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Kawasaki KX250F - Service Manual

Manual is about: Motorcycle

Summary of KX250F -

  • Page 1

    Kx250f motorcycle service manual.

  • Page 3: Quick Reference Guide

    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 th...

  • Page 5: Kx250F

    Kx250f 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/consume...

  • Page 6

    List of abbreviations a ampere(s) lb pound(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inch...

  • Page 7: Foreword

    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 prope...

  • Page 9: General Information 1-1

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 10: 1-2 General Information

    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...

  • Page 11: General Information 1-3

    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. Inspectio...

  • Page 12: 1-4 General Information

    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 tighten...

  • Page 13: General Information 1-5

    General information 1-5 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 pressu...

  • Page 14: 1-6 General Information

    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 i...

  • Page 15: General Information 1-7

    General information 1-7 model identification kx250t6f left side view kx250t6f right side view.

  • Page 16: 1-8 General Information

    1-8 general information general specifications items kx250t6f dimensions overall length 2 160 mm (85.04 in.) overall width 820 mm (32.3 in.) overall height 1 270 mm (50 in.) wheelbase 1 469 mm (57.83 in.) road clearance 372 mm (14.6 in.) seat height 960 mm (37.8 in.) dry mass 92.5 kg (204 lb) curb m...

  • Page 17: General Information 1-9

    General information 1-9 general specifications items kx250t6f clutch type wet, multi disc, manual transmission: type 5-speed, constant mesh, return shift gear ratios: 1st 2.142 (30/14) 2nd 1.785 (25/14) 3rd 1.444 (26/18) 4th 1.200 (24/20) 5th 1.052 (20/19) final drive system: type chain drive reduct...

  • Page 18: 1-10 General Information

    1-10 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 19: Periodic Maintenance 2-1

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-3 torque and locking agent..................................................................................

  • Page 20: 2-2 Periodic Maintenance

    2-2 periodic maintenance drive chain lubrication..................................................................................................... 2-35 sprocket wear inspection................................................................................................. 2-36 rear sprocket warp...

  • Page 21: Periodic Maintenance 2-3

    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 operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page spark plug - clean,...

  • Page 22: 2-4 Periodic Maintenance

    2-4 periodic maintenance periodic maintenance chart frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page wheels/tires - inspect • 2-30 rear sprocket - inspect † • 2-36 front fork - inspect and clean • 2-47 front fork oil - change • 2...

  • Page 23: Periodic Maintenance 2-5

    Periodic maintenance 2-5 torque and locking 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 t...

  • Page 24: 2-6 Periodic Maintenance

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks radiator mounting bolts 9.8 1.0 87 in·lb radiator shroud bolts 9.8 1.0 87 in·lb engine top end auto-decompressor bolt 12 1.2 104 in·lb decompressor plug 9.8 1.0 87 in·lb cylinder head cover bolts 9.8 1.0 87 in·...

  • Page 25: Periodic Maintenance 2-7

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil filter cap bolts 9.8 1.0 87 in·lb oil pump mounting bolts 7.0 0.7 61 in·lb l water pump cover bolts 9.8 1.0 87 in·lb l (1) water pump cover bolt (with washer) 9.8 1.0 87 in·lb l (1) right engine cover bolts...

  • Page 26: 2-8 Periodic Maintenance

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks brake reservoir cap bolts 1.5 0.15 13 in·lb brake disc mounting bolts: (front) 9.8 1.0 87 in·lb l (rear) 23 2.3 16.6 l caliper bleed valves (front, rear) 7.8 0.8 69 in·lb front caliper holder shaft 22 2.2 16 l ...

  • Page 27: Periodic Maintenance 2-9

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks crankshaft sensor bolts 7.0 0.7 61 in·lb spark plug 13 1.3 115 in·lb c.D.I. Unit bolts 9.8 1.0 87 in·lb magneto cover bolts l: 30 9.8 1.0 87 in·lb l: 35 9.8 1.0 87 in·lb l.

  • Page 28: 2-10 Periodic Maintenance

    2-10 periodic maintenance specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – hot start lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – idle speed 2 000 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – c...

  • Page 29: Periodic Maintenance 2-11

    Periodic maintenance 2-11 specifications item standard service limit standard tire: front: size 80/100-21 51m – – – make bridestone – – – type m401, tube, – – – (eur) m201, tube – – – rear: size 100/90-19 57m – – – make bridestone – – – type m402, tube, – – – (eur) m202, tube – – – final drive drive...

  • Page 30: 2-12 Periodic Maintenance

    2-12 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 attachment jack: 57001-1252 spark plug wrench, hex 16: 57001-1262 carburetor drain plug wrench, hex 3: 57001-1269 filler cap driver: 57001-1454 pilot screw adjuster, d: 5700...

  • Page 31: Periodic Maintenance 2-13

    Periodic maintenance 2-13 periodic maintenance procedures fuel system fuel hose and connection inspection ○ if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [a]. • check the fuel hose. Replace the fuel hose if any fraying, cracks [b], bulges [c], or ozonic c...

  • Page 32: 2-14 Periodic Maintenance

    2-14 periodic maintenance periodic maintenance procedures if the throttle grip free play cannot be adjusted with the adjuster, replace the throttle cables. • turn the handlebar from side to side while idling the en- gine. If idle speed varies, the throttle cable may be poorly routed or it may be dam...

  • Page 33: Periodic Maintenance 2-15

    Periodic maintenance 2-15 periodic maintenance procedures • start the engine and warm it up thoroughly. • 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 incorrectly routed, or it may be da...

  • Page 34: 2-16 Periodic Maintenance

    2-16 periodic maintenance periodic maintenance procedures • start the engine and warm it up thoroughly. • turn the idle adjusting screw [a] until the idle speed is correct. To increase idle speed [b] to decrease idle speed [c] • open and close the throttle a few times to make sure that the idle spee...

  • Page 35: Periodic Maintenance 2-17

    Periodic maintenance 2-17 periodic maintenance procedures • separate the element [a] from the frame [b]. • clean the element [a] in a bath of a high-flash-point sol- vent using a soft bristle brush. • squeeze it dry in a clean towel [a]. Do not wring the ele- ment or blow it dry; the element can be ...

  • Page 36: 2-18 Periodic Maintenance

    2-18 periodic maintenance periodic maintenance procedures • install the air cleaner element so that its tab [a] faces upward and its projections [b] align with the holes [c] in the frame. • tighten the wing bolt [d]. • install the seat. Fuel system clean warning gasoline is extremely flammable and c...

  • Page 37: Periodic Maintenance 2-19

    Periodic maintenance 2-19 periodic maintenance procedures 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. Immediat...

  • Page 38: 2-20 Periodic Maintenance

    2-20 periodic maintenance periodic maintenance procedures caution for refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum en- gine parts. In an emergency, soft wa...

  • Page 39: Periodic Maintenance 2-21

    Periodic maintenance 2-21 periodic maintenance procedures engine top end valve clearance inspection note ○ valve clearance must be checked and adjusted when the engine is cold (at room temperature). • remove: cylinder head cover (see cylinder head cover re- moval in the engine top end chapter) timin...

  • Page 40: 2-22 Periodic Maintenance

    2-22 periodic maintenance periodic maintenance procedures note ○ mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions. • clean the shim to remove any dust or oil. • measure the thickness of the removed shim [a]. • select a new shim ...

  • Page 41: Periodic Maintenance 2-23

    Periodic maintenance 2-23 periodic maintenance procedures 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. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valv...

  • Page 42: 2-24 Periodic Maintenance

    2-24 periodic maintenance periodic maintenance procedures cylinder wear inspection note ○ measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • visually inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly w...

  • Page 43: Periodic Maintenance 2-25

    Periodic maintenance 2-25 periodic maintenance procedures exhaust system inspection • the 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, exhau...

  • Page 44: 2-26 Periodic Maintenance

    2-26 periodic maintenance periodic maintenance procedures • install the end [a] of the silencer pipe [b] to the baffle [c]. • apply a non-permanent locking agent to the silencer pipe cover bolts. • install the silencer cover. Torque - silencer cover bolts: 12 n·m (1.2 kgf·m, 109 in·lb) • apply silic...

  • Page 45: Periodic Maintenance 2-27

    Periodic maintenance 2-27 periodic maintenance procedures clutch lever free play adjustment • turn the adjuster [a] so that the clutch lever [b] will have 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. Note ○ be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch leve...

  • Page 46: 2-28 Periodic Maintenance

    2-28 periodic maintenance periodic maintenance procedures engine lubrication system warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, and injury. Engine oil change • warm up the e...

  • Page 47: Periodic Maintenance 2-29

    Periodic maintenance 2-29 periodic maintenance procedures oil filter change • drain: engine oil (see engine oil change) • remove: oil filter cap bolt [a] oil filter cap [b] • remove the oil filter [a]. • replace the oil filter with a new one. • apply grease [a] to the grommet. • be sure to install t...

  • Page 48: 2-30 Periodic Maintenance

    2-30 periodic maintenance periodic maintenance procedures crankshaft/transmission crankshaft inspection • make sure that the crankshaft rotate smoothy (in the neu- tral position). If the crankshaft will not turn smoothly, check the cranks shaft assembly. Connecting rod big end side clearance • remov...

  • Page 49: Periodic Maintenance 2-31

    Periodic maintenance 2-31 periodic maintenance procedures tires inspection as the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • remove any imbedded stones or other foreign particles from the tread. • visually inspect the tire for cracks and cuts, replacing th...

  • Page 50: 2-32 Periodic Maintenance

    2-32 periodic maintenance periodic maintenance procedures rim runout inspection • place the jack under the frame so that the front/rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • inspect the rim for small cracks, dents, bending, or warp- ing. ...

  • Page 51: Periodic Maintenance 2-33

    Periodic maintenance 2-33 periodic maintenance procedures • turn the handlebar until the handlebar doesn’t move to either side. • the 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. If the play is found, replace the bear...

  • Page 52: 2-34 Periodic Maintenance

    2-34 periodic maintenance periodic maintenance procedures drive chain slack inspection • raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • check the wheel alignment (see wheel alignment inspec- tion in the wheels c...

  • Page 53: Periodic Maintenance 2-35

    Periodic maintenance 2-35 periodic maintenance procedures note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [a] up to next alignment. ○ it should be within 30 degree. ○ loosen one and tighten again when th...

  • Page 54: 2-36 Periodic Maintenance

    2-36 periodic maintenance periodic maintenance procedures sprocket wear inspection • visually inspect the front and rear sprocket teeth for wear and damage. If they are worn as illustrated or damaged, replace the sprocket. [a] worn tooth (engine sprocket) [b] worn tooth (rear sprocket) [c] direction...

  • Page 55: Periodic Maintenance 2-37

    Periodic maintenance 2-37 periodic maintenance procedures note ○ usually 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. • measure the length indicated in the figure. Length [a] standard: 68.5 ±1 mm (3....

  • Page 56: 2-38 Periodic Maintenance

    2-38 periodic maintenance periodic maintenance procedures brake fluid level inspection • check the brake fluid level in the front or rear brake reser- voir [a]. Note ○ hold the reservoir horizontal when checking brake fluid level. • the front or rear reservoir must be kept above the lower level line...

  • Page 57: Periodic Maintenance 2-39

    Periodic maintenance 2-39 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 ai...

  • Page 58: 2-40 Periodic Maintenance

    2-40 periodic maintenance periodic maintenance procedures note ○ the procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove the screw [a], reservoir cap [b] and diaphragm [c]. • remove the rubber cap ...

  • Page 59: Periodic Maintenance 2-41

    Periodic maintenance 2-41 periodic maintenance procedures • remove the clear plastic hose. • tighten the bleed valves, and install the rubber caps. Torque - caliper bleed valve: 7.8 n·m (0.8 kgf·m, 69 in·lb) brake reservoir cap screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) • after changing the fluid, check...

  • Page 60: 2-42 Periodic Maintenance

    2-42 periodic maintenance periodic maintenance procedures • remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • slide the dust cover [a] on the push rod [b] out of place, and remove the circlip [c]. Special tool - inside circlip pliers: 57001-143 • pull out the push ...

  • Page 61: Periodic Maintenance 2-43

    Periodic maintenance 2-43 periodic maintenance procedures • separate the caliper holder [a] from the caliper [b] and remove the anti-rattle spring. • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ re...

  • Page 62: 2-44 Periodic Maintenance

    2-44 periodic maintenance periodic maintenance procedures • pull out the piston [a] by hand. • remove the dust seal [b] and fluid seal [c]. • clean the caliper parts except for the pads. Caution for cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • the bleed va...

  • Page 63: Periodic Maintenance 2-45

    Periodic maintenance 2-45 periodic maintenance procedures • replace the shaft rubber friction boot [a] and dust boot [b] if they are damaged. • 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...

  • Page 64: 2-46 Periodic Maintenance

    2-46 periodic maintenance periodic maintenance procedures • remove each banjo bolts [a] and washers [b]. • replace the washers with new ones. For front brake hose • remove bolts [a] brake hose clamps [b] for rear brake hose • remove: master cylinder [a] hose clamps [b] caliper cover [c] • when insta...

  • Page 65: Periodic Maintenance 2-47

    Periodic maintenance 2-47 periodic maintenance procedures suspension front fork inspection • holding the brake lever, pump the front fork back and forth manually to check for smooth operation. • visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner t...

  • Page 66: 2-48 Periodic Maintenance

    2-48 periodic maintenance periodic maintenance procedures • loosen the front fork lower clamp bolts [a]. • remove the front fork. ○ with a twisting motion, work the fork leg [b] down and out. • record the position of the damping adjusters [a] and then turn [b] it to the softest position. • measure t...

  • Page 67: Periodic Maintenance 2-49

    Periodic maintenance 2-49 periodic maintenance procedures • temporarily install the fork cylinder unit [a] to the outer tube [b]. Special tool - top plug wrench, 50 mm: 57001-1645 • hold the axle holder part [a] with a vise [b]. ○ protect the axle holder part with a soft jaws [c] or heavy cloth when...

  • Page 68: 2-50 Periodic Maintenance

    2-50 periodic maintenance periodic maintenance procedures • with the outer tube compressed by hand, remove the top plug wrench. 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. Be careful of...

  • Page 69: Periodic Maintenance 2-51

    Periodic maintenance 2-51 periodic maintenance procedures • hold the fork cylinder unit [a] upside down over a clean container [b] and pump it to drain the oil. Note ○ pump the piston rod up and down to discharge the fork oil. • hold the front fork at the inverted position for more than 20 minutes t...

  • Page 70: 2-52 Periodic Maintenance

    2-52 periodic maintenance periodic maintenance procedures • with the piston rod fully stretched, check the oil level in the fork cylinder unit. ○ measure the oil level [a] from the step [b] in the cylinder unit using the suitable gauge. Fork cylinder unit oil level 42 ∼ 49 mm (1.65 ∼ 1.93 in.) • rep...

  • Page 71: Periodic Maintenance 2-53

    Periodic maintenance 2-53 periodic maintenance procedures • discharge the extra oil off the cylinder unit [a] by pumping the piston rod [b] to full stroke [c]. Caution be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil files out from the oil...

  • Page 72: 2-54 Periodic Maintenance

    2-54 periodic maintenance periodic maintenance procedures • wipe the oil off completely from the cylinder unit [a]. • compress the piston rod [b] to 200 ∼ 250 mm (7.9 ∼ 9.8 in.) [c] and hold the cylinder unit upright position for 10 minutes. • there should be no oil leak from the base valve assembly...

  • Page 73: Periodic Maintenance 2-55

    Periodic maintenance 2-55 periodic maintenance procedures • compress the outer tube by hands and insert the top plug wrench [a] between the axle holder part bottom [b] and locknut [c]. Special tool - top plug wrench, 50 mm: 57001-1645 warning be careful of reaction force in spring and fix surely so ...

  • Page 74: 2-56 Periodic Maintenance

    2-56 periodic maintenance periodic maintenance procedures • compare the length [a] at assembly and at disassembly. ○ there should be same length. If the length at assembly is longer than at disassembly, check the adjuster assembly and locknut installation. Axle holder [b] outer tube [c] length stand...

  • Page 75: Periodic Maintenance 2-57

    Periodic maintenance 2-57 periodic maintenance procedures the torque of fork cylinder unit is specified to 34 n·m (3.5 kgf·m, 25 ft·lb) however, when you use the top plug wrench [a], reduce the torque to 90% of the specified value [31 n·m (3.1 kgf·m, 23 ft·lb)] due to the distance between the center...

  • Page 76: 2-58 Periodic Maintenance

    2-58 periodic maintenance periodic maintenance procedures 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...

  • Page 77: Periodic Maintenance 2-59

    Periodic maintenance 2-59 periodic maintenance procedures • 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. • remove the circlip [a]. • lightly move the piston rod back and forth, and pull ...

  • Page 78: 2-60 Periodic Maintenance

    2-60 periodic maintenance periodic maintenance procedures • inspect the slide bushing [a]. If the bushing is damaged, replace it. • cut the slide bushing [a]. • remove the o-rings [b]. • replace the o-rings with new ones. • install the o-rings and a new bushing on the piston. • wrap the threads [a] ...

  • Page 79: Periodic Maintenance 2-61

    Periodic maintenance 2-61 periodic maintenance procedures • replace the following with new ones. Oil seals rebound rubber (if damaged) o-ring • install each parts direction as shown in the figure. Oil seal [a] oil seal [b] spring holder [c] collar [d] rebound rubber [e] spring [f] o-ring [g] • remov...

  • Page 80: 2-62 Periodic Maintenance

    2-62 periodic maintenance periodic maintenance procedures • install: damper holder [a] damper [b] stopper [c] • wrap the threads of the piston rod with tape [a]. • apply thin coat of shock oil to the sliding surface of the piston rod. • insert the oil seal assembly [b]. • install: washer [a] stopper...

  • Page 81: Periodic Maintenance 2-63

    Periodic maintenance 2-63 periodic maintenance procedures ○ install the piston direction as shown in the figure. Locknut side face [a] • stake [a] the end of the piston rod in three place [b]. • check the oil seal assembly moving smoothly on the rod. • check that the bladder [a] on the gas reservoir...

  • Page 82: 2-64 Periodic Maintenance

    2-64 periodic maintenance periodic maintenance procedures • mount the circlip [a] in the groove in the gas reservoir. • 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]. Warning if the end of the gas reservoi...

  • Page 83: Periodic Maintenance 2-65

    Periodic maintenance 2-65 periodic maintenance procedures • force the stop [a] into the rear shock body by lightly tap- ping around the edge of the stop with a mallet. • fully extend the piston rod assembly. • remount the upper portion of the shock absorber in a vise with soft jaws or a heavy cloth....

  • Page 84: 2-66 Periodic Maintenance

    2-66 periodic maintenance periodic maintenance procedures • inject nitrogen gas to a pressure of 50 kpa (0.5 kgf/cm², 7 psi) through the valve on the gas reservoir. • check the rear shock body and gas reservoir for oil and gas leaks. If there are leaks reassemble the related parts. • replace the o-r...

  • Page 85: Periodic Maintenance 2-67

    Periodic maintenance 2-67 periodic maintenance procedures • push and pull on the swingarm [a] to check for wear. A 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. Swing...

  • Page 86: 2-68 Periodic Maintenance

    2-68 periodic maintenance periodic maintenance procedures • slide the holder belt [a] out off. • remove: number plate bolt [b] number plate [c] handlebar pad cover [d] handlebar pad [e] • remove: handlebar clamp bolts [a] handlebar clamps [b] handle bar [c] vent tube [d] • loosen the front fork uppe...

  • Page 87: Periodic Maintenance 2-69

    Periodic maintenance 2-69 periodic maintenance procedures • check the steering again. If the steering is too tight or too loose, repeat the adjust- ment as mentioned above. • install the handlebar [a] on the handlebar holder as shown. Same length [b] bridge bar [c] • install the handlebar clamps [a]...

  • Page 88: 2-70 Periodic Maintenance

    2-70 periodic maintenance periodic maintenance procedures frame frame inspection • clean the frame with steam cleaner. • visually inspect the frame and rear frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly ...

  • Page 89: Periodic Maintenance 2-71

    Periodic maintenance 2-71 periodic maintenance procedures • measure the gap [a] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [b] with a suitable tool to obtain the correct gap. Spark plug gap standard: 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) • insert the spar...

  • Page 90: 2-72 Periodic Maintenance

    2-72 periodic maintenance periodic maintenance procedures cables: lubricate with rust inhibitor. Throttle cables clutch cable hot start cable pivots: lubricate with motor oil. Clutch lever host starter lever brake lever brake pedal rear master cylinder joint pin • with the cable disconnected at the ...

  • Page 91: Periodic Maintenance 2-73

    Periodic maintenance 2-73 periodic maintenance procedures 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, fi...

  • Page 93: Fuel System 3-1

    Fuel system 3-1 3 fuel system table of contents exploded view........................................................................................................................ 3-2 specifications ......................................................................................................

  • Page 94: 3-2 Fuel System

    3-2 fuel system exploded view.

  • Page 95: Fuel System 3-3

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolt 3.4 0.3 30 in·lb 2 throttle cable locknut 7.0 0.7 61 in·lb 3 hot start plunger cap bolt 1.0 0.1 10 in·lb 4. Hot start lever 5. Hot start cable 6. Throttle grip 7. Throttle cables 8. Carburetor cap ...

  • Page 96: 3-4 Fuel System

    3-4 fuel system exploded view.

  • Page 97: Fuel System 3-5

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolts 34 3.5 25 2 air cleaner duct clamp screw 3.0 0.3 27 in·lb 3 air cleaner duct bolt and nuts 3.0 0.3 27 in·lb 4 air cleaner element wing bolt – – – hand tighten 5 air cleaner housing bolts 9.8 7.0 87 ...

  • Page 98: 3-6 Fuel System

    3-6 fuel system specifications item standard service limit carburetor make/type keihin fcr37 – – – starter jet #68 – – – leak jet #60 – – – main jet #180, (eur) #175 – – – throttle valve cutaway ca1.5 – – – jet needle ncyu, (eur) nhju – – – jet needle clip position 2nd groove from the top (eur) 3rd ...

  • Page 99: Fuel System 3-7

    Fuel system 3-7 special tools fuel level gauge, m18 × 1.0: 57001-122.

  • Page 100: 3-8 Fuel System

    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 wi...

  • Page 101: Fuel System 3-9

    Fuel system 3-9 throttle grip and cable • unscrew the bolt [a]. • remove the throttle pulley cover [b]. • loosen the mounting bolts [a]. • remove the cables [b] from the carburetor. • free the tips [c] from the pulley. • remove the cables from the frame. • lubricate the cable. • apply grease to the ...

  • Page 102: 3-10 Fuel System

    3-10 fuel system throttle grip and cable throttle cable lubrication • whenever the throttle cable is removed or in accordance with the periodic maintenance chart, lubricate the these cables, refer to general lubrication in the periodic main- tenance chapter. ○ apply a thin coating of grease to the c...

  • Page 103: Fuel System 3-11

    Fuel system 3-11 throttle grip and cable • remove: fuel tank (see fuel tank removal) • pull out the cable [b] from the clamps [a]. Hot start cable installation torque - hot start plunger cap bolt: 1.0 n·m (0.1 kgf·m, 10 in·lb) • install the hot start cable in accordance with the cable, wire and hose...

  • Page 104: 3-12 Fuel System

    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 im...

  • Page 105: Fuel System 3-13

    Fuel system 3-13 carburetor • 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 ±0.039 in.) if the fuel level is incorrect, adjust it. • turn the fuel tap to the off position and remove the fu...

  • Page 106: 3-14 Fuel System

    3-14 fuel system carburetor note ○ float 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. ○ do not push the needle rod [d] in during the float height m...

  • Page 107: Fuel System 3-15

    Fuel system 3-15 carburetor • remove: seat side cover silencer rear frame bolts [b] • loosen the clamp screws [a] of the air cleaner duct. • pull out the rear frame [c] with the air cleaner housing. ○ lift up the rear frame little and then pass the end position [a] of the duct between the frame and ...

  • Page 108: 3-16 Fuel System

    3-16 fuel system carburetor • loosen the mounting bolts [a]. • pull out the end of the throttle cables [b]. • free the tips [c]. • pull out the air vent tubes and drain tube [a] from the clamp [b]. • remove the carburetor to the left side of the frame. • drain the fuel from the float bowl by removin...

  • Page 109: Fuel System 3-17

    Fuel system 3-17 carburetor • fit the claw [a] of the clamp onto the groove [b] of the inlet duct. • insert the duct end between the frame and shock ab- sorber. • install the upper bolt temporary. • insert the duct end onto the carburetor. • tighten the clamps securely. Torque - carburetor holder cl...

  • Page 110: 3-18 Fuel System

    3-18 fuel system carburetor • unscrew the screw [a]. • pull out the fuel hose fitting [b]. • unscrew the carburetor cap bolts [a]. • remove the carburetor cap [b]. • unscrew the throttle valve link screw [a]. • pull out the throttle valve assembly [b]. • disassemble the throttle valve assembly; jet ...

  • Page 111: Fuel System 3-19

    Fuel system 3-19 carburetor • remove the throttle pulley shaft [a] with the spring [b], steel washer [c], plastic washer [d] and throttle valve link [e]. ○ turn the throttle pulley shaft [a] clockwise while holding down the acceleration pump lever [b] and clear the idle stop screw [c] to the stopper...

  • Page 112: 3-20 Fuel System

    3-20 fuel system carburetor • unscrew the screws [a]. • remove the acceleration pump cover [b] from the carbu- retor. • remove the spring [a], diaphragm [b], and the o-rings [c]. • remove the following parts from the carburetor body. [a] idle adjusting screw [b] screws [c] clamps [d] float bowl [e] ...

  • Page 113: Fuel System 3-21

    Fuel system 3-21 carburetor • unscrew the leak jet [a]. • remove: e-clip [a] washer [b] • pull out the acceleration pump lever assembly [c] as a set. • remove the throttle sensor mounting bolt [a]. • before removing the throttle sensor [b], mark [c] the car- buretor body and sensor so that it can be...

  • Page 114: 3-22 Fuel System

    3-22 fuel system carburetor carburetor cleaning 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...

  • Page 115: Fuel System 3-23

    Fuel system 3-23 carburetor • remove the carburetor. • before disassembling the carburetor, check the fuel level (see fuel level inspection). If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. • turn the throttle pulley to check that the throttle valve [a] mov...

  • Page 116: 3-24 Fuel System

    3-24 fuel system carburetor • check the jet needle for wear. A worn jet needle should be replaced. • for the throttle sensor inspection, see throttle sensor in- spection in the electrical system chapter. • check the valve seat [a] of the choke plunger [b] for dam- age or stepped wear. Replace the ch...

  • Page 117: Fuel System 3-25

    Fuel system 3-25 carburetor • install: washer [a] e-clip [b] • apply thin coat silicone grease to the shaft. • fit the hook [a] of the return spring onto the stopper [b] of the throttle cable pulley. • insert the throttle cable pulley shaft [a] and install the steel washer [d], nylon washer [c] and ...

  • Page 118: 3-26 Fuel System

    3-26 fuel system carburetor • install the push rod [a] into the push rod holder [b]. • apply a grease to the o-ring [a]. • fit the stopper [b] of the throttle sensor onto the projection [c] on the throttle cable pulley shaft. ○ install the throttle sensor so that the marks aligns and check it positi...

  • Page 119: Fuel System 3-27

    Fuel system 3-27 carburetor • install: starter jet [a] pilot jet [b] baffle plate [c] needle jet [d] main jet [e] • replace the o-ring with new one. • install: pilot air screw [a] spring [b] washer [c] o-ring [d] ○ turn in the pilot air screw fully but not tightly, and the back it out the counted nu...

  • Page 120: 3-28 Fuel System

    3-28 fuel system carburetor • replace the o-rings with new ones. • fit the o-rings [a]. • install: diaphragm [b] spring [c] acceleration pump cover ○ install the diaphragm so that its mark facing [d] outward. ○ fit the spring end into the circle groove [e] in the cover. • tighten the screws. • insta...

  • Page 121: Fuel System 3-29

    Fuel system 3-29 carburetor • if turn the adjusting screw of the acceleration pump, follow the procedure below. ○ adjust the acceleration pump timing. ○ select 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 (...

  • Page 122: 3-30 Fuel System

    3-30 fuel system air cleaner air cleaner housing removal • remove: side covers (see side cover removal in the frame chapter) seat (see seat removal in the frame chapter) silencer (see engine top end chapter) bolts and rear fender [a] screws and rear flap [b] • loosen the air cleaner duct clamp screw...

  • Page 123: Fuel System 3-31

    Fuel system 3-31 air cleaner element installation • 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. • apply grease to all conne...

  • Page 124: 3-32 Fuel System

    3-32 fuel system fuel tank fuel tank removal 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 l...

  • Page 125: Fuel System 3-33

    Fuel system 3-33 fuel tank • install the rubber dampers [a] position as shown in the figure. ○ apply adhesive cement to the contact portion of the damper. • be sure the fuel hose is clamped to the fuel tap to prevent leaks. • insert the fuel tank breather hose outlet end into the steer- ing stem hol...

  • Page 127: Cooling System 4-1

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 128: 4-2 Cooling System

    4-2 cooling system exploded view.

  • Page 129: Cooling System 4-3

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump cover bolts 9.8 1.0 87 in·lb l (1) 2 water pump cover bolts (with washer) 9.8 1.0 87 in·lb l (1) 3 coolant drain plug 7.0 0.7 61 in·lb 4 water pump impeller bolt 7.0 0.7 61 in·lb 5 right engine cover bolts 9.8 ...

  • Page 130: 4-4 Cooling System

    4-4 cooling system specifications item 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 1.10 l (1.16 us qt.) radiator cap relief pressure 93 ∼ 123 kpa (0.95 ∼ 1.25 ...

  • Page 131: Cooling System 4-5

    Cooling system 4-5 special tool bearing driver set: 57001-1129.

  • Page 132: 4-6 Cooling System

    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 coolant level inspection in the periodic maintenance chapter). Warning to avoid burns, do n...

  • Page 133: Cooling System 4-7

    Cooling system 4-7 coolant • 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. • inspect the old coolant for visual...

  • Page 134: 4-8 Cooling System

    4-8 cooling system coolant air bleeding before putting the motorcycle into operation, any air trapped in the cooling system must be removed as follows. • start the engine, warm up the engine thoroughly, and then stop the engine. Wait until the engine cools down. • remove the radiator cap. • check th...

  • Page 135: Cooling System 4-9

    Cooling system 4-9 coolant 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...

  • Page 136: 4-10 Cooling System

    4-10 cooling system water pump water pump cover removal • drain the engine oil from the water pump cover. ○ unscrew the bolts [a] and remove the oil filter cap [b]. • drain the coolant (see coolant draining). ○ unscrew the drain bolt [c]. • remove: spring (see oil filter change in the periodic maint...

  • Page 137: Cooling System 4-11

    Cooling system 4-11 water pump • apply grease to the water pipe o-ring [a]. • insert the water pipe [b] straightly into the hole of the wa- ter pump cover. • tighten: torque - water pipe bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the oil filter (see oil filter change in the periodic maintenance c...

  • Page 138: 4-12 Cooling System

    4-12 cooling system water pump • check the drainage outlet passage [a] at the bottom of the right engine cover for coolant leaks. If the oil seal is damaged, the coolant leaks through the seal and drains through the passage. Replace the oil seals. Water pump gear removal • remove: water pump cover (...

  • Page 139: Cooling System 4-13

    Cooling system 4-13 water pump • 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 and bearing installation caution if the oil seal or ball bearing is removed, replace all of the...

  • Page 140: 4-14 Cooling System

    4-14 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: bolts [a] radiator shrouds [b] • loosen: clamp screws [a] • remove: radiator hoses [b] bolt [c] right radiator screen [d] • unscrew the bolts [a]. • loosen: clamp [b] (slide out) • remove: right radia...

  • Page 141: Cooling System 4-15

    Cooling system 4-15 radiator radiator installation • run the radiator hose [a] between the hot start cable, engine stop switch lead [b] and main harness [c]. • hold the clutch cable with clamps. • fit the projections [a] of the screen in the holes [b] of the radiator. Torque - radiator hose clamp sc...

  • Page 142: 4-16 Cooling System

    4-16 cooling system radiator radiator cap inspection • 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. • wet the top and bottom valve seals with water or coolant to prevent pressure lea...

  • Page 143: Engine Top End 5-1

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools & sealants ................... 5-9 cylinder head cover ......................... 5-12 cylinder head cover removal .... 5-12...

  • Page 144: 5-2 Engine Top End

    5-2 engine top end exploded view.

  • Page 145: Engine Top End 5-3

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 auto-decompressor bolt 12 1.2 104 in·lb 2 cylinder head cover bolts 9.8 1.0 87 in·lb 3 cylinder head bolts m6 12 1.2 104 in·lb s 4 camshaft cap bolts 9.8 1.0 87 in·lb s 5 carburetor holder clamp screws 2.0 0.2 17 in·lb 6 ...

  • Page 146: 5-4 Engine Top End

    5-4 engine top end exploded view.

  • Page 147: Engine Top End 5-5

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 camshaft chain tensioner mounting bolts 9.8 1.0 87 in·lb 2 camshaft chain tensioner cap bolt 20 2.0 14.5 3 cylinder bolt m6 12 1.2 104 in·lb s 4 exhaust pipe cover screws 12 1.2 104 in·lb 5 exhaust pipe holder nuts 21 2.1...

  • Page 148: 5-6 Engine Top End

    5-6 engine top end specifications item standard service limit camshafts cam height: exhaust 33.941 ∼ 34.057 mm 33.84 mm (1.3363 ∼ 1.3408 in.) (1.3322 in.) inlet 34.642 ∼ 34.758 mm 34.54 mm (1.3639 ∼ 1.3684 in.) (1.3598 in.) camshaft bearing clearance 0.020 ∼ 0.062 mm 0.15 mm (0.0008 ∼ 0.0024 in.) (0...

  • Page 149: Engine Top End 5-7

    Engine top end 5-7 specifications item standard service limit valve seat surface outside diameter: exhaust 24.62 ∼ 24.82 mm – – – (0.9693 ∼ 0.9772 in.) inlet 30.62 ∼ 30.82 mm – – – (1.2055 ∼ 1.2134 in.) valve seat surface width: exhaust 0.5 ∼ 1.0 mm – – – (0.0197 ∼ 0.0394 in.) inlet 0.5 ∼ 1.0 mm – –...

  • Page 150: 5-8 Engine Top End

    5-8 engine top end specifications cam height cam height [a] camshaft runout valve stem diameter valve stem diameter [a] 45° [b] valve stem bend dial gauge [a].

  • Page 151: Engine Top End 5-9

    Engine top end 5-9 special tools & sealants compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston ring compressor grip: 57001-1095 piston ring compressor belt, 67 ∼ 79: 57001-1097 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 45° - 32: 57001-1115 ...

  • Page 152: 5-10 Engine Top End

    5-10 engine top end special tools & sealants spark plug wrench, hex 16: 57001-1262 compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter, 60° - 25: 57001-1328 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 valve seat cutt...

  • Page 153: Engine Top End 5-11

    Engine top end 5-11 special tools & sealants kawasaki bond (silicone sealant): 92104-0004.

  • Page 154: 5-12 Engine Top End

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) stick coil (see spark plug cleaning and inspection in the periodic maintenance chapter) • unscrew the bracket nuts [a] and remove the bolts [b]. • loosen the mou...

  • Page 155: Engine Top End 5-13

    Engine top end 5-13 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 ten...

  • Page 156: 5-14 Engine Top End

    5-14 engine top end camshaft camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] flywheel cap [b] special tool - filler cap driver: 57001-1454 • first, bring the piston to the tdc (of either the compres- sion or exhaust stroke). ○ place a wren...

  • Page 157: Engine Top End 5-15

    Engine top end 5-15 camshaft • remove: bolt [a] auto-decompressor [b] spring [c] camshaft installation • install: spring [a] auto-decompressor [b] bolt [c] torque - auto-decompressor bolt: 12 n·m (1.2 kgf·m, 104 in·lb) • fill the passage of the cylinder head with molybdenum disulfide oil. ○ pure in ...

  • Page 158: 5-16 Engine Top End

    5-16 engine top end camshaft 1st pin [a] punch marks (exhaust) [d] 2nd pin [b] punch marks (inlet) [e] 28th pin [c] upper cylinder head surface [f] • be sure to install the dowel pins [a] and positioning rings [b]. • install the camshaft caps in their original positions by fac- ing their triangle ma...

  • Page 159: Engine Top End 5-17

    Engine top end 5-17 camshaft • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ bolts [a] are long. ○ following the sequence numbers on the camshaft caps, tighten the cap bolts [1 ∼ 4] after applying engine oil to the seat and thread of them. Torqu...

  • Page 160: 5-18 Engine Top End

    5-18 engine top end camshaft camshaft and camshaft cap wear • measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [a]. ○ tighten the camshaft cap bolts after applying engine oil to the seat and thread of them. Torque - camshaft cap bolt: 9.8 n·m (1.0 ...

  • Page 161: Engine Top End 5-19

    Engine top end 5-19 cylinder head cylinder compression measurement • start the engine. • thoroughly 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. • stop the engine. • remove: fuel tank (see fuel tank re...

  • Page 162: 5-20 Engine Top End

    5-20 engine top end cylinder head cylinder head removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) carburetor (see carburetor removal in the fuel system chapter) camshaft chain tensioner (see camshaft chain ten- sioner removal) cylinder head cover (see cylinder head cover...

  • Page 163: Engine Top End 5-21

    Engine top end 5-21 cylinder head • pull the cylinder head upward. ○ do not damage the radiator core. ○ clear the front [a] and rear [b] chain guides. • remove the cylinder head gasket. Cylinder head installation • fit the projection [a] of the front camshaft chain guide [b] in the groove [c] of the...

  • Page 164: 5-22 Engine Top End

    5-22 engine top end cylinder head • tighten the 6 mm bolts. M6 cylinder bolt [a] m6 cylinder head bolt with clamp [b] m6 cylinder head bolt [c] torque - 6 mm cylinder bolt: 12 n·m (1.2 kgf·m, 104 in·lb) 6 mm cylinder head bolt: 12 n·m (1.2 kgf·m, 104 in·lb) • install: camshaft (see camshaft installa...

  • Page 165: Engine Top End 5-23

    Engine top end 5-23 valves valve clearance inspection ○ refer to the valve clearance inspection in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and the shim from the valve. Note ○ use the valve spring compressor ass...

  • Page 166: 5-24 Engine Top End

    5-24 engine top end valves valve guide removal • remove: valve (see valve removal) oil seal spring seat • 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 oi...

  • Page 167: Engine Top End 5-25

    Engine top end 5-25 valves • ream the valve guide with valve guide reamer [a], even if the old guide is reused. ○ always rotate the reamer clockwise. Special tool - valve guide reamer, 4.5: 57001-1333 valve/valve guide clearance measurement (wobble method) ○ if a small bore gauge is not available, i...

  • Page 168: 5-26 Engine Top End

    5-26 engine top end valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. • measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 169: Engine Top End 5-27

    Engine top end 5-27 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 fai...

  • Page 170: 5-28 Engine Top End

    5-28 engine top end valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Original seating surface [b] ○ remove all pittings of flaws f...

  • Page 171: Engine Top End 5-29

    Engine top end 5-29 valves • the seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. • when the engine is assembled, be s...

  • Page 172: 5-30 Engine Top End

    5-30 engine top end valves valve seat repair.

  • Page 173: Engine Top End 5-31

    Engine top end 5-31 cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remove the cylinder base gasket. Piston removal • remove...

  • Page 174: 5-32 Engine Top End

    5-32 engine top end cylinder and piston • install the top ring [a] so that the "r" mark [b] faces up. Note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston rings. • apply engine oil to the inside wall of the small end of ...

  • Page 175: Engine Top End 5-33

    Engine top end 5-33 cylinder and piston • apply engine oil to the cylinder bore. • determine the position of the piston ring ends. • install 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 ...

  • Page 176: 5-34 Engine Top End

    5-34 engine top end cylinder and piston piston ring groove width • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard top 0.83 ∼ 0.85 mm (0.0327 ∼ 0.335 in.) service limit top 0.93 mm (0.0366 in.) if any of the groove widths exceeds...

  • Page 177: Engine Top End 5-35

    Engine top end 5-35 cylinder and piston piston, piston pin, connecting rod wear inspection • visually inspect the snap ring [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the diam...

  • Page 178: 5-36 Engine Top End

    5-36 engine top end carburetor holder carburetor holder installation • install the carburetor holder [a] with the marked [b] side facing toward the cylinder head outside. ○ install the holder clamp [c] with its screw head [d] facing left side. Torque - carburetor holder clamp screw: 2.0 n·m (0.2 kgf...

  • Page 179: Engine Top End 5-37

    Engine top end 5-37 muffler 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 • loosen the silencer clamp bolt [a]. • remove the exhaust pipe holder nuts [b]. • remove the exhaust pipe [c]. • remove right side ...

  • Page 181: Engine Right Side 6-1

    Engine right side 6-1 6 engine right side table of contents exploded view........................................................................................................................ 6-2 specifications ..........................................................................................

  • Page 182: 6-2 Engine Right Side

    6-2 engine right side exploded view.

  • Page 183: Engine Right Side 6-3

    Engine right side 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 primary gear nut 98 10 72 lh 2 clutch cover bolts 9.8 1.0 87 in·lb 3 clutch cover bolt (with right engine cover) 9.8 1.0 87 in·lb l (2) 4 right engine cover bolts 9.8 1.0 87 in·lb 5 clutch spring bolts 9.8 1.0 87 in·lb...

  • Page 184: 6-4 Engine Right Side

    6-4 engine right side exploded view.

  • Page 185: Engine Right Side 6-5

    Engine right side 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 kick ratchet guide bolt 8.8 0.9 78 in·lb l 2 kick pedal mounting bolt 25 2.5 18 l 3 shift pedal bolt 9.8 1.0 87 in·lb 4 ratchet plate mounting bolt 9.8 1.0 87 in·lb l 5 ratchet plate mounting screw 6.4 0.65 56 in·lb l ...

  • Page 186: 6-6 Engine Right Side

    6-6 engine right side specifications item standard service limit clutch lever clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.62 mm (0.1031 in.) steel plate thickness 1.5 ∼ 1.7 mm (0.059 ∼ 0.067 in.) 1.4 mm (0.055 in.) fric...

  • Page 187: Engine Right Side 6-7

    Engine right side 6-7 special tools outside circlip pliers: 57001-144 clutch holder: 57001-1243 gear holder, m2.0: 57001-1557.

  • Page 188: 6-8 Engine Right Side

    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. Warning to avoid a serious burn, never touch the hot engine or exhaust chamber during clutch ad...

  • Page 189: Engine Right Side 6-9

    Engine right side 6-9 clutch lever and cable • slide the dust covers [a] out of place. • line up the slots [a] in the clutch lever [b], and adjuster [c] and then free the cable from the lever. • free the cable from the cable holder [a]. • free the clutch inner cable tip [b] from the clutch release l...

  • Page 190: 6-10 Engine Right Side

    6-10 engine right side clutch cover and right engine cover clutch cover removal • drain the engine oil at the transmission oil sump (see en- gine oil change in the periodic maintenance chapter). • set the stand attached. • remove the clutch cover bolts [a] and remove the clutch cover [b]. Clutch cov...

  • Page 191: Engine Right Side 6-11

    Engine right side 6-11 clutch cover and right engine cover • remove: water pipe bolt [a] water pipe [b] water pump cover [c] • remove the right engine cover bolts [d] to remove the right engine cover [e]. Right engine cover installation • two dowel pins [a] are installed at the mating surface betwee...

  • Page 192: 6-12 Engine Right Side

    6-12 engine right side clutch cover and right engine cover • install: water pump cover (see water pump cover installation in the cooling system chapter) • apply grease to the water pipe o-ring [a]. • insert the water pipe [b] straitly into the hole [c] of the water pump cover. Torque - water pump co...

  • Page 193: Engine Right Side 6-13

    Engine right side 6-13 clutch cover and right engine cover • apply plenty of high temperature grease to the oil seal lips. • press in the oil seals direction as shown. ○ press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the right engine ...

  • Page 194: 6-14 Engine Right Side

    6-14 engine right side clutch clutch removal • drain the engine oil at the transmission oil sump (see en- gine oil change in the periodic maintenance chapter). • remove the clutch cover (see clutch cover removal). • remove the clutch spring bolts [a], spring, and clutch pressure plate [b]. • remove ...

  • Page 195: Engine Right Side 6-15

    Engine right side 6-15 clutch • install the clutch housing [a]. ○ turning the oil pump idle gear with the thin blade screw- driver [b] push in the clutch housing and then install the housing to the kick idle gear. ○ do not forget to install the thrust washer [a] before in- stalling the clutch hub [b...

  • Page 196: 6-16 Engine Right Side

    6-16 engine right side clutch • if a clutch part was replaced, install the standard adjust- ing washer (1.5 mm thickness) [a] of the push rod holder assy, and check the release lever position as explained later procedure. • tighten the clutch spring bolts [a] holding the clutch hous- ing with the ha...

  • Page 197: Engine Right Side 6-17

    Engine right side 6-17 clutch clutch spring free length inspection • measure the free length [a] of the clutch springs. If any clutch spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 45.82 mm (1.804 in.) service limit: 43.7 mm (1.720 in.) clutch hous...

  • Page 198: 6-18 Engine Right Side

    6-18 engine right side primary gear primary gear removal • remove: right engine cover (see right engine cover removal) clutch (see clutch removal) • temporarily install the clutch housing [a]. • using the gear holder [b], secure the primary gear. Special tool - gear holder, m2.0: 57001-1557 • remove...

  • Page 199: Engine Right Side 6-19

    Engine right side 6-19 external shift mechanism external shift mechanism removal • remove: shift pedal bolt [a] shift pedal [b] • remove: right engine cover (see right engine cover removal) clutch housing (see clutch removal) • pull out the shift shaft [a]. • remove the screw [b] and bolt [c], take ...

  • Page 200: 6-20 Engine Right Side

    6-20 engine right side external shift mechanism • set up the shift ratchet assembly as shown in the figure. Ratchet [a] pawls [b] pins [c] springs [d] crankcase side [e] • then install the ratchet assembly [a] to the ratchet plate [b] as shown in the figure. Crankcase side [c] • install the ratchet ...

  • Page 201: Engine Right Side 6-21

    Engine right side 6-21 external shift mechanism • check the ratchet assembly for damage. If ratchet [a], pawls [b], pins [c] or springs [d] are dam- aged in any way, replace them. • check the gear set lever [a] and its spring [b] for cracks or distortion. If the lever or spring is damaged in any way...

  • Page 202: 6-22 Engine Right Side

    6-22 engine right side kickstarter kick pedal assy removal • remove: mounting bolt [a] kick pedal assy [b] kick pedal assy installation • install the kick pedal assy [a] at the angle shown. 10 ∼ 20 mm (0.39 ∼ 0.79 in.) [b] • apply a non-permanent locking agent to the mounting bolt. • tighten the mou...

  • Page 203: Engine Right Side 6-23

    Engine right side 6-23 kickstarter idle gear installation • apply engine oil to the inside of the idle gear. • install the washer [a]. • fit the idle gear [b] with the boss [c] facing toward the engine side. Kickshaft removal • remove: right engine cover (see right engine cover removal) clutch housi...

  • Page 204: 6-24 Engine Right Side

    6-24 engine right side kickstarter kickstarter assembly disassembly/assembly • the kickstarter assembly consists of the following parts. • check the kickstarter assembly parts for damage. Any damaged parts should be replaced with new ones. A. Kick gear e. Ratchet gear b. Circlips f. Kick shaft c. Wa...

  • Page 205: Engine Lubrication System

    Engine lubrication system 7-1 7 engine lubrication system table of contents exploded view........................................................................................................................ 7-2 lubrication system chart ................................................................

  • Page 206

    7-2 engine lubrication system exploded view.

  • Page 207

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain plug m10 (for transmission room oil sump) 15 1.5 11 2 engine oil drain bolt m6 (for crank room oil sump) 7.0 0.7 61 in·lb 3 oil pump mounting bolts 7.0 0.7 61 in·lb l 4 water pump cover bolts 9...

  • Page 208

    7-4 engine lubrication system lubrication system chart.

  • Page 209

    Engine lubrication system 7-5 lubrication system chart 1. Oil screen (scavenge) 2. Oil screen (feed) 3. Oil pump (scavenge) 4. Oil pump (feed) 5. Right crankcase oil passage (from scavenge oil pump to transmission oil shower passage) 6. Right engine cover oil passage (from feed oil pump to oil filte...

  • Page 210

    7-6 engine lubrication system specifications item standard engine oil grade castrol “r4 superbike” 5w-40 or 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 1.3 l (1.4 us qt) oil change - when filter is removed 1.35 l (1.43 us...

  • Page 211

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm²: 57001-125 outside circlip pliers: 57001-144 gear holder, m2.0: 57001-1557 oil pressure gauge adapter, m6 × 1.0: 57001-1664.

  • Page 212

    7-8 engine lubrication system engine oil and oil filter 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 clutch cover ...

  • Page 213

    Engine lubrication system 7-9 engine oil and oil filter oil filter change • refer to the engine lubrication system in the periodic maintenance chapter. Oil screen cleaning • separate the crankcase (see crankcase disassembly in the crankshaft/transmission chapter). • remove the oil screens [a] from t...

  • Page 214

    7-10 engine lubrication system oil pump oil pump removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant draining in the cooling system chapter) • remove: brake pedal (see brake pedal removal in the brakes chapter) kick pedal (see kick pedal rem...

  • Page 215

    Engine lubrication system 7-11 oil pump • remove the inner [a] and outer [b] rotors of the scavenge oil pump. • disassemble the feed oil pump assembly. Oil pump cover [a] inner rotor [b] outer rotor [c] pin [d] oil pump body [e] oil pump gear [f] oil pump installation • apply molybdenum disulfide gr...

  • Page 216

    7-12 engine lubrication system oil pump • install the outer rotor [a]. • install the dowel pin [b] and dowel pin [c]. • install the scavenge and feed oil pump assembly [d]. • apply a non-permanent locking agent to the oil pump mounting bolts. • tighten the oil pump mounting bolts. Torque - oil pump ...

  • Page 217

    Engine lubrication system 7-13 oil pressure oil pressure measurement • start the engine and warm up the engine thoroughly. Note ○ warm up the engine thoroughly before measuring the oil pressure. • remove: oil filter cap bolts [a] oil filter cap [b] water pump cover bolt [c] • install the oil pressur...

  • Page 219: Engine Removal/installation

    Engine removal/installation 8-1 8 engine removal/installation table of contents exploded view........................................................................................................................ 8-2 special tools .......................................................................

  • Page 220

    8-2 engine removal/installation exploded view.

  • Page 221

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine mounting bolt, nut (m10) 49 5.0 36 2 middle engine mounting bolt, nut (m10) 49 5.0 36 3 lower engine mounting bolt, nut (m10) 49 5.0 36 4 upper engine bracket bolt, nuts (m8) 29 3.0 22 5 middle e...

  • Page 222

    8-4 engine removal/installation special tools jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608.

  • Page 223

    Engine removal/installation 8-5 engine removal/installation engine removal • place the jack [a] under the frame to support the motor- cycle. Special tools - jack: 57001-1238 jack attachment :57001-1252 or 57001-1608 warning for engine removal, the swingarm pivot shaft must be pulled out, causing the...

  • Page 224

    8-6 engine removal/installation engine removal/installation • disconnect: magneto lead connector [a] neutral switch lead connector [b] • remove: stick coil [c] • loosen: carburetor clamp screws • remove: inlet duct with rear frame [a] (see rear frame re- moval in the frame chapter) carburetor [b] (s...

  • Page 225

    Engine removal/installation 8-7 engine removal/installation • remove: middle engine bracket bolts [a] middle engine mounting bolt [b] middle engine brackets [c] lower engine mounting bolts [d] • remove the swingarm pivot shaft [a]. ○ pull out the swingarm pivot shaft half way from right side to free...

  • Page 226

    8-8 engine removal/installation engine removal/installation • install the removed parts. • run the cables, hoses, and leads according to the cable, wire and hose routing section of the appendix chapter. • fill: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coo...

  • Page 227: Crankshaft/transmission 9-1

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view........................................................................................................................ 9-2 specifications ..............................................................................

  • Page 228: 9-2 Crankshaft/transmission

    9-2 crankshaft/transmission exploded view.

  • Page 229: Crankshaft/transmission 9-3

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 crankcase bolts 9.8 1.0 87 in·lb s 2 gear set lever nut 8.8 0.9 78 in·lb 3 neutral switch 12 1.2 104 in·lb 4 engine oil drain bolt (for crank room oil sump) 7.0 0.7 61 in·lb 5 engine oil drain bolt (for transmi...

  • Page 230: 9-4 Crankshaft/transmission

    9-4 crankshaft/transmission specifications item standard service limit connecting rods connecting rod big end radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.0006 in.) 0.06 mm (0.0024 in.) connecting rod big end side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.55 mm (0.0217 in.) crankshaft runou...

  • Page 231: Crankshaft/transmission 9-5

    Crankshaft/transmission 9-5 special tools bearing puller: 57001-135 outside circlip pliers: 57001-144 crankcase splitting tool assembly: 57001-1098 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 kawasaki bond (liquid gasket - gray): 92104-1063.

  • Page 232: 9-6 Crankshaft/transmission

    9-6 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine re- moval/installation in the engine removal/installation chapter) • set the engine on clean surface while parts are being re- moved. • remove: cylinder head cover (see cylinder head cover re- ...

  • Page 233: Crankshaft/transmission 9-7

    Crankshaft/transmission 9-7 crankcase • remove the crankcase bolts [a]. • install the jig [a] between the crankshaft flywheels [b]. Special tool - crankshaft jig: 57001-1174 • attach the crankcase splitting tool [a] to the left crankcase. ○ adjust the gap is between the splitting tool arm and adapte...

  • Page 234: 9-8 Crankshaft/transmission

    9-8 crankshaft/transmission crankcase • remove: shift rods [a] (see transmission shaft removal) 3 shift forks [b] (see transmission shaft removal) shift drum [c] (see transmission shaft removal) transmission [d] (see transmission shaft removal) crankshaft [e] (see crankshaft removal) • remove the re...

  • Page 235: Crankshaft/transmission 9-9

    Crankshaft/transmission 9-9 crankcase • be sure to replace any oil seal removed with a new one. • press in the new oil seals using a press and bearing driver so that the seal surface [a] is flush [b] with the surface of the crankcase [c]. • apply high-temperature grease to the oil seal lips [d]. Rig...

  • Page 236

    9-10 crankshaft/transmission crankcase • press the new output shaft bearings [a] in the left crankcase half [b], so that the stepped side [c] faces inside of the engine. Special tool - bearing driver set: 57001-1129 • apply a non-permanent locking agent to the retaining screws [a] and bolts [b]. • i...

  • Page 237

    Crankshaft/transmission 9-11 crankcase • install: shift drum [a] (see transmission installation) shift rods [b] (see transmission installation) shift forks [c] (see transmission installation) • install: oil screens [a] ○ install the oil screen so that the longer pipe side [b] faces in right crankcas...

  • Page 238

    9-12 crankshaft/transmission crankcase • tighten the crankcase bolts, starting with the periphery of the crankshaft, then outward. ○ tighten the [8], [12] bolts with the clamp. Torque - crankcase bolt: 9.8 n·m (1.0 kgf·m, 87 in·lb) note ○ after tightening the crankcase bolts, wipe up the liquid gask...

  • Page 239

    Crankshaft/transmission 9-13 crankcase • replace the o-rings [a] on the output shaft with new ones. • install two o-rings on the grinding faces of the output shaft while expanding the o-ring by the hand. • apply grease to the inside of the output shaft collar [b]. • insert the collar with the oil gr...

  • Page 240

    9-14 crankshaft/transmission crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • remove the transmission shaft (see transmission shaft removal). • using the hand press [a], remove the crankshaft [b] from the right crankcase [c]. If the bearing stay on the crank...

  • Page 241

    Crankshaft/transmission 9-15 crankshaft • 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. • reassemble the crankshaft according to the standard tol- erances in specifications. ○ connecting rod bend, twist (see ...

  • Page 242

    9-16 crankshaft/transmission crankshaft crankshaft runout • set the crankshaft in a flywheel alignment jig or on v blocks, and place a 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 serv...

  • Page 243

    Crankshaft/transmission 9-17 crankshaft connecting rod bend • remove the connecting rod. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end. • select an arbor of the same diameter as the piston pin and more than 105 m...

  • Page 244

    9-18 crankshaft/transmission transmission transmission shaft removal • disassemble the crankcase halves (see crankcase dis- assembly). • pull out the oil screens, if fitted the screens at the right crankcase. Crank room side oil screen [a] transmission room side oil screen [b] • pull out the shift r...

  • Page 245

    Crankshaft/transmission 9-19 transmission • apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear. • the shift forks can be identified by their shape or mark. Install them noting the direction shown. ○ the drive shaft shift fork [a] i...

  • Page 246

    9-20 crankshaft/transmission transmission • the output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 5th. 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 pl...

  • Page 247

    Crankshaft/transmission 9-21 transmission • check each gear spins or slides freely on the transmission shaft without binding after assembly. Shift fork bending • visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmissi...

  • Page 248

    9-22 crankshaft/transmission bearings/oil seals bearing replacement caution do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • remove the ball bearing and/or needle bearing outer race using a press or suitable puller [a]. Note ○ in the absence of the above mentione...

  • Page 249

    Crankshaft/transmission 9-23 bearings/oil seals • check the needle bearing. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition ...

  • Page 251: Wheels/tires 10-1

    Wheels/tires 10-1 10 wheels/tires table of contents exploded view........................................................................................................................ 10-2 specifications .................................................................................................

  • Page 252: 10-2 Wheels/tires

    10-2 wheels/tires exploded view.

  • Page 253: Wheels/tires 10-3

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples 2.2 0.22 19 in·lb 2 front axle nut 79 8.0 58 3 front axle clamp bolts 20 2.0 14.5 al 4 rear axle nut 110 11.0 80 5. Spokes 6. Front tire 7. Rims 8. Front axle 9. Rear tire 10. Rear axle al: tighten the two cl...

  • Page 254: 10-4 Wheels/tires

    10-4 wheels/tires specifications item standard service limit 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 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) tires air pressure front and rear 100 kpa (1.0 kgf/cm², ...

  • Page 255: Wheels/tires 10-5

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bead breaker assembly: 57001-1072 bearing driver set: 57001-1129 jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608.

  • Page 256: 10-6 Wheels/tires

    10-6 wheels/tires wheels (rims) front wheel removal • using the jack [a] under the frame, and stabilize the mo- torcycle. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • loosen the left and right axle clamp bolts [a]. • unscrew the axle nut [b]. • place a commercially a...

  • Page 257: Wheels/tires 10-7

    Wheels/tires 10-7 wheels (rims) • remove the jack. • before tightening the 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 ○ do not apply the front brake during this process to stop the moto...

  • Page 258: 10-8 Wheels/tires

    10-8 wheels/tires wheels (rims) • take off the collars [a] and caps [b] 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. • insert a wood wedg...

  • Page 259: Wheels/tires 10-9

    Wheels/tires 10-9 wheels (rims) • check the drive chain slack (see final drive chapter). • tighten the axle nut. Torque - rear axle nut: 110 n·m (11.0 kg·m, 80 ft·lb) • install the new cotter pin [a] and spread its end. Note ○ when inserting the cotter pin, if the slots in the nut do not align with ...

  • Page 260: 10-10 Wheels/tires

    10-10 wheels/tires 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. • remove the wheel from the motorcycle (see wheels re- moval). • to maintain front wheel b...

  • Page 261: Wheels/tires 10-11

    Wheels/tires 10-11 tires • 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 ...

  • Page 262: 10-12 Wheels/tires

    10-12 wheels/tires tires • tighten the bead protector nut [a] and valve stem nut [b]. • check and adjust the air pressure after installing. • put on the valve cap [c]. Air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter..

  • Page 263: Wheels/tires 10-13

    Wheels/tires 10-13 hub bearings hub bearing removal • 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. • remove the oil seals and circ...

  • Page 265: Final Drive 11-1

    Final drive 11-1 11 final drive table of contents exploded view........................................................................................................................ 11-2 specifications ...................................................................................................

  • Page 266: 11-2 Final Drive

    11-2 final drive exploded view.

  • Page 267: Final Drive 11-3

    Final drive 11-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 2 engine sprocket cover bolts 9.8 1.0 87 in·lb 3. Engine sprocket 4. Output shaft 5. Chain slipper 6. Swingarm 7. Chain guide 8. Locknut 9. Adjusting bolt 10. Chain adjuster 11. Drive chain 12. R...

  • Page 268: 11-4 Final Drive

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.05 ∼ 2.28 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.72 in.) standard chain: make: daido – – – type: d.I.D 520dma2 – – – length: 112 links – – – sprocket rear sprock...

  • Page 269: Final Drive 11-5

    Final drive 11-5 special tools outside circlip pliers: 57001-144.

  • Page 270: 11-6 Final Drive

    11-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection • check that the rear en...

  • Page 271: Final Drive 11-7

    Final drive 11-7 drive chain • install the clip [a] so that the closed end of the "u" [b] pointed in the direction of chain rotation [c]. • adjust the drive chain slack (see drive chain slack ad- justment in the periodic maintenance chapter)..

  • Page 272: 11-8 Final Drive

    11-8 final drive sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • remove: drive chain [a] (free of engine sprocket) • remove the circlip [b], and pull off the engine sprocket [c]. ○ if remove the circlip difficult, using th...

  • Page 273: Final Drive 11-9

    Final drive 11-9 sprockets rear sprocket installation • install the rear sprocket [a] so that the marked side [b] faces out. • install the rear sprocket bolts and tighten the nuts. Torque - rear sprocket nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) sprocket wear inspection • refer to the sprocket wear inspect...

  • Page 275: Brakes 12-1

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-2 specifications .............................................................................................................

  • Page 276: 12-2 Brakes

    12-2 brakes exploded view.

  • Page 277: Brakes 12-3

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front master cylinder clamp bolts 8.8 0.9 78 in·lb s 2 brake hose banjo bolts 34 3.5 25 3 brake pad bolt 17 1.7 12.5 4 caliper bleed valve 7.8 0.8 69 in·lb 5 caliper mounting bolts 25 2.5 18 6 front brake disc mounting bolts 9.8...

  • Page 278: 12-4 Brakes

    12-4 brakes exploded view.

  • Page 279: Brakes 12-5

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 34 3.5 25 2 rear master cylinder mounting bolts 10 1.0 87 in·lb 3 rear master cylinder push rod locknut 17 1.7 12.5 4 caliper bleed valve 7.8 0.8 69 in·lb 5 brake pad bolt 17 1.7 12.5 6 rear brake pad bolt...

  • Page 280: 12-6 Brakes

    12-6 brakes specifications item standard service limit 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 4.0 mm (0.157 in.) 1 mm (0.04 in.) rear 6.4 mm (0.252 in.) 1 ...

  • Page 281: Brakes 12-7

    Brakes 12-7 special tools inside circlip pliers: 57001-143.

  • Page 282: 12-8 Brakes

    12-8 brakes brake lever, brake pedal brake lever play adjustment • refer to the brake lever play adjustment in the periodic maintenance chapter. Brake pedal position/pedal play adjustment • refer to brake pedal position/pedal play adjustment in the periodic maintenance chapter. Brake pedal removal •...

  • Page 283: Brakes 12-9

    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...

  • Page 284: 12-10 Brakes

    12-10 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 le...

  • Page 285: Brakes 12-11

    Brakes 12-11 brake fluid • bleed the brake line and the caliper as follows: ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close the bleed valve while ho...

  • Page 286: 12-12 Brakes

    12-12 brakes caliper caliper removal front brake: • loosen the banjo bolt [a] so as not to spill brake fluid. • remove the caliper mounting bolts [b]. • remove the banjo bolt and take off the brake hose from the caliper [c]. • if the caliper is to be disassembled after removal and if compressed air ...

  • Page 287: Brakes 12-13

    Brakes 12-13 caliper • bleed the brake line (see bleeding the brake line). • check the brake for good braking power, no brake drag, and no fluid leakage. 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 ar...

  • Page 288: 12-14 Brakes

    12-14 brakes caliper brake pad removal for front brake pad • unscrew the pad bolt [a]. • take the piston side pad [b]. • push the caliper holder toward the piston, and then re- move another pad [c] from the caliper holder. For rear brake pad • remove: pad bolt plug [a] • unscrew the pad bolt [a]. • ...

  • Page 289: Brakes 12-15

    Brakes 12-15 caliper • tighten the brake pad bolt. Torque - brake pad bolt: 17 n·m (1.7 kgf·m, 12.5 ft·lb) brake pad bolt plug: 2.5 n·m (0.25 kgf·m, 22 in·lb) • check the brake for good braking power, no brake drag, and no fluid leakage. Warning do not attempt to drive the motorcycle until a full br...

  • Page 290: 12-16 Brakes

    12-16 brakes master cylinder caution brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wished up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the upper brake hose [b] from the master cylinder [c]. • when removing t...

  • Page 291: Brakes 12-17

    Brakes 12-17 master cylinder • the master cylinder clamp must be installed with the ar- row mark [a] upward. ○ tighten 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 - front master cylinder clamp bolts: 8...

  • Page 292: 12-18 Brakes

    12-18 brakes master cylinder • replace the cotter pin with a new one. • install the joint pin, washer and a new cotter pin. • bend the ends [a] of the cotter pin. • bleed the brake line (see bleeding the brake line). • check the brake for good braking power, no brake drag, and no fluid leakage. • ch...

  • Page 293: Brakes 12-19

    Brakes 12-19 master cylinder master cylinder inspection (visual inspection) • disassemble the front and rear master cylinders. • 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]. If a master cylinder or piston show...

  • Page 294: 12-20 Brakes

    12-20 brakes brake disk brake disc inspection • visually inspect the disc [a]. If it is scratched or damaged, replace the disc. • 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: front 2.85 ∼ 3...

  • Page 295: Brakes 12-21

    Brakes 12-21 brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose and connection check in the periodic maintenance chapter..

  • Page 297: Suspension 13-1

    Suspension 13-1 13 suspension table of contents exploded view................................... 13-2 specifications .................................... 13-6 special tools ..................................... 13-7 front fork .......................................... 13-9 air pressure ...............

  • Page 298: 13-2 Suspension

    13-2 suspension exploded view.

  • Page 299: Suspension 13-3

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork cylinder 34 3.5 25 2 front fork lower clamp bolts 20 2.0 14.5 al 3 front fork upper clamp bolts 20 2.0 14.5 l, al 4 steering stem head nut 98 10 72 5 adjuster assembly locknuts 21.6 2.2 16 6 front axle clamp bolts...

  • Page 300: 13-4 Suspension

    13-4 suspension exploded view.

  • Page 301: Suspension 13-5

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 98 10 72 2 rocker arm pivot nut 83 8.5 61 3 tie-rod mounting nut (front, rear) 83 8.5 61 4 rear shock absorber mounting nut (upper) 39 4.0 29 5 rear shock absorber mounting nut (lower) 34 3.5 25 6 re...

  • Page 302: 13-6 Suspension

    13-6 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – rebound damping adjustment (adjustable range) (from the seated position adjuster turned fully clockwise) 10 clicks counterclockwise (eur) 14 clicks counterclockwise 20 ±4 clicks compression ...

  • Page 303: Suspension 13-7

    Suspension 13-7 special tools oil seal & bearing remover: 57001-1058 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 attachment jack: 57001-1252 bearing remover shaft, 9: 57001-1265 bearing remover head, 15 × 17: 57001-1267 hook wrench t=3.2 r37: 57001-1539 jack at...

  • Page 304: 13-8 Suspension

    13-8 suspension special tools fork oil seal driver, 47: 57001-1662.

  • Page 305: Suspension 13-9

    Suspension 13-9 front fork air pressure 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 ...

  • Page 306: 13-10 Suspension

    13-10 suspension front fork compression damping adjustment • place the jack under the frame so that the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • clean the bottom of the fork tubes. • remove the caps on the bottom of the fork tubes. • t...

  • Page 307: Suspension 13-11

    Suspension 13-11 front fork • rest the caliper [b] on some kind of stand [a] so that it doesn’t dangle. • loosen the upper [a], and lower fork clamp bolts [b]. • remove the front fork. ○ with a twisting motion [a], work the fork leg [b] down and out. • remove: bolts [a] fork protector [b] front fork...

  • Page 308: 13-12 Suspension

    13-12 suspension front fork • route the cables and hose according to the cable, har- ness, hose routing section in the appendix chapter. • unscrew the upper clamp bolts [a]. ○ apply a non-permanent locking agent to the bolts. • tighten the fork clamp bolts. Torque - front fork upper clamp bolts: 20 ...

  • Page 309: Suspension 13-13

    Suspension 13-13 front fork • unscrew the fork cylinder unit [a] from the outer tube [b]. • slowly slide down the outer tube. • hold the fork tube [a] upside down over a clean container [b] and pump it to drain the oil. Note ○ pump the outer tube up and down to discharge the fork oil. • temporarily ...

  • Page 310: 13-14 Suspension

    13-14 suspension front fork • hold the locknut [a] with a wrench [b] and remove the adjuster assembly [c]. Note ○ do not remove the locknut from the piston rod. The piston rod may slide into the inner tube. • take the rebound damping adjuster rod [a] out of the pis- ton rod. • with the outer tube co...

  • Page 311: Suspension 13-15

    Suspension 13-15 front fork • holding the top plug wrench [a] with a vise, unscrew the base valve assembly [b] on the fork cylinder unit [c]. ○ use the hexagon box wrench [d]. • pull out the base valve assembly [a] from the fork cylinder unit [b]. ○ slowly compress the piston rod until it stops so t...

  • Page 312: 13-16 Suspension

    13-16 suspension front fork • unscrew the locknut [a]. • wrap the end of the piston rod with a vinyl tape [b]. • push the piston rod [c] into the cylinder [d]. • remove the bushing [a] from the cylinder. ○ carefully remove the bushing by prying the slot [b] with a blade type screwdriver until the bu...

  • Page 313: Suspension 13-17

    Suspension 13-17 front fork • remove the guide bushes [a], washer [b], oil seal [c], retaining ring [d], and dust seal [e] from the inner tube. • wipe off the fork oil from the removed parts. Front fork assembly • replace the following with new ones: dust seal [a] retaining ring [b] oil seal [c] gui...

  • Page 314: 13-18 Suspension

    13-18 suspension front fork ○ turning in [a] the piston rod with a wrench [b]. • remove a vinyl tape and install the locknut. • clean the threads [a] of the fork cylinder unit and base valve assembly. • hold the fork cylinder unit [a] upright with the piston rod fully stretched. • plug the two oil h...

  • Page 315: Suspension 13-19

    Suspension 13-19 front fork • replace the o-ring [a] on the base valve assembly with new ones. • apply fork oil to the o-rings and bushings [b]. Caution do not damage the bushings when assembling the base valve. • with the piston rod held immovable fully stretched, gently install the base valve asse...

  • Page 316: 13-20 Suspension

    13-20 suspension front fork • check the compression damping force setting to the soft- est. • check the piston rod sliding surface for damage. • drain the extra oil from the cylinder unit oil hole. • blow out the extra oil from the oil hole of the cylinder unit with the compressed air [a] blow to th...

  • Page 317: Suspension 13-21

    Suspension 13-21 front fork • there should be no oil leak from the base valve assembly part [a] or bottom [b] of the cylinder. If oil leaks from the base valve assembly part or bottom of the cylinder. • hold the cylinder unit on level ground and release the piston rod then check the piston rod exten...

  • Page 318: 13-22 Suspension

    13-22 suspension front fork • compress the outer tube by hands and insert the top plug wrench [a] between the axle holder part bottom [b] and locknut [c]. 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 servi...

  • Page 319: Suspension 13-23

    Suspension 13-23 front fork • compare the length [a] at assembly and at disassembly. ○ there should be same length. If the length at assembly is longer than at disassembly, check the adjuster assembly and locknut installation. Axle holder [b] outer tube [c] length standard: 317 ±2 mm (125 ±0.08 in.)...

  • Page 320: 13-24 Suspension

    13-24 suspension front fork the torque of fork cylinder unit is specified to 34 n·m (3.5 kgf·m, 25 ft·lb) however, when you use the top plug wrench [a], reduce the torque to 90% of the specified value [31 n·m (3.1 kgf·m, 23 ft·lb)] due to the distance between the center of the square hole [b], where...

  • Page 321: Suspension 13-25

    Suspension 13-25 front fork slide/guide bushing inspection • visually inspect the guide bushing [a], and replace them if necessary. Dust seal/oil seal inspection • inspect the dust seal [a] for any signs of deterioration or damage. Replace it if necessary. • replace the oil seal [b] with a new one w...

  • Page 322: 13-26 Suspension

    13-26 suspension rear suspension (uni-trak) rear shock absorber the rear 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 th...

  • Page 323: Suspension 13-27

    Suspension 13-27 rear suspension (uni-trak) • adjust the high speed 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. Seated position: adjuster turned fully clockw...

  • Page 324: 13-28 Suspension

    13-28 suspension rear suspension (uni-trak) • using the hook wrenches [a], loosen the locknut [b] on the rear shock absorber. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench t=3.2 r37: 57001-1539 • using the hook wrench [a], turn the adjusting nut [b] as required. Turning the adjustin...

  • Page 325: Suspension 13-29

    Suspension 13-29 rear suspension (uni-trak) rear shock absorber removal • remove: seat (see seat removal in the frame chapter) side covers (see side cover removal in the frame chapter) silencer (see muffler removal engine top end chapter) rear frame with air cleaner housing (see spring preload adjus...

  • Page 326: 13-30 Suspension

    13-30 suspension rear suspension (uni-trak) • hold the upper end of the rear shock absorber in a vise with soft jaws [a] or a heavy cloth. • using the hook wrenches [b], loosen the locknut [c] and turn the adjusting nut [d] all way up. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench t...

  • Page 327: Suspension 13-31

    Suspension 13-31 swingarm swingarm removal • place the jack [a] under the frame so that the rear wheel is off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • remove rear wheel (see rear wheel removal in the wheels/tires chapter) clamps [b] brake pedal [c] (s...

  • Page 328: 13-32 Suspension

    13-32 suspension swingarm swingarm bearing removal • remove: swingarm collars [a] grease seals [b] sleeves [c] needle bearings [d] • remove the needle bearings [e] using the oil seal & bear- ing remover. Special tool - oil seal & bearing remover: 57001-1058 swingarm bearing installation • replace th...

  • Page 329: Suspension 13-33

    Suspension 13-33 swingarm • visually inspect the upper and lower chain guide rollers [a] and replace them if excessively worn or damaged. Swingarm bearing, sleeve inspection caution do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] installed in t...

  • Page 330: 13-34 Suspension

    13-34 suspension tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 caution when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a b...

  • Page 331: Suspension 13-35

    Suspension 13-35 tie-rod, rocker arm • remove the tie-rod rear mounting bolt [a]. • remove: rear shock absorber lower mounting bolt [a] rocker arm pivot shaft [b] rocker arm [c] rocker arm installation • apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease se...

  • Page 332: 13-36 Suspension

    13-36 suspension tie-rod, rocker arm tie-rod and rocker arm bearing removal • remove: tie-rod (see tie-rod removal) rocker arm (see rocker arm removal) washers [a] sleeves [b] oil seals [c] grease seals [d] • remove the needle bearings [e], using the bearing re- mover head and bearing remover shaft....

  • Page 333: Suspension 13-37

    Suspension 13-37 tie-rod, rocker arm • install the needle bearings [a], [b], grease seals [c], and oil seals [d] position as shown. ○ the installation procedure is the same as the counter side. Front [e] right side [f] left side [g] rear shock absorber [h] tie-rod [i] rocker arm [j] needle bearing i...

  • Page 334: 13-38 Suspension

    13-38 suspension uni-trak maintenance uni-trak linkage inspection • refer to the uni-trak linkage inspection in the periodic maintenance chapter. Tie-rod and rocker arm sleeve wear • pull out the sleeves [a] of the tie-rod and rocker arm. • measure the outside diameter of the sleeve. If the sleeve i...

  • Page 335: Steering 14-1

    Steering 14-1 14 steering table of contents exploded view........................................................................................................................ 14-2 special tools ..........................................................................................................

  • Page 336: 14-2 Steering

    14-2 steering exploded view.

  • Page 337: Steering 14-3

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18.0 s 2 steering stem head nut 98 10 72 3 steering stem locknut 4.9 0.5 43 in·lb t 4 front fork upper clamp bolts 20 2.0 14.5 al, l 5 front fork lower clamp bolts 20 2.0 14.5 al 6. Pad cover with ...

  • Page 338: 14-4 Steering

    14-4 steering special tools bearing puller adapter: 57001-317 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 head pipe outer race driver, 54.5: 57001-1077 steeri...

  • Page 339: Steering 14-5

    Steering 14-5 steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter. Steering stem, stem bearing removal • remove: front wheel (see front wheel removal in the...

  • Page 340: 14-6 Steering

    14-6 steering steering • 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 • take off the upper stem bearing inner race (tapered roller bea...

  • Page 341: Steering 14-7

    Steering 14-7 steering • replace the lower inner races with new ones. ○ apply 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 ad...

  • Page 342: 14-8 Steering

    14-8 steering steering • install the parts removed. Warning do not impede the handlebar turning by routing the cables, wires and hoses improperly (see the gen- eral information chapter). • check and adjust: steering front brake clutch cable throttle cable stem bearing lubrication • refer to the stem...

  • Page 343: Steering 14-9

    Steering 14-9 handlebar handlebar removal • remove: band [a] pad cover and pad [b] • remove: clutch lever holder assembly [a] engine stop switch [b] bands [c] left handlebar grip [d] • remove: throttle grip assy [a] (see throttle cable replacement in the fuel system chapter) front brake master cylin...

  • Page 344: 14-10 Steering

    14-10 steering handlebar • install the clutch lever holder assembly [a] position as shown in the figure. [b] 170 mm [c] horizontal line of frame [d] handlebar • install the engine stop button [e]. • apply grease to the throttle cable upper end and clutch cable upper end. • apply a 2 stroke oil to th...

  • Page 345: Steering 14-11

    Steering 14-11 handlebar ○ install the master cylinder [a] position as shown in the figure. [b] 185 mm (7.28 in.) [c] horizontal line of frame [d] handlebar [e] horizontal line of cap upper surface torque - front master cylinder clamp bolts: 8.8 n·m (0.9 kgf·m, 78 in·lb) • install the handlebar clam...

  • Page 347: Frame 15-1

    Frame 15-1 15 frame table of contents exploded view........................................................................................................................ 15-2 frame ........................................................................................................................

  • Page 348: 15-2 Frame

    15-2 frame exploded view.

  • Page 349: Frame 15-3

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper rear frame mounting bolt 34 3.5 25 2 lower rear frame mounting bolts 34 3.5 25 3 footpeg bracket upper bolts 54 5.5 40 l g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 350: 15-4 Frame

    15-4 frame frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Rear frame removal • remove: seat (see seat removal) right & left side cover (see side cover removal) silencer (see muffler removal in the engine top end chapter) rear fender (see rear fender rem...

  • Page 351: Frame 15-5

    Frame 15-5 frame • insert the duct end [a] slantly between the frame [b] and upper portion [c] of the shock absorber. • install the rear frame upper mounting bolt [a] through the hook [b] of the band [c]. • tighten the rear frame mounting bolts. Torque - rear frame mounting bolts: 34 n·m (3.5 kgf·m,...

  • Page 352: 15-6 Frame

    15-6 frame seat seat removal • unscrew the bolts [a]. • pull the seat [b] out from the back. Seat installation • fit the hooks [a] of the seat under the flange collar [b] and brackets [c]..

  • Page 353: Frame 15-7

    Frame 15-7 side cover side cover removal • unscrew the bolts [a] and remove the side cover. Side cover installation • stick the pads [a] on the inside of the right side cover [b]. • install the damper. • insert the tabs [a] of the cover into the slots [b] of the air cleaner housing..

  • Page 354: 15-8 Frame

    15-8 frame fender front fender removal • unscrew the bolts [a] and remove the front fender [b]. Rear fender removal • remove: seat • unscrew the bolts [a] and remove the rear fender [b]. Rear flap removal • unscrew the screws [a] and remove the rear flap [b]..

  • Page 355: Electrical System 16-1

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-2 specifications .......................................................................................

  • Page 356: 16-2 Electrical System

    16-2 electrical system exploded view.

  • Page 357: Electrical System 16-3

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 neutral switch 12 1.2 104 in·lb 2 flywheel nut 49 5.0 36 3 stator bolts 7.0 0.7 61 in·lb 4 spark plug 13 1.3 115 in·lb 5 magneto cover bolts l35 9.8 1.0 87 in·lb l 6 magneto cover bolts l30 9.8 1.0 87 in·lb 7 neutral ...

  • Page 358: 16-4 Electrical System

    16-4 electrical system specifications item standard magneto crankshaft sensor resistance 80 ∼ 120 Ω magneto output voltage in the text stator coil resistance in the text ignition system ignition timing 8° btdc @2 000 r/min (rpm) stick coil: primary winding resistance 0.077 ∼ 0.104 Ω (at 20°c) second...

  • Page 359: Electrical System 16-5

    Electrical system 16-5 special tools timing light: 57001-1241 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 filler cap driver: 57001-1454 needle adapter set: 57001-1457 rotor puller: 57001-1565 rot...

  • Page 360: 16-6 Electrical System

    16-6 electrical system wiring diagram.

  • Page 361: Electrical System 16-7

    Electrical system 16-7 precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the ...

  • Page 362: 16-8 Electrical System

    16-8 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean...

  • Page 363: Electrical System 16-9

    Electrical system 16-9 flywheel magneto magneto cover removal • drain the engine oil from the crank room oil sump (see engine oil change in the periodic maintenance chapter). • remove the left radiator shroud (see radiator removal in the cooling system chapter). • push down the stopper [a]. • remove...

  • Page 364: 16-10 Electrical System

    16-10 electrical system flywheel magneto • hold the flywheel steady, with the rotor holder [a], and remove the nut [b]. Special tool - rotor holder: 57001-1567 • remove the flywheel holder. • screw the rotor puller [a] into the flywheel. • remove the flywheel from the crankshaft by turning in the pu...

  • Page 365: Electrical System 16-11

    Electrical system 16-11 flywheel magneto stator removal • remove: magneto cover (see magneto cover removal) stator bolts [a] crankshaft sensor bolts [b] wiring holder [c] wiring grommet [d] • remove the stator [e] and crankshaft sensor [f] as a set. Stator installation • route the wires according to...

  • Page 366: 16-12 Electrical System

    16-12 electrical system flywheel magneto ○ connect the hand tester [a] to the connector [b] as shown in the table 1, using the needle adapter set [c]. ○ start the engine. ○ run it at the rpm given in the table 1. ○ note the voltage readings (total 2 measurements). Special tool - needle adapter set: ...

  • Page 367: Electrical System 16-13

    Electrical system 16-13 ignition timing ignition timing inspection • remove the timing inspection cap [a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • star...

  • Page 368: 16-14 Electrical System

    16-14 electrical system ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the stick coil while the engine is running, or you could receive a severe electrical shock. Stick coil removal • remove: fuel tank (see fuel tank removal in the fue...

  • Page 369: Electrical System 16-15

    Electrical system 16-15 ignition system spark plug gap inspection • refer to the spark plug gap inspection in the periodic maintenance chapter. C.D.I. Unit removal • remove: belt (open) [a] bolt [b] number plate [c] • disconnect the main harness connector [a]. • unscrew the mounting bolts [b] and re...

  • Page 370: 16-16 Electrical System

    16-16 electrical system ignition system stick coil primary peak voltage check • disconnect the stick coil from the spark plug, but do not remove the spark plug. • connect the good spark plug [a] to the stick coil [b], then touch the engine with it. Note ○ measure the voltage with each lead connected...

  • Page 371: Electrical System 16-17

    Electrical system 16-17 ignition system trouble shooting chart.

  • Page 372: 16-18 Electrical System

    16-18 electrical system ignition system crankshaft sensor peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the connector of the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value ma...

  • Page 373: Electrical System 16-19

    Electrical system 16-19 ignition system charge coil peak voltage check • disconnect the connector of the magneto lead connector from the main harness. • to check the peak voltage, do the following procedures. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not ...

  • Page 374: 16-20 Electrical System

    16-20 electrical system ignition system • to check the output voltage, do the following procedures. ○ connect the digital voltmeter as follows. Tester (+) → yellow lead tester (–) → black lead ○ start the engine. ○ measure the throttle sensor output voltage with the engine idling speed and with the ...

  • Page 375: Electrical System 16-21

    Electrical system 16-21 throttle sensor throttle sensor inspection note ○ if the variable rheostat is not available, refer to throttle sensor output/input voltage check in the c.D.I. Unit in- spection. ○ when inspecting the throttle sensor the throttle valve of the carburetor shall be completely clo...

  • Page 376: 16-22 Electrical System

    16-22 electrical system throttle sensor throttle sensor position adjustment • remove the carburetor (see carburetor removal in the fuel system chapter). • measure the resistance between the blue and black lead terminals of the sensor side connector. Blue lead terminal [a] black lead terminal [b] yel...

  • Page 377: Electrical System 16-23

    Electrical system 16-23 neutral switch neutral switch inspection • slide out the dust cover [a]. • disconnect the connector [b]. ○ unscrew the screw. • using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). If the switch has an open or sho...

  • Page 379: Appendix 17-1

    Appendix 17-1 17 appendix table of contents cable, wire, and hose routing .............................................................................................. 17-2 troubleshooting guide ...........................................................................................................

  • Page 380: 17-2 Appendix

    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 start cable 6. Clutch cable 7. Clamp (run the clutch and hot start ca- ble.) 8. Clamp (run the throttle cables.).

  • Page 381: Appendix 17-3

    Appendix 17-3 cable, wire, and hose routing 1. Clutch cable 2. Engine stop switch lead 3. C.D.I. Unit 4. Main harness 5. Frame ground 6. Clamps (run the clutch cable.) 7. Upper radiator hose 8. Clamp (run the clutch cable.) 9. Hot start cable 10. Clamp (run the hot start cable, clutch ca- ble, and e...

  • Page 382: 17-4 Appendix

    17-4 appendix cable, wire, and hose routing 1. C.D.I. Unit 2. Main harness 3. Clamp (run the hot start cable and main harness.) 4. Neutral switch lead connector 5. Magneto lead connector 6. Stick coil connector 7. Magneto lead 8. Clamps (hold the magneto lead.) 9. Radiator overflow tube 10. Stick co...

  • Page 383: Appendix 17-5

    Appendix 17-5 cable, wire, and hose routing 1. Clumps (position the clamp claw front.) 2. Install the upper radiator tube so that the yellow painted mark faces upward. 3. Left radiator 4. Radiator overflow tube 5. Joint pipe (align the stopper and yellow painted mark.) 6. Right radiator 7. Water pip...

  • Page 384: 17-6 Appendix

    17-6 appendix cable, wire, and hose routing 1. Run the fuel hose inside the hot start cable. 2. Align the end of the net protector with the cam chain tensioner cap. 3. Breather tube 4. Align the white painted mark of the tube with the rib of the crankcase. 5. Band 6. Clamp (position the clamp claw f...

  • Page 385: Appendix 17-7

    Appendix 17-7 cable, wire, and hose routing 1. Brake lever 2. Front brake master cylinder 3. Front brake hose 4. Clamp 5. Viewed 6. Clamps 7. Front brake caliper 8. Front brake disc 9. Brake pedal 10. Rear brake master cylinder 11. Rear brake hose 12. Clamps 13. Rear brake caliper 14. Rear brake cal...

  • Page 386: 17-8 Appendix

    17-8 appendix 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: valv...

  • Page 387: Appendix 17-9

    Appendix 17-9 troubleshooting guide drive train trouble engine overheating clutch slipping poor running or no power at high speed: firing incorrect: spark plug dirty, broken, or gap malad- justed stick coil not in good contact spark plug incorrect heat value faulty cdi unit crankshaft sensor trouble...

  • Page 388: 17-10 Appendix

    17-10 appendix troubleshooting guide clutch housing seized clutch release function trouble clutch hub nut loose clutch plate warped or rough clutch hub spline damaged gear shifting faulty: doesn’t go into gear; shift pedal doesn’t return: clutch not disengaging shift fork bent, worn, or seized shift...

  • Page 389: Appendix 17-11

    Appendix 17-11 troubleshooting guide 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 too high brown smoke: main jet too small fuel level in carburetor float bowl too lo...

  • Page 390: Model Application

    Model application year model beginning frame no. 2006 kx250t6f jkakxmtc □ 6a000001 or jkakx250tta000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1354-01 printed in japan.