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• Contents
• Table of Contents
• Troubleshooting
• Bookmarks

Quick Links

• 9

  General Information

• 19

  Periodic Maintenance 2-1 Periodic Maintenance

• 93

  Fuel System 3-1 Fuel System

  • 94

    Exploded View

  • 98

    Specifications

  • 99

    Special Tools

  • 100

    Throttle Grip and Cable

  • 104

    Carburetor

  • 122

    Air Cleaner

  • 124

    Fuel Tank

• 127

  Cooling System 4-1 Cooling System

• 143

  Engine Top End 5-1 Engine Top End

  • 144

    Exploded View

  • 148

    Specifications

  • 151

    Special Tools & Sealants

  • 154

    Cylinder Head Cover

  • 155

    Camshaft Chain Tensioner

  • 156

    Camshaft

  • 161

    Cylinder Head

  • 165

    Valves

  • 173

    Cylinder and Piston

  • 178

    Carburetor Holder

  • 179

    Muffler

• 181

  Engine Right Side 6-1 Engine Right Side

  • 182

    Exploded View

  • 186

    Specifications

  • 187

    Special Tools

  • 188

    Clutch Lever and Cable

  • 190

    Clutch Cover and Right Engine Cover

  • 194

    Clutch

  • 198

    Primary Gear

  • 199

    External Shift Mechanism

  • 202

    Kickstarter

• 205

  Engine Lubrication System

• 219

  Engine Removal/Installation

• 227

  Crankshaft/Transmission 9-1 Crankshaft/Transmission

  • 228

    Exploded View

  • 230

    Specifications

  • 231

    Special Tools

  • 232

    Crankcase

  • 240

    Crankshaft

  • 244

    Transmission

  • 248

    Bearings/Oil Seals

KX250F

Motorcycle

Service Manual

Chapters

• 9

  General Information

• 19

  Periodic Maintenance 2-1 Periodic Maintenance

• 93

  Fuel System 3-1 Fuel System

  • 94

    Exploded View

  • 98

    Specifications

  • 99

    Special Tools

  • 100

    Throttle Grip and Cable

  • 104

    Carburetor

  • 122

    Air Cleaner

  • 124

    Fuel Tank

• 127

  Cooling System 4-1 Cooling System

• 143

  Engine Top End 5-1 Engine Top End

  • 144

    Exploded View

  • 148

    Specifications

  • 151

    Special Tools & Sealants

  • 154

    Cylinder Head Cover

  • 155

    Camshaft Chain Tensioner

  • 156

    Camshaft

  • 161

    Cylinder Head

  • 165

    Valves

  • 173

    Cylinder and Piston

  • 178

    Carburetor Holder

  • 179

    Muffler

• 181

  Engine Right Side 6-1 Engine Right Side

  • 182

    Exploded View

  • 186

    Specifications

  • 187

    Special Tools

  • 188

    Clutch Lever and Cable

  • 190

    Clutch Cover and Right Engine Cover

  • 194

    Clutch

  • 198

    Primary Gear

  • 199

    External Shift Mechanism

  • 202

    Kickstarter

• 205

  Engine Lubrication System

• 219

  Engine Removal/Installation

• 227

  Crankshaft/Transmission 9-1 Crankshaft/Transmission

  • 228

    Exploded View

  • 230

    Specifications

  • 231

    Special Tools

  • 232

    Crankcase

  • 240

    Crankshaft

  • 244

    Transmission

  • 248

    Bearings/Oil Seals

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  Summary of Contents for Kawasaki KX250F

• Page 1 KX250F Motorcycle Service Manual...
• Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j...
• Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
• Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...

• Page 7: How To Use This Manual

  NOTE maintenance. ○ • This note symbol indicates points of par- Use proper tools and genuine Kawasaki Mo- ticular interest for more efficient and con- torcycle parts. Special tools, gauges, and venient operation. testers that are necessary when servicing •...
• Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-10...

• Page 10: Before Servicing

  1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
• Page 11 Replacement Parts Replacement Parts must be KAWASAKI genuine or rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
• Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.
• Page 13 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 pressure on the correct bearing race as shown.
• Page 14 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.

• Page 15: Model Identification

  GENERAL INFORMATION 1-7 Model Identification KX250T6F Left Side View KX250T6F Right Side View...

• Page 16: General Specifications

  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...
• Page 17 GENERAL INFORMATION 1-9 General Specifications Items KX250T6F Clutch Type Wet, multi disc, Manual Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.142 (30/14) 1.785 (25/14) 1.444 (26/18) 1.200 (24/20) 1.052 (20/19) Final Drive System: Type Chain drive Reduction Ratio 3.692 (48/13) Overall Drive Ratio 13.020 @Top gear...

• Page 18: Unit Conversion Table

  1-10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ...

• Page 19: Table Of Contents

  PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-10 Special Tools .......................... 2-12 Periodic Maintenance Procedures..................2-13 Fuel System......................... 2-13 Fuel Hose and Connection Inspection ................2-13 Throttle Grip Free Play Inspection ..................2-13 Throttle Grip Free Play Adjustment...................
• Page 20 2-2 PERIODIC MAINTENANCE Drive Chain Lubrication..................... 2-35 Sprocket Wear Inspection....................2-36 Rear Sprocket Warp Inspection ..................2-36 Brakes..........................2-36 Brake Lever and Pedal Adjustment .................. 2-36 Brake Fluid Level Inspection..................... 2-38 Brake Fluid Change ......................2-39 Brake Pad Wear Inspection ....................2-41 Brake Master Cylinder Cup and Dust Seal Replacement ..........

• Page 21: Periodic Maintenance Chart

  PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Each Every 3 Every 6 Every 12 race or races or races or races or Page OPERATION 2.5 hr...
• Page 22 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 race or races or races or races or Page OPERATION 2.5 hr 7.5 hr 15 hr 30 hr • Wheels/tires - inspect 2-30 • Rear sprocket - inspect † 2-36 •...

• Page 23: Torque And Locking Agent

  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 the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
• Page 24 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Radiator Mounting Bolts 87 in·lb Radiator Shroud Bolts 87 in·lb Engine Top End Auto-Decompressor Bolt 104 in·lb Decompressor Plug 87 in·lb Cylinder Head Cover Bolts 87 in·lb Cylinder Head Bolts: 104 in·lb Camshaft Cap Bolts...
• Page 25 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter Cap Bolts 87 in·lb Oil Pump Mounting Bolts 61 in·lb Water Pump Cover Bolts 87 in·lb L (1) Water Pump Cover Bolt (with washer) 87 in·lb L (1) Right Engine Cover Bolts 87 in·lb...
• Page 26 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake Reservoir Cap Bolts 0.15 13 in·lb Brake Disc Mounting Bolts: (Front) 87 in·lb (Rear) 16.6 Caliper Bleed Valves (Front, Rear) 69 in·lb Front Caliper Holder Shaft Rear Caliper Holder Shaft Caliper Pin Bolts 104 in·lb...
• Page 27 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft Sensor Bolts 61 in·lb Spark Plug 115 in·lb C.D.I. Unit Bolts 87 in·lb Magneto Cover Bolts L: 30 87 in·lb L: 35 87 in·lb...

• Page 28: Specifications

  2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) Hot Start Lever Free Play – – – Idle Speed 2 000 r/min (rpm) –...
• Page 29 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 –...

• Page 30: Special Tools

  2-12 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Carburetor Drain Plug Wrench, Hex 3: 57001-143 57001-1269 Steering Stem Nut Wrench: Filler Cap Driver: 57001-1100 57001-1454 Jack: Pilot Screw Adjuster, D: 57001-1238 57001-1588 Attachment Jack: Jack Attachment: 57001-1252 57001-1608 Spark Plug Wrench, Hex 16: Top Plug Wrench, 50 mm: 57001-1262 57001-1645...

• Page 31: Periodic Maintenance Procedures

  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 cracks [D] are noticed.

• Page 32: Hot Start Lever Free Play Inspection

  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 damaged.

• Page 33: Idle Speed Adjustment (Carburetor Adjustment)

  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 damaged.

• Page 34: Air Cleaner Element Cleaning And Inspection

  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 speed is within the specified range.
• Page 35 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;...

• Page 36: Fuel System Clean

  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 can be ex-...

• Page 37: Cooling System

  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.

• Page 38: Coolant Deterioration Inspection

  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 water alone can be added.

• Page 39: Engine Top End

  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) Timing Inspection Cap [A] Flywheel Cap [B] Special Tool - Filler Cap Driver: 57001-1454...
• Page 40 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].

• Page 41: Cylinder Head Warp Inspection

  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 valve clearance.

• Page 42: Cylinder Wear Inspection

  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 worn, replace it with a new one.

• Page 43: Exhaust System Inspection

  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, exhaust efficiency is reduced, causing engine performance to drop.

• Page 44: Engine Right Side

  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) •...

• Page 45: Friction And Steel Plates Inspection

  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 lever, or it could slip into the place later, creating enough cable play to prevent clutch disengagement.

• Page 46: Engine Lubrication System

  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 engine thoroughly so that the oil will pick up any sediment and drain easily.

• Page 47: Oil Filter Change

  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. •...

• Page 48: Crankshaft/Transmission

  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 •...

• Page 49: Tires Inspection

  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 the tire in case of bad damage.

• Page 50: Rim Runout Inspection

  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: Final Drive

  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.

• Page 52: Drive Chain Slack Inspection

  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 chapter), and adjust it if necessary (see Wheel Alignment Adjustment in the Wheels chapter).

• Page 53: Drive Chain Lubrication

  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. ○...

• Page 54: Sprocket Wear Inspection

  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 of Rotation NOTE ○...
• Page 55 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 (3.09 ±0.04 in.)

• Page 56: Brake Fluid Level Inspection

  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 [B].

• Page 57: Brake Fluid Change

  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 air quickly and completely whenever the brake line parts are removed.
• Page 58 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].

• Page 59: Brake Pad Wear Inspection

  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) •...

• Page 60: Caliper Piston Seal And Dust Seal Replacement

  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 •...
• Page 61 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]. ○...
• Page 62 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.

• Page 63: Brake Hose And Connection Check

  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 grease).
• Page 64 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]...

• Page 65: Suspension

  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 tube [A]. If necessary, repair any damage.
• Page 66 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.
• Page 67 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 using a vise.
• Page 68 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 reaction force from the fork spring when removing the top plug wrench.
• Page 69 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.
• Page 70 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 ∼...
• Page 71 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 hole of the cylinder unit.
• Page 72 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.
• Page 73 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 that special tool should not come off.
• Page 74 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 Standard:...

• Page 75: Rear Shock Absorber Oil Change

  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 of the square hole [B], where the torque wrench is fitted [C], and that of the octagonal hole of the wrench.
• Page 76 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 prevent explosive separation of parts.
• Page 77 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].
• Page 78 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. •...
• Page 79 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]...
• Page 80 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. •...
• Page 81 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. •...
• Page 82 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].
• Page 83 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: Swingarm And Uni-Trak Linkage Inspection

  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.

• Page 85: Swingarm And Uni-Track Linkage Pivot Lubricate

  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.
• Page 86 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] •...

• Page 87: Stem Bearing Lubrication

  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] •...

• Page 88: Frame

  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 causing an accident.

• Page 89: Chassis Parts Lubrication And Cable Inspection

  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 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) Standard: •...

• Page 90: Nut, Bolt, And Fastener Tightness Inspection

  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 both ends, the cable should move freely [A] within the cable housing.

• Page 91: General Information

  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, first loosen it by 1/2 turn, then tighten it.
• Page 93 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable Replacement ..................... Throttle Cable Lubrication....................3-10 Throttle Cable Inspection ....................3-10 Hot Start Cable Removal ....................

• Page 94: Exploded View

  3-2 FUEL SYSTEM Exploded View...
• Page 95 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Pulley Cover Bolt 30 in·lb Throttle Cable Locknut 61 in·lb Hot Start Plunger Cap Bolt 10 in·lb 4. Hot Start Lever 5. Hot Start Cable 6. Throttle Grip 7.
• Page 96 3-4 FUEL SYSTEM Exploded View...
• Page 97 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Frame Mounting Bolts Air Cleaner Duct Clamp Screw 27 in·lb Air Cleaner Duct Bolt and Nuts 27 in·lb Air Cleaner Element Wing Bolt – – – Hand Tighten Air Cleaner Housing Bolts 87 in·lb 6.

• Page 98: Specifications

  3-6 FUEL SYSTEM Specifications Item Standard Service Limit Carburetor Make/Type KEIHIN FCR37 – – – Starter Jet – – – Leak Jet – – – Main Jet #180, (EUR) #175 – – – Throttle Valve Cutaway CA1.5 – – – Jet Needle NCYU, (EUR) NHJU –...

• Page 99: Special Tools

  FUEL SYSTEM 3-7 Special Tools Fuel Level Gauge, M18 × 1.0: 57001-122...

• Page 100: Throttle Grip And Cable

  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.
• Page 101 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. •...

• Page 102: Throttle Cable Lubrication

  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 cable upper or lower ends.

• Page 103: Hot Start Cable Installation

  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) •...

• Page 104: Carburetor

  3-12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.

• Page 105: Service Fuel Level Adjustment

  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. •...

• Page 106: Carburetor Removal

  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. ○...
• Page 107 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 shock absorber as shown.

• Page 108: Carburetor Installation

  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]. •...

• Page 109: Fuel Inspection

  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. •...
• Page 110 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]. •...
• Page 111 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 [D] of the pulley.
• Page 112 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...
• Page 113 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 installed later in the same position.

• Page 114: Carburetor Cleaning

  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 or low flash -point solvent to clean the carburetor.
• Page 115 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] moves smoothly and returns by spring pressure.

• Page 116: Carburetor Assembly

  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.
• Page 117 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 valve link [B].
• Page 118 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. ○...
• Page 119 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] ○...
• Page 120 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. •...
• Page 121 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 (0.0492 in.) ○...

• Page 122: Air Cleaner

  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] •...

• Page 123: Element Installation

  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. •...

• Page 124: Fuel Tank

  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;...

• Page 125: Fuel Tap Removal

  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.
• Page 127 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Water Pump..........................

• Page 128: Exploded View

  4-2 COOLING SYSTEM Exploded View...
• Page 129 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 87 in·lb L (1) Water Pump Cover Bolts (with washer) 87 in·lb L (1) Coolant Drain Plug 61 in·lb Water Pump Impeller Bolt 61 in·lb Right Engine Cover Bolts 87 in·lb Radiator Hose Clamp Screws...

• Page 130: Specifications

  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 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi) Cap Relief Pressure...

• Page 131: Special Tool

  COOLING SYSTEM 4-5 Special Tool Bearing Driver Set: 57001-1129...

• Page 132: Coolant

  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).

• Page 133: Coolant Filling

  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.

• Page 134: Air Bleeding

  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. •...

• Page 135: Cooling System Flushing

  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 passages and considerably reduce the effi- ciency of the cooling system.

• Page 136: Water Pump

  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]. •...

• Page 137: Impeller Removal

  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) •...

• Page 138: Water Pump Gear Removal

  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.

• Page 139: Oil Seal And Bearing Installation

  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 them with new ones at the same time...

• Page 140: Radiator

  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]. •...

• Page 141: Radiator Installation

  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.

• Page 142: Radiator Cap Inspection

  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 leaks.
• Page 143 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Removal ......5-23 Specifications ........Valve Installation ......5-23 Special Tools & Sealants ....Valve Guide Removal ....5-24 Cylinder Head Cover ......5-12 Valve Guide Installation ....5-24 Cylinder Head Cover Removal ..

• Page 144: Exploded View

  5-2 ENGINE TOP END Exploded View...
• Page 145 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Auto-Decompressor Bolt 104 in·lb Cylinder Head Cover Bolts 87 in·lb Cylinder Head Bolts M6 104 in·lb Camshaft Cap Bolts 87 in·lb Carburetor Holder Clamp Screws 17 in·lb Plug Lower Camshaft Chain Guide Bolt 87 in·lb Cylinder Head Bolts M10...
• Page 146 5-4 ENGINE TOP END Exploded View...
• Page 147 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Tensioner Mounting Bolts 87 in·lb Camshaft Chain Tensioner Cap Bolt 14.5 Cylinder Bolt M6 104 in·lb Exhaust Pipe Cover Screws 104 in·lb Exhaust Pipe Holder Nuts Silencer Mounting Bolts Silencer Cover Bolts 109 in·lb...

• Page 148: Specifications

  5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.941 ∼ 34.057 mm Exhaust 33.84 mm (1.3363 ∼ 1.3408 in.) (1.3322 in.) 34.642 ∼ 34.758 mm Inlet 34.54 mm (1.3639 ∼ 1.3684 in.) (1.3598 in.) 0.020 ∼ 0.062 mm Camshaft Bearing Clearance 0.15 mm (0.0008 ∼...
• Page 149 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Valve Seat Surface Outside Diameter: 24.62 ∼ 24.82 mm Exhaust – – – (0.9693 ∼ 0.9772 in.) 30.62 ∼ 30.82 mm Inlet – – – (1.2055 ∼ 1.2134 in.) Valve Seat Surface Width: 0.5 ∼...
• Page 150 5-8 ENGINE TOP END Specifications Cam Height Camshaft Runout Cam Height [A] Valve Stem Diameter Valve Stem Bend Valve Stem Diameter [A] Dial Gauge [A] 45° [B]...

• Page 151: Special Tools & Sealants

  ENGINE TOP END 5-9 Special Tools & Sealants Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 32: 57001-221 57001-1115 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 28: 57001-241 57001-1119 Piston Ring Compressor Grip: Valve Seat Cutter Holder Bar: 57001-1095 57001-1128 Piston Ring Compressor Belt, 67 ∼...
• Page 152 5-10 ENGINE TOP END Special Tools & Sealants Spark Plug Wrench, Hex 16: Valve Guide Reamer, 4.5: 57001-1262 57001-1333 Compression Gauge Adapter, M10 × 1.0: Valve Seat Cutter, 60° - 33: 57001-1317 57001-1334 Valve Seat Cutter, 60° - 25: Filler Cap Driver: 57001-1328 57001-1454 Valve Seat Cutter Holder, 4.5:...
• Page 153 ENGINE TOP END 5-11 Special Tools & Sealants Kawasaki Bond (Silicone Sealant): 92104-0004...

• Page 154: Cylinder Head Cover

  [E] left side of the frame. Cylinder Head Cover Installation • Apply silicon sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the head cover gasket. • Install the head cover gasket [A] on the cylinder head [B].

• Page 155: Camshaft Chain Tensioner

  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 tensioner, do not take out the mounting bolts only halfway.

• Page 156: Camshaft

  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).

• Page 157: Camshaft Installation

  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.
• Page 158 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]. •...

• Page 159: Camshaft Chain Removal

  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.

• Page 160: Camshaft And Camshaft Cap Wear

  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 kgf·m, 87 in·lb) NOTE ○...

• Page 161: Cylinder Head

  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. •...

• Page 162: Cylinder Head Removal

  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 Re- moval) Camshaft (see Camshaft Removal)

• Page 163: Cylinder Head Installation

  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 cylinder [D].

• Page 164: Cylinder Head Cleaning

  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) •...

• Page 165: Valves

  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 ○...

• Page 166: Valve Guide Removal

  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.

• Page 167: Valve/Valve Guide Clearance

  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) ○...

• Page 168: Valve Seat Inspection

  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.
• Page 169 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.
• Page 170 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.
• Page 171 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;...
• Page 172 5-30 ENGINE TOP END Valves Valve Seat Repair...

• Page 173: Cylinder And Piston

  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. •...
• Page 174 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.

• Page 175: Cylinder Wear

  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 Compressor Belt, 67 to...

• Page 176: Piston Ring Groove Width

  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 0.83 ∼ 0.85 mm (0.0327 ∼ 0.335 in.) Service Limit 0.93 mm (0.0366 in.) If any of the groove widths exceeds the service limit, re- place the piston.

• Page 177: Piston, Piston Pin, Connecting Rod Wear Inspection

  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.

• Page 178: Carburetor Holder

  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·m, 17 in·lb) •...

• Page 179: Muffler

  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]. •...
• Page 181 ENGINE RIGHT SIDE 6-1 Engine Right Side Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Lever Installation....................Clutch Cable Removal ...................... Clutch Cable Installation ....................

• Page 182: Exploded View

  6-2 ENGINE RIGHT SIDE Exploded View...
• Page 183 ENGINE RIGHT SIDE 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Primary Gear Nut Clutch Cover Bolts 87 in·lb Clutch Cover Bolt (with right engine cover) 87 in·lb L (2) Right Engine Cover Bolts 87 in·lb Clutch Spring Bolts 87 in·lb Clutch Hub Nut 7.
• Page 184 6-4 ENGINE RIGHT SIDE Exploded View...
• Page 185 ENGINE RIGHT SIDE 6-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Kick Ratchet Guide Bolt 78 in·lb Kick Pedal Mounting Bolt Shift Pedal Bolt 87 in·lb Ratchet Plate Mounting Bolt 87 in·lb Ratchet Plate Mounting Screw 0.65 56 in·lb Gear Set Lever Nut 78 in·lb Shift Drum Cam Bolt...

• Page 186: Specifications

  6-6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction Plate Thickness 2.62 mm (0.1031 in.) 1.5 ∼...

• Page 187: Special Tools

  ENGINE RIGHT SIDE 6-7 Special Tools Outside Circlip Pliers: Gear Holder, m2.0: 57001-144 57001-1557 Clutch Holder: 57001-1243...

• Page 188: Clutch Lever And Cable

  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 adjustment.

• Page 189: Clutch Cable Installation

  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].

• Page 190: Clutch Cover And Right Engine Cover

  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].

• Page 191: Right Engine Cover Installation

  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 •...

• Page 192: Release Shaft Removal

  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.
• Page 193 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 cover.

• Page 194: Clutch

  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].
• Page 195 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. ○...

• Page 196: Friction And Steel Plates Wear, Damage Inspection

  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 hand.

• Page 197: Clutch Spring Free Length Inspection

  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 Housing Finger Damage •...

• Page 198: Primary Gear

  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 •...

• Page 199: External Shift Mechanism

  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]. •...

• Page 200: External Shift Mechanism Inspection

  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.
• Page 201 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.

• Page 202: Kickstarter

  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] •...

• Page 203: Idle Gear Installation

  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 •...

• Page 204: Kickstarter Assembly Disassembly/Assembly

  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.
• Page 205 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Lubrication System Chart ....................... Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Change ....................... Oil Screen Cleaning ......................Oil Pump..........................

• Page 206: Exploded View

  7-2 ENGINE LUBRICATION SYSTEM Exploded View...
• Page 207 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug M10 (for transmission room oil sump) Engine Oil Drain Bolt M6 (for crank room oil sump) 61 in·lb Oil Pump Mounting Bolts 61 in·lb Water Pump Cover Bolts 87 in·lb L (1)

• Page 208: Lubrication System Chart

  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 Filter Oil Chamber) 7.

• Page 210: Specifications

  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 qt) when engine is completely dry...

• Page 211: Special Tools

  ENGINE LUBRICATION SYSTEM 7-7 Special Tools Oil Pressure Gauge, 5 kgf/cm²: Gear Holder, m2.0: 57001-125 57001-1557 Outside Circlip Pliers: Oil Pressure Gauge Adapter, M6 × 1.0: 57001-144 57001-1664...

• Page 212: Engine Oil And Oil Filter

  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 oil level gauge is very sensitive to the motorcycle's position and en- gine rpm at time of shut down.

• Page 213: Oil Filter Change

  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 the crankcase. •...

• Page 214: Oil Pump

  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 Removal in the Engine Right Side chapter)

• Page 215: Oil Pump Installation

  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 •...

• Page 216: Oil Pump Inspection

  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.

• Page 217: Oil Pressure

  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] •...
• Page 219 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tools .......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................

• Page 220: Exploded View

  8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
• Page 221 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Mounting Bolt, Nut (M10) Middle Engine Mounting Bolt, Nut (M10) Lower Engine Mounting Bolt, Nut (M10) Upper Engine Bracket Bolt, Nuts (M8) Middle Engine Bracket Bolts (M8) Swingarm Pivot Nut...

• Page 222: Special Tools

  8-4 ENGINE REMOVAL/INSTALLATION Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Attachment Jack: 57001-1252...

• Page 223: Engine Removal/Installation

  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 swingarm and rear wheel assembly to become detached.
• 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] (see Carburetor Removal in the Fuel Sys- tem chapter) Clutch Cable Lower Part [C] (see Clutch Cable Removal...

• Page 225: Engine Installation

  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 the engine.
• 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 Coolant Filling in the Cooling System chap- ter)
• Page 227 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Crankcase ..........................Crankcase Disassembly ....................Crankcase Assembly ......................Crankshaft ..........................9-14 Crankshaft Removal ......................9-14 Crankshaft Installation ...................... 9-14 Crankshaft Disassembly ....................9-14 Crankshaft Assembly ......................9-14 Crankshaft Inspection .......................

• Page 228: Exploded View

  9-2 CRANKSHAFT/TRANSMISSION Exploded View...
• Page 229 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener marks N·m kgf·m ft·lb 1 Crankcase Bolts 87 in·lb 2 Gear Set Lever Nut 78 in·lb 3 Neutral Switch 104 in·lb 4 Engine Oil Drain Bolt (For Crank Room Oil Sump) 61 in·lb 5 Engine Oil Drain Bolt (For Transmission Room Oil Sump) 6 Shift Drum Cam Bolt 7 Piston Oil Nozzle 0.29...

• Page 230: Specifications

  9-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Connecting Rods Connecting Rod Big End Radial Clearance 0.002 ∼ 0.014 mm 0.06 mm (0.0024 in.) (0.00008 ∼ 0.0006 in.) 0.25 ∼ 0.35 mm Connecting Rod Big End Side Clearance 0.55 mm (0.0217 in.) (0.0098 ∼...

• Page 231: Special Tools

  CRANKSHAFT/TRANSMISSION 9-5 Special Tools Bearing Puller: Crankshaft Jig: 57001-135 57001-1174 Outside Circlip Pliers: Crankcase Splitting Tool Assembly: 57001-144 57001-1362 Crankcase Splitting Tool Assembly: Kawasaki Bond (Liquid Gasket - Gray): 57001-1098 92104-1063 Bearing Driver Set: 57001-1129...

• Page 232: Crankcase

  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- moval in the Engine Top End chapter) Camshaft Chain Tensioner (see Camshaft Chain Ten- sioner Removal in the Engine Top End chapter)
• Page 233 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 adapter, using the collars or nuts [B].

• Page 234: Crankcase Assembly

  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 reed valve [A] from the left crankcase half. ○...
• Page 235 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].
• 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].
• Page 237 Special Tool - Crankshaft Jig: 57001-1174 • Apply liquid gasket to the mating surface [A] of the left crankshaft half. Sealant - Kawasaki Bond (Liquid Gasket - Gray): 92104 -1063 NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the left crankcase half is applied.
• 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 gasket seeping out around the mating surface, espe- cially around the area.
• 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]. •...

• Page 240: Crankshaft

  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 crankshaft when splitting the crankcase, or removing the crankshaft from the right re- move the bearings from the crankshaft with a bearing puller.

• Page 241: Crankshaft Inspection

  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. ○...
• 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 Service Limit: TIR 0.08 mm (0.0031 in.)

• Page 243: Connecting Rod Bend

  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 mm long, and insert the arbor [B] through the connecting rod small end.

• Page 244: Transmission

  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] •...

• Page 245: Transmission Shaft Disassembly

  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.
• 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 place.

• Page 247: Shift Fork Bending

  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 transmission to jump out of gear when under power.

• Page 248: Bearings/Oil Seals

  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 ○...

• Page 249: Oil Seal Inspection

  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 of a needle bear- ing, replace it.
• Page 251 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheels Inspection......................10-9 Spoke Tightness Inspection....................

• Page 252: Exploded View

  10-2 WHEELS/TIRES Exploded View...
• Page 253 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spoke Nipples 0.22 19 in·lb Front Axle Nut Front Axle Clamp Bolts 14.5 Rear Axle Nut 11.0 5. Spokes 6. Front Tire 7. Rims 8. Front Axle 9. Rear Tire 10.

• Page 254: Specifications

  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...

• Page 255: Special Tools

  WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Rim Protector: Attachment Jack: 57001-1063 57001-1252 Bead Breaker Assembly: Jack Attachment: 57001-1072 57001-1608 Bearing Driver Set: 57001-1129...

• Page 256: Wheels (Rims)

  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]. •...

• Page 257: Rear Wheel Removal

  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 ○...

• Page 258: Rear Wheel Installation

  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.

• Page 259: Wheels Inspection

  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 ○...

• Page 260: 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).

• Page 261: Tire Installation

  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 tire irons so deeply that...

• Page 262: Air Pressure Inspection/Adjustment

  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: Hub Bearings

  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.
• Page 265 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection ..................... 11-6 Wheel Alignment Adjustment.................... 11-6 Drive Chain Wear Inspection ....................

• Page 266: Exploded View

  11-2 FINAL DRIVE Exploded View...
• Page 267 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Sprocket Nuts Engine Sprocket Cover Bolts 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.

• Page 268: Specifications

  11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 52 ∼ 58 mm (2.05 ∼ 2.28 in.) Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Chain 20-link Length 323 mm (12.72 in.) Standard Chain: Make: DAIDO –...

• Page 269: Special Tools

  FINAL DRIVE 11-5 Special Tools Outside Circlip Pliers: 57001-144...

• Page 270: Drive Chain

  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 •...
• Page 271 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: Sprockets

  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].

• Page 273: Rear Sprocket Installation

  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 •...
• Page 275 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tools .......................... 12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Play Adjustment.................... 12-8 Brake Pedal Position/Pedal Play Adjustment ..............12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................12-8 Brake Fluid ..........................

• Page 276: Exploded View

  12-2 BRAKES Exploded View...
• Page 277 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Master Cylinder Clamp Bolts 78 in·lb Brake Hose Banjo Bolts Brake Pad Bolt 12.5 Caliper Bleed Valve 69 in·lb Caliper Mounting Bolts Front Brake Disc Mounting Bolts 87 in·lb Brake Lever Pivot Bolt Locknut 52 in·lb Brake Reservoir Cap Screws...
• Page 278 12-4 BRAKES Exploded View...
• Page 279 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts 87 in·lb Rear Master Cylinder Push Rod Locknut 12.5 Caliper Bleed Valve 69 in·lb Brake Pad Bolt 12.5 Rear Brake Pad Bolt Plug 0.25 22 in·lb Caliper Holder Shaft...

• Page 280: Specifications

  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.)

• Page 281: Special Tools

  BRAKES 12-7 Special Tools Inside Circlip Pliers: 57001-143...

• Page 282: Brake Lever, Brake Pedal

  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: Brake Fluid

  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.

• Page 284: Bleeding The Brake Line

  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 lever or pedal movement will be partially used in compressing the air.
• Page 285 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].

• Page 286: Caliper

  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]. •...

• Page 287: Caliper Disassembly

  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 are against the disc.

• Page 288: Brake Pad Removal

  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 •...

• Page 289: Brake Pad Inspection

  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.

• Page 290: Master Cylinder

  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]. •...

• Page 291: Rear Master Cylinder Removal

  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.

• Page 292: Front Master Cylinder Disassembly

  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). •...

• Page 293: Master Cylinder Inspection (Visual Inspection)

  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].

• Page 294: Brake Disk

  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: 2.85 ∼...

• Page 295: Brake Hose

  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 Table of Contents Exploded View........13-2 Rear Shock Absorber Specifications ........13-6 Disassembly (Oil Change) ..13-30 Special Tools ........13-7 Rear Shock Absorber Assembly .. 13-30 Front Fork .......... 13-9 Rear Shock Absorber Scrapping . 13-30 Air Pressure .........

• Page 298: Exploded View

  13-2 SUSPENSION Exploded View...
• Page 299 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Cylinder Front Fork Lower Clamp Bolts 14.5 Front Fork Upper Clamp Bolts 14.5 L, AL Steering Stem Head Nut Adjuster Assembly Locknuts 21.6 Front Axle Clamp Bolts 14.5 Front Fork Base Valve Assemblies 29.5 21.8...
• Page 300 13-4 SUSPENSION Exploded View...
• Page 301 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut Tie-rod Mounting Nut (Front, Rear) Rear Shock Absorber Mounting Nut (Upper) Rear Shock Absorber Mounting Nut (Lower) Rear Shock Absorber Spring Locknut Piston Rod Locknut Gas Reservoir Damping Adjuster Assembly 9.

• Page 302: Specifications

  13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Atmospheric pressure – – – Rebound Damping Adjustment (Adjustable Range) (from the seated position adjuster 10 clicks counterclockwise 20 ±4 clicks turned fully clockwise) (EUR) 14 clicks counterclockwise Compression Damping Adjustment (Adjustable Range) (from the seated position adjuster 11 clicks counterclockwise...

• Page 303: Special Tools

  SUSPENSION 13-7 Special Tools Oil Seal & Bearing Remover: Bearing Remover Shaft, 9: 57001-1058 57001-1265 Hook Wrench R37.5, R42: Bearing Remover Head, 15 × 17: 57001-1101 57001-1267 Bearing Driver Set: Hook Wrench T=3.2 R37: 57001-1129 57001-1539 Jack: Jack Attachment: 57001-1238 57001-1608 Attachment Jack: Top Plug Wrench, 50 mm:...
• Page 304 13-8 SUSPENSION Special Tools Fork Oil Seal Driver, 47: 57001-1662...

• Page 305: Front Fork

  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 relief screw located in each cap of the base valve assembly.

• Page 306: Compression Damping Adjustment

  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. •...

• Page 307: Front Fork Installation

  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.

• Page 308: Front Fork Disassembly (Each Fork Leg)

  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.
• Page 309 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 ○...
• Page 310 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.
• Page 311 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].
• Page 312 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. ○...

• Page 313: Front Fork Assembly

  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]...
• Page 314 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.
• Page 315 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 assembly [A] to the fork cylinder unit [B].
• Page 316 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 the oil hole.
• Page 317 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 extend to maximum.
• Page 318 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.
• Page 319 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: Inner Tube Inspection

  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 the torque wrench [C] is fitted, and that of the octagonal hole of the wrench.

• Page 321: Slide/Guide Bushing Inspection

  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. •...

• Page 322: Rear Suspension (Uni-Trak)

  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 the spring can be replaced with an optional one.

• Page 323: Spring Preload Adjustment

  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 clockwise [A].

• Page 324: Spring Tension

  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.

• Page 325: Rear Shock Absorber Removal

  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 Adjustment) •...

• Page 326: Rear Shock Absorber Disassembly (Oil Change)

  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=3.2 R37: 57001-1539 •...

• Page 327: Swingarm

  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] (see Brake Pedal Removal in the Brakes...

• Page 328: Swingarm Bearing Removal

  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 •...

• Page 329: Swingarm Bearing, Sleeve Inspection

  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 the swingarm.

• Page 330: Tie-Rod, Rocker Arm

  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.

• Page 331: Rocker Arm Installation

  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 seals outside of the sleeve.

• Page 332: Tie-Rod And Rocker Arm Bearing Removal

  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: Needle Bearing Inspection

  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]...

• Page 334: Uni-Trak Maintenance

  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 is worn past the service limit, replace the sleeve.
• Page 335 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem, Stem Bearing Removal ................14-5 Steering Stem, Stem Bearing Installation ................. 14-6 Stem Bearing Lubrication....................14-8 Stem Bearing Wear, Damage ...................

• Page 336: Exploded View

  14-2 STEERING Exploded View...
• Page 337 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts 18.0 Steering Stem Head Nut Steering Stem Locknut 43 in·lb Front Fork Upper Clamp Bolts 14.5 AL, L Front Fork Lower Clamp Bolts 14.5 6. Pad Cover with Pad 7.

• Page 338: Special Tools

  14-4 STEERING Special Tools Bearing Puller Adapter: Head Pipe Outer Race Driver, 54.5: 57001-317 57001-1077 Steering Stem Bearing Driver: Steering Stem Nut Wrench: 57001-137 57001-1100 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft:...

• Page 339: Steering Inspection

  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 Wheels/Tires chapter) Front Fender Bolts [A] Front Fender [B]...

• Page 340: Steering Stem, Stem Bearing Installation

  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 •...
• Page 341 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 Adapter, 34.5: 57001-1074 •...

• Page 342: Stem Bearing Lubrication

  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 •...

• Page 343: Handlebar

  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 Cylinder [B] (see Front Master Cylin- der Removal in the Brakes chapter)
• Page 344 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.
• Page 345 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) •...
• Page 347 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Frame ............................. 15-4 Frame Inspection ......................15-4 Rear Frame Removal......................15-4 Rear Frame Installation..................... 15-4 Engine Guard Installation....................15-5 Seat ............................15-6 Seat Removal ........................15-6 Seat Installation ........................ 15-6 Side Cover..........................15-7 Side Cover Removal ......................

• Page 348: Exploded View

  15-2 FRAME Exploded View...
• Page 349 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Rear Frame Mounting Bolt Lower Rear Frame Mounting Bolts Footpeg Bracket Upper Bolts G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...

• Page 350: Frame Inspection

  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 Removal) Rear Flap (see Rear Flap Removal)

• Page 351: Engine Guard Installation

  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.

• Page 352: Seat

  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: Side Cover

  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: Fender

  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 Table of Contents Exploded View........................16-2 Specifications ......................... 16-4 Special Tools .......................... 16-5 Wiring Diagram........................16-6 Precautions..........................16-7 Electrical Wiring........................16-8 Wiring Inspection ......................16-8 Flywheel Magneto ........................16-9 Magneto Cover Removal ....................16-9 Magneto Cover Installation ....................16-9 Flywheel Magneto Removal....................

• Page 356: Exploded View

  16-2 ELECTRICAL SYSTEM Exploded View...
• Page 357 ELECTRICAL SYSTEM 16-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Neutral Switch 104 in·lb Flywheel Nut Stator Bolts 61 in·lb Spark Plug 115 in·lb Magneto Cover Bolts L35 87 in·lb Magneto Cover Bolts L30 87 in·lb Neutral Lead Terminal Screw 0.13 12 in·lb Timing Inspection Cap...

• Page 358: Specifications

  16-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto 80 ∼ 120 Ω Crankshaft Sensor Resistance 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: 0.077 ∼ 0.104 Ω (at 20°C) Primary Winding Resistance 4.56 ∼...

• Page 359: Special Tools

  Filler Cap Driver: 57001-1241 57001-1454 Hand Tester: Needle Adapter Set: 57001-1394 57001-1457 Throttle Sensor Setting Adapter #1: Rotor Puller: 57001-1400 57001-1565 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1567 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 92104-0004...

• Page 360: Wiring Diagram

  16-6 ELECTRICAL SYSTEM Wiring Diagram...

• Page 361: Precautions

  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 parts can damage them.

• Page 362: Electrical Wiring

  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 it carefully.

• Page 363: Flywheel Magneto

  Be sure to install the dowel pins [A]. • Apply silicone sealant to the area [B] to the magneto lead grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Tighten the cover bolts. ○ Apply a non-permanent locking agent to the L35 cover bolts [A].

• Page 364: Flywheel Magneto Installation

  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. •...

• Page 365: Stator Removal

  Torque - Crankshaft Sensor Bolts: 7.0 N·m (0.7 kgf·m, 61 in·lb) • Apply silicone sealant around the circumference of the wiring grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Set the stator wiring grommet [B] securely in the notch [C]. •...
• Page 366 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. ○...

• Page 367: Ignition Timing

  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 •...

• Page 368: Ignition 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 Fuel System chapter) •...

• Page 369: Spark Plug Gap Inspection

  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]. •...
• Page 370 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.
• Page 371 ELECTRICAL SYSTEM 16-17 Ignition System Trouble shooting chart...
• Page 372 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.
• Page 373 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.

• Page 374: Crankshaft Sensor Inspection

  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 idle throttle valve opening.

• Page 375: Throttle Sensor

  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 closed and remain the throttle cable connected.

• Page 376: Throttle Sensor Position Adjustment

  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] Yellow Lead Terminal [C] Hand Tester [D]...

• Page 377: Neutral Switch

  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).
• Page 379 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-8...
• Page 380 17-2 APPENDIX Cable, Wire, and Hose Routing 1. Throttle Cables 6. Clutch Cable 2. Marked (AAA) cable is accelerator side. 7. Clamp (Run the clutch and hot start ca- 3. Band (Hold the engine stop switch lead.) ble.) 4. Engine Stop Switch Lead 8.
• Page 381 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clutch Cable 11. Engine Stop Switch Lead Connector 2. Engine Stop Switch Lead 12. Clamp (Run the hot start cable and main 3. C.D.I. Unit harness.) 4. Main Harness 13. Clamp (Hold the hot start cable and throt- 5.
• Page 382 17-4 APPENDIX Cable, Wire, and Hose Routing 1. C.D.I. Unit 12. Fuel Hose 2. Main Harness 13. Hot Start Cable 3. Clamp (Run the hot start cable and main 14. Throttle Sensor Lead harness.) 15. Install the clamp direction as shown in the 4.
• Page 383 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clumps (Position the clamp claw front.) 7. Water Pipe 2. Install the upper radiator tube so that the 8. Install the screw head of the clamps di- yellow painted mark faces upward. rection as shown in the figure.
• Page 384 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.
• Page 385 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Brake Lever 10. Rear Brake Master Cylinder 2. Front Brake Master Cylinder 11. Rear Brake Hose 3. Front Brake Hose 12. Clamps 4. Clamp 13. Rear Brake Caliper 5. Viewed 14. Rear Brake Caliper Guard 6.

• Page 386: Troubleshooting Guide

  17-8 APPENDIX Troubleshooting Guide This is not an exhaustive list, giving every Piston ring bad (worn, weak, broken, or possible cause for each problem listed. it is sticking) meant simply as a rough guide to assist the Piston ring/groove clearance excessive troubleshooting for some of the more common Cylinder head gasket damaged difficulties.

• Page 387: Engine Overheating

  APPENDIX 17-9 Troubleshooting Guide Drive train trouble Air cleaner clogged Engine overheating Water or foreign matter in fuel Clutch slipping Clutch slipping Overheating Poor Running or No Power at High Engine oil level too high Speed: Engine oil viscosity too high Drive train trouble Firing incorrect: Crankshaft bearing worn or damage...

• Page 388: Gear Shifting Faulty

  17-10 APPENDIX Troubleshooting Guide Clutch housing seized Exhaust pipe leaking at cylinder head con- Clutch release function trouble nection Clutch hub nut loose Crankshaft runout excessive Clutch plate warped or rough Engine mounts loose Clutch hub spline damaged Crankshaft bearing worn Camshaft chain tensioner trouble Gear Shifting Faulty: Camshaft chain, sprocket, chain guide worn...
• Page 389 APPENDIX 17-11 Troubleshooting Guide Valve guide worn Rear wheel misalignment Engine oil level too high Swingarm bent or twisted Black smoke: Swingarm pivot shaft bent Air cleaner element clogged Steering maladjusted Main jet too large or fallen off Steering stem bent Starter plunger stuck open Front fork bent Fuel level in carburetor float bowl too high...
• Page 390 MODEL APPLICATION Year Model Beginning Frame No. □ JKAKXMTC 6A000001 or 2006 KX250T6F JKAKX250TTA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1354-01 Printed in Japan...

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