Adjustment e Apply molybdenum disulfide oil to the inside of the clutch housing gear
147. emove the adjuster assembly C SUSPENSION 13 13 Front Fork e Remove the push rod A e With the outer tube compressed by hands remove the top plug wrench A CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal Do not remove the locknut from the piston rod e Remove the fork leg from the vise e Loosen the fork top plug subtank A with the top plug wrench B Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Cylinder Unit A Spring Seat B Spacer C Washer D Fork Spring E CAUTION Disassembling the cylinder unit can lead to trouble Do not disassemble the cylinder unit e Remove the dust seal A and the retaining ring B CAUTION Be careful not to scratch the inner tube 13 14 SUSPENSION Front Fork e Grasp the outer tube and stroke A the inner tube several times The shock to fork seal separates the inner tube from the outer tube e Remove the following parts from the inner tube A Guide Bushes B Washer C Oil Seal D Retaining Ring E Dust Seal e Holding the top plug wrench A with a vise loosen the base assembly B on the subtank C Special Tool Top Plug Wrench 49 mm 57001 1653 e Remove the base valve assembly A from the subtank B NOTE OSlowly compress the piston rod until it stops so that the base valve assembly can be removed easily CAUTION Disassembl
148. en J repair the seat see Valve Seat Repair Valve Seat Repair e For the instructions on how to use the valve seat cutter A follow the operation manual provided by the to man ufacturer Special Tools Valve Seat Cutter Holder 55 5 57001 1125 B Valve Seat Cutter Holder Bar 57001 1128 Exhaust Valve Seat Cutter 45 535 57001 1116 Valve Seat Cutter 32 535 57001 1121 Valve Seat Cutter 55 535 57001 1247 Inlet Valve Seat Cutter 45 540 57001 1496 Valve Seat Cutter 32 438 5 57001 1122 Valve Seat Cutter 55 538 5 57001 1497 If the tool manufacturer s instructions are not available operate in accordance with the following procedure ENGINE TOP END 5 27 GE15011732 5 28 ENGINE TOP END Valves Seat Cutter Operation Care 1 This valve seat cutter is developed to grind the vale for repair Therefore the cutter must not be used for other purposes than seat repair 2 Do not drop or shock the valve seat cutter or the dia mond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior
149. ending e Visually inspect the shift forks and replace any fork that is bent A bent fork may cause difficulty in shifting or allow A the transmission to jump out of gear when under power 90 A GI13235B81 GC CRANKSHAFT TRANSMISSION 9 21 Transmission shift Fork Gear Groove Wear e Measure the thickness A of the shift fork ears and mea sure the width B of the gear grooves with which the fork engages Shift Fork Ear Thickness Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 19 in Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in ponds Service Limit 5 25 mm 0 207 in x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced x If the gear groove is worn exceeding the service limit the gear must be replaced shift Fork Guide Pin Shift Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 25 in x If the guide pin on any shift fork is less than the service limit the fork must be replaced xlf any shift drum groove is worn exceeding the service limit the drum must be replaced 6113237BS1 Gear Damage e Visually inspect the gear dogs A and gear dog holes
150. ending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e Tighten the banjo bolts on the hose fittings Torque Brake Hose Banjo Bolts 34 N m 3 5 kgf m 25 ft Ib e Fill the brake line after installing the brake hose see Brake Fluid Changing Suspension Front Fork Inspection e Holding the brake lever pump the front fork back and forth manually to check for smooth operation e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube A x If necessary repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage If the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e f the fork is not smooth confirm the cause CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube Front Fork Oil Change each fork leg e Loosen the front fork upper clamp bolts A 65138777 GS heh sd P n PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures e Loosen the fork top plug A Special Tool Top Plug Wrench 49 mm 57001 1653 B e Remove Front Wheel see Front Whee
151. eners check the tightness of them when the engine is cold at room temperature 6604011451 4004020152 C Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 63 x If there are loose fasteners retorque them to the specified torque following the specified tightening sequence Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications For each fastener first loosen it by 1 2 turn then tighten it x If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknut Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Brake Lever Pivot Nut Front Caliper Mounting Bolts Brake Pedal Bolt Rear Brake Joint Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts Suspension Front Fork Clamp Bolts Front Fender Bolts Rear Shock Absorber Mounting Bolts Nuts Swingarm Pivot Nut Steering Steering Stem Head Bolt Handlebar Clamp Bolts Engine Throttle Cable Adjuster Locknuts Engine Mounting Bolts Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Clamp Bolt Clutch Cable Adjuster Locknut Clutch Lever Pivot Nut Others Footpeg Cotter Pins Rear Frame Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents EXPLICO P M EEUU ET Seccatid loa
152. ength 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Standard Chain Make DAIDO CERA Type D I D 520DMA2 m Length 114 Links 2 Sprocket Rear Sprocket Warp Under 0 4 mm 0 016 in 0 5 mm 0 020 in Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wheel Alignment Inspection e Check that the rear end A of the left chain adjuster aligns with the same swing arm mark B as the right chain ad juster WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Wheel Alignment Adjustment This procedure is the same as Drive Chain Slack Adjust ment see Drive Chain Slack Adjustment in the Periodic Maintenance chapter Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication in the Periodic Main tenance chapter Drive Chain Removal e Remove the engine sprocket cover see Engine Sprocket Removal e Remove the clip A from the master link using pliers and free the drive chain from the rear sprocket e Remove the drive chain from the chassis Drive Chain Installation e Fit the drive chain back onto the sprockets with the ends at the rear sprocket e
153. ent Adjustable Range Adjusting nut position from the 127 5 mm 5 020 in 121 5 138 5 mm center of the mounting hole upper 4 783 5 453 in Rear Shock Spring Free Length 260 mm 10 2 in 255 mm 10 0 in Gas Reservoir High Speed Compression Adjustable Range 1 1 6 turn out Damping Adjustment 2 0 5 turn out Low Compression Damping Adjustment Adjustable Range from the seated position adjuster 11 clicks counterclockwise 16 clicks turned fully clockwise Gas Pressure 980 kPa 10 kgf cm 142 psi Tie Rod Rocker Arm Sleeve Outside Diameter Tie rod 19 987 20 000 mm 19 85 mm 0 781 in 0 78688 0 78740 in Rocker Arm Large 19 987 20 000 mm 19 85 mm 0 781 in 0 78688 0 78740 in Small 15 995 16 000 mm 15 85 mm 0 624 in 0 62972 0 62992 in Rocker Arm Mounting Bolt Runout under 0 1 mm 0 004 in 0 2 mm 0 008 in EUR Europe Model SUSPENSION 13 7 Special Tools Oil Seal amp Bearing Remover Bearing Remover Shaft 9 57001 1058 57001 1265 ST5 10588T ST5712658T Steering Stem Nut Wrench Bearing Remover Head 415 x 17 57001 1100 57001 1267 ST571100ST ST5712678T Hook Wrench R37 5 R42 Fork Oil Seal Driver 5548 57001 1101 57001 1509 T571101ST T5715098T Bearing Driver Set Top Plug Wrench 49 mm 57001 1129 57001 1653 75711298T T5716538T 57001 1238 T5712385T 13 8 SUSPENSION Front Fork Air P
154. er removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper ORemove the pads OPump the brake lever to remove the piston Rear Brake e Unbolt the caliper guard bolts A and remove the caliper guard B e Unbolt the disc guard bolts C and remove the disc guard D e Loosen the banjo bolt A so as not to spill brake fluid e Loosen the brake pad bolt plug B and pad bolt C before the caliper removal if the caliper is to be disassembled NOTE Olf the caliper is to be disassembled after removal and compressed air is not available disassemble the caliper before brake hose removal see Caliper Disassembly e Remove the rear wheel see Rear Wheel Removal in the Wheels Tires chapter e Unscrew the banjo bolt and remove the brake hose D from the caliper see Brake Hose Replacement in the Pe riodic Maintenance chapter CAUTION Immediately wipe up any brake fluid that is spilled Caliper Installation e Tighten the brake pad bolts if it was removed Torque Brake Pad Bolts 17 N m 1 7 kgf m 13 ft Ib Front Brake e Install the caliper and tighten the bolts Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Rear Brake e Before install the caliper install the rear wheel see Rear Wheel Installation in the Wheels Tires chapter e Install the brake hose lower end OReplace the washers that are on each side
155. er the piston ORelease the rail into the bottom piston ring groove AAA PEE GE18044B31 Cylinder and Piston e Install the top ring A so that the R mark B faces up NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston rings e Apply engine oil to the inside wall of the small end of the connecting rod e Face the circle mark A on the top of the piston must point toward the front B of the engine e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole OWhen installing the piston pin snap ring compress it only enough to install it and no more CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Install Dowel Pins A New Cylinder Base Gasket B e he piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be 20 of angle from the opening of the oil ring expander Circle Mark A Top Ring B Upper Oil Ring Steel Rails C Oil Ring Expander D Lower Oil Ring Steel Rail E ENGINE TOP END 5 33 B GE16042BS1 GE16132BS1 GE16134BS1 5 34 ENGINE TOP END Cylinder and Piston e Apply engine oil to the cylinder bore e Determine the position of the piston ring ends e In
156. ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap lever A to the OFF position e Slide out the clamp B and pull the fuel hose C off the fuel tap D e Remove the bolt E e Remove Seat see Seat Removal in the Frame chapter Bolts A e Remove the fuel tank mounting bolt B and band C e Pull out the fuel tank breather hose D from the steering stem e Remove the fuel tank E together with the radiator shrouds e Drain the fuel Fuel Tank Installation e Check the rubber dampers A on the frame xlIf the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Insert the fuel tank breather hose outlet end into the steer ing stem hole Fuel Filter Removal e Remove the fuel tank and drain it see Fuel Tank Re moval e Remove the mounting bolts A and take out the fuel filter B Fuel Filter Installation e Be sure the O ring is in good condition to prevent leaks e Be sure to clamp the fuel hose to the tap and fuel filter to prevent leaks Fuel Tank Fuel Tank Filter and Tap Cleaning e Refer to the Fuel Tank Filter and Tap Cleaning in the Periodic Maintenance chapter Fuel Tap and Filter Inspection e Refer to the Fuel Tap and Filter Inspection i
157. f the meter does not read 0 Q the lead is defective Re place the lead or the wiring harness if necessary GPO7019BS1 ELECTRICAL SYSTEM 16 9 Flywheel Magneto Magneto Cover Removal e Remove the left radiator shroud e Drain the engine oil from the crank room oil sump see Engine Oil Change in the Periodic Maintenance chapter e Pull the stopper A to the this side to remove the magneto lead connector B e Disconnect the magneto lead connector from the main harness i A T e a A R A E a as m E LAU a kl e Remove the shift pedal see External Shift Mechanism Removal in the Engine Right Side chapter e Open the clamp A then free the breather hose B e Remove Magneto Cover Mounting Bolts C Magneto Cover D Magneto Cover Installation e Replace the gasket with a new one e Be sure to install the dowel pins A e Apply silicone sealant to the area A to the magneto lead grommet Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Put in the magneto lead wire to the lead holder A e Tighten Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib e Run the breather hose B and magneto lead wire accord ing the Cable Wire and Hose Routing section in the Ap pendix chapter e Connect the lead connector Flywheel Removal e Remove the magneto cover see Magneto Cover Re moval 16 10 ELECTRICAL SYSTEM Flywheel Magneto e Hold the flywheel steady with the
158. following the core fin direction C Radiator Cap Inspection e Check the condition of the valve seals A and the top and bottom valve spring B of the radiator cap If any one of them shows visible damage replace the cap COOLING SYSTEM 4 13 EX SN REA SHAG GD07000BS31 4 14 COOLING SYSTEM Radiator e Wet the top and bottom valve seals with water or coolant to prevent pressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge hand must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge hand flicking downward The relief valve must open within the specified range Radiator Cap Relief Pressure Standard 112 142 kPa 1 14 1 45 kgf cm 16 2 20 6 psi If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Radiator Hoses Breather Hose Inspection e Refer to the Radiator Hoses and Connections Inspection in the Periodic Maintenance chapter Radiator Hoses Breather Hose Insta
159. g Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench If insufficiently tightened a bolt or nut may become damaged strip an internal thread or break and then fall out The following table lists the tightening toque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or liquid gasket When checking the tightening toque of the bolts and nuts first loosen the bolt or nut by half a turn and then tighten to specified torque Letters used in the Remarks column mean AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent to the threads Lh Left hand Threads S Tighten the fasteners following the specified sequence 2T Apply 2 stroke oil Fuel System Throttle Pulley Cover Bolt Throttle Cable Locknut Air Cleaner Duct Clamp Screw Air Cleaner Duct Mounting Nuts Air Cleaner Duct Mounting Screw Air Cleaner Housing Bolts Cooling System Water Pump Cover Bolts Water Pump Impeller Bolt Radiator Hose Clamp Screws Coolant Drain Plug Radiator Mounting Bolts Radiator Screen Bolts Radiator Shroud Bolts Engine Top End 30 in Ib 61 in lb 18 in lb 27 in lb 27 in lb 87 in lb 87 in lb 87 in lb 13 in Ib 61 in lb 87 in lb 87 in lb 87 in lb Cylinder Head Cover Bolts 9 8 1 0 87 in lb Cylinder Head Bolts M10 59 6 0 44 S MO Cylinder Head Bolts M6 12 1 2 106 in Ib S Camshaft Cap Bolts 9
160. ged e Visually inspect the upper and lower chain guide rollers A and replace them if excessively worn or damaged e Visually inspect the chain slipper A on the swingarm B and replace it if worn or damaged SUSPENSION 13 29 13 30 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Unscrew the nut A and remove the guide roller B CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the tie rod rear mounting bolt A e Remove the tie rod front mounting bolt B and then take out the tie rod C Tie Rod Installation e Apply plenty of grease to the inside of the oil seals e Tighten the tie rod front and rear mounting nuts Torque Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft Ib Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt A e Remove the tie rod rear mounting bolt B e Remove the rocker arm pivot shaft C e Remove the rocker arm D SUSPENSION 13 31 Tie Rod Rocker Arm Rocker Arm Installa
161. h a new one and install it e Replace the circlip with a new one and install it to the output shaft 9 14 CRANKSHAFT TRANSMISSION Crankshaft Crankshaft Removal e Disassemble the crankcase see Crankcase Disassem bly e Using the hand pull out the crankshaft A from the right crankcase B Crankshaft Installation e Apply high temperature grease to the outer side of the crankshaft bearings and use the bearing driver set C to face the stepped side A to the engine inside and drive the bearing to the bottom of the crankcase B While driving the bearing in make sure to use a holder to support the boss area Special Tool Bearing Driver Set 57001 1129 e Install the crankshaft to the right crankcase e Apply engine oil to the connecting rod big end bearing Crankshaft Disassembly Since assembly of the crankshaft demands exacting tol erances the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools and equipment e f it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment e Carefully align the oil passage hole in the right flywheel A with the one in the crankpin B at rebuilding of the crankshaft as shown e Reassemble the
162. hat they can be reinstalled in their original positions e Clean the shim to remove any dust or oil e Measure the thickness of the removed shim A e Select a new shim thickness calculation as follows A B C D A Replace Shim Thickness B Measured Valve Clearance C Specified Valve Clearance D Present Shim Thickness Example 0 31 mm 0 10 0 15 mm 2 60 mm 2 81 2 76 mm OExchange the shims for the 2 775 or 2 800 size shim CAUTION Don t use the shims for another models This could cause wear of the valve stem end and valve stem damage E EAS AY PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Thick LN 0 2525 92025 1984 Adjustment shims 2 00 92025 1870 2 05 92025 1871 2 10 92025 1872 GSO7011BS1 CAUTION Be sure to remeasure the clearance after selecting a shim The clearance can be out of the specified range because of the shim tolerance 93 99 98 65 70 15 85 5 ness Olf there is no valve clearance use a shim that is a few sizes smaller and remeasure the valve clearance e When installing the shim face the marked side A toward the valve lifter B At this time apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation CAUTION Do not put shim stock under the shim This may cause the shim to pop out at high rpm causing ex tensive engine damage Do not grind the shim Th
163. he brake hose banjo bolt Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage BRAKES 12 15 amp omin P 12 16 BRAKES Master Cylinder Rear Master Cylinder Removal e Remove the cotter pin A e Pull off the joint pin B with washer NOTE OPull off the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts C and re move the master cylinder D e Unscrew the brake hose banjo bolt E e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers are on each side of hose fitting with new ones e Tighten the following Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib Rear Master Cylinder Mounting Bolts 10 N m 1 0 kgf m 89 in Ib e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage e Check the brake pedal position see Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Front Master Cylinder Disassembly e Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter Rear Master Cylinder Disassembly e Refer to
164. he caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to where the brake line fits into the caliper WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or finger e Pull out the piston A by hand e Remove the dust seal B and fluid seal C e Clean the caliper parts except for the pads CAUTION For cleaning of the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e he bleed valve was removed install the bleed valve and rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seal s A with new ones OApply brake fluid to the fluid seal s and install them into the cylinders by hand e Replace the dust seal s B with new ones OApply brake fluid to the dust seal s and install them into the cylinder by hand e Apply brake fluid to the outside of the pistons C and push them into each cylinder by hand 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Install the anti rattle spring A in the caliper as shown e Replace the shaft rubber friction boot A and dust boot B if they are damaged e Apply a thin coat of PBC Poly Butyl Cuprysil grease to the caliper holder shafts C and holder holes PBC is a special high temperature water resistance grease
165. he coolant level see Coolant Level Inspection in the Periodic Maintenance chapter x If the coolant level is low add coolant up to the bottom of the filler neck e Install the radiator cap e Check the cooling system for leaks COOLING SYSTEM 4 7 GD04016B31 4 8 COOLING SYSTEM Coolant Cooling System Pressure Testing CAUTION During pressure testing do not exceed the pres sure for which the system is designed to work The maximum pressure is 123 kPa 1 25 kgf cm 18 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds If the pressure holds steady the cooling system is all right e Remove the pressure tester replenish the coolant and install the radiator cap lf the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the
166. he link screw e Insert the throttle valve assembly Olnsert the link rollers A on the throttle link into the slits B of the throttle valve e Tighten the screw e Apply a grease to the O ring A e Fitthe stopper B of the throttle sensor onto the projection C on the throttle cable pulley shaft Olnstall the throttle sensor so that the marks aligns and check it position see Throttle Sensor Inspection in the Electrical System chapter e Install O ring A Carburetor Cap B Bolts tighten e Install Starter Jet A Pilot Jet B Baffle Plate C Needle Jet D Main Jet E 3 26 FUEL SYSTEM Carburetor e Replace the O ring with new one A e Install d Pilot Air Screw A Spring B Washer C O ring D OTurn in the pilot air screw fully but not tightly and the back it out the counted number of turn see Carburetor Disassembly e Hanging the float valve A on the tang B of the float C e Fit the float valve into the valve seat e Insert the pin D e Install Leak Jet A e Replace the O ring with new one e Fit the O ring B onto the groove of the float chamber e Install Float Bowl e Tighten the screws with hose clamps A and cable holder B as shown e Replace the O rings with new ones e Fit the O rings A e Install Diaphragm B Spring C Acceleration Pump Cover Olnstall the diaphragm so that its mark facing D outward e Tighten the bolts Carburetor e I
167. hich could at tack the plastic parts instead use a 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 a 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 A e Assemble the carburetor and install it on the motorcycle Carburetor 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 FUEL SYSTEM 3 21 3 22 FUEL SYSTEM Carburetor e Remove the carburetor see Carburetor Removal e Before disassembling the carburetor check the fuel level see Service Fuel Level Inspection x If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e urn the throttle pulley to check that the throttle valve A moves smoothly and returns by spring pressure x If the throttle valve does not move smoothly Replace the throttle valve or pulley spring e Disassemble the carburetor see Carburetor Disassem bly e Clean the carburetor see Carburetor Cleaning e Check the tapered portion
168. hings e Wipe off any excess oll Oil applied area A 6K04030351 Sprocket Wear Inspection e Visually inspect the front and rear sprocket teeth for wear and damage xlf they are worn as illustrated or damaged replace the sprocket A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation NOTE GK05017BS1 Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Sprocket Warp Inspection e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp x lf the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard Under 0 4 mm 0 016 in Service Limit 0 5 mm 0 02 in Brakes Brake Lever and Pedal Position Adjustment A WARNING Always maintain proper brake adjustment If ad justment is improper the brake could drag and overheat This could damage the brake assembly and possibly lock the wheel resulting in loss of control e Adjust the front brake lever A to suit you e Slide the brake lever dust cover B out of place e oosen the adjuster
169. ht A of each cam with a micrometer Alf the cams are worn down past the service limit replace the camshaft Cam Height Standard Exhaust 36 943 37 057 mm 1 4544 1 4589 in Inlet 37 743 37 857 mm 1 4859 1 4904 in Service Limit Exhaust 36 84 mm 1 450 in Inlet 37 64 mm 1 482 in ENGINE TOP END 5 19 GE11077B31 GE11012231 5 20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement e Start the engine e horoughly warm up the engine so that the engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running e Stop the engine e Remove Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Remove the spark plug A with spark plug wrench B or owner s tool Special Tool Spark Plug Wrench Hex 16 57001 1262 Owner s Tool Spark Plug Wrench 92110 1172 e Attach the compression gauge A and the adapter hose B firmly into the spark plug hole e With the throttle fully open turn the engine over sharply with the kickstarter several times until the compression gauge stops rising the compression is the highest read ing obtainable Special Tools Compression Gauge 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 Cylinder Compression Service Range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 5 kicks e Install the spark plug Torque Spark Plug 13 N m 1 3 kgf m 115 in Ib
170. ick Pedal Assy B Kick Pedal Assy Installation e Install the kick pedal assy A at the angle shown 17 27 mm 0 67 1 1 in B e Apply a non permanent locking agent to the kick pedal bolt e Tighten Torque Kick Pedal Bolt 25 N m 2 5 kgf m 18 ft Ib Kick Pedal Assy Disassembly e Remove the kick pedal assy e Remove Plug Screw A Spring B Steel Ball C Detente Screw D Oil Seal E GROSO017BS1 Kick Pedal Assy Assembly e Apply high temperature grease to the steel ball oil seal lip spring and the sliding portion of the lever e After tightening the screws stake it with a punch Idle Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal Circlip A Idle Gear B 6 22 ENGINE RIGHT SIDE Kickstarter Idle Gear Installation e Apply engine oil to the inside of the idle gear e Replace the circlip A with a new one e Install the idle gear C facing embossed letter B to the outside e Install the circlip Kickshaft Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal e Pull the end A of the kick spring B out of the hole in the crankcase e Turn the kickshaft counterclockwise C and pull out the kickstarter assembly D e Remove the bolt A take off the ratchet guide B Kickshaft Installation e Apply a non permanent locking agent to the ratchet guide
171. ie Rod and Rocker Arm Bearing REMOVAL A Tie Rod and Rocker Arm Bearing Installation Needle Bearing Inspection Uni Trak Linkage Inspection Tie Rod and Rocker Arm Sleeve Tie Rod and Rocker Arm Mounting Bolt Bend 13 33 13 2 SUSPENSION Exploded View 6M021408W5 C SUSPENSION 13 3 Exploded View 1 Base Vave Assemby Ia 29 2 2 Front Fork Top Pg ao 31 2 5 Steering StemHead Nut e 10 72 6 LocknutiAdjuster Assemby 1 2 34 2 8 Front Axle Clamp Be La 20 15 A 9 Screw 10 O ring 11 Piston Rod 12 Rebound Damping Adjuster Rod 13 Subtank 14 Cylinder Unit 15 Outer Tube 16 Washer 17 Spacer 18 Spring Seat 19 Fork Spring 20 Bushings 21 Washer 22 Oil Seal 23 Retaining Ring 24 Dust Seal 25 Inner Tube 26 O ring 27 Gasket 28 Steering Stem Head 29 Steering Stem AL Tighten the two clamp bolts alternately two times to ensure even tightening torque L Apply a non permanent locking agent to the threads R Replacement Parts 13 4 SUSPENSION Exploded View 6M021418W5 C SUSPENSION 13 5 Exploded View we DM ig Remarks j rmm ka uem REC 1 Swingarm Pivot ShaftNut 98 10 72 2 Rocker Arm PivotNut 83 85 61 3 Tierod Mounting Nut Front Rea 83 85 61 4 Rear Shock Absorber Mounting N
172. ience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your vehicle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has
173. iew FUEL SYSTEM 3 3 Exploded View Nm km fb 1 rrote Puey Covert aa oss sne KS 69 070 6tin 3 Hot Starter Cable 4 Throttle Cables 5 Throttle Grip 6 Carburetor Cap 7 Throttle Valve Plate 8 Throttle Valve 9 Jet Needle 10 Throttle Pulley Shaft 11 Choke Knob 12 Idle Adjusting Screw 13 Pilot Air Screw 14 Slow Jet 15 Main Jet 16 Needle Jet 17 Starter Jet 18 Float 19 Leak Jet 20 Throttle Sensor 21 Hot Start Plunger 22 Acceleration Pump Diaphragm 23 Slow Air Jet EO Apply engine oil G Apply grease L Apply a non permanent locking agent 2T Apply 2 stroke oil 3 4 FUEL SYSTEM Exploded View FUEL SYSTEM 3 5 Exploded View Teque J Remarks s Nm kgfm ftib 1 Rear Frame Mounting Bots s 35 25 2 Air Cleaner Duct Clamp Screw 20 020 tin 3 Air Cleaner Duct Mounting Nuts 30 03 27imb 4 Ar Cleaner Duct Mounting Screw 30 031 27imb 5 Ar Cleaner Housing Bots 98 to 87imb 6 Fuel Tank Cap 7 Fuel Tank 8 Fuel Tap 9 Element 10 Frame 11 Holder 12 13 14 Air Cleaner Duct Air Cleaner Housing Rear Frame AD Apply adhesive cement G Apply grease O High quality foam air filter oil 3 6 FUEL SYSTEM Specifications tem Standard Throttle Grip and Cable Throttle Grip Free Play 2 3 mm 0 08 0 12 in Hot Starter Lever Free Play 0 5 1 0 mm 0 02 0 04 in
174. il e Hammer lightly on the valve guide arbor A to remove the guide Special Tool Valve Guide Arbor 65 5 57001 1021 GE15070651 Valve Guide Installation e Apply a thin coat of oil to the outer surface of the valve guide e Heat the area around the valve guide up to 120 150 C 248 302 F CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil e Assemble the valve guide driver A and valve guide driver attachment D B Special Tools Valve Guide Driver 44 5 57001 1564 Valve Guide Driver Attachment D 57001 1659 e When install the exhaust valve guide using the attached washer t 2 0 C e Using the valve guide driver press and insert the valve guide in until the valve guide driver surface D touches 815114881 the head surface E Exhaust 11 1 11 3 mm 0 437 0 445 in F Inlet 13 1 13 3 mm 0 516 0 524 in 5 26 ENGINE TOP END Valves e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 5 5 57001 1079 Valve Valve Guide Clearance Measurement Wobble Method Olf a small bore gauge is not available inspect the valve guide wear by measuring the valve valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as
175. ilated area and take care that there is no spark or flame anywhere near G607002BS1 the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screens check for any metal parti cles that might indicate internal engine damage e Check the screens carefully for any damage holes and broken wires x If the screen is damaged replace the oil screen 7 12 ENGINE LUBRICATION SYSTEM Cil Pressure Relief Valve Oil Pressure Relief Valve Removal e Remove Clutch see Clutch Removal in the Engine Right Side chapter Right Engine cover see Right Engine Cover Removal in the Engine Right Side chapter e Remove the oil pressure relief valve A Oil Pressure Relief Valve Installation e Apply a non permanent locking agent to the threads of oil pressure relief valve and tighten it Torque Oil Pressure Relief Valve 15 N m 1 5 kgf m 11 ft Ib Oil Pressure Relief Valve Inspection e Remove the relief valve see Oil Pressure Relief Valve Removal e Using a wooden stick push the inner valve to make sure that the valve A moves smoothly and that it returns to its original position by the force of the spring B NOTE OThe relief valve cannot be disassembled and it must be inspected in the assembled state x If the valve movement is not smooth wash the relief valve with high flash point solvent and use compressed air to remove any fo
176. in coating of grease to the cable upper or lower ends OUse a commercially available pressure cable lubricator to lubricate these cables Throttle Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 9 GC04019BS1 C 3 10 FUEL SYSTEM Throttle Grip and Cable Hot Starter Cable Removal e Remove Dust Cover A Slide out Locknut B Loosen e Turn in the adjuster C fully e Remove the cable end D from the hot starter lever E e Remove Carburetor see Carburetor Removal e Unscrew the plunger cap bolt A and remove the cable end e Disassemble the cable end from the plunger A Spring B Plunger Cap Assy C e Remove Left Radiator Shroud Clamps A Open Hot Starter Cable B Hot Starter Cable Installation e Install the hot starter cable in accordance with the Cable Wire and Hose Routing section in the appendix chapter e After the installation adjust the cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition Hot Starter Lever Free Play Inspection e Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter Throttle Grip and Cable Hot Starter Lever Free Play Adjustment e Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter Hot Starter Cable Lubrication e Whenever the hot starter cab
177. inal resistance B Throttle sensor resistance at idle speed Example e f the blue and black lead terminals resistance is 5 KO then the throttle sensor resistance at idle speed is 0 58 0 78 V 5kQOx 580 7800 5 V e Adjust the throttle sensor position so the resistance be tween yellow and black lead terminals is as calculated example 580 780 0 e oosen the throttle sensor mounting bolt A e Adjust the position of the sensor B until the resistance is within the specified resistance range x If it is not within the specified resistance range replace the sensor e nstall the carburetor see carburetor Installation in the Fuel System chapter e Start the engine and warm it up thoroughly e Check the idle speed x If the idle speed is out of the specified range adjust it see Idle speed Adjustment in the Periodic Maintenance chapter GP25006BS1 16 24 ELECTRICAL SYSTEM Switches Switch Inspection e Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms Special Tool Hand Tester 57001 1394 x If the switch has an open or short repair it or replace it with a new one Engine Stop Switch Connection Gear Position Switch Removal e Remove Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator forward D e Pry open the clamps A e Disconnect the gear position switch conn
178. ine oil L Apply non permanent locking agent M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil R Replacement Parts 9 Follow the specific tightening sequence SS Apply silicon sealant heim meo Pomars 10 EE 60 a2 a2 NENNEN 10 a2 020 Bib m m o SS SS EE U C O 0 5 10 Sri 10 Sri 4 20 15 is M 10 Sri Co sr Cost 4j Ib Ib 87 in lb Ib Ib 1 0 1 2 1 2 1 0 1 2 0 1 5 1 0 1 0 1 0 1 0 98 as 98 98 98 98 10 11 1 1 14 15 5 4 ENGINE TOP END Exploded View ENGINE TOP END 5 5 Exploded View ns teen e Pom nr a 1 JExhaust Pipe Cover Bois 12 12 meet 2 Exhaust Pipe Holder Nuts 21 21 15 3 Muffler Mounting Bos a 21 15 4 omdersot 12 12 Leen 5 Circle Mark 6 Top Ring 7 Oil Ring EO Apply engine oil G Apply high temperature grease L Apply non permanent locking agent R Replacement Parts SS Apply silicone sealant 5 6 ENGINE TOP END Specifications tem Standard Camshafts Cam Height Exhaust Inlet Camshaft Journal Clearance Camshaft Journal Diameter Camshaft Journal Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression Cylinder Head Warp Valve Valve Clearance Exhaust Inlet Valve Stem Bend Valve Stem Diameter Exhaust Inlet Valve Guide Inside Diameter Exhaust Inlet Valve valve Guide C
179. ing a thickness gauge A Connecting Rod Big End Side Clearance Standard 0 25 0 35 mm 0 0098 0 014 in Service Limit 0 6 mm 0 02 in xIf the clearance exceeds the service limit replace the crankshaft assembly e Make sure that the crankshaft rotates smoothly after as sembling the engine Wheel Tires Air Pressure Inspection Adjustment e Using tire air pressure gauge A measure the tire pres sure when the tires are cold Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure When the track is wet muddy sandy 80 kPa 0 8 kgf cm or slippery reduce the tire pressure 11 psi to increase the tire tread surface on H n the ground When the track is pebbly or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily 100 kPa 1 0 kgf cm 14 psi sion P 6J05010331 PERIODIC MAINTENANCE 2 29 ae Periodic Maintenance Procedures Tires Inspection As the tire tread wears down the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement WARNING To ensure safe handling and stability use only the recommended
180. ing the base valve assembly can lead to trouble Do not disassemble the base valve assembly e Drain the fork oil A from the cylinder unit B by pumping the piston rod several times Front Fork Front Fork Assembly e When the fork tubes are not disassembled hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain e Replace the following with new ones Dust Seal A Retaining Ring B Oil Seal C Guide Bushes D e Place an oil coated plastic bag E over the end of the inner tube to protect the oil seals OThe inner tube guide bush groove has a sharp edge F that can out the sealing lip of the seals as they as are pushed down over the inner tube e Install in order these parts on the inner tube e When assembling the new outer tube guide bush A hold the washer against the new one and tap the washer with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 648 57001 1509 e After installing the washer install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 548 57001 1509 e Install the retaining ring to the outer tube e Push the dust seal into the outer tube and put the spring band on the dust seal e Clean the threads A of subtank and base valve assem bly SUSPENSION 13 15 GM04042031 13 16 SUSPENSION Front Fork e With the piston rod in fully compressed position pour the spe
181. insert the arbor through the connect ing rod big end e Select an arbor of the same diameter as the piston pin and more than 105 mm long and insert the arbor B through the connecting rod small end e On a surface plate set the big end arbor on a V block C e With the connecting rod held vertically use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend x If connecting rod bend exceeds the service limit the con necting rod must be replaced Connecting Rod Bend Service Limit TIR 0 2 100 mm 0 08 3 94 in G105004B52 6105040651 CRANKSHAFT TRANSMISSION 9 17 Crankshaft Connecting Rod Twist e With the big end arbor A still on the V block C hold the connecting rod horizontally and measure the amount that the arbor B varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist If connecting rod twist exceeds the service limit the con necting rod must be replaced Connecting Rod Twist Service Limit TIR 0 2 100 mm 0 08 3 94 in 6105040731 9 18 CRANKSHAFT TRANSMISSION Transmission Transmission Shaft Removal e Disassemble the crankcase halves see Crankcase Dis assembly e Pull out the shift rods A allowing the shift fork guide pins to free from the shift drum B e Remove the shift fork C e Rem
182. iodic Maintenance chapter Friction and Steel Plate Warp Inspection e Refer to the Friction and Steel Plate Inspection in the Pe riodic Maintenance chapter Clutch Spring Free Length Inspection e Measure the free length A of the clutch springs If any clutch spring is shorter than the service limit it must be replaced NT C Clutch Spring Free Length CN Standard 49 2 mm 1 94 in S Service Limit 46 7 mm 1 84 in N A GFOGO30381 C 6 16 ENGINE RIGHT SIDE Clutch Clutch Housing Finger Damage e Visually inspect the clutch housing fingers A that come in contact with the friction plate tangs x If they are damaged or if there are groove cuts in the areas that come in contact with the tangs replace the housing Replace the friction plates if their tangs are damaged as well Friction Plate Clutch Housing Clearance e Measure the clearance between the tangs A on the fric tion plate and the fingers B of the clutch housing x If this clearance is excessive the clutch will be noisy x If the clearance exceeds the service limit replace the fric tion plates Friction Plate Clutch Housing Clearance Standard 0 20 0 60 mm 0 0079 0 024 in Service Limit 0 8 mm 0 03 in Clutch Hub Spline Damage e Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates x If there are notches worn into the clutch hub splines A replace the clutch hub Replace
183. ion x If the crankshaft will not turn probably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet A to reposition it e Install the gear set lever A OFit each end B of the spring or original positions ODo not forget to install the collar and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 90 kgf m 78 in Ib G104201BS1 GC CRANKSHAFT TRANSMISSION 9 13 Crankcase e To install the shift drum cam A use the driver B to bring the gear set lever C to the bottom of the crankcase e Mate the shift drum pin D into the shift drum hole OFit the groove E of the shift drum cam on the shift drum pin e Apply non permanent locking agent to the shift drum cam bolts and tighten them Torque Shift Drum Cam Bolt 24 N m 2 4 kgf m 17 ft Ib e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st while spinning the output shaft e Set the shift drum in the neutral position e Replace the O rings A on the output shaft with new ones e Install two O rings on the grinding faces of the output shaft while expanding the O ring by the hand e Apply grease to the inside of the output shaft collar B e Insert the collar with the oil groove end facing C in e Install the balancer drive gear C so that the punch mark A of the balancer drive gear and groove B of the crank shaft align e Replace the circlip wit
184. ion can clog oil passages and cause serious damage Press For items such as bearings or oil seals that must be pressed into place apply small amount of oil to the con tact area Be sure to maintain proper alignment and use smooth movements when installing GONE 5 66020130 3 68020168 5 68020178 3 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to the lip of seal before installing the seal Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation Lubri cation points are called out throughout this manual apply the specific oil o
185. ion said acia SOC a ee EE Throttle Gip ana Kee Free Play EE HEEL Free e EE E EE 3 8 Tarode Cable RepacemeN GE 3 8 Throttle Cable Bei Le te ET 3 9 Trote Cable INSPECHON e site set ed ix eo Condo ae 3 9 FIOL clatter Cable Removal idas adi 3 10 Hot Starter Cable Installation 3 10 Hot Starter Lever Free Play Inspection ss 3 10 Hot Starter Lever Free Play Adjustment ss 3 11 Hot tarter able UID CATON oia ld vs ceased tcs Oia cm 3 11 Hot Starter Cable INSPSCUOM iz uso eve Etpe equ Ever ovra idiotas 3 11 A T EE TEES 3 12 dle Speed Bi ee den WEE 3 12 jale Speed AdSense qo EET 3 12 Service Fuel Level Inspechon E 3 12 Service Fuel Level AUS TM uiuo ia 3 13 Carburetor Removal esien a idol 3 14 Carburetor Installations TTE 3 16 FULN OS CUI ON EEN 3 17 Carourelor DISASSEMBLY cias ic 3 17 CarDUretor EE Em 3 21 CAD OF iier e D Mc 3 21 CarbpHretor Assemb EE 3 23 MO EE Cm LT 3 28 Air Cleaner ROUSING Removal sitas ct o Uber tt 3 28 Air Cleaner HOUSING INStallANON ocre idas 3 28 Element SemoValos evento quas our a a dates Fai cents 3 28 Element InstallatlOriisse oet aio e du bt d e tote Pra Pea a P ate dad 3 29 Element Cleaning and Inspection 4 3 29 FUE ET PRE RE RS A SP D aabnraceaun yee 3 30 Fuel Tank Remo A ei ee Rat 3 30 Fuel Tank Installduobi dadas 3 30 FUEL c Removal ina ic tait 3 30 Fuel Ile E en RE 3 30 Fuel Tank Filter and Tap Cleaning ss 3 31 Fuel Tap ana Flter ae elen BETEN 3 31 3 2 FUEL SYSTEM Exploded V
186. ions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl see Carburetor Disassembly e Drive out the pivot pin A and remove the float B with valve needle C e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 8 1 mm 0 315 10 039 in FUEL SYSTEM 3 13 3 14 FUEL SYSTEM Carburetor NOTE OFloat height A is the distance from the float bowl mat ing surface B of the carburetor body with the gasket removed to the top of the float C Measure the height with the carburetor upside down ODo not push the needle rod D in during the float height measurement e Assemble the carburetor and recheck the fuel level x If the fuel level cannot be adjusted by this method the float or the float valve is damaged Carburetor Removal A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap lever A to the OFF position OSlid
187. ip Pliers Jack 57001 143 57001 1238 ST570143ST C DTS ST571238ST C 12 8 BRAKES Brake Lever Brake Pedal Brake Lever Adjustment e Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Brake Pedal Position Adjustment e Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer C e Remove the mounting bolt D and take off the brake pedal E and return spring Brake Pedal Installation e Replace O rings with new one and apply high tempera ture grease to the O rings e Apply high temperature grease to the shaft portion and a non premanent locking agent to the thread of the brake pedal mounting bolt and install the pedal with return spring onto the frame Olnstall the return spring direction A as shown Torque Brake Pedal Mounting Bolt 25 N m 2 5 kgf m 18 ft Ib e Check the brake pedal position e Install the joint pin washer and a new cotter pin OBend the ends A of the cotter pin GLO4020B81 GLO4008BS1 BRAKES 12 9 Brake Fluid WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling poi
188. is damaged replace both pads in the caliper as a set lf the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Lining Thickness Standard Front 3 8 mm 0 15 in Rear 6 4 mm 0 25 in Service Limit Front 1 mm 0 04 in Rear 1 mm 0 04 in Brake Master Cylinder Cup and Dust Seal Replacement e Remove the front master cylinder see Front Master Cylin der Removal in the Brakes chapter e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Pull the dust cover A out of place and remove the circlip B Special Tool Inside Circlip Pliers 57001 143 e Remove the washer C e Pull out the piston D secondary cup E primary cup F and return spring C G 13042BS1 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures CAUTION Do not remove the secondary cup from the piston since removal will damage it e Remove the rear master cylinder see Rear Master Cylin der Removal in the Brakes chapter NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi tion adjustment e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Slide the dust cover A on the push rod B out of place and remove the circlip C Special Tool Inside Circ
189. is may cause it to fracture causing extensive engine damage e Apply engine oil to the valve lifter surface and install the lifter e Install the camshaft see Camshaft Installation in the En gine Top End chapter e Recheck the valve clearance and readjust if necessary e nstall the cylinder head cover see Engine Top End chap ter timing inspection cap and the balancer weight cap 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Warp Inspection e Remove the cylinder head see Cylinder Head Removal in the Engine Top End chapter e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge between the straightedge and the head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 05 mm 0 002 in e Remove the valves see Valve Removal in the Engine Top End chapter e Scrape the carbon out of the combustion chamber and exhaust port with a scraper A or a suitable tool e Clean the cylinder head using high flash point solvent e Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air e Install the valves see Valve Installation in the Engine Top End chapter Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is col
190. istance Standard 7 mm 0 26 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead x If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Remove the ignition coil see Ignition Coil Removal e Measure the primary winding resistance A OConnect an ohmmeter between the coil terminals OSet the meter to the x 1 O range and read the meter e Measure the secondary winding resistance B OPull the spark plug cap off the lead OConnect an ohmmeter between the spark plug lead and the ground lead terminal OSet the meter to the x 1 kO range and read the meter Ignition Coil Winding Resistance Primary windings 0 28 0 38 O at 20 C 68 F Secondary windings 7 65 10 35 kQ at 20 C 68 F If the meter does not read as specified replace the coil xlf the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with o
191. l Removal in the Wheels Tires chapter Front Brake Caliper see Caliper Removal in the Brakes chapter Brake Hose Clamps see Brake Hose Replacement e Loosen the front fork lower clamp bolts A e Remove the front fork OWith a twisting motion work the fork leg B down and out NOTE OSet rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging Record the setting before turning the adjuster e Thoroughly clean the fork before disassembly CAUTION Be careful not scratch the inner tube and not to damage the dust seal Avoid scratching or damaging the inner tube or the dust seal Use a mild detergent and sponge out dirt with plenty of water e Using the top plug wrench A remove the fork top plug B subtank from the outer tube and slowly slide down the outer tube C Special Tool Top Plug Wrench 49 mm 57001 1653 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Place a drain pan under the front fork and drain fork oil A NOTE OPump the fork tube several times to discharge the fork oll e Raise the outer tube and temporarily install the fork top plug A subtank to the outer tube B with the top plug wrench C Special Tool Top Plug Wrench 49 mm 57001 1653 e Hold the axle holder A with a vise OProtect the axle holder with a rag when using a vise e oosen the adjuster assembly B completely
192. l tap to the carburetor using a suitable hose e Remove the drain plug from the bottom of the float bowl and screw a fuel level gauge B into the plug hole Special Tools Fuel Level Gauge 57001 122 e Hold the gauge vertically against the side of the carbure tor body so that the zero line C is several millimeters higher than the bottom edge D of the carburetor body e urn the fuel tap to the ON position to feed fuel to the carburetor e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the zero line is even with the bottom edge of the carbu retor body NOTE ODo not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again GC06122BS2 C Carburetor e Read the fuel level in the gauge and compare it to the specification Service Fuel Level below the bottom edge of the carb body Standard 6 5 1 mm 0 256 20 039 in x If the fuel level is incorrect adjust it e Turn the fuel tap to the OFF position and remove the fuel level gauge e Install the drain plug on the bottom of the float bowl Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex plosive under certain condit
193. le e Slide the adjuster cover A back e Loosen the locknut B and turn the adjuster C to obtain the proper lever free play e Tighten the locknut securely e Check that the hot starter lever moves smoothly from full open to close and the lever closes quickly and completely in all steering positions by the return spring x If the hot starter lever does not return properly check the hot starter cable routing free play and cable damage Then lubricate the hot starter cable Idle Speed Inspection CAUTION This motorcycle is designed for competition use only Therefore the radiator does not incorporate a coolant reserve tank or cooling fan Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine over heating resulting in possible engine damage Any riding conditions that increase engine temperature Will further reduce idling time before coolant loss occurs These conditions include high ambient temperature sandy or muddy terrain or other con ditions causing high engine loads at low speeds Furthermore warming the engine up excessively before operation or leaving idling with the hot engine temperature after operation results in the engine overheating too e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides A If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or in
194. le is removed or in accor dance with the Periodic Maintenance Chart lubricate the these cable see Lubrication in the Periodic Maintenance chapter Hot Starter Cable Inspection e Refer to the Cable Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 11 3 12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine there are two general types of carbure tor trouble too rich a mixture too much fuel and too lean a mixture too little fuel Such trouble can be caused by dirt wear maladjustment or improper fuel level in the float chamber A dirty or damaged air cleaner can also alter the fuel to air ratio Idle Speed Inspection e Refer to the Idle Speed Inspection in Periodic Mainte nance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in Periodic Mainte nance chapter Service Fuel Level Inspection WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove the fuel tank e Remove the carburetor and hold it in true vertical position on a stand The fuel hose and carburetor cable do not have to be removed to inspect the fuel level A e Put the fuel tank on a bench and connect the fue
195. learance wobble method Exhaust Inlet Valve Seat Cutting Angle Valve Seat Surface Outside Diameter Exhaust Inlet Valve Seat Surface Width Exhaust Inlet Valve Spring Free Length Exhaust Outer Inner Inlet Outer Inner 36 943 37 057 mm 1 4544 1 4589 in 37 743 37 857 mm 1 4859 1 4904 in 0 020 0 062 mm 0 00079 0 0024 in 22 959 22 980 mm 0 90390 0 90472 in 23 000 23 021 mm 0 90551 0 90634 in TIR 0 02 mm 0 0008 in or less Usable range 450 750 kPa 4 59 7 65 kg cm 65 2 109 psi 5 kicks 0 17 0 22 mm 0 0067 0 0087 in 0 10 0 15 mm 0 0039 0 0059 in TIR 0 01 mm 0 0004 in or less 5 455 5 470 mm 0 2148 0 2154 in 5 465 5 480 mm 0 2152 0 2157 in 9 500 5 512 mm 0 2165 0 2170 in 5 500 5 512 mm 0 2165 0 2170 in 0 09 0 16 mm 0 0035 0 0063 in 0 06 0 14 mm 0 0024 0 0055 in 45 32 60 30 4 30 6 mm 1 197 1 205 in 35 4 35 6 mm 1 39 1 40 in 0 8 1 2 mm 0 03 0 047 in 0 5 1 0 mm 0 02 0 039 in 38 92 mm 1 532 in 35 67 mm 1 404 in 39 28 mm 1 546 in 36 04 mm 1 419 in 36 84 mm 1 450 in 37 64 mm 1 482 in 0 15 mm 0 0059 in 22 93 mm 0 9072 in 23 08 mm 0 9087 in TIR 0 1 mm 0 004 in TIR 0 05 mm 0 002 in 5 44 mm 0 214 in 5 45 mm 0 215 in 5 58 mm 0 220 in 5 58 mm 0 220 in 0 36 mm 0 014 in 0 33 mm 0 013 in 37 5 mm 1
196. lip Pliers 57001 143 e Pull out the push rod with the piston stop D e ake off the piston E secondary cup F primary cup G and return spring H CAUTION Do not remove the secondary cup from the piston since removal will damage it e Before assembly clean all parts including the master cylinder with brake fluid or alcohol CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning of these parts Gasoline engine GL0O7057B32 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 e Apply brake fluid to the removed parts and to the inner wall of the cylinder e ake care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact Rear Dust Covers e Tighten Torque Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in 1b Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in lb 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Piston Seal and Dust Seal Replacement e oosen the brake pad pin A and banjo bolt B and tighten them loosely e Remove Front Caliper Mounting Bolt
197. little e Holding the top plug wrench A with a vise Special Tool Top Plug Wrench 49 mm 57001 1653 e Holding the subtank B with the top plug wrench torque the base valve assembly C Torque Base Valve Assembly 28 N m 2 9 kgf m 21 ft Ib 2 50 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Protect the piston rod end A with a rag B to prevent fork damage e Discharge the extra oil off the cylinder unit by pumping C the piston rod to full stroke CAUTION Be careful not to bend or damage the piston rod when the piston rod is stroked Service carefully because oil flies out from the oil hole of the cylinder unit NOTE OSet the compression damper setting to the softest OCheck the piston rod sliding surface for damage OApply fork oil to the piston rod sliding surface e Drain the extra oil from the subtank oil hole A e With the cylinder unit in horizontal position move A the piston rod B by hand to inspect it if operating smoothly Olf the piston rod is not extend remove the base valve assembly and perform the air bleeding pour the specified amount fork oil and discharge an excess of oil e Make sure about 16 mm 0 63 in A of push rod thread is exposed from the locknut B PERIODIC MAINTENANCE 2 51 Periodic Maintenance Procedures e Completely wipe of the fork oil from the spring A spacer B and cylinder unit C e Insert above mentioned parts into the fork
198. llation e Install the radiator hoses or breather hose being careful to follow the performed bends see Cable Wire and Hose Routing section in the Appendix chapter Avoid sharp bending kinking flattening or twisting e Tighten the hose clamps securely Torque Radiator Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib GD07001BS31 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded View 5 2 Valve Remowval 0 24 Spectator dios 5 6 Valve Installation 5 24 Special Tools and Sealant 5 9 Valve Guide Removal 5 25 Cylinder Head Cover 0 12 Valve Guide Installation Cylinder Head Cover Removal 5 12 Valve Valve Guide Clearance Cylinder Head Cover Installation 5 12 Measurement Wobble Method 5 26 Camshaft Chain Tensioner 5 13 Valve Seat Inspection 5 27 Camshaft Chain Tensioner Valve Seat Repair 5 27 REMOVA sonda dietas re 9 13 Cylinder and Piston 0 32 Camshaft Chain Tensioner Cylinder Removal 5 32 Installation iio is 0 13 Piston Removal 0 32 Sup ei ir 0 15 Cylinder and Piston Installation 0 32 Camshaft Removal 0 15 Cylinder Wear 5 34 Camshaft Installation
199. m 1 2 kgf m 104 in lb e Apply molybdenum disulfide oil to the ball bearing all cam and journal surfaces of the camshaft e f the camshaft is replaced with a new part apply a thin coat of molybdenum disulfide grease to the cam and jour nal surfaces e First bring the crankshaft to the TDC of either the com pression or exhaust stroke OPlace a wrench over the balancer weight nut and turn it counterclockwise to align the TDC mark A with the center of the groove B of the inspection hole GE11151BS1 ENGINE TOP END 5 17 Camshaft e Engage the camshaft chain with the camshaft sprockets OPull the tension side exhaust side of the chain taut to install the chain OThe timing marks on the sprocket must be aligned with the cylinder head upper surface e Pull the chain taut and fit it onto the camshaft sprocket e Starting with the timing mark on the front of the exhaust sprocket count to the 1st pin Feed the exhaust camshaft thought the chain and align the 29th pin with the timing mark on the inlet camshaft sprocket 1st Pin A Mark exhaust D 2nd Pin B Punch Mark inlet E 29th Pin C Upper Cylinder Head Surface F e Be sure to install the positioning rings A and dowel pins B e Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase GE111528W2 C 5 18 ENGINE TOP END Camshaft e Apply grease to the rubber portions
200. m with a clean cloth Then confirm that it is not pulled out with above torque e Holding the flywheel steady with the flywheel holder and tighten the flywheel nut Special Tool Rotor Holder 57001 1654 Torque Flywheel Nut 78 N m 8 0 kgf m 58 ft lb e Install the magneto cover see Magneto Cover Installa tion Flywheel Magneto Stator Removal e Remove Magneto Cover see Magneto Cover Removal Stator Bolts A Crankshaft Sensor Bolts B Wiring Holder C Wiring Grommet D e Remove the stator E and crankshaft sensor F as a set Stator Installation e Route the wires according to the Cable Wiring and Hose Routing section in the Appendix chapter e Install the stator and tighten it Torque Stator Bolts 4 0 N m 0 41 kgf m 35 in Ib e Install the crankshaft sensor and wiring holder A ORun the magneto leads under the holder and sensor Torque Crankshaft Sensor Bolts 7 0 N m 0 71 kgf m 61 in 1b e Apply silicone sealant around the circumference of the wiring grommet Sealant Kawasaki Bond Silicone Sealant 92104 0004 e Set the stator wiring grommet B securely in the notch C e nstall the magneto cover see Magneto Cover Installa tion Flywheel Inspection e here are three types of magneto problems short open wire burned out or loss in flywheel A short or open in one of the coil wires will result in either a low output or no output at all A loss in flywheel which may
201. m the back Seat Installation e Fitthe hooks A of the seat under the flange collar B and brackets C e Tighten the seat mounting bolts 15 6 FRAME Side Cover Side Cover Removal e Remove Bolts A Side Cover B e Remove the other side according to similar procedure Side Cover Installation e Stick the pads A on the inside of the right side cover B e Install the dampers C e Insert the tabs A of the cover into the air cleaner housing B FRAME 15 7 Fender Front Fender Removal e Unscrew the bolts A and remove the front fender B Rear Fender Removal e Remove Seat see Seat Removal e Unscrew the bolts A and remove the rear fender B Rear Flap Removal e Unscrew the screws A and remove the rear flap B ELECTRICAL SYSTEM 16 1 Electrical System Table of Contents EXDIOdEG NIE PM EEUU PT OSC IMS AON RS ad Se ee CP nn ot in Special Tools And Seale cce ca molta iio WENO DIAG AMen doe ed aec do mta io tm erp ti ees aa Precaution MN ECC TP HER EIS CHICA Aule EE Seas eas RS ee ce ieee eek ic sees eee WIFI O IIS DO CHOM c wheel Magneto E Magneto Cover Removal e teenie Magneto Cover Instalatii unreal iii aia Set E le EE SR a E den EE A A CUA a A a PES II ee masia A PEC TRU Tc IOMON TMG ete P HD AT MES Ignition TIMING ICsSpe le EE MIOS SM tU UE SAMA PM RT M Ignition SO Remo lit di fejaijif
202. med worn or carbon accumulation on the seating surface Decompression trouble Poor Running at Low Speed Spark weak opark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect heat value Faulty CDI unit Crankshaft sensor trouble Flywheel damaged Ignition coil trouble Wiring connector not in good contact Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Needle Jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Hot start stuck open Fuel level in carburetor float bowl too high or too low Fuel tank cap air vent obstructed Fuel tap clogged Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak 17 8 APPENDIX Troubleshooting Guide Valve not seating properly valve bent de formed worn or carbon accumulation on the seating surface Decompression trouble Other Faulty CDI unit Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Poor Running or No Power at High Speed
203. med in clutch housing gear teeth Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient low viscosity Kick ratchet gear not properly disengaging from kick gear Kick shaft idle gear worn or chipped Drive chain noise Drive chain maladjusted Drive chain worn Rear and or engine sprocket worn Drive chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Abnormal Engine Noise Knocking Faulty CDI unit Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect heat value Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn opring weak or broken Front fork air pressure high Rear shock absorber noise Shock absorber trouble opring weak or broken Disc brake noise Pad surface glazed Disc warped Caliper trouble Pad installed incorrectly 17 10 APPENDIX Troubleshooting Guide Master cylinder damaged Other noise Bracket nut bolt etc not properly mounted or tightened Abnormal Exhaust Color White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner element clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl
204. mended coolant Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Water and coolant mixture ratio 1 1 water 50 Coolant 50 Total amount 1 05 L 1 11 US qt Coolant Deterioration Inspection e Visually inspect the coolant x If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system x If the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system GDO4016BS1 GS06008BS1 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Radiator Hoses and Connections Inspection OThe high pressure inside the radiator hose A can cause coolant to leak B or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen Replace the hose if any fraying cracks C or bulges D are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Radiator Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib 4806027BS81 Engine Top End Valve Clearance Inspection NOTE OValve clearance must be checked and adjusted when the engine i
205. n see Piston Removal in the Engine Top End chap ter Right Engine Cover see Right Engine Cover Removal in the Engine Right Side chapter Clutch see Clutch Removal in the Engine Right Side chapter Primary Gear see Primary Gear Removal in the Engine Right Side chapter Balancer see Balancer Removal Oil Pumps see Oil Pump Scavenge Feed Removal in the Engine Lubrication System chapter Kick Shaft Assembly see Kick Shaft Removal in the En gine Right Side chapter Kick Shaft Idle Gear see Idle Gear Removal in the En gine Right Side chapter External Shift Mechanism see External Shift Mecha nism Removal in the Engine Right Side chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Remove the output shaft sleeve A and the O rings B ODo not reuse the O rings e Remove Gear Position Switch Screws A Gear Position Switch B CRANKSHAFT TRANSMISSION 9 7 Crankcase e Remove Gear Position Switch Finger opring A e Remove Circlip A Special Tool Outside Circlip Pliers 57001 144 e Remove the crankcase bolts A IEI P e Install the jig A between the crankshaft flywheels Special Tool Crankshaft Jig 57001 1174 e Attach the crankcase splitting tool A to the left crankcase Special Tool Crankcase Splitting Tool Assembly 57001 1362 e Tighten the center bolt of the crankcase splitting tool to split the crankcase halves ORemove the left crankcase half 9 8 CRANKSH
206. n the Periodic Maintenance chapter FUEL SYSTEM 3 31 COOLING SYSTEM 4 1 Cooling System Table of Contents EXPLICO PM MEET 4 2 e Ee 4 4 e NOON e o PP UU UI T mmm 4 5 Solent t oo Tm 4 6 Sereni ee de met D mm 4 6 Goolant D terloration INSPEC UOM odo it tec i Eo s t li sda 4 6 Al nee eut E 4 6 Coolant FING Rene ee M I RES Rens Le 4 7 Luten Un Le EE 4 7 Cooling System Pressure esti usina iia 4 8 Cooling System PIUSMING sist occ 4 8 Water UPD Tu TE CO 4 9 Water Pump COVer En e EE 4 9 Water PUMP Cover Installation rats At 4 9 is A TN 4 10 mpellerInstalat Orens oie lit ss 4 10 Water I UMD ASDC CUO Nr A De enema pde 4 10 OirS al nd B anng Removal a ate aeta boa ade te nur REI A A 4 10 Oil Seal Instellalo merida a 4 11 PS ACO M2 asec 4 12 Radiator REMOVAL serren idc aE pase ote oc bcr tema tad o up t d cabe nc ferit ean 4 12 Radiator IristallatiOftsaxuse cente etae pisn twn EA Pb rad dd ia attis imt ada s 4 13 Kellere daa dae 4 13 Radiator Gab Inspeccion 4 13 FING MINGCK INS Pecos ida 4 14 Radiator Hoses Breather Hose lInspechon 4 14 Radiator Hoses Breather Hose Installation ii 4 14 4 2 COOLING SYSTEM Exploded View COOLING SYSTEM 4 3 Exploded View A s em a mt Nm arm ftib 1 Water Pump Cover Bols 98 10 iY 2 Coolant Drain Pug 69 070 61mb 3 WaerPumpimpeleBot 98 10 SL iY 4 Right Engine Cover Bols 98
207. n the text in the text 10 BTDC 1 800 r min rpm 7 mm 0 26 in or more 0 28 0 38 O at 20 C 68 F 7 65 10 35 kO at 20 C 68 F NGK CPR8EB 9 0 8 0 9 mm 0 03 0 04 in in the text around 5 V 0 58 0 78 V 3 5 3 7 V ELECTRICAL SYSTEM 16 5 Special Tools and Sealant Timing Light Filler Cap Driver 57001 1241 57001 1454 T571241ST ST5714548T Spark Plug Wrench Hex 16 Needle Adapter Set 57001 1262 57001 1457 5757126257 8T5714578T C Hand Tester Rotor Puller 57001 1394 57001 1565 T571394ST 5757156557 Throttle Sensor Setting Adapter 1 Rotor Holder 57001 1400 57001 1654 ST571400ST T5716548T Peak Voltage Adapter Kawasaki Bond Silicone Sealant 57001 1415 92104 0004 75714155T ST9200048T 16 6 ELECTRICAL SYSTEM Wiring Diagram Engine Stop Switch 7 4 E Throttle Crankshaft nu Ignition Gear E Ground Unit Coil Sensor Position iip SE SENSE Color Code BK Black BL Blue G Green O Orange R Red w White GPO50BG6BW3 C Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTroubles may involve one or in some cases all items
208. nal of primary lead orange and ground connection of the unit with the lead of the ignition coil C connected OSet the tester to DC 250 V range Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Needle Adapter Set 57001 1457 Connection Adapter Positive Ground Lead D Adapter Negative Orange Lead E C D I Unit F Needle Adapter G e Shift the gear to the neutral position then free the engine stop switch e Crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil Peak Voltage 128 V or above A WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock x If the voltage is less than the specified value see the next page ELECTRICAL SYSTEM 16 17 GP10284BS1 16 18 ELECTRICAL SYSTEM Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition No good system inspection Good No good Spark plug inspection l No good Spark plug cap inspection Good Ignition coil primary peak voltage inspection Good No good Voltage is Voltage is specified none or almost none but faulty ignition Defective ignition coil Inspect 1 Adapter connection is incorrect or adapter is directive Replace 2 Engine stop switch 3 Crankshaft sensor peak voltage
209. ne e Ground the stop switch black white lead of the main har ness side while the engine is running x If does not stop the engine replace the C D I Unit Crankshaft Sensor Inspection e Remove Magneto Lead Connector see Magneto Cover Re moval e Set the hand tester A to the x 100 O range and connect it to the Green White B and White Yellow C Leads in the connector Special Tool Hand Tester 57001 1394 x If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance Standard 180 280 Q at 20 C 68 F e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground x Any tester reading less than infinity indicates a short necessities replacement of the crankshaft sensor assem bly ELECTRICAL SYSTEM 16 21 GP10250BS1 GP10276BS1 16 22 ELECTRICAL SYSTEM Throttle Sensor Throttle Sensor Inspection NOTE Olf the variable rheostat is not available refer to throttle sensor output input voltage check in the C D I Unit in spection OWhen inspecting the throttle sensor the throttle valve of the carburetor shall be completely closed and remain the throttle cable connected e Remove the carburetor see Carburetor Removal in the Fuel System chapter e Connect the throttle senso
210. ne Oil Level Inspection e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower levels B in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf no oil appears in the gauge tip the motorcycle slightly to the right until oil is visible then return to an upright po sition If no oil appears even when tipped at an extreme angle remove both drain bolts to empty any oil that may be in the transmission and crankcase reinstall the drain bolts and refill with the specified amount of oil Olf the motorcycle has just been used wait several min utes for all the oil to drain down Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil ODo notrun the engine at high engine speed Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure x If the oil level is too high remove the excess oil through the filler opening using a syringe or some other suitable device x If the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level rather than running the engine with the oil
211. ne known to be good e Check the spark plug lead for visible damage If the spark plug lead is damaged replace the coil Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter ELECTRICAL SYSTEM 16 15 Y 6P10199B51 C GP10274BS81 16 16 ELECTRICAL SYSTEM Ignition System Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter C D I Unit Removal e Remove Belt Open A Bolt B Number Plate C e Disconnect the main harness connector A e Unscrew the mounting bolts B and remove the C D I Unit C C D I Unit Inspection CAUTION When inspecting the C D I unit observe the follow ing to avoid damage to the C D I unit Do not disconnect the C D I unit while the engine is running This may damage the C D I unit Ignition System Ignition Coil Primary Peak Voltage Check e Disconnect the spark plug cap from the spark plug but do not remove the spark plug e Connect the good spark plug A to the spark plug cap then touch the engine with it NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug install to the cylinder head e Connect the peak voltage adapter B between the termi
212. ning the bolts af A E g nuts or screws first loosen all of them by about a quar edo v IDS A ter turn and them remove them If the specified tightening aor edis P n A sequence is not indicated tighten the fasteners alternating diagonally GoM 5 1 4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is 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 Non permanent 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 Non permanent locking agent Do not apply them ex cessively Excessive applicat
213. nstall the choke knob starter plunger A e Replace the O rings A with the new ones e Install the fuel hose fitting B e Tighten the screws e Install all hoses A e Install the carburetor see Carburetor Installation e f turn the adjusting screw of the acceleration pump follow the procedures below OAdjust the acceleration pump timing OSelect an arbor A of the same diameter as the throttle valve height B and insert it under the throttle valve Throttle Valve Height 1 25 mm 0 0492 in OTurn in the adjusting screw A fully OCheck the push rod holder B play OTurn the adjusting screw counterclockwise gradually to adjust with the push rod holder moving forward or back ward till no free play is available Push Rod C FUEL SYSTEM 3 27 GC06121BS1 GC08084B31 C 3 28 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal e Remove Side Covers see Side Cover Removal in the Frame chapter Seat see Seat Removal in the Frame chapter Muffler see Muffler Removal in the Engine Top End chapter Rear Fender A see Rear Fender Removal in the Frame chapter Rear Frame Bolts B e Loosen the air cleaner duct clamp C e Remove the rear frame e Unscrew the bolts A e Remove the air cleaner housing B Air Cleaner Housing Installation e Installation is the reverse of the removal e Tighten Torque Air Cleaner Housing Bolts 9 8 N m 1 0 kgf m 87 in Ib Rear Frame Mounting Bolts
214. nstalling Swingarm Bearing Removal e Remove owingarm see Swingarm Removal Collars A Grease Seals B Sleeves C Needle Bearings D e Remove the needle bearings E using the oil seal amp bear ing remover Special Tool Oil Seal amp Bearing Remover 57001 1058 Swingarm Bearing Installation e Replace the needle bearings and grease seals with new ones e Apply plenty of grease to the sleeves grease seals C and needle bearings A B NOTE Olnstall the needle bearings so that the manufacturer s marks face out Olnstall the grease seals so that the deep groove side of the rip in ward Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings and grease seals position as shown OThe installation procedure is the same as the counter side 1mm GM06034BS1 C Swingarm Swingarm Bearing Sleeve Inspection CAUTION Do not remove the bearings for inspection Re moval may damage them e Inspect the needle bearings installed in the swingarm OThe rollers in a bearing normally wear very little and wear is difficult to measure Instead of measuring visually inspect the bearing for abrasion discoloration or other damage x If the needle bearing and sleeve show any sings of ab normal wear discoloration or damage replace them as a set Drive Chain Guide Guide Roller Chain Slipper Wear e Visually inspect the drive chain guide A and replace it if excessively worn or dama
215. nt and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter 1
216. nudge each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the steering binds or catches before the stop check the routing of the cables hoses and harnesses x lf the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling the forks x If you feel looseness adjust the steering Steering Adjustment e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 y eani p PERIODIC MAINTENANCE 2 59 Periodic Maintenance Procedures e Slide the holder belt A out off e Remove number plate bolt B and number plate C e Remove the handlebar pad D e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C e oosen the front fork upper clamp bolts A and remove the steering stem head nut B and steering stem head C e urn the steering stem nut A with the steering stem nut wrench B to obtain the proper adjustment x If the steering is too tight loosen the stem nut a fraction of a turn if the steering is too loose tighten the nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE OTurn the stem nut 1 8 turn at a time maximum e Install the steering stem head e Tighten the following Torque Steering Stem Head Nut 98 N m 10 kgf m 72 ft Ib Upper Front Fork Clamp Bolts 23 N m 2 3 kgf m
217. nut and axle and spread its ends GK04001BS31 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen one and tighten again when the slot goes past the nearest hole A WARNING If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Check the rear brake NOTE Oln wet and muddy conditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break To prevent this adjust the chain to 58 68 mm 2 28 2 68 in of slack whenever necessary Drive Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry A Bushing B Roller C Pin D Pin Link E Roller Link e Stretch the chain taut by hanging a 98 N 10 kgf 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take measurements at several places Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Ser
218. o gi Gol INSDeCTION 42m T EUM Spark Plug Cleaning and Inspechon Spark Flug Gab nee de cara ren C DE DIE Ee EE BM BIS ue et e EET A Crankshiart Sensor INSPECCION BEE A SO EU Thiotte Sensor Inspection one Fea bib du Sev I Pu De Exi odia Sa aee bu e Throttle Sensor Position Adjustment ss SWICNES id AA SWIC IMIS DOCH OND EE Gear Position Switch Removal ninia Gear Position Switch Installation Gear Position Switch Inspection iii 16 2 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 3 Exploded View mete 2 36mb i Soe Inn 8 1 ain Li CS iio eet ro um Leen 7 jeniuntede es een emt IL 0 Magneto Cover n Flywheel 12 Stator 13 Ignition Coil 14 C D I Unit 15 Spark Plug Cap 16 Main Harness 17 Crankshaft Sensor 18 Throttle Sensor 19 Engine Stop Switch 20 Breather Hose L Apply a non permanent locking agent R Replacement Parts SS Apply silicon sealant 16 4 ELECTRICAL SYSTEM Specifications Mem Standard Magneto Crankshaft Sensor Resistance Magneto Output Voltage otator Coil Resistance Ignition System Ignition Timing Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Spark Plug Type Gap C D I Unit Throttle Sensor Input Voltage Output Voltage when the Throttle Valve Completely Closed when the Throttle Fully Opened 180 280 O at 20 C 68 F i
219. o the condition of either needle bearing replace the bearing and sleeve as a set SUSPENSION 13 33 Uni Trak Maintenance Uni Irak Linkage Inspection e Refer to the Uni Trak Linkage Inspection in the Periodic Maintenance chapter Tie Rod and Rocker Arm Sleeve Wear e Pull out the sleeves A of the tie rod and rocker arm e Measure the outside diameter of the sleeve xlf the sleeve is worn past the service limit replace the sleeve Sleeve Outside Diameter Standard 19 987 20 000 mm 0 7888 0 78740 Tie rod i in GM07036BS1 C Rocker Arm 19 987 20 000 mm 0 78688 0 78740 Large in 15 995 16 000 mm 0 62972 0 62992 Small in Service Limit Tie rod 19 85 mm 0 781 in Rocker Arm Large 19 85 mm 0 781 in Small 15 85 mm 0 624 in Tie Rod and Rocker Arm Mounting Bolt Bend A bent bolt causes vibration poor handling and instabil ity e o measure the bolt runout remove the bolt place it in V blocks and set a dial gauge to the bolt at a point halfway between the blocks Turn A the bolt to measure the runout The amount of dial variation is the amount of runout x If runout exceeds the service limit replace the bolt Bolt Runout Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in GM07038BS1 STEERING 14 1 Steering Table of Contents EXPIDO VIEW MR EEUU PT 14 2 A A SR A N 14 4 SO dnd 14 5 SICEHING MINS PECHOMN PEE EO DD E o T 14 5 ee lee US USIN
220. of hose fitting with new ones Torque Brake Hose Banjo Bolt 34 N m 3 5 kgf m 25 ft Ib GLOSO35BS1 C Caliper e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Caliper Disassembly e Refer to the Caliper Piston Seal and Dust Seal Replace ment in the Periodic Maintenance chapter Fluid Seal Damage The fluid seal around the piston maintains the proper pad disc clearance lf this seal is not in good condition pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in left and right pad wear d the seal is stuck to the piston If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Cover Damage e Check that the dust seals and covers are not cracked worn swollen or otherwise damaged x If they show any damage replace them Piston Cylinder Damage e Visually inspect the piston and c
221. oil sump Bearing Retaining Screw Gear Set Lever Nut Shift Drum Cam Bolt Balancer Weight Mounting Nut Exhaust Pipe Holder Nuts Muffler Mounting Bolts 49 29 98 2 9 12 15 15 7 0 15 8 8 24 92 9 0 3 0 10 0 30 1 2 1 5 1 5 0 71 1 5 0 90 2 4 9 3 18 78 in lb 12 78 in lb 87 in lb 57 in lb 78 in lb 18 87 in lb 87 in lb 87 in lb 11 62 in lb 87 in lb 87 in lb 87 in lb 87 in lb 11 26 in lb 11 36 21 12 26 in lb 106 in Ib 1 1 11 62 11 78 in lb 17 38 PERIODIC MAINTENANCE 2 7 Torque and Locking Agent T e Dum Doe mm Gear Position Switch Screws 26 in lb Ub 3 Wheels Tires Front Axle 79 8 1 58 Front Axle Clamp Bolts 20 2 0 15 Rear Axle Nut 110 11 2 81 1 Spoke Nipples Not less Not less Not less than 2 2 than 0 22 than 19 in lb Final Drive Rear Sprocket Nuts 3 5 25 Engine Sprocket Nut 13 0 93 7 Engine Sprocket Cover Bolts 1 0 87 in Ib Brakes Brake Lever Pivot Locknut 5 9 0 60 52 in 1b Brake Reservoir Cap Screws 1 5 0 15 13 ml Brake Lever Pivot Bolt 5 9 0 60 52 in 1b Caliper Mounting Bolts Front 25 2 5 18 Brake Hose Banjo Bolts 34 9 5 25 Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Rear Master Cylinder Mounting Bolts 10 1 0 89 in Ib Rear Master Cylinder Push Rod Locknut 17 1 7 13 Brake Reservoir Cap Bolts 1 5 0 15 13 in 1b Brake Disc Mounting Bolts Front 10 1 0 89 in lb L Rear 23 2 3 17 L Caliper Bleed Valves Front Rear
222. ol 45 Cutter Purpose increase width of seat 55 Grind Tool 55 Cutter Purpose reduce seat width to specification area beyond spec to increase O D FINISHED GE1511 B F 5 32 ENGINE TOP END Cylinder and Piston Cylinder Removal e Remove Cylinder Head see Cylinder Head Removal Front Camshaft Chain Guide A Cylinder Bolt B e ap lightly up with a plastic mallet to separate the cylinder from the crankcase e Remove the cylinder base gasket Piston Removal e Remove the cylinder see Cylinder Removal e Place a clean cloth under the piston and remove the pis ton snap ring A from one end of the piston pin CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall iis P e Remove the piston pin using a piston pin puller Special Tool Piston Pin Puller Assembly 57001 1568 A e Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring A to remove it e Remove the oil ring in the same procedure GE16131BS1 Cylinder and Piston Installation NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt together e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail ov
223. ons 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 Sege Le MN RE m TT 1 2 Model Identification 1 7 General SpeECINCAUONS nre TT T D 1 8 Unit CONVERSION E Ee E 1 10 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly Dirt or other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle Arrangement and Cleaning of Removed Parts Disassembled parts are easy to
224. or Inspection If the crankshaft sensor are normal check the C D I unit see C D I Unit Inspection e Install the timing inspection cap 16 14 ELECTRICAL SYSTEM Ignition System Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you could receive a severe electrical shock Ignition Coil Removal e Remove Fuel Tank Fuel Tank Removal in the Fuel System chap ter Bolt A Left Radiator Screen B Left Radiator Mounting Bolts C e Push the left radiator forward D e Pry open the clamps A e Disconnect the ignition coil primary lead connector A e Pull the plug cap off the spark plug e Unscrew the mounting bolts B and remove the ignition coil C Ignition System Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle method e Remove the ignition coil e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead A to the tester B and measure the arcing distance WARNING To avoid extremely high voltage shocks do not touch the coil or lead x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing D
225. ose select a proper one according to the rider s weight or course conditions e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Clean the threaded portion on the upper of the rear shock absorber e Hold the lower of the rear shock absorber with a vise SUSPENSION 13 25 13 26 SUSPENSION Rear Suspension Uni Trak e Using the hook wrenches C loosen the locknut B and turn the adjusting nut A all way up Special Tool Hook Wrench R37 5 R42 57001 1101 e Remove the rear shock absorber from the vise e Slide down the rubber bumper A e Remove the spring guides B from the shock absorber and lift off the spring C e Exchange the spring for an optional part Install the spring so that closed coil large diameter end A faces upward e Install the spring guide e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber e Install the parts removed Rear Shock Absorber Disassembly Oil Change e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Assembly e Refer to the Rear Shock Absorber Oil Change in the Pe riodic Maintenance chapter Rear Shock Absorber Scrapping A WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode e Remove the shock absorber see Rear Shock Absorber
226. ove the shift drum e Pull out the drive shaft A and output shaft B together with their gears meshed Transmission Shaft Installation e Apply engine oil to the sliding portion of the transmission shaft gears and ball bearings e Install the drive shaft A and output shaft B in the right crankcase C with their gears meshed e Install the shift drum e Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear e The shift forks can be identified by their shape or mark Install them noting the direction shown Olnstall each shift forks with its mark A facing the engine left side Marks 020 Drive shaft 021 Output shaft e Assembly the crankcase see Crankcase Assembly OFit each shift fork guide pin into the corresponding groove in the shift drum OApply a small amount of engine oil to the shift rods and slide them into the shift forks OAssembly the crankcase see Crankcase Assembly Transmission Shaft Disassembly e Remove the transmission shafts e Remove the circlips washers then gears Special Tool Outside Circlip Pliers 57001 144 e Do not reuse the removed circlips CRANKSHAFT TRANSMISSION 9 19 Transmission Transmission Shaft Assembly e Apply engine oil liberally to the transmission shaft gears and bearings e Replace any circlips that were removed with new ones OAlways install the circlips A so that the opening B is
227. pter Coolant Draining e he coolant should be changed periodically to ensure long engine life A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Place a container under the coolant drain plug A and drain the coolant from the radiator and engine by remov ing the drain plug on the water pump cover Immediately wipe or wash out any coolant that spills on the frame or engine e Inspect the old coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Inspection in the Periodic Maintenance chapter Coolant Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system f hard water is use
228. r grease as specified GENERAL INFORMATION 1 5 68020138 5 Gang GB02046B31 GB02026B 5 OME 3 1 6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand the free play amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side Electrical Wires A two color wire is identified first by the primary color and then the stripe color Unless instructed otherwise electrical wires must be connected to those of the same color 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 Mr OME 5 GB02062BS1 GENERAL INFORMATION 1 7 Model Identification KX450D6F Left Side View KX450D6F Right Side View 1 8 GENERAL INFORMATION General Specifications ems KX450DGF Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing Inlet Open Close Duration Exhaust Open Close Duration Lubrication System Engine Oil Type
229. r lead connector A with the battery B variable rheostat C and hand testers D as shown Variable Rheostat Blue Lead Terminal E Hand Tester Yellow Lead terminal F Hand Tester Black Lead terminal G e Check the sensor input voltage Throttle Sensor Input Voltage Standard around 5 V e Check the sensor output voltage with the throttle valve is completely closed Throttle Sensor Output Voltage Standard 0 68 0 1 V when the engine speed is idle Alf it is not within the specified voltage adjust the throt tle sensor position see Throttle Sensor Position Adjust ment x If it is within specified voltage go to next test e Check the sensor output voltage with the throttle fully opened Throttle sensor Output Voltage Standard 3 5 3 7 V When throttle fully opened x If itis not within the specified voltage replace the sensor GP25003B32 ELECTRICAL SYSTEM 16 23 Throttle Sensor Throttle Sensor Position Adjustment e Remove the carburetor see Carburetor Removal in the Fuel System chapter e Measure the resistance between the blue and black lead terminals of the sensor side connector Blue Lead Terminal A Black Lead Terminal B Yellow Lead Terminal C Hand Tester D Special Tool Hand Tester 57001 1394 GP18196BS2 C e Calculated the throttle sensor resistance at idle speed us ing the equation 0 58 0 78 V Ax s B 5 V A Blue and Black lead term
230. rade Castrol R4 Superbike 5W 40 API SG SH SJ or SL with JASO MA Viscosity SAE 10W 30 10W 40 or 10W 50 Capacity Oil Change when filter is not removed 0 96 L 1 01 US at Oil Change when filter is removed 0 98 L 1 03 US at when engine is completely dry 1 2 L 1 3 US qt Oil Level after warm up or driving Upper level Oil Pressure Measurement oil temperature 90 C engine speed 4 000 rpm 39 98 kPa 0 4 1 0 kgf cm 5 6 14 psi Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 ENGINE LUBRICATION SYSTEM 7 7 Oil Pressure Gauge Adapter M10 x 1 25 57001 1182 T5701258T 75711828T Outside Circlip Pliers 57001 144 Oil Pressure Cap 57001 1656 T570144ST 8T5716568T 7 8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter A WARNING Motorcycle operation with insufficient deteri orated or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure accident and injury The engine oil level indicated in the right engine cover oil level gauge is very sensitive to the motorcycle s posi tion and engine rpm at time of shut down Because of the semi dry sump lubrication system with separate oil cham bers in the crank room and transmission room under cer tain conditions oil can accumulate in the crank room and give a false low reading at the oil level gauge which indi cates oil volume in the transmission room Engi
231. reign particles from it A WARNING Clean the oil pressure relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents x If the valve does not move smoothly even after washing it replace the relief valve The oil pressure relief valve is precision made with no allowance for replacement of individual parts 66408060251 ENGINE LUBRICATION SYSTEM 7 13 Oil Pump Oil Pump Scavenge Removal e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Coolant System chapter e Remove Shift Pedal see External Shift Mechanism in the Engine Right Side chapter Flywheel see Flywheel Removal in the Electrical Sys tem chapter e Remove Oil Pump Cover Bolts A Lower Camshaft Chain Guide B Oil Pump Cover C e Remove Inner Rotor A Outer Rotor B Oil Pump Scavenge Installation e Install the dowel pin A to the crankcase e Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft e Install Outer Rotor B Inner Rotor C OWhile turn the oil pump shaft install the oil pump so that the left and right oil pump shaft may mesh in the crankcase e Install Oil Pump Cover A Lower Camshaft Chain Guide B e While pushing the oil pump cover tighten the oil pump
232. repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in the element material or any other damage to the ele ment replace the element with a new one A WARNING Clean the element in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Remove Seat see Seat Removal in the Frame chapter Wing Bolt A Air Cleaner Element B e Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract e Separate the element A from the frame B e Clean the element A in a bath of a high flash point sol vent using a soft bristle brush 6505025B51 e Squeeze it dry in a clean towel A Do not wring the ele ment or blow it dry the element can be damaged e Check all the parts of the element for visible damage xlf
233. replace the disc e Measure the thickness of each disc at the point B where it has worn the most Replace the disc if it has worn past the service limit Thickness Standard e SR Front 2 85 3 15 mm 0 112 0 124 in A ia Rear 3 85 4 15 mm 0 152 0 163 in Service Limit Front 2 5 mm 0 10 in Rear 3 5 mm 0 14 in e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Set up a dial gauge against the disc A as illustrated OFor the front disc turn the handlebar fully to one side e Measure the disc runout while rotating the wheel slowly B K E runout exceeds the service limit replace the disc GLOS025BS1 Runout Standard Not more than 0 25 mm 0 098 in Service Limit 0 3 mm 0 01 in Brake Hose Brake Hose Removal Installation e Refer to the Brake Hose Replacement in the Periodic Maintenance chapter Brake Hose Inspection e Refer to the Brake Hose and Connection Check in the Periodic Maintenance chapter BRAKES 12 19 SUSPENSION 13 1 Suspension Table of Contents Exploded View elei euer Le EE Special TO0lS i ete e c c FONO Air Eil Rebound Damping Adjustment Compression Damping e elt Ed NEE Oil Change each fork leg Front Fork Removal Front Fork Installation Front Fork Disassembly each MOM NCO erc OC Fron
234. ressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during opera tion Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Remove the screws A atthe top of the front fork top plugs to let the air pressure equalize NOTE ODo not use the sidestand when adjusting the air pres sure OAdjust the air pressure when the front forks are cold e Replace the O ring with a new one e Install the screw Rebound Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e o adjust rebound damping turn the adjuster A on the front fork cylinder valve with the blade of a screwdriver until you feel a click Adjust the rebound damping to suit your preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated positions adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard 13 clicks B Softer Counterclockwise C Harder Clockwise D Number of turns counterclockwise usable range 16 clicks or more Counter
235. ribed in Camshaft Chain Ten sioner Installation Do not turn over the crankshaft while the tensioner is removed This could upset the camshaft chain timing and damage the valves e oosen the cap bolt A e Remove the tensioner mounting bolts B and remove the chain tensioner body C Camshaft Chain Tensioner Installation e Remove the tensioner cap bolt and O ring e While compressing the push rod A turn it clockwise with a suitable screwdriver until the rod stopped CAUTION Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled e While holding the rod in position with a suitable push rod holder plate A install the tensioner on the cylinder block ENGINE TOP END 5 13 GE10014B81 5 14 ENGINE TOP END Camshaft Chain Tensioner e Replace the chain tensioner gasket with a new one e Tighten Torque Chain Tensioner Mounting Bolts A 9 8 N m 1 0 kgf m 87 in Ib e Take out the holder plate B e Install the O ring and tighten the cap bolt Torque Tensioner Cap Bolt 5 0 N m 0 51 kgf m 44 in Ib Camshaft Camshaft Removal e Remove Cylinder Head Cover see Cylinder Head Cover Re moval Timing Inspection Cap A Balancer Shaft Cap B Special Tool Filler Cap Driver 57001 1454 e First bring the piston to the TDC of either the compres sion or exhaust stroke OPlace a wrench over the balancer weight nut and turn
236. rocket bolts A and remove the rear sprocket B FINAL DRIVE 11 7 GK05003BS31 11 8 FINAL DRIVE Sprockets Rear Sprocket Installation e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and tighten the nuts Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 ft lb KO Cas GK05004B31 Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Inspection e Refer to the Rear Sprocket Warp Inspection in Periodic Maintenance chapter BRAKES 12 1 Brakes Table of Contents sb dello e ie VICON Rm 12 2 ejerfelifec iie dE TT en OTT EOSDEM 12 6 Ile EN Tera RETENTO TEE EET EN 12 7 Brake Lever Brake P dale tnt tion 12 8 Brake Lever Ads iMac me nn din o mas Cus e mE bee 12 8 Brake Pedal Position Adjustment Gage ebe eege 12 8 Brake PEA REMO TTE 12 8 Brake Pedal Installation natum qu rude xs cpu cena dI un Dres 12 8 Blake Fluid RENNES ist Tm 12 9 Fla Level ISD SCHON BEE 12 9 PUG Shands M 12 9 Bleeding the Brake me cuca cado 12 10 A T nes sem eu le ue 12 12 SS A NU TE TR 12 12 Caliper Installations taedet tede A ebrei des v cad eon caa p eme a deem nae Dees 12 12 CalperbisassemDI I EET 12 13 Fud Seal DAMANR ELT EE 12 13 RI ne Bn Ra Ee EE 12 13 Piston Cylinder Damage ni die 12 13 Caliper Holder Shaft We iii as 12 13 128 Brake
237. rotor holder A and remove the nut B Special Tool Rotor Holder 57001 1654 e Remove the flywheel holder e Screw the rotor puller A into the flywheel e Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tool Rotor Puller 57001 1565 CAUTION Never strike the grab bar or the flywheel itself Strik ing the bar can bond it If the flywheel is struck the magnets may lose their magnetism Flywheel Installation e Using a high flash point solvent clean off any oil or dirt that may be on the crankshaft taper A or in the hole B in the flywheel Dry them with a clean cloth e Fit the woodruff key C securely in the slot in the crank shaft e Install the flywheel following procedures NOTE OConfirm the flywheel fit or not to the crankshaft before tightening it with specified torque Olnstall the flywheel and tighten it with 45 N m 4 5 kgf m 33 ft lb of torque ORemove the flywheel nut OCheck the tightening torque with rotor puller x If the flywheel is not pulled out with 20 N m 2 kgf m 15 ft lb of drawing torque it is installed correctly x If the flywheel is pulled out with under 20 N m 2 kgf m 15 ft lb of drawing torque clean off any oil dirt or flaw of the crankshaft and flywheel tapered portion and dry the
238. rottle closes quickly and completely in all steering positions by the return spring x If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If the idle speed increase check the throttle cable free play and the cable routing Throttle Grip Free Play Adjustment e Loosen the locknuts A B at the upper end of the throttle cable e Screw both throttle cable adjuster C D to give the throt tle grip plenty of play e Turn out the decelerator adjuster C until there is no play when the throttle grip is completely closed e Tighten the locknut A e urn the accelerator cable adjuster D until 2 3 mm 0 08 0 12 in of throttle grip play is obtained e Tighten the locknut B A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition GS05080BS1 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Hot Starter Lever Free Play Inspection e Slide the clutch lever dust cover A back e Check the hot starter lever play B when pulling the start lever C lightly Hot Starter Lever Free Play Standard 0 5 1 0 mm 0 02 0 04 in x If the free play is improper adjust the hot starter cab
239. rtially collapsed blad der because it may burst gently reducing rear shock performance GMOSOG6BS1 C e Apply grease to the lip B of the bladder and install the reservoir cap C e Push the bladder into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil CAUTION Ensure that no air remains in the system 2 56 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Check the circlip for weakening deformity and flaws x If necessary replace it with a new one CAUTION If weakened deformed or flawed circlip is used the gas reservoir cap may not hold when injecting the nitrogen gas This would allow oil and internal parts to explode out of the reservoir e Mount the circlip A in the groove in the gas reservoir e Pull up the gas reservoir cap A against the circlip The end of the gas reservoir cap must align B with the end of the gas reservoir C A WARNING If the end of the gas reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitting in the groove in the gas reservoir or is deformed In this case the oil and internal parts could explode out of the reservoir when injecting the nitrogen gas or while riding the motorcycle e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the rear shock body to 55 mm 1 77 in A from the lower end of the rear shock body B GMO5011BS1 GM05068B32 C PERIO
240. s C Banjo Bolt Brake Hose E Front Caliper D see Front Caliper Removal in the Brakes chapter Brake Pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder A from the caliper B and remove the anti rattle spring e Using compressed air remove the pistons One way to remove the pistons is as follows OCover the caliper opening with a clean heavy cloth A ORemove the pistons by lightly applying compressed air B to the hose joint opening A WARNING To avoid serious injury never place your fingers or palm in front of the piston If you apply compressed air into the caliper the piston may crush your hand or fingers OPull out the piston A by hand e Remove the dust seals B and fluid seals C NOTE Olf compressed air is not available do as follows for both calipers coincidentally with the brake hose connected to the caliper OPrepare a container for brake fluid and perform the work above it ORemove the spring and pads see Brake Pad Removal in the Brakes chapter OPump the brake lever until the pistons come out of the cylinders and then disassembly the caliper PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures e Remove the rear caliper see Caliper Removal in the Brakes chapter e Remove the pads see Brake Pad Removal in the Brakes chapter e Separate the caliper holder B from the caliper A e Using compressed air remove the piston OCover t
241. s push the reservoir cap B in 10 mm 0 39 in e Remove the circlip C from the gas reservoir e Pull the gas reservoir cap B out of the gas reservoir using the pliers A e Pry or tap A at the gaps B in the stop C with suitable tools to free the stop from the rear shock body D e Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm 0 39 in down e Remove the circlip A e Lightly move the piston rod back and forth and pull out the piston rod assembly e Pour the oil out of the rear shock body GM05065B51 PERIODIC MAINTENANCE 2 55 Periodic Maintenance Procedures e Visually inspect the piston A O ring B and oil seal assy C e f the piston O ring and oil seal assy are badly scored rusty or damaged replace them e Using the grinder shave off the stopper portion A of the rod e Remove Nut B Washer C Piston D e Install the new piston and tighten the locknut ODiscard a washer or two e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the gas reservoir to 60 70 mm 2 63 2 76 in A from the gas reservoir upper end e Check that the bladder A on the gas reservoir cap is not partially collapsed If it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack x If necessary replace it with a new one CAUTION Do not use a damaged or pa
242. s cold at room temperature e Remove Cylinder Head Cover see Cylinder Head Cover Re moval in the Engine Top End chapter Balancer Shaft Cap A Timing Inspection Cap B Special Tool Filler Cap Driver 57001 1454 e First bring the piston to the top dead center of its com pression stroke to inspect the valve clearance the posi tion at the end of the compression stroke when the cam lobe faces outside of the camshaft OPlace a wrench over the balancer weight nut and turn it counterclockwise to align the TDC mark A with the center of the groove B of the inspection hole 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Using a thickness gauge A measure the clearance be tween each cam lob and valve lifter for all four valves OFor the purpose of adjusting the valve clearances record the measured values Valve clearance between cam and valve lifter Standard Exhaust 0 17 0 22 mm 0 0067 0 0087 in Inlet 0 10 0 15 mm 0 0039 0 0059 in lf the valve clearance is not within the specified range adjust it Valve Clearance Adjustment e Remove the camshaft caps A see Camshaft Removal in the Engine Top End chapter e Remove the camshafts B see Camshaft Removal in the Engine Top End chapter e Remove the valve lifters C of the applicable valve e Remove the shim D from the top of the spring retainer NOTE OMark and record the locations of the valve lifters and shims so t
243. s leaks If there are no leaks inject the nitrogen gas up to the 980 kPa 10 kgf cm 142 psi pressure A WARNING Pressurize the gas reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire hazard or substandard performance High pressure gas is dangerous Have a qualified mechanic perform this procedure e Install the spring and spring guide e Adjust spring preload Reinstall the rear shock absorber e Install the parts removed GM05067B31 GMO5069BS1 C GMO5105BS1 C 2 58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm and Uni Trak Linkage Inspection e Check the uni trak component parts for wear periodically or whenever excessive play is suspected e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Push and pull on the swingarm A up and down to check for wear xA small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear Swingarm and Uni Track Linkage Pivot Lubricate e Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in Suspension chapter Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 e With the front wheel pointing straight ahead alternately
244. s operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D OFill the reservoir with fresh specified brake fluid NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line 4s13121BS2 C 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage xlf necessary bleed the air from the lines see Bleeding the Brake Line in the Brakes chapter A WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified Brake Pad Wear Inspection e Remove the brake pad see Brake Pad Removal in Brakes chapter e Check the lining thickness and condition of the pads in each caliper x If either pad
245. s under the wheel so the disc does not touch the ground e Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper posi tion should the brake lever be squeezed accidentally Front Wheel Installation e Apply grease to the seals e Fit the projection A on the cap to the groove B on the collar e Install the caps and collars on the left and right side of the hub J04136BS1 Wheels Rims e Insert the axle A from right side e Tighten the right B axle clamp bolts temporally e Tighten the axle nuts C e Tighten the left axle clamp bolts D Torque Front Axle 79 N m 8 0 kgf m 58 ft lb Left Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Remove the jack e Before tightening the right clamp bolts on the right fork leg pump the forks up and down A 4 or 5 times to allow the right fork leg to find a neutral position on the front axle NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block B in front of the wheel to stop it from moving e Tighten the right axle clamp bolts Torque Right Axle Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the front brake for good braking power and no brake drag
246. stall the cylinder while compressing the piston rings with your fingers or the special tool A Special Tools Piston Ring Compressor Grip 57001 1095 Piston Ring Compressor Belt 595 4108 57001 1358 e Drive the front chain guide in e Install the removed parts Cylinder Wear e Refer to the Cylinder Wear Inspection in Periodic Mainte nance chapter Piston Wear e Using a micrometer measure the outside diameter A of each piston 8 5 mm 0 33 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the pistons outside diameter is smaller than the service limit replace the piston Piston Diameter Standard 95 970 95 980 mm 3 7783 3 7787 in Service Limit 95 82 mm 3 772 in Piston Cylinder Clearance e Refer to the Piston Cylinder Clearance in the Periodic Maintenance chapter Piston Ring Ring Groove Clearance e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Ring Groove Clearance Standard Top 0 04 0 07 mm 0 002 0 003 in Service Limit Top 0 17 mm 0 0067 in x If the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove wi
247. standard tires for replacement in flated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one Standard Tire Front Size 90 100 21 57M Make DUNLOP Type D742F Tube Rear Size 120 80 19 63M Make DUNLOP Type D756 Tube Spoke Tightness Inspection e Check that all the spokes are tightened evenly x If spoke tightness is uneven or loose tighten the spoke nipples evenly Torque Spoke Nipples 2 2 N m 0 22 kgf m 19 in Ib e Check the rim runout A WARNING If any spoke breaks it should be replaced immedi ately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break 6J05002B31 G811041BS81 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tool Jack 57001 1238 e Inspect the rim for small cracks dents bending or warp ing x If there is any damage to the rim it must be replaced e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A The difference be tween the highest and lowest dial readings is the amount of runout e Set a dial gauge against the outer circumference of the rim and rotate the rim to measure radial runout B The difference between the highest and lowest dial readings is the amount of runout
248. stment Frame Frame Inspection e Clean the frame with steam cleaner e Visually inspect the frame and rear frame for cracks dents bending or warp x If there is any damage to the frame replace it A WARNING A repaired frame may fail in use possibly causing an accident If the frame is bent dented cracked or warped replace it G815024BS81 G816003BS1 PERIODIC MAINTENANCE 2 61 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection e Remove Seat see Seat Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter Spark Plug Cap e Clean the plug hole A using the compressed air B e Remove the spark plug A using the spark plug wrench B Special Tool Spark Plug Wrench 57001 1262 Owner s Tool Spark Plug Wrench 16 mm 92110 0005 e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool xlf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug e Measure the gap A with a wire type thickness gauge xlf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap SKK a ae Oo A y y Y m A Spark Plug Gap Standard 0 8 0 9 mm 0
249. t Fork Assembly Adjuster Assembly Inspection Base Valve Assembly Inspection Cylinder Unit Inspection Inner Tube Inspection Guide Bush Inspection Dust Seal Oil Seal Inspection Spring Tension Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment Compression Damping Tel En Spring Preload Adjustment Spring Tension Rear Shock Absorber Removal Rear Shock Absorber Installation 13 2 13 6 13 7 13 8 13 8 13 8 13 9 13 9 13 9 Uni Trak Maintenance Spring Replacement 13 25 Rear Shock Absorber Disassembly Oil Change 13 26 Rear Shock Absorber Assembly 13 26 Rear Shock Absorber Scrapping 13 26 WIND Moss unidad 13 27 Swingarm Removal 13 27 Swingarm Installation 13 28 Swingarm Bearing Removal 13 28 Swingarm Bearing Installation 13 28 Swingarm Bearing Sleeve Inspections ove ecd 13 29 Drive Chain Guide Guide Roller Chain Slipper Wear 13 29 Tie Rod Rocker Arm 13 30 Tie Rod Removal 13 30 Tie Rod Installation 13 30 Rocker Arm Removal 13 30 Rocker Arm Installation 13 31 T
250. t shaft apply high temperature grease to the oil seal lips and shift shaft splines e Insert the shift shaft A e Replace the circlip B with a new one e Install Oil Pump Driven Gear C Circlip Clutch see Clutch Installation Right Engine Cover see Right Engine Cover Installa tion e Install the shift pedal so that the split portion A on the pedal and punch mark B on the shift align e Tighten Torque Shift Pedal Bolt 9 8 N m 1 0 kgf m 87 in lb External Shift Mechanism Inspection e Check the shift shaft A for bending or damage to the splines x If the shaft is bent straighten or replace it If the splines are damaged replace the shift mechanism e Check the return spring B for cracks or distortion x If the spring is damaged in any way replace it e Check the shift lever C for distortion x If the shift lever is damaged in any way replace the shift shaft 6 20 ENGINE RIGHT SIDE External Shift Mechanism e Check the ratchet assembly for damage x If ratchet A pawls B pins C or springs D are dam aged in any way replace them e Check the gear set lever A and its spring B for cracks or distortion x If the lever or spring is damaged in any way replace them e Visually inspect the shift drum cam A x If it is badly worn or if it shows any damage replace it GRO7022BS1 ENGINE RIGHT SIDE 6 21 Kickstarter Kick Pedal Assy Removal e Remove Mounting Bolt A K
251. tallation e Run the clutch cable correctly see Cable Wire and Hose Routing section in the Appendix chapter e Adjust the clutch cable see Clutch Lever Free Play Ad justment in the Periodic Maintenance chapter Clutch Cable Inspection and Lubrication e During a periodic inspection or when the cable has been removed inspect and lubricate the cable see Lubrication in the Periodic Maintenance chapter ENGINE RIGHT SIDE 6 9 6 10 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover Clutch Cover Removal e Drain the engine oil see Engine Oil Change in the Peri odic Maintenance chapter e Remove the brake pedal see Brake Pedal Removal in the Brakes chapter e Remove the clutch cover bolts A and remove the clutch cover B Clutch Cover Installation e Replace the clutch cover gasket with a new one e Be sure to install the dowel pins e Apply a non permanent locking agent to the brake pedal bolt e Install the clutch cover A Torque Clutch Cover Bolts B 9 8 N m 1 0 kgf m 87 ft Ib Right Engine Cover Bolts C 9 8 N m 1 0 kgf m 87 in lb Brake Pedal Bolt 25 N m 2 5 kgf m 18 ft Ib Right Engine Cover Removal e Drain Engine Oil see Engine Cil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling System chapter e Remove Kick Pedal A see Kick Pedal Removal Brake Pedal B see Brake Pedal Removal in the Brakes chapter e Remove Engine Guard
252. th JASO MA SAE 10W 30 10W 40 or 10W 50 1 2 L 1 3 US at 0 25 0 35 mm 0 0098 0 014 in 0 6 mm 0 02 in Under 1 0 mm 0 039 in 2 mm 0 08 in Under 1 0 mm 0 039 in 2 mm 0 08 in 100 kPa 1 0 kgf cm 14 psi 90 100 21 57M DUNLOP D742F 2 10 PERIODIC MAINTENANCE Specifications Wem Standard 120 80 19 63M DUNLOP D756 Tube Final Drive Drive Chain Slack 52 58 mm 2 0 2 3 in Drive Chain 20 Link Length 317 5 318 2 mm 12 50 12 53 in 323 mm 12 7 in Rear Sprocket Warp Under 0 4 mm 0 016 in 0 5 mm 0 020 in Brakes Brake Lever Free Play to suit rider Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 Brake pad lining thickness Front 3 8 mm 0 15 in 1 mm 0 04 in Rear 6 4 mm 0 25 in 1 mm 0 04 in Suspension Fork Oil Oil Viscosity KHL15 10 KAYABA 01 or equivalent Oil Quantity Adjustable range Outer Outer Inner Tubes 345 mL 11 7 US oz 325 365 mL 11 0 12 3 US oz EUR 350 mL 11 8 US oz EUR 330 370 mL 11 2 12 5 US oz Inner Subtank 170 mL 5 75 US oz Electrical System Spark Plug Gap 0 8 0 9 mm 0 03 0 04 in TIR Total Indicator Readings EUR Europe Model PERIODIC MAINTENANCE 2 11 Special Tools Steering Stem Nut Wrench Pilot Screw Adjuster Adapter 4 57001 1100 57001 1371 ST571100ST 8T5713718T Jack Filler Cap Driver 57001 1238 57001 1454 T5712385T ST5714548T
253. the parts removed see the appropriate chapter A WARNING Do not impede the handlebar turning by routing the cables wires and hoses improperly see the Gen eral Information chapter e Check and Adjust oteering Front Brake Clutch Cable Throttle Cable Stem Bearing Lubrication e Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter Stem Bearing Wear Damage e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer rase and the rollers Replace the bearing assembly if it show damage Stem Warp e Whenever the steering stem is removed or if the steering cannot be adjusted for smooth action check the steering stem for straightness x If the steering stem shaft is bent A replace the steering stem GNO4013B81 STEERING 14 9 Handlebar Handlebar Removal e Remove Number Plate A Clutch Holder B Engine Stop Switch C Clamps D Left Handlebar Grip E e Remove Throttle Grip Assy A see Throttle Cable Replacement in the Fuel System chapter Master Cylinder B see Front Master Cylinder Removal in the Brakes chapter Guo68197 P e Remove Handlebar Clamp Bolts A Handlebar Clamps B Handlebar C Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e
254. tion e Apply plenty of grease to the inside of the rocker arm needle bearings oil seals and grease seals outside of the sleeve e Tighten Torque Rear Shock Absorber Mounting Nut Lower 34 N m 3 5 kgf m 25 ft lb Rocker Arm Pivot Nut 83 N m 8 5 kgf m 61 ft lb Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft Ib Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rod see Tie Rod Removal Rocker Arm see Rocker Arm Removal Collars A Sleeves B Oil Seals C Grease Seals D e Remove the needle bearings E using the bearing re mover head and bearing remover shaft e Remove the needle bearing F using the oil seal amp bear ing remover Special Tools Bearing Remover Head 57001 1267 Bearing Remover Shaft 57001 1265 Oil Seal 8 Bearing Remover 57001 1058 GM07034B S2 C 13 32 SUSPENSION Tie Rod Rocker Arm Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing grease seals and oil seals with new ones e Apply plenty of grease to the oil seal and needle bearings A NOTE Olnstall the grease seals so that the deep groove side of the rip out ward e Install the needle bearings A B and grease seals C position as shown OThe installation procedure is the same as the counter side 1 mm 0 04 in D Rear Shock Absorber G 4 5 mm 0 18 in E Tie rod H 4 25 mm 0 167 in F Rocker Arm I 6M07035BW2 C Needle Bearing Inspection x If there is any doubt as t
255. to grinding apply engine oil to the cutter and dur ing the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamped on the back of the cutter A represent the following O pee pr te Cutter Angle B 391500 seas teneis Cutter Outer Diameter C Repair Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 55 cutter 55 F GE15011831 GE150115931 Valves e Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Original Seating Surface B ORemove all pittings of flaws from 45
256. to the Fuel Inspection in the Periodic Maintenance chapter Carburetor Disassembly e Remove the carburetor e Remove all vent hoses A and fuel hose B e Unscrew the screw A e Pull out the fuel hose fitting B e Unscrew the carburetor cap bolts A e Remove the carburetor cap B e Unscrew the throttle valve link screw A e Pull out the throttle valve assembly B 3 18 FUEL SYSTEM Carburetor e Disassemble the throttle valve assembly jet needle holder A unscrew spring B retainer C jet needle with circlip D O ring with throttle valve plate E and throttle valve F e Remove the choke knob starter plunger assembly A from the carburetor e Remove the throttle pulley shaft A with the spring B steel washer C plastic washer D and throttle valve link E OTurn the throttle pulley shaft A clockwise while holding down the acceleration pump lever B and clear the idle stop screw C to the stopper D of the pulley e Turn in the pilot air screw A fully but not tightly and count the number of turns ORecord this number as the manufacture set number of turns out e Unscrew the pilot air screw FUEL SYSTEM 3 19 Carburetor e Unscrew the screws A e Remove the acceleration pump cover B from the carbu retor e Remove the spring A diaphragm B and the O rings C e Remove the following parts from the carburetor body A Idle Adjusting Screw B Screws
257. uid Level Inspection 2 35 Fuel Tap and Filter Inspection 2 17 Brake Fluid Change 2 36 Cooling System 2 17 Brake Pad Wear Inspection 2 38 Coolant Level Inspection 2 18 Brake Master Cylinder Cup and Coolant Deterioration Inspection 2 18 Dust Seal Replacement 2 38 Radiator Hoses and Connections Caliper Piston Seal and Dust Seal INSPECUON iia 2 19 Replacement 2 40 Engine Top End 2 19 Brake Hose and Connection Valve Clearance Inspection 2 19 A PPP ee eben latest 2 43 Valve Clearance Adjustment 2 20 Brake Hose Replacement 2 43 Cylinder Head Warp Inspection 2 22 Suspensi n caia 2 44 Cylinder Wear Inspection 2 22 Front Fork Inspection 2 44 Piston Cylinder Clearance 2 23 Front Fork Oil Change each fork Piston Piston Ring and Piston IEG ere ss anses 2 44 Pin Replacement 2 23 Rear Shock Absorber Inspection 2 53 Exhaust System Inspection 2 23 Rear Shock Absorber Oil Change 2 53 Muffler Baffle Change 0000000n 2 23 Swingarm and Uni Trak Linkage Engine Right Side 2 24 Jee ee EE 2 58 Clutch Lever Free Play Check 2 25 Swingarm and Uni Track Linkage Clutch Lever Free Play Pivot Lubricate 2 58 Adjustment
258. unevenly worn replace the rotors cover or body or the crankcase 7 16 ENGINE LUBRICATION SYSTEM Cil Pressure Oil Pressure Measurement e Remove the oil filter cover A e Install the O rings to the oil pressure cap Special Tool Oil Pressure Cap 57001 1656 e Install the oil pressure cap e Attach the oil pressure gauge adapter A and oil pressure gauge B Special Tools Oil Pressure Gauge Adapter M10 x 1 0 57001 1182 Oil Pressure Gauge 5 kgf cm 57001 125 e Start the engine and warm up the engine thoroughly e Run the engine at the specified speed and read the oil pressure gauge x If the oil pressure is much lower than the standard check the feed oil pump If the reading is much higher than the standard check the oil filter first and oil passages for dirt or clogging Oil Pump Pressure oil temperature 90 C 4 000 rpm Standard 39 98 kPa 0 4 1 0 kgf cm 5 6 14 psi NOTE OWarm up the engine thoroughly before measuring the oil pressure e Stop the engine and remove the oil pressure cap oil pres sure gauge adapter and gauge A WARNING Take care against burns from hot engine oil that will drain through the oil passage when the oil pressure gauge adapter is removed e Install the oil filter cover Torque Oil Filter Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib ENGINE REMOVAL INSTALLATION 8 1 Engine Removal Installation Table of Contents e SP tan EE a eee ee em ane ne eee
259. ut Upper 39 40 29 5 Rear Shock Absorber Mounting Nut Lower 34 35 25 ERI MENT or 7 Swingarm Pivot Shaft 8 Swingarm 9 Rocker Arm 10 Tie Rod 11 Rear Shock Absorber Cylinder 12 O ring 13 Bladder 14 Cap 15 Circlip 16 Valve Cap 17 Locknut 18 Adjusting Nut 19 Spring 20 Spring Guides 21 Circlip 22 Piston Rod Assembly 23 Piston 24 O ring 25 Oil Seal 26 Stopper 27 Rear Shock Absorber G Apply grease L Apply a non permanent locking agent R Replacement Parts 13 6 SUSPENSION Specifications Mem Standard Front Fork Air Pressure Atmospheric pressure Rebound Damping Adjustment Adjustable Range from the seated position adjuster 13 clicks counterclockwise 16 clicks turned fully clockwise Compression Damping Adjustment Adjustable Range from the seated position adjuster 12 clicks counterclockwise 16 clicks turned fully clockwise Oil Viscosity KHL15 10 KAYABA 01 Oil Quantity Adjustable Range Outer Outer Inner Tubes 345 mL 11 7 US oz 325 365 mL 11 0 12 3 US oz EUR 350 mL 11 8 US oz 330 370 mL 11 2 12 5 US oz Inner subtank 170 mL 5 75 US oz Fork Spring Free Length 480 mm 18 9 in 470 mm 18 5 in Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment Adjustable Range from the seated position adjuster 11 clicks counterclockwise 16 clicks turned fully clockwise Spring Preload Adjustm
260. ver The engine or the motorcycle could be damaged GH04056BS1 e Drain Engine Oil see Engine Oil Change in the Periodic Main tenance chapter Coolant see Coolant Draining in the Cooling system chapter e Remove the mounting bolt A and remove the engine guard B e Remove Seat see Seat Removal in the Frame chapter oide Covers see Side Cover Removal in the Frame chapter Fuel Tank see Fuel Tank Removal in the Fuel System chapter e Remove Radiator Hoses A Bolt B Radiator Screen C 8 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Remove Radiator Mounting Bolts A i y Radiator B 7 t K wf A ul y A e Hu A e Remove Muffler see Muffler Removal in the Engine Top End chapter Radiator Hoses B Bolt C Radiator Screen D e Remove Radiator Mounting Bolts A Radiator B e oosen Carburetor Clamp Bolts A e Remove Air Cleaner Duct B with Rear Frame see Rear Frame Removal in the Frame chapter Carburetor C see Carburetor Removal in the Fuel Sys tem chapter Clutch Cable Lower End D see Engine Right Side chapter Drive Chain E cut out e Remove Bolts A Rear Brake Pedal B Master Cylinder C ENGINE REMOVAL INSTALLATION 8 7 Engine Removal Installation e Pry open the clamps A e Disconnect Magnet Lead Connector B Gear Position Switch Connector C Ignition Coil Lead Connector D Spark Plug Cap e Remove Ignition
261. vice Limit 323 mm 12 7 in x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced 6J04034B31 GK04060831 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Standard Chain Make DAIDO Type D I D 520DMA2 Link 114 Links Drive Chain Lubrication OThe chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain xlf the chain is especially dirty it should be washed in diesel oil or kerosene and afterward soaked in a heavy oil Shake the chain while it is in the oil so that oil will pen etrate to the inside of each roller e An effective good quality lubricant specially formulated for chains is best for regular chain lubrication e f a special lubricant is not available a heavy oil such as SAEO9O0 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication PT A VELAT ULLA e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bus
262. w E take off the shift ratchet assembly F with ratchet plate C e Remove the bolt A and shift dram cam B e Remove the nut C and take off the gear set lever D External Shift Mechanism Installation e Install the gear set lever A OFit each end of the spring B or original positions ODo not forget to install the color and washer C e Tighten the gear set lever nut D Torque Gear Set Lever Nut 8 8 N m 0 09 kgf m 78 in Ib e Holding the gear set lever A with the driver B and install the shift dram cam C OApply a non permanent locking agent to the shift dram cam bolt OFit the groove D on the pin E e Align the roller of the gear set lever with the slot of the shift dram cam ENGINE RIGHT SIDE 6 19 External Shift Mechanism e Set up the shift ratchet assembly as shown in the figure Ratchet A Pawls B Pins C Springs D OAssembly the shift ratchet so that groove E of the pawl facing the crankcase side F e hen install the ratchet assembly A to the ratchet plate B as shown in the figure e Install the ratchet assembly to the shift drum cam e Apply a non permanent locking agent to the ratchet plate mounting screw e Tighten the screw first and tighten the bolt e Tighten Torque Ratchet Plate Mounting Screw 6 4 N m 0 65 kgf m 56 in lb Ratchet Plate Mounting Bolt 9 8 N m 1 0 kgf m 87 in lb e Install the collar C e Before installing the shif
263. ylinder A see Front Master Cylinder Removal in the Brakes chapter e Slide out the dust cover B and cable housing dust cover C e Unscrew the screws A e Separate the throttle cable housing B e Free the tips A from the grip B Throttle Grip and Cable e Remove the rear frame assy see Rear Frame Removal in the Frame chapter e Remove the carburetor e Unscrew the bolt A e Remove the throttle pulley cover B e oosen the mounting bolts A e Remove the cables B from the carburetor e Free the tips C from the pulley e Pull out the cables from the frame e Lubricate the cable e Apply grease to the tips of the cables e Install the throttle cable lower end A e Install the mounting bolts B to the holder as shown e Install the throttle pulley cover Torque Throttle Cable Mounting Bolts 6 9 N m 0 70 kgf m 61 ft Ib Throttle Pulley Cover Bolt 3 4 N m 0 35 kgf m 30 in 1b e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e After the installation adjust each cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition Throttle Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cables see Lubrication in the Periodic Maintenance chapter OApply a th
264. ylinder surfaces Replace the cylinder and piston if they are badly scored or rusty Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts If the body does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check too see if the caliper holder shafts are not badly worn or stepped or the rubber friction boot is not dam aged x If the shafts or rubber friction boot are damaged replace the shafts rubber friction boot and the caliper holder BRAKES 12 13 12 14 BRAKES Caliper Brake Pad Removal For Front Brake Pad e Unscrew the pad bolt A e ake the piston side pad B e Push the caliper holder toward the piston and then re move another pad C from the caliper holder For Rear Brake Pad e Remove Plug A e Unscrew the pad bolt A e Take the piston side pad B e Push the caliper hold toward the piston and then remove another pad C from the caliper holder Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the piston side pad first and then another pad OFit the pad end A into the groove B of the anti rattle spring securely e Tighten the brake pad bolt Torque Brake Pad Bolt 17 N m 1 7 kgf m 13 ft Ib e Check the brake for good braking power no brake drag and no fluid leakage A WARNING

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