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Kawasaki KFX700 V-Force 2003 Service Manual Kawasaki KFX700 V-Force 2003 Service Manual
User Manual: 2004 Kawasaki KFX 700 V Force Service Manual
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KFX 700V FORCE Quick Reference Guide This quick reference guide will assist you in locating a desired topic or procedure. Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. Refer to the sectional table of contents for the exact pages to locate the specific topic required. • • General Information 1 j Periodic Maintenance 2 j Fuel System 3 j Cooling System 4 j Engine Top End 5 j Converter System 6 j Engine Lubrication System 7 j Engine Removal/Installation 8 j Crankshaft / Transmission 9 j Wheels / Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix 17 j KFX 700 V FORCE All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Feb. 28, 2003 (M) LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC C DC F F ft g h L ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celcius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s) Read OWNER’S MANUAL before operating. EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board. 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s "tampering provisions." "Sec. 203(a) The following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..." NOTE The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level. Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Don’t take shortcuts. • • • • to keep complete records of main• Remember tenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done. Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly. GENERAL INFORMATION 1-1 General Information 1 TABLE OF CONTENTS Before Servicing ...................................................................................................................... Model Identification.................................................................................................................. General Specifications............................................................................................................. Unit Conversion Table ............................................................................................................. 1111- 2 5 6 9 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: (1) Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine will shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (–) wire from the battery before performing any disassembly operations on the vehicle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4–turn before removing them. (5) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (6) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. (7) Edges Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (8) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (9) Gasket, O-Ring Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks. GENERAL INFORMATION 1-3 Before Servicing (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. (11)Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component. (13)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks, press it in with the marks facing out. (14)Circlip, Retaining Ring, and Cotter Pin When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the vehicle is driven, leading to a major problem. (15)Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. (16)Direction of Engine Rotation To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well. (17)Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts. (18)Electrical Wires All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same color. 1-4 GENERAL INFORMATION Before Servicing Two-Color Electrical (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20)Specifications Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. "Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts. GENERAL INFORMATION 1-5 Model Identification KSV700–A1 Left Side View KSV700–A1 Right Side View 1-6 GENERAL INFORMATION General Specifications Items KSV700-A1 Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance: Rear final gear case Center of frame Seat height Dry mass Curb mass: Front Rear Fuel tank capacity Performance: Minimum turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing: Inlet Exhaust: Lubrication system Engine oil: Open Close Duration Open Close Duration Type Viscosity Capacity 1 1 1 1 985 195 170 285 mm mm mm mm (78.15 (47.05 (46.06 (50.60 in.) in.) in.) in.) 160 mm (6.30 in.) 245 mm (9.65 in.) 850 mm (33.46 in.) 234 kg (516 lb) 115 kg (254 lb) 135 kg (298 lb) 12 L (3.2 US gal) 3.2 m (10.50 ft) 4-stroke, SOHC, V2-cylinders Liquid-cooled 82.0 × 66.0 mm (3.23 × 2.60 in.) 697 mL (42.5 cu in.) 9.9 : 1 36.3 kW (49.4 PS) @6 500 r/min (rpm), (US) 59.2 N·m (6.04 kgf·m, 43.67 ft·lb) @5 000 r/min (rpm) Carburetor, Keihin CVKR–D32 Electric Starter Digital DC-CDI Electronically advanced From 5 BTDC @1 100 r/min (rpm) to 28 BTDC @5 000 r/min (rpm) NGK CR7E 20 BTDC 44 ABDC 244 44 BBDC 20 ATDC 244 Forced lubrication (wet sump) API SF or SG API SH or SJ with JASO MA class SAE 10W-40 2.2 L (2.33 US qt) GENERAL INFORMATION 1-7 General Specifications Items KSV700-A1 Drive Train: Primary reduction system: Type Reduction ratio Transmission: Type Gear ratios: Forward: Reverse Final drive system: Type Reduction ratio Overall drive ratio: Forward: Reverse Final gear case oil: Type Frame: Type Caster (rake angle) Camber King pin angle Trail Tread: Front tire: Rear tire: Suspension: Front: Rear: Brake: Front Rear Electrical Equipment: Battery Headlight: Belt converter 3.122 ~ 0.635 1-speed and reverse 2.416 (29/27 × 27/20 × 20/12) 4.285 (16/12 × 20/14 × 27/20 × 20/12) Shaft 2WD 4.375 (35/8) Capacity 32.999 ~ 6.711 58.527 ~ 11.904 MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID 900 mL (0.95 US qt) Front Rear Type Size Type Size Double cradle, tubular steel 4.5 –0.5 12.5 20 mm (0.79 in.) 1 000 mm (39.37 in.) 900 mm (35.43 in.) Tubeless AT22 × 7 – 10 Tubeless AT22 × 11 – 10 Type Wheel travel Type Wheel travel Double A-arms 236 mm (9.29 in.) Swingarm 200 mm (7.87 in.) Disc × 2 Enclosed wet multi-plate Type Bulb 12 V 14 Ah Semi-sealed beam 12 V 45/45 W × 2 1-8 GENERAL INFORMATION General Specifications Items Tail/brake light Alternator: Bulb Alternator: Type Rated output KSV700-A1 12 V 5/21 W Three - phase AC 25 A, 14 V @6 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country. US: United States model. GENERAL INFORMATION 1-9 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro Symbol M k c m m Units of Length: × × × × × Power 1 000 000 1 000 0.01 0.001 0.000001 Units of Mass: kg g × × 2.205 0.03527 = = lb oz = = = = = = = = = gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in Units of Volume: L L L L L L mL mL mL × × × × × × × × × 0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102 km m mm × × × 0.6214 3.281 0.03937 = = = mile ft in = = = = = = kg·m ft·lb in·lb N·m ft·lb in·lb 0.01020 0.1450 0.7501 98.07 14.22 1.333 = = = = = = kg/cm² psi cmHg kPa psi kPa 0.6214 = mph 1.360 1.341 0.7355 0.9863 = = = = PS HP kW HP Units of Torque: N·m N·m N·m kg·m kg·m kg·m × × × × × × 0.1020 0.7376 8.851 9.807 7.233 86.80 Units of Pressure: kPa kPa kPa kg/cm² kg/cm² cm Hg × × × × × × Units of Speed: km/h × Units of Force: N N kg kg × × × × 0.1020 0.2248 9.807 2.205 Units of Temperature: = = = = kg lb N lb Units of Power: kW kW PS PS × × × × PERIODIC MAINTENANCE 2-1 Periodic Maintenance 2 TABLE OF CONTENTS Periodic Maintenance Chart ............... Torque and Locking Agent.................. Specifications ..................................... Special Tools ...................................... Periodic Maintenance Procedures...... Fuel System..................................... Throttle Lever Free Play Inspection................................... Throttle Lever Free Play Adjustment ................................. Choke Lever Free Play Check ...... Choke Lever Free Play Adjustment ................................. Idle Speed Inspection ................... Idle Speed Adjustment.................. Fuel System Cleanliness Inspection................................... Air Cleaner Element Cleaning and Inspection................................... Air Cleaner Draining...................... Fuel Hoses and Connections Inspection................................... Fuel Hose and Fuel Filter Replacement .............................. Cooling System................................ Radiator Cleaning ......................... Radiator Hose and Connection Inspection................................... Coolant Change ............................ Coolant Filter Cleaning ................. Engine Top End ............................... Valve Clearance Inspection .......... Valve Clearance Adjustment......... Spark Arrester Cleaning................ Converter System ............................ Drive Belt Inspection ..................... Drive Belt Deflection Inspection .... Drive Belt Deflection Adjustment .. Engine Lubrication System .............. Engine Oil Change........................ Oil Filter Change ........................... Crankshaft/Transmission ................. 2- 3 2- 5 2-11 2-13 2-14 2-14 2-14 2-14 2-15 2-15 2-15 2-16 2-16 2-16 2-17 2-17 2-18 2-19 2-19 2-19 2-20 2-22 2-22 2-22 2-23 2-24 2-24 2-24 2-25 2-26 2-27 2-27 2-27 2-28 Shift Control Grip Free Play Inspection................................... Shift Control Grip Free Play Adjustment ................................. Wheels/Tires .................................... Tire Inspection .............................. Final Drive........................................ Final Gear Case Oil Change......... Propeller Shaft Joint Boot Inspection................................... Brakes.............................................. Front Brake Pad Wear Inspection. Front Brake Hoses and Connections Inspection.............. Front Brake Hose Replacement.... Brake Fluid Level Inspection......... Brake Fluid Change ...................... Brake Line Air Bleeding ................ Master Cylinder Inspection (Visual Inspection).................................. Caliper Fluid Seal Replacement ... Caliper Dust Seal and Friction Boot Replacement...................... Rear Brake Plates Replacement... Rear Brake Lever Free Play Inspection................................... Rear Brake Pedal Free Play Inspection................................... Rear Brake Lever and Pedal Free Play Adjustment ......................... Suspension ...................................... Knuckle Joint Inspection ............... Steering ........................................... Steering Inspection ....................... Tie Rod End Inspection................. Electrical System ............................. Spark Plug Cleaning / Inspection.. Spark Plug Gap Inspection ........... Brake Light Switch Inspection....... Brake Light Timing Adjustment ..... General Lubrication ......................... Lubrication .................................... 2-28 2-28 2-29 2-29 2-29 2-29 2-30 2-30 2-30 2-30 2-30 2-31 2-31 2-32 2-33 2-34 2-34 2-34 2-34 2-34 2-35 2-35 2-35 2-36 2-36 2-36 2-37 2-37 2-37 2-37 2-37 2-37 2-37 2-2 PERIODIC MAINTENANCE Bolts and Nuts Tightening................ 2-39 Tightness Inspection ..................... 2-39 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY First Regular Service Service After 10 hrs. or 100 km (60 mi.) of use OPERATION Every 90 days, 1 Every Every 700 km (1 10 30 100 mi.) or days days when belt Every or 200 or 600 See indicator year km km page light turns of use (120 (360 on (100 mi.) of mi.) of hrs of use) use use whichever comes first ENGINE • • Converter drive belt wear – inspect * Converter drive belt deflection - inspect * Air cleaner – inspect * Throttle lever play – inspect Cable adjustment* Idle speed – inspect • • • • • • Valve clearance – inspect Fuel system cleanliness – inspect * Engine oil – change * Oil filter – replace * Spark plug – clean and gap Spark arrester – clean • Radiator hoses, and connections – check* 2–15 • • • • 4 years • • • Coolant – change* 2–16 2–28 Fuel hoses and connections – inspect Radiator – clean* 2–25 2–15 • • • • Fuel hose and fuel filter replace 2–24 • 2–22 2–16 2–27 2–27 2–37 • 2–24 2–17 2–18 2–19 • 2 years 2–20 • Coolant filter of carburetor – clean CHASSIS 2–19 2–22 Joint boots – inspect * • • 2–30 2–35 2–36 Rear brake pedal and lever play – inspect * • • 2–34 Rear brake plates – change * Bolts and nuts – tighten every 9 600 km (6 000 mi.) • • 2–34 2–39 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY First Regular Service Service OPERATION Front brake pad wear – inspect * Brake light switch – inspect * Steering – inspect Tire wear – inspect * Final gear case oil – change General lubrication * Front brake fluid level – inspect Front brake fluid – change Every 90 days, 1 Every Every 700 km (1 10 30 100 mi.) or After 10 days days when belt Every hrs. or or 200 or 600 See indicator 100 km year km km page light turns of use (60 mi.) (120 (360 on (100 of use mi.) of mi.) of hrs of use) use use whichever comes first • • • • • • • • 2–30 2–37 • 2–36 2–29 • • • 2–29 2–37 2–31 • 2–31 Front brake master cylinder piston assembly and dust seal – replace 2 years 2–33 Front brake caliper piston seal and dust seal – replace 2 years 2–34 Front brake hoses and connections– inspect Front brake hose – replace • 4 years 2–30 2–30 *: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy loads or pulling a trailer. •: Clean, adjust, lubricate, torque, or replace parts as necessary. PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1). EO: Apply engine oil. SS: Apply silicone sealant (Kawasaki Bond: 56019-120). Lh: Left-hand Threads R: Replacement Parts S: Follow the specific tightening sequence. Torque Fastener N·m kgf·m ft·lb Remarks Throttle Limiter Screw 3.7 0.38 33 in·lb Throttle Limiter Locknut 3.7 0.38 33 in·lb Throttle Case Assembly Screws 3.7 0.38 33 in·lb Choke Lever Mounting Screw 3.5 0.36 35 in·lb Left Handlebar Switches Assembly Screws 3.5 0.36 35 in·lb Air Cleaner Housing Bolts (M5) 5.9 0.60 52 in·lb Air Cleaner Housing Bolts (M6) 8.8 0.90 78 in·lb Air Cleaner Element Bracket Screws 4.9 0.60 43 in·lb Fuel Tap Plate Screws 0.80 0.080 7 in·lb Fuel Tap Cover Screws 1.0 0.10 8 in·lb Fuel Pump Bolts 2.0 0.20 17 in·lb Radiator Fan Switch 18 1.8 13 Water Pump Fitting Bolt 9.8 1.0 87 in·lb Water Pump Impeller 7.8 0.80 69 in·lb Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb Coolant Temperature Warning Light Switch 7.8 0.80 69 in·lb Radiator Fan Assembly Bolts 8.8 0.90 78 in·lb Radiator Mounting Bolts 8.8 0.90 78 in·lb Water Pump Cover Bolts 8.8 0.90 78 in·lb Coolant Drain Plug 8.8 0.90 78 in·lb Water Pipe Bolts 9.8 1.0 87 in·lb Rocker Case Bolts 55 mm (2.2 in.) 8.8 0.90 78 in·lb S Rocker Case Bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb S Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb S Cylinder Head Bolts (M10), First Torque 25 2.5 18 S, MO Fuel System: L Cooling System SS Engine Top End: 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Cylinder Head Bolt (M10), Final Torque 49 5.0 36 S Cylinder Head Bolts (M6) 9.8 1.0 87 in·lb Cylinder Head Jacket Plugs 20 2.0 14 Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb Valve Adjusting Screw Locknuts 12 1.2 104 in·lb Rocker Shaft Bolts 8.8 0.90 78 in·lb Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb Chain Tensioner Cap Bolt 22 2.2 16 Intermediate Shaft Sprocket Nut 44 4.5 33 Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb Camshaft Sprocket Bolts 12 1.2 104 in·lb Position Plate Bolts 8.8 0.90 78 in·lb Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb Cylinder Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb Front Cylinder Camshaft Chain Guide Bolt 20 2.0 14 Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 14 Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb Muffler Cover Bolts 8.8 0.90 78 in·lb Muffler Mounting Bolts 20 2.0 14 Exhaust Pipe Clamp Bolts 8.8 0.90 78 in·lb Converter Cover Bolts 8.8 0.90 78 in·lb Driven Pulley Nut 93 9.5 69 Ramp Weight Nuts 6.9 0.70 61 in·lb Spider 275 28 203 Drive Pulley Cover Bolts 13 1.3 113 in·lb Drive Pulley Bolt 93 9.5 69 Joint Duct Bolts 8.8 0.90 78 in·lb Engine Drain Plug 20 2.0 14 Oil Filter 18 1.8 13 R Oil Pressure Switch 15 1.5 11 SS Oil Pressure Relief Valve 15 1.5 11 L Oil Pump Bolt 8.8 0.90 78 in·lb Oil Pipe Bolts 8.8 0.90 78 in·lb Oil Filter Mounting Bolt 25 2.5 18 Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb Chain Guide Bolts 8.8 0.90 78 in·lb L Converter System: S Lh R, Lh Engine Lubrication System: L (15mm) PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb 25 2.5 18 Engine Mounting Bracket Bolts 52 5.3 38 Engine Mounting Nuts 62 6.3 46 Crankcase Bolts (M8) 20 2.0 14 Crankcase Bolts (M6) 9.8 1.0 87 in·lb Shift Shaft Positioning Bolt 25 2.5 18 Shift Shaft Spring Bolt 25 2.5 18 Shift Shaft Cover Bolts 8.8 0.90 78 in·lb Connecting Rod Big End Cap Nuts 34 3.5 25 Engine Drain Plug 20 2.0 14 Position Plate Mounting Screws 4.9 0.50 43 in·lb Shift Shaft Lever Nut 8.8 0.90 78 in·lb Shift Shaft Lever Bolts 14 1.4 10 Reverse Cable Bracket Mounting Bolts 8.8 0.90 78 in·lb Neutral Position Switch 8.8 0.90 78 in·lb Reverse Position Switch 15 1.5 11 Reverse Cable Locknut 12 1.2 104 in·lb Cable Holder Mounting Bolts 9.8 1.0 87 in·lb Tire Rod End Nuts 42 4.3 31 Tie-Rod Adjusting Locknuts 22 2.2 16 Wheel Nuts 78 8.0 58 Front Axle Nuts 52 5.3 38 Rear Axle Nuts 265 27 195 Output Driven Bevel Gear Housing Bolts 26 2.7 20 Output Drive Bevel Gear Cover Bolts 8.8 0.90 78 in·lb Bearing Holder 137 14 101 L Bevel Gear Holder Nut 157 16 116 L Output Drive Bevel Gear Housing Bolts 26 2.7 20 Bearing Holder 120 12 89 L Output Shaft Holder Nut 157 16 116 L Oil Filler Cap 29 3.0 22 Oil Drain Plug 20 2.0 14 Final Gear Case Bolts 42 4.3 31 Oil Pump Drive Chain Tensioner Bolt Remarks Engine Removal/Installation Crankshaft/Transmission: S, L (1) L MO L Wheels/Tires: Final Drive: (Output Bevel Gears) (Final Gear Case) S 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Pinion Gear Bearing Holder 137 14 101 L Final Gear Case Left Cover Bolts 49 5.0 36 L Final Gear Case Right Cover Bolts (M8) 24 2.4 17 L,S Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L,S Final Gear Case Right Cover Bolts (M12) 94 9.6 69 L,S Pinion Gear Bearing Holder Nut 157 16 116 L Reservoir Cap Screws 1.5 0.15 13 in·lb Bleed Valves 7.9 0.80 69 in·lb Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb Brake Switch Mounting Bolt 1.2 0.12 10 in·lb Brake Hose Banjo Bolts 25 2.5 18 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb Caliper Mounting Bolts 25 2.5 18 Disc Mounting Bolts 37 3.8 27 L Parking Brake Lever Screw – – – L Gasket Screws – – – L 8.8 0.90 78 in·lb Front Shock Absorber Clamp Bolts and Nuts 47 4.8 35 Front Shock Absorber Mounting Nuts 42 4.3 31 Rear Shock Absorber Mounting Nuts 62 6.3 46 Suspension Arm Pivot Bolts 42 4.3 31 Steering Knuckle Joint Nuts 29 3.0 21 Swingarm Pivot Right Shaft 152 15.5 112 L Swingarm Pivot Left Shaft 20 2.0 14 L Swingarm Pivot Left Nut 152 15.5 112 Steering Stem Bottom End Nut 40 4.1 30 Steering Stem Clamp Bolts 25 2.5 18 Tie-Rod End Nuts 42 4.3 31 Steering Knuckle Joint Nuts 29 3.0 22 Tie-Rod Adjusting Locknuts 22 2.2 16 Handlebar Lower Holder Nuts 37 3.8 27 L Handlebar Holder Bolts 29 3.0 22 S Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb 52 5.3 38 Brakes: Brake Pedal Bolt Suspension: Steering: Frame: Engine Mounting Bracket Bolts PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Engine Mounting Nut 62 6.3 46 Footrest Mounting Bolts 44 4.5 33 Alternator Cover Bolts 8.8 0.90 78 in·lb Alternator Rotor Bolts 127 13 94 Alternator Stator Bolts 13 1.3 113 in·lb Alternator Cover Plugs 18 1.8 13 Spark Plug 13 1.3 113 in·lb Crankshaft Sensor Mounting Bolts 5.9 0.60 52 in·lb Starter Motor Mounting Bolts 8.8 0.90 78 in·lb Starter Motor Terminal Nut 4.9 0.50 43 in·lb Starter Motor Terminal Locknut 6.9 0.70 61 in·lb Starter Motor Bolts 4.9 0.50 43 in·lb Starter Motor Clutch Bolts 34 3.5 25 Reverse Position Switch 15 1.5 11 Neutral Position Switch 15 1.5 11 Oil Pressure Switch 15 1.5 11 Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb Radiator Fan Switch 18 1.8 13 Coolant Temperature Warning Light Switch 6.9 0.70 61 in·lb Remarks Electrical System: L SS SS 2-10 PERIODIC MAINTENANCE Torque and Locking Agent The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners of Engine Parts Threads dia. Mark of Torque mm bolt head N·m kgf·m ft·lb 5 4T 2.2 ~ 2.6 0.22 ~ 0.27 19 ~ 23 in·lb 6 9T 12 ~ 15 1.2 ~ 1.5 104 ~ 130 in·lb 6 7T 7.8 ~ 9.8 0.80 ~ 1.0 69 ~ 87 in·lb 6 4T 3.9 ~ 4.9 0.40 ~ 0.50 35 ~ 43 in·lb 8 7T 18 ~ 22 1.8 ~ 2.2 13 ~ 16 8 4T 10 ~ 14 1.0 ~ 1.4 87 ~ 122 in·lb 10 7T 39 ~ 44 4.0 ~ 4.5 29 ~ 33 10 4T 20 ~ 24 2.0 ~ 2.4 14 ~ 17 Basic Torque for General Fasteners of Frame Parts Threads dia. Torque mm N·m kgf·m ft·lb 5 3.4 ~ 4.9 0.35 ~ 0.50 30 ~ 43 in·lb 6 5.9 ~ 7.8 0.60 ~ 0.80 52 ~ 69 in·lb 8 14 ~ 19 1.4 ~ 1.9 10.0 ~ 14 10 25 ~ 34 2.6 ~ 3.5 19.0 ~ 25 12 44 ~ 61 4.5 ~ 6.2 33 ~ 45 14 73 ~ 98 7.4 ~ 10 54 ~ 72 16 115 ~ 155 11.5 ~ 16 83 ~ 155 18 165 ~ 225 17 ~ 23 125 ~ 165 20 225 ~ 325 23 ~ 33 165 ~ 240 PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System: Throttle lever free play 2 ~ 3 mm (0.08 ~ 0.12 in.) – – – Air cleaner element oil High-quality foam air filter oil – – – Exhaust 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) – – – Inlet 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) – – – 1.16 ~ 3.48 mm (0.0457 ~ 0.1370 in.) 0.64 mm Engine Top End: Valve clearance: Converter System: Belt height (Parallel portion) (0.0251 in.) Belt deflection 22 ~ 27 mm (0.87 ~ 1.06 in.) – – – API SF or SG – – – API SH or SJ with JASO MA class – – – Viscosity SAE10W-40 – – – Capacity 1.7 L (1.80 US qt) – – – Engine Lubrication System: Engine oil: Type (When filter is not removed) 1.9 L (2.01 US qt) – – – (When filter is removed) 2.2 L (2.33 US qt) – – – (When engine is completely dry) Wheels/Tires Tire tread depth: Front ––– 3 mm (0.12 in.) Rear ––– 3 mm (0.12 in.) Standard tire: Front Rear AT 22 X 7-10 – – – CARLISLE, HOLE SHOT XC – – – AT 22 x 11-10 – – – CARLISLE, HOLE SHOT XCT – – – MOBIL Fluid 424 or CITGO – – – Final Drive: Final Gear Case: Gear Case Oil: Type TRANSGARD TRACTOR HYDRAULIC FLUID Oil level Filler opening bottom – – – Capacity 900 mL (0.95 US qt) – – – 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Brakes: Front Brake Fluid: Type DOT 3 or DOT 4 – – – Front Disc Brake: Pad lining thickness 4 mm (0.16 in.) 1 mm (0.04 in.) Rear Brake Lever, Pedal and Cables: Rear brake lever free play 1 ~ 2 mm (0.04 ~ 0.08 in.) – – – Brake pedal free play 15 ~ 25 mm (0.6 ~ 1.0 in.) – – – Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.) – – – Rear brake light switch timing On after 10 mm (0.4 in.) of pedal travel – – – Electrical System: PERIODIC MAINTENANCE 2-13 Special Tools Oil Filter Wrench : 57001–1249 Pulley Holder Attachment : 57001–1472 Carburetor Drain Plug Wrench, Hex 3 : 57001–1269 Filler Cap Driver: 57001–1454 Flywheel & Pulley Holder : 57001–1343 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection that the throttle lever [A] moves smoothly from full • Check open to close, and the throttle closes quickly and com- • • pletely in all steering positions by the return spring. If the throttle lever does not return properly, check the throttle cable routing, lever free play, and possible cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle lever free play and the cable routing. Stop the engine and check the throttle lever free play [B]. If the free play is not within the specified range, adjust the cable. Throttle Lever Free Play Standard: 2 ~ 3 mm (0.08 ~ 0.12 in.) Throttle Lever Free Play Adjustment the rubber cover off the adjuster at the throttle case. • Slide Loosen locknut [A] and turn the throttle cable upper • adjuster the [B] until the cable has proper amount of play. • Tighten the locknut and reinstall the rubber cover. If the free play cannot be adjusted by using the upper cable adjuster, remove the air cleaner cover and then use the cable adjusting nuts [A] at the lower end of the throttle cable and make the necessary free play. PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Choke Lever Free Play Check if the choke lever [A] returns properly and if the • Check inner cable slides smoothly. sure that the choke lever returns to its released po• Make sition all the way. determine the amount of choke cable play at the lever, • To pull the choke lever to the left until feeling the operation of • the lever tough; the amount of choke lever is equivalent to that of cable play. The proper amount of play ranges about 3 mm (0.12 in.) at the choke lever. If the free play is not within the specified range, adjust the cable. Choke Lever Free Play [B] Standard: about 3 mm (0.12 in.) Choke Lever Free Play Adjustment the locknut [A] of the choke cable. • Loosen the adjuster [B] until the cable has proper amount of • Turn play. • Tighten the locknut securely. Idle Speed Inspection the engine and warm it up thoroughly. • Start the engine idling, turn the handlebar to both sides to • With check for any changes in the idle speed. If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted incorrectly routed, or damaged. Be sure to correct any of these conditions before riding. WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition. idle speed with a suitable tachometer. • Check If the idle speed is out of the specified range, adjust it. Idle Speed Standard: 1,100 ± 50 r/min (rpm) 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment the engine and warm it up thoroughly. • Start Turn • correct.the idle adjusting screw [A] until the idle speed is Open and close the throttle a few times to make sure that the idle speed is within the specified range. Fuel System Cleanliness Inspection WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the fuel tap to the OFF position. • Turn Place suitable container under the drain plugs [A]. • Turn outthethe carburetor drain plug a few turns and drain • the fuel system. Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269 to see if water or dirt comes out. • Check Tighten the drain plug. • If any water or dirt appears during the above inspection, clean the fuel system (carburetor, fuel tank, fuel hose). Air Cleaner Element Cleaning and Inspection NOTE In dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain or muddy terrains, the element should be cleaned immediately. Also, if there is a break in the element material or any other damage to the element, replace the element with a new one. WARNING Clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the foam element. the air cleaner element (see Fuel System chap• Remove ter). PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Clean the element [A] in a bath of high-flash point solvent. it dry in a clean towel [A]. Do not wring the ele• Squeeze ment or blow it dry; the element can be damaged. the element for damage. • Inspect If it is torn, punctured, or hardened, replace it. cleaning, saturate the element with a high-quality • After foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element. Air Cleaner Draining any water or oil accumulates in the tube, drain it by • Iftaking off the tube plug [A]. After draining, be sure to install the tube plug and clamp firmly. Fuel Hoses and Connections Inspection the air cleaner cover (see Frame chapter) • Remove the fuel tap to the OFF position. • Turn Check the fuel hoses [A]. • If the fuel hose is frayed, cranked, or bulged, replace the • • • fuel hose. Check that the hose is securely connected and clamps [B] are tightened. If the fuel hose has been sharply bent or kinked, replace the fuel hose. If the clamps are loosened or damaged, replace the clamps. When installing the fuel hose, route the hose according to Cable, Wire, and Hose Routing section in Appendix chapter. When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed. 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose and Fuel Filter Replacement WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the air cleaner cover (see Frame chapter). • Remove Turn the • Remove:fuel tap to the OFF position. • Clamps [A] • • • Clamp (Fuel Tank Side) Fuel Hoses [B] Fuel Filter [C] Replace the fuel hoses and fuel filter with a new one. When installing the fuel hose, route the hose according to Cable, Wire, and Hose Routing section in Appendix chapter. When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed. the fuel hose [A] onto the pipe fully and install the • Fit clamps [B] beyond the raised rib [C]. PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Cooling System Radiator Cleaning CAUTION Clean the radiator screen and the radiator in accordance with the Periodic Maintenance Chart. In dusty areas, they should be cleaned more frequently than the recommended interval. After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately. • Remove: Radiator Cover (see Frame chapter) • Radiator Screen Mounting Screws [A] Radiator Screen [B] (With the Shroud [C]) Clean the radiator screen in a bath of tap water, and then dry it with compressed air or by shaking it. • Clean the radiator. CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. Keep the steam gun away more than 0.5 m (20 in.) from the radiator core [A]. Hold the steam gun perpendicular to the core surface. Run the steam gun following the core fin direction. Radiator Hose and Connection Inspection • The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps are tightened correctly. 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the frame, engine, or wheels. Since coolant is harmful to the human body, do not use for drinking. • Remove: Front Fender (see Frame chapter) • • Reserve Tank Cap Place the container under the reserve tank. Pull off the cooling hose [A], and drain the coolant. a container under the drain plug [A] at the bottom • Place of the water pump [B], then remove the drain plug. the radiator cap [A] in two steps. First turn the • Remove cap counterclockwise to the first step. Then push and turn • it further in the same direction and remove the cap. The coolant will drain from the radiator and engine. PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures the cooling hose [A]. • Install Tighten the drain plug. • Torque - Coolant Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb) the vehicle on a stand or the jack so that the front • Support wheels are off the ground. This makes air bleeding easier. the radiator up to the radiator filler neck [B] with • Fill coolant. NOTE Pour in the coolant slowly so that the air in the engine and radiator can escape. the reserve tank up to the full level line with coolant, • Fill and install the reserve tank cap. CAUTION Soft or distilled water must be used with antifreeze (see Specifications in this chapter) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, considerably reducing the efficiency of the cooling system. Water and Coolant Mixture Ratio (when shipping) Soft Water: 50% Coolant: 50% Freezing Point: –35 C (–31 F) Total Amount: 2.5 L (2.64 US qt) NOTE Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. the air from the cooling system as follows. • Bleed Start the engine with the radiator cap removed and run it • • • until no more air bubbles [A] can be seen in the coolant. Tap the radiator hoses to force any air bubbles caught inside. Stop the engine and add coolant up to the radiator filler neck. Install the radiator cap. Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine. Check the coolant level in the reserve tank after the engine cools down. If the coolant level is lower than the low level line, add coolant to the full level line. CAUTION Do not add more coolant above the full level line. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Filter Cleaning the coolant (see Coolant change). • Drain Remove the filter [A] from the cooling hoses [B] of carbu• retor system. [C] off dirt and sediment on the filter with com• Blow pressed air. Engine Top End Valve Clearance Inspection NOTE Check the valve clearance only when the engine is cold (at room temperature). • Remove: Air Cleaner Cover (see Frame chapter) Air Cleaner Housing (see Fuel System chapter) Front Fender (see Frame chapter) Valve Adjusting Caps [A] • Remove the timing inspection plug [A]. Special Tool - Filler Cap Driver: 57001–1454 • Remove the alternator bolt cover [B]. Turn the crankshaft counterclockwise with a wrench on • the alternator rotor bolt until “T-F” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the front cylinder head. PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures the clearance for all four valves, one at a time • Measure between the end of the valve stem and the adjusting screw [A] with the thickness gauge [B]. Valve Clearance (when cold) Exhaust: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) Inlet: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment). Then, turn the crankshaft counterclockwise with a • wrench on the alternator rotor bolt until “T-R” mark [A] on • the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the rear cylinder head. Measure the clearance for all four valves, one at a time between the end of the valve stem and the adjusting screw with the thickness gauge. Valve Clearance (when cold) Exhaust: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) Inlet: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment). Valve Clearance Adjustment the valve adjusting caps. • Remove Loosen the locknut [A] and turn the adjusting screw [B] • until the clearance is correct. Hold the adjusting screw from turning and tighten the lock• nut to the specified torque. Torque - Valve Adjusting Screw Locknuts: 12 N·m (1.2 kgf·m, 104 in·lb) the clearance. • Recheck If the clearance is incorrect, repeat the adjustment proce- dure. If the clearance is correct, perform the adjustment procedure on the other valve. • Apply grease to the O-rings [A]. Torque - Valve Adjusting Cap Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Arrester Cleaning WARNING To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot. the drain plug [A] on the muffler. • Remove In an open area away from combustible materials, start • the engine with the transmission in neutral. Raise and lower speed while tapping on the muf• fler with a rubberengine mallet until carbon particles are purged from the muffler. WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. the engine. • Stop Install the drain plug. • Converter System Drive Belt Inspection Inspection of the drive belt is required at least every 90 days of vehicle use (average 12 mile/day) not to exceed 1,700 km (1,100 mile) or belt indicator light turn on (100 hours of use) counted by the hour meter. More frequent inspection is necessary if the vehicle is subjected to hard usage. WARNING Neglect, abuse, or failure to maintain the transmission can result in a severely worn or damaged drive belt locking up the transmission and wheels. This can cause the operator to lose control and have an accident resulting in injury or death. the torque converter cover (see Converter Sys• Remove tem chapter). the height [A] of the belt paralle portion at sev• Measure eral locations. If any measurements exceed the service limit, replace the belt. Belt Height (Paralle Portion) Standard: 1.16 ~ 3.48 mm (0.0457 ~ 0.1370 in.) Service Limit: 0.64 mm (0.0251 in.) PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures the belt [A] for abnormal wear [B]. • Check Measure the width [C] of the belt at abnormal wear point. If any measurements exceed 0.5 mm (0.02 in.), replace the belt. the belt for cracks, breaks, or peeling. • Check If necessary, replace the belt with a new one. Belt [A] Crack [B] Broken [C] Peeling [D] NOTE Whenever the belt is replaced, inspect the drive and the driven pulleys. Drive Belt Deflection Inspection the torque converter cover (see Converter Sys• Remove tem chapter). the transmission in neutral and rotate the driven pulley • Put by hand to make sure the belt is shifted all the way to the top of the driven pulley. the belt deflection [A] as shown: • Measure Place a straightedge [B] on top of the belt between the drive pulley [C] and the driven pulley [D]. Use a ruler to push the belt away from the straightedge. Push hard, but with no more force than 59 N (6 kgf, 13 lb). Belt Deflection Standard: 22 ~ 27 mm (0.87 ~ 1.06 in.) • If the belt deflection is not within the specified range, first measure the height of the belt pralle portion (see Drive Belt Inspection). Adjust the deflection by adding or removing spacers on the fixed sheave. When adjusting the deflection, less is better than more. Less deflection will maintain better performance for more time as the belt width decreases by normal wear, which causes the deflection to increase with usage. 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Deflection Adjustment the driven pulley (see Converter System • Disassemble chapter). If the belt deflection is more than 27 mm (1.06 in.), remove the spacers to decrease it. The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.3 mm (0.051 in.) change in belt deflection. If the belt deflection is less than 22 mm (0.87 in.), add the spacers [A] to increase it. The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.6 mm (0.063 in.) change in belt deflection. Spacers Part No. 92026-1569 92026-1617 92026-1565 92026-1570 0.6 0.8 1.0 1.4 Thickness mm (0.024 mm (0.032 mm (0.039 mm (0.055 in.) in.) in.) in.) the driven pulley (see Converter System chap• Assemble ter). the transmission in neutral, rotate the driven pulley • With to allow the belt to return to the top of the sheaves before • • measuring the belt deflection. Measure the belt deflection again and repeat the above procedures until it is within the standard range. Using the flywheel & pulley holder and adapter, tighten the driven pulley nut. Special Tools - Flywheel & Pulley Holder: 57001–1343 Pulley Holder Attachment: 57001–1472 Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb) PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change the vehicle so that it is level side to side and front • Support to back after warming up the engine. the engine drain plug [A] to drain the oil. • Remove The oil in the filter can be drained by removing the filter • (see Oil Filter Change). Replace the drain plug gasket with a new one. Tighten: Torque - Engine Drain Plug : 20 N·m (2.0 kgf·m, 14 ft·lb) • Pour in the specified type and amount of oil. Engine Oil Type: Viscosity: Amount: API SF or SG API SH or SJ with JASO MA class SAE 10W-40 1.7 L (1.80 US qt) (When filter is not removed) 1.9 L (2.01 US qt) (When filter is removed) 2.2 L (2.33 US qt) (When engine is completely dry) NOTE Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Oil Filter Change the engine oil. • Drain • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench : 57001–1249 the filter with a new one. • Replace installing the oil filter, be careful of the following. • When Apply oil to the gasket [A] before installation. Tighten the filter with the oil filter wrench. Special Tool - Oil Filter Wrench: 57001–1249 Torque - Oil Filter : 18 N·m (1.8 kgf·m, 13 ft·lb) Pour in the specified type and amount of oil. 2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Crankshaft/Transmission Shift Control Grip Free Play Inspection the distance the shift control grip moves with the • Measure push button depressed. the shift control cable free play of both directions. • Check If the free play is not within the specified range, adjust the cable. Shift Control Cable Grip Free play [A] Standard: 0 ~ 2 mm (0 ~ 0.08 in.) Shift Control Grip Free Play Adjustment the battery with the battery case (see Electrical • Remove System). sure that the shift control grip is in neutral position. • Make Make • tion. sure that the gear change lever is in neutral posiNeutral position is the shift cable lower ends [A] and reverse lock cable bracket bolt [B] aligned state. Drive Position [C] Reverse Position [D] the adjusting nuts [A] at shift control cable lower end • Turn make the inner cables [B] tight with no free play. the shift control grip from “N” to “D” and to “R” respec• Turn tively and make sure the change lever [C] works correctly. • Tighten the all adjusting nuts securely. back the rubber covers. • Slide Loosen [A] and turn the shift cable upper • adjustersthe[B]locknuts to obtain the specified free play. the locknuts securely and re install the rubber • Tighten covers. PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Wheels/Tires Tire Inspection the tire for damage and wear. • Examine If the tire is cut or cracked, replace it. • Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement. Remove any foreign objects from the tread. After removal, check for leaks with a soap and water solution. Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurements at several places. If any measurements are less than the service limit, replace the tire. Tire Tread Depth Service Limit: Front: 3 mm (0.12 in.) Rear: 3 mm (0.12 in.) Standard Tire Front: AT 22 x 7 - 10 CARLISLE, HOLE SHOT XC Rear: AT 22 x 11 - 10 CARLISLE, HOLE SHOT XCT Final Drive Final Gear Case Oil Change up the oil by running the vehicle so that the oil will • Warm pick up any sediment and drain easily. Then stop the • • vehicle. Park the vehicle so that it is level, both side-to-side and front-to-rear. Place an oil pan beneath the rear final gear case and remove the drain plug [A]. WARNING When draining or filling the final gear case, be careful that no oil gets on the tire or rim because oil will deteriorate the tire. Clean off any oil that inadvertently gets on them with a high-flash point solvent. the oil has completely drained out, install the drain • After plug with a new aluminum gasket. Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb) the final gear case up to the bottom of filler opening • Fill with the oil specified below. Final Gear Case Oil Type: MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Capacity: 900 mL (0.95 US qt) • Be sure the O-ring is in place. Torque - Oil Filler Cap [B]: 29 N·m (3.0 kgf·m, 22 ft·lb) 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Propeller Shaft Joint Boot Inspection inspect the rear propeller shaft joint boot [A] in • Visually accordance with the Periodic Maintenance Chart or if the shaft is noisy during operation. If the joint boot is torn, worn, or deteriorated, replace the joint boot and check the propeller shaft (see Final Drive chapter). Brakes Front Brake Pad Wear Inspection the lining thickness [A] of the pads in each caliper. • Check If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness Standard: 4 mm (0.16 in.) Service Limit: 1 mm (0.04 in.) Front Brake Hoses and Connections Inspection the brake hose and • Inspect cracks and signs of leakage. • fittings for deterioration, The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any cracks [B] or bulges [C] are noticed. Tighten any loose fittings. Front Brake Hose Replacement the brake fluid out of the line as explained in the • Pump Brake Fluid Change. the banjo bolts at both ends of the brake hose, • Remove and pull the hose off the vehicle. • Immediately wipe up any brake fluid that spills. CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. a new flat washer for each side of the hose fittings. • Use Install new brake hose in its place (see Appendix • chapter),theand tighten the banjo bolts. Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake Fluid Level Inspection the reservoir horizontal, and check that the fluid • Position level in the reservoir is higher than the lower level line [A]. If the fluid level is lower than the lower level line, check for fluid leakage of the brake line, and add the fluid as follows: Remove the reservoir cap, and fill the reservoir to the upper level line [A] in the reservoir with the same type and brand of the fluid that is already in the reservoir. And then install the reservoir cap. WARNING Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified. • Tighten: Torque - Reservoir Cap Screws : 1.5 N·m (0.15 kgf·m, 13 in·lb) Brake Fluid Change the reservoir cap and the rubber cap on the bleed • Remove valve. a clear plastic hose to the bleed valve on the • Attach caliper, and run the other end of the hose into a container. the reservoir with new brake fluid. • Fill the brake fluid as follows: • Change Open the bleed valve [A]. • Apply the brake lever and hold it [B]. Close the bleed valve [C]. Release the brake lever [D]. Check the fluid level in the reservoir often, replenishing it as necessary. NOTE If the fluid in the reservoir runs completely out any time during fluid changing, air will enter the line, and the system must be bled. 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures this operation until fresh brake fluid comes out into • Repeat the plastic hose or the color of the fluid changes. WARNING Do not mix two brands of fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are not known. • Tighten: Torque - Bleed Valves: 7.9 N·m (0.80 kgf·m, 69 in·lb) the brake lever forcefully for a few seconds, and • Apply check for fluid leakage around the fittings. If necessary, bleed the air from the brake line (see Brake Line Air Bleeding). WARNING If the brake lever has a soft or "spongy feeling" when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, bleed the air from the brake line immediately. Brake Line Air Bleeding the air whenever brake parts are replaced or re• Bleed assembled. the reservoir cap and fill the reservoir with new • Remove brake fluid. pump the brake lever several times until no air • Slowly bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir. This bleeds the air from the master cylinder and the brake line. NOTE Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir. PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures a clear plastic hose to the bleed valve on the • Attach caliper, and run the other end of the hose into a container. the brake line and the caliper as follows: • Bleed Hold the brake lever applied [A]. • Quickly open and close the valve [B]. Release the brake lever [C]. The fluid level must be checked several times during the bleeding operation and replenished as necessary. NOTE If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. If the brake lever action still feels soft or "spongy", tap the brake hose from bottom to top and air will rise up to the top part of the hose. Slowly pump the brake lever in the same manner as above. • Tighten: Torque - Bleed Valves : 7.9 N·m (0.80 kgf·m, 69 in·lb) the brake lever forcefully for a few seconds, and • Apply check for fluid leakage around the fittings. Master Cylinder Inspection (Visual Inspection) the master cylinder (see Brakes chapter). • Disassemble Check that there are no scratches, rust or pitting on the • inner wall of the master cylinder [A] and on the outside of • • • • the piston [B]. If the master cylinder or piston shows any damage, replace them. Inspect the primary [C] and secondary [D] cups. If a cup is worn, damaged, softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups. Check the dust cover [E] for damage. If it is damaged, replace it. Check that the relief [F] and supply [G] ports are not plugged. If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air. Check the piston return spring [H] for any damage. If the spring is damaged, replace it. 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Fluid Seal Replacement The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. Disassemble the brake caliper (see Brakes chapter). Replace the fluid seals under any of the following conditions: (a) fluid leakage around the pad; (b) brakes overheat; (c) there is a large difference in inner and outer pad wear; (d) the seal is stuck to the piston. If the fluid seal is replaced, replace the dust seal as well. Also, replace all seals every other time the pads are changed. • • Caliper Dust Seal and Friction Boot Replacement the brake caliper (see Brakes chapter). • Disassemble Check that the dust seals [A] and friction boots [B] are not • cracked, worn swollen, or otherwise damaged. If they show any damage, replace them. Rear Brake Plates Replacement the internal wet brake (see Brakes chapter). • Disassemble Replace the steel pressure plates, steel plates and friction • plates in accordance with the specified interval. Rear Brake Lever Free Play Inspection the rear brake lever free play [A]. • Check Pull the rear brake lever lightly until the brake is applied. If the play is incorrect, adjust it. Rear Brake Lever Free Play Standard: 1 ~ 2 mm (0.04 ~ 0.08 in.) Rear Brake Pedal Free Play Inspection the brake pedal free play [A]. • Check Depress the brake pedal lightly by hand until the brake is applied. If the free play is incorrect, adjust it. Brake Pedal Free Play Standard: 15 ~ 25 mm (0.6 ~ 1.0 in.) PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Rear Brake Lever and Pedal Free Play Adjustment NOTE Since the rear brake lever and pedal free play adjustments affect each other, make them at the same time. Rear Brake Lever: Loosen the knurled locknut [A] and turn the adjuster [B] at the rear brake lever in as far as it will go. Tighten the locknut. • • the brake lever adjuster [A] at the rear end of the • Turn brake cable until the rear brake lever has the correct amount of play. Brake Pedal: Turn the brake pedal adjuster [B] at the rear end of the brake cable until the brake pedal has the correct amount of play. • the pedal a few times to see that it returns to its • Operate rest position immediately upon release. the rear wheels to check for brake drag. • Rotate braking effectiveness. • Check If there is any doubt as to the conditions of the brake, check the brake parts for wear or damage. Suspension Knuckle Joint Inspection inspect the boot [A] of knuckle joint. • Visually If damage, wear or deterioration is found, replace the knuckle joint. 2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection the handlebar left and right, and check the steering • Turn action. If the steering action is not smooth, or if the steering binds or catches before the stop, lubricate the steering stem bearing. NOTE The cables and wires will have some effect on the steering action which must be taken into account. the steering action again. • Check If steering stem bearing lubrication does not remedy the • problem, inspect the steering stem for straightness, steering stem clamps, and tie-rod bearings. If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts. Tighten loose bolts and nuts to the specified torque (see Steering chapter), and check the steering action again. If the steering action does not change by tightening the bolts and nuts, inspect the steering stem clamps, steering stem bearings, tie-rod bearings, and steering knuckle joints. Tie Rod End Inspection inspect the grease seal [A] of tie rod end. • Visually If damage, wear or deterioration is found, replace the tie rod end. PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning / Inspection the spark plug (see Electrical System chapter). • Remove Clean the spark plug, preferably in a sandblasting device, • and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent. Spark Plug Gap Inspection the gap [A] with a wire-type thickness gauge. • Measure 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.) Brake Light Switch Inspection on the ignition switch. • Turn the operation of the rear brake light switch by de• Check pressing the brake pedal [A]. If it does not as specified, adjust the brake light timing. Brake Light Timing Standard: On after about 10 mm (0.4 in.) of pedal travel [B] Brake Light Timing Adjustment the foot guard (see Frame chapter). • Remove Adjust the brake light switch [A] up or down. To change • the switch position, turn the adjusting nut [B]. CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. General Lubrication Lubrication lubricating each part, clean off any rusty spots with • Before rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication. 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Cable Lubricant Brake Cables Throttle Cable Choke Cable Shift Control Cables Lubricate the cables by seeping the oil between the cable and housing. The cable may be lubricated by using a pressure cable lubber with an aerosol cable lubricant. • the cable disconnected at the both ends, the cable • With should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable. Points: Lubricate with Grease. Throttle Inner Cable Ends [A] Choke Cable Lower End Brake Cable Ends Shift Control Cable Upper Ends Slide Points: Lubricate with Grease. Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Bolts and Nuts Tightening Tightness Inspection the tightness of the bolts and nuts listed here in • Check accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition. If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not listed in the appropriate chapter, see the Basic Torque Table (see Torque and Locking Agent). For each fastener, first loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones. Bolts, Nuts, and Fasteners to be checked Wheels: Front Axle Nuts and Cotter Pins Rear Axle Nuts and Cotter Pins Wheel Nuts Brakes: Front Brake Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Brake Lever Pivot Nut Front Brake Caliper Mounting Bolts Brake Pedal Cotter Pin Steering/Suspension: Handlebar Clamp Bolts Stem Clamp Bolts Stem Bearing Housing Bolts Tie-Rod End Nuts and Cotter Pins Tie-Rod Adjusting Sleeve Locknuts Shock Absorber Mounting Bolts and Nuts Suspension Arm Pivot Bolts Engine: Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Others: Footrest Mounting Bolts Throttle Mounting Bolts FUEL SYSTEM 3-1 Fuel System TABLE OF CONTENTS Exploded View.................................... Specifications ..................................... Special Tools ...................................... Throttle Lever and Cable .................... Throttle Lever Free Play Inspection................................... Throttle Lever Free Play Adjustment ................................. Throttle Case Removal/Disassembly................ Throttle Case Assembly/Installation ................. Throttle Cable Installation ............. Throttle Case Inspection ............... Throttle Cable Lubrication............. Throttle Cable Inspection .............. Choke Lever and Cable...................... Choke Lever Free Play Check ...... Choke Lever Free Play Adjustment ................................. Choke Lever and Cable Removal . Choke Lever and Cable Installation .................................. Choke Cable Lubrication............... Choke Cable Inspection................ Carburetor .......................................... Idling Speed Inspection................. Idle Speed Adjustment.................. Pilot Screw Adjustment ................. Service Fuel Level Inspection ....... Service Fuel Level Adjustment ..... Carburetor Synchronization Inspection................................... 3333- 2 6 7 8 3- 8 3- 8 3- 8 3- 8 3- 9 3- 9 3-10 3-10 3-11 3-11 3-11 3-11 3-12 3-12 3-12 3-13 3-13 3-13 3-13 3-13 3-14 3-15 Carburetor Synchronization Adjustment ................................. Fuel System Cleanliness Inspection................................... Carburetor Removal...................... Carburetor Installation................... Carburetor Disassembly ............... Carburetor Assembly .................... Carburetor Separation .................. Carburetor Joining ........................ Carburetor Cleaning...................... Carburetor Inspection ................... Air Cleaner.......................................... Air Cleaner Element Removal....... Air Cleaner Element Cleaning and Inspection................................... Air Cleaner Draining...................... Air Cleaner Housing Removal....... Air Cleaner Housing Installation.... Fuel Tank ............................................ Fuel Tank Removal ....................... Fuel Tank Installation .................... Fuel Tank Cleaning ....................... Fuel Tap Removal ......................... Fuel Tap Installation ...................... Fuel Tap Inspection....................... Fuel Pump .......................................... Fuel Pump Removal ..................... Pump Filter Cleaning .................... Fuel Pump Installation .................. Fuel Pump Inspection ................... 3 3-16 3-16 3-16 3-17 3-18 3-20 3-21 3-21 3-22 3-23 3-25 3-25 3-25 3-25 3-25 3-27 3-28 3-28 3-28 3-29 3-29 3-30 3-30 3-31 3-31 3-31 3-32 3-32 3-2 FUEL SYSTEM Exploded View FUEL SYSTEM 3-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Throttle Limiter Screw 3.7 0.38 33 in·lb 2 Throttle Limiter Locknut 3.7 0.38 33 in·lb 3 Throttle Case Assembly Screws 3.7 0.38 33 in·lb 4 Choke Lever Mounting Screw 3.5 0.36 31 in·lb 5 Left Handlebar Switches Assembly Screws 3.5 0.36 31 in·lb 6. Throttle Lever 7. Throttle Cable 8. Choke Lever 9. Choke Cable 10. Jet Needle 11. Pilot Jet 12. Main Jet 13. Needle Jet 14. Pilot Screw O: Apply engine oil. G: Apply grease. Remarks 3-4 FUEL SYSTEM Exploded View FUEL SYSTEM 3-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Air Cleaner Housing Bolts (M5) 5.9 0.60 52 in·lb 2 Air Cleaner Housing Bolts (M6) 8.8 0.90 78 in·lb 3 Air Cleaner Element Bracket Screws 4.9 0.50 43 in·lb 4 Fuel Tap Plate Screws 0.80 0.080 7 in·lb 5 Fuel Tap Cover Screws 1.0 0.10 8 in·lb 6 Fuel Pump Bolts 2.0 0.20 17 in·lb 7. Fuel Pump 8. Check Valve L: Apply a non-permanent locking agent. G: Apply grease. R: Replacement Part Remarks L 3-6 FUEL SYSTEM Specifications Item Throttle Case and Cable: Throttle lever free play Choke Lever and Cable: Choke lever free play Carburetor: Make/Type Main jet: Standard Front Rear Main air jet: Needle jet: Jet needle Pilot jet Pilot air jet Pilot screw Carburetor synchronization vacuum Starter jet Idle speed Service fuel level Float height Optional parts: Main jet: *Altitude: 0 ~ 500 m (0 ~ 1600 ft): Front Rear 500 ~ 1500 m (1600 ~ 4900 ft): Front Rear 1500 ~ 2500 m (4900 ~ 8200 ft): Front Rear 2500 ~ 3500 m (8200 ~ 11500 ft): Front Rear 3500 ~ 4500 m (11500 ~ 14800 ft): Front Rear Air Cleaner: Air cleaner element oil Service Limit 2 ~ 3 mm (0.08 ~ 0.12 in.) – – – about 3 mm (0.12 in.) – – – KEIHIN, CVKR-D32 #135 #140 #80 #6 NBZH #40 #130 1 1/2 turns out less than 2.7 kPa (2 cmHg) difference between carburetors #95 1100 ± 50 r/min (rpm) 12 ± 1 mm (0.47 ± 0.04 in.) below the punch mark 4.0 ± 1 mm (0.16 ± 0.04 in.) – – – – – – – – – – #135 (92063-1014) #140 (92063-1013) – – – – – – #132 (92063-1076) #138 (92063-1015) – – – – – – #130 (92063-1075) #135 (92063-1014) – – – – – – #128 (92063-1074) #130 (92063-1075) – – – – – – #120 (92063-1073) #125 (92063-1069) – – – – – – High-quality foam air filter oil – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – FUEL SYSTEM 3-7 Special Tools Fuel Level Gauge : 57001–1017 Pilot Screw Adjuster, A : 57001–1239 Carburetor Drain Plug Wrench, Hex 3 : 57001–1269 3-8 FUEL SYSTEM Throttle Lever and Cable Throttle Lever Free Play Inspection to the Fuel System in the Periodic Maintenance • Refer chapter. Throttle Lever Free Play Adjustment to the Fuel System in the Periodic Maintenance • Refer chapter. Throttle Case Removal/Disassembly the throttle case screws [A] and pull the case • Remove open. • Slide the cable adjuster dust cover out of place. • Remove the rubber cover [A]. the cable tip [A] out of the throttle lever catch with the • Pull throttle lever opened. the locknut [B] and unscrew the adjuster [C]. • Loosen Disassemble the throttle case as follows: • Remove the throttle lever screw [D], lockwasher, and flat washer, and lift the throttle lever [E] and return spring from the case. Pull the throttle control lever [F] out of the case. Throttle Case Assembly/Installation the throttle case and cable before assembly/in• Lubricate stallation. certain that the return spring is correctly installed on • Be the throttle lever [A]. the throttle case so that fit the projection on the • Instal lower throttle case and hole on the handlebar. • Tighten the throttle case assembly screws. Torque - Throttle Case Assembly Screws: 3.7 N·m (0.38 kgf·m, 33 in·lb) FUEL SYSTEM 3-9 Throttle Lever and Cable the throttle control lever so that the carburetor throt• Swing tle valve is fully open. Turn the throttle limiter screw [A] until it is spaced about 1 mm (0.04 in.) [B] away from the throttle lever stop [C]. Tighten the locknut [D]. Torque - Throttle Limiter Screw: 3.7 N·m (0.38 kgf·m, 33 in·lb) Throttle Limiter Locknut: 3.7 N·m (0.38 kgf·m, 33 in·lb) NOTE Refer to the Owner’s Manual for the function of the throttle limiter and adjustment procedure of it. WARNING Operation with an improperly assembled throttle case could result in an unsafe riding condition. the throttle lever free play (see Fuel System in Pe• Check riodic Maintenance chapter). back the cable adjuster dust cover to the original • Slide position. Throttle Cable Installation the throttle cable before installation. • Lubricate Route the cable correctly according to the Appendix chap• ter. WARNING Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition. the throttle cable (see Fuel System in Periodic • Check Maintenance chapter). Throttle Case Inspection the throttle cable disconnected from the throttle • With lever, the lever should move freely and return smoothly • by spring. If the lever is heavy, disassemble the throttle case, clean and lubricate the throttle case. Examine the lever and case for cracks. Replace the case assembly if it is cracked. 3-10 FUEL SYSTEM Throttle Lever and Cable Throttle Cable Lubrication Whenever the throttle cable is removed, lubricate the cable as follows: Apply a small amount of multi-purpose grease to the cable both ends. Lubricate the cable with a penetrating rust inhibitor through the pressure cable lubber. • • Throttle Cable Inspection the throttle cable disconnected at both ends, the ca• With ble should move freely within the cable housing. If the cable does not move freely after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable. FUEL SYSTEM 3-11 Choke Lever and Cable Choke Lever Free Play Check to the Fuel System in the Periodic Maintenance • Refer chapter. Choke Lever Free Play Adjustment to the Fuel System in the Periodic Maintenance • Refer chapter. Choke Lever and Cable Removal the air cleaner housing (see Air Cleaner Housing • Remove Removal). the carburetor from the carburetor holder. • Remove Remove the cooling hoses and fuel hose. • Remove the screws [A] and holder plates. • Pull out the starter plungers. • the starter plunger springs compressed, and free the • Hold choke cable lower ends [A] from the plungers [B]. • Remove: Choke Lever Mounting Screw [A], Plane Washer, and Wave Washer Switch Case Mounting Screws [B] the choke cable upper end [A] from the choke lever • Free [B]. 3-12 FUEL SYSTEM Choke Lever and Cable off the retaining clip [A]. • Pull Pull • the cable out of the vehicle. Choke Lever and Cable Installation the choke cable before installation. • Lubricate Install the • order. wave washer, plain washer and screw in that • Route the choke cable according to the Appendix chapter. WARNING Operation with an incorrectly routed, or damaged cable could result in an unsafe riding condition. Choke Cable Lubrication Whenever the choke cable is removed, lubricate the cable as follows: Lubricate the cable with a penetrating rust inhibitor through the pressure cable lubber. • Choke Cable Inspection the choke cable disconnected at both ends, the ca• With ble should move freely [A] in the cable housing. If the cable does not move freely after lubricating, if the cable is frayed [B], or if the housing is kinked [C], replace the cable. FUEL SYSTEM 3-13 Carburetor Idling Speed Inspection to the Fuel System in the Periodic Maintenance • Refer chapter. Idle Speed Adjustment to the Fuel System in the Periodic Maintenance • Refer chapter. Pilot Screw Adjustment the pilot screw if necessary. • Adjust Remove the converter exhaust joint duct (see Converter • System chapter). the carburetor pilot screw [A] all the way in until it • Turn seats lightly. Special Tool - Pilot Screw Adjuster, A: 57001–1239 [B] CAUTION Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement. • Back the pilot screw out the specified number of turns. Carburetor Pilot Screw Setting Standard: 1 1/2 turns out Service Fuel Level Inspection WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove the carburetor (see Carburetor Removal). 3-14 FUEL SYSTEM Carburetor the carburetor [A], fuel level gauge [B], and fuel [C] as • Set follows. Special Tool - Fuel Level Gauge: 57001–1017 Place the additional graduation [D] 10 mm (0.39 in.) higher than the top graduation [E]. Put the carburetor horizontally and so that the outlet side faces downward. Connect the fuel gauge and hose to the drain fitting of the carburetor. Connect the fuel to the fuel inlet fitting. 210 mm (8.27 in.) [F] 12 mm (0.47 in.) [G] Hold the gauge so that the additional graduation is placed slightly higher than the punch mark [H]. Feed the fuel into the carburetor, then loosen the carburetor drain screw. Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269 until the fuel level in the gauge settles. • Wait the gauge vertically and lower it slowly so that the • Hold additional graduation aligns with the punch mark. NOTE Do not align the additional graduation on the gauge lower than the punch mark. If it is lowered and then raised, the gauge will show a fluid level that is higher than the actual level, which will require a remeasurement. the fuel level [G]. • Read If the fuel level is incorrect, adjust it. Service Fuel Level Standard: 12 ± 1 mm (0.47 ± 0.04 in.) below the punch mark the drain screw. • Tighten Repeat the same procedure for the other carburetor. • Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch to OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the carburetors, and drain the fuel. • Remove Remove float chamber. • Remove the the [A]. • Slide out the screw pivot pin [B] and remove the float [C]. • FUEL SYSTEM 3-15 Carburetor the tang [A] on the float arm very slightly to change • Bend the float height. Float Height Standard: 4.0 ± 1 mm (0.157 ± 0.040 in.) • Measure the float height [A] from the mating surface [B] of float by tilting the carburetor so that the tang of the float [C] just touches the needle rod [D]. At this time, the float valve [E] rod must not be depressed. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Assemble the carburetor and recheck the fuel level. If the fuel level cannot be adjusted by this method, the float or the float valve is damaged. Carburetor Synchronization Inspection idle speed. • Check Remove: • Converter Exhaust Joint Duct (see Converter System chapter) Fuel Tap Vacuum Hose [A] Caps [B] on the Carburetor Holder the battery wires to the battery. • Connect Attach a vacuum gauge [A] to the fitting on the • carburetorsuitable holder. Start the engine and read the intake vacuum of each car• buretor when idling. If the vacuum is out of the specified range, adjust it. Carburetor Synchronization Vacuum Standard: Less than 2.7 kPa (2 cmHg) difference between carburetors 3-16 FUEL SYSTEM Carburetor Carburetor Synchronization Adjustment the air cleaner cover (see Frame chapter). • Remove Turn the adjust [A] to synchronize the carburetors. • If the carburetorscrew synchronization cannot be obtained by • using the adjusting screw, check for dirt or blockage, and then check the pilot screw settings. Check the carburetor synchronization again. NOTE Do not turn the pilot screws carelessly during carburetor synchronization. You may cause poor running at low engine speed. • Check idle speed. Fuel System Cleanliness Inspection to the Fuel System in the Periodic Maintenance • Refer chapter. Carburetor Removal WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Drain the coolant (see Cooling System chapter). • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Side Inner Cover (see Frame chapter) Fuel Hose [A] Coolant Hoses [B] the clamp screws [A] on the carburetor holders. • Loosen Remove the carburetor out of the frame. • FUEL SYSTEM 3-17 Carburetor the throttle cable cover screw [A] and throttle • Remove cable cover [B]. the nut [A] on the throttle cable. • Loosen Remove the throttle cable lower end [B]. • the screws [A] and holder plates [B]. • Remove Pull out of the starter plungers. • Carburetor Installation • Check fuel leakage from the carburetors. WARNING Fuel spilled from the carburetors is hazardous. the idle speed (see Fuel System in Periodic Main• Adjust tenance chapter). the throttle cable (see Fuel System in Periodic • Check Maintenance chapter). 3-18 FUEL SYSTEM Carburetor Carburetor Disassembly • Remove the carburetors (see Carburetor Removal). WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch to OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. NOTE The carburetors can be disassembled in the joined state. the upper chamber cover [A], spring [B], and vac• Remove uum piston [C]. CAUTION During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm. the jet needle [D] from the vacuum piston. These • Remove can be detached together with the spring seat [E]. Do not remove the pilot screw if possible, synchronization of the carburetors is necessary if pilot screws are removed (see Pilot Screw Adjustment). • Remove: Screws [A] Float Chamber [B] FUEL SYSTEM 3-19 Carburetor • Remove: Screw [A] Float Pivot Pin [B], Float [C], and Float Needle Valve Pilot Jet [D] Main Jet [E] • Remove: Screws [A] Coasting Enricher Cover [B] • Remove: Diaphragm [A] O-ring [B] 3-20 FUEL SYSTEM Carburetor Carburetor Assembly WARNING Fuel spilled from the carburetors is hazardous. CAUTION Do not apply force to the jet or overtighten it, or this could damage the jet or the carburetor body, requiring replacement. the float valve needle in the valve seat and hook • Install the needle hanger [A] onto the float tang. the float pivot pin [B] into the pivot post and the float. • Insert the screw [C]. • Tighten Set the float to the standard height (see Service Fuel • Level Adjustment). the jet needle [A] into the hole in the center of the • Insert vacuum piston [B], and place the spring seat [C] over the needle. the needle through the hole in the center of the vac• Slip uum piston, and put the spring seat [A] on the top of the • needle. Turn the seat so that it does not block the hole [B] at the bottom of the vacuum piston. After installing the upper chamber cover, check that the vacuum piston slides up and down smoothly without binding in the carburetor bore. FUEL SYSTEM 3-21 Carburetor the projection [A] of the vacuum piston diaphragm in • Fit the recess [B] of the body. installing the upper chamber cover, check to make • After sure that the vacuum piston moves smoothly in the carburetor body. Carburetor Separation • Remove: Carburetor (see Carburetor Removal) • Carburetor Joining Bolts [A] and Nuts Separate the carburetors. Carburetor Joining center lines of the carburetor bores must be parallel • The both horizontally and vertically. If they are not, loosen the mounting screws and align the carburetors on a flat surface. Retighten the carburetor joining bolts. • synchronize the throttle (butterfly) valves. • Visually Check to see that all throttle valves open and close • • smoothly without binding when turning the pulley. Visually check the clearance [A] between the throttle valve and the carburetor bore in each carburetor. If there is a difference between two carburetors, turn the balance adjusting screw [B] to obtain the same clearance. Install the carburetors (see Carburetor Installation). Adjust the synchronization (see Synchronization Adjustment). 3-22 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash–point solvents to clean the carburetor. CAUTION Do not use compressed air on an assembled carburetor, the float may be crushed by the pressure, and the vacuum piston diaphragm may be damaged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high flash-point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged. the carburetor and clean all the metal parts • Disassemble in a carburetor cleaning solution. the parts in water and dry them with compressed • Rinse air. through the air and fuel passages with compressed • Blow air. the float valve, spray cleaning solution from the • Remove valve seating surface into the fuel passage, and clean the • strainer (press-fitted) with compressed air [A]. Assemble the carburetor (see Carburetor Assembly). FUEL SYSTEM 3-23 Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the carburetor (see Carburetor Removal). • Remove Before disassembling the carburetors, check the fuel level • (see Fuel Level Inspection). the throttle cable pulley [A] to check that the throttle • Turn butterfly valve [B] moves smoothly and return back with the spring tension. If the throttle valve does not move smoothly, replace the carburetor. the carburetors (see Carburetor Disassem• Disassemble bly). the carburetor (see Carburetor Cleaning). • Clean Check the vacuum piston diaphragm [A], and the O-rings • [B] on the float bowl, pilot screw, coasting enricher, and starter plunger cap. If any of the diaphragm or O-rings are not in good condition, replace them. 3-24 FUEL SYSTEM Carburetor the plastic tip [A] of the float valve needle. It should • Check be smooth, without any grooves, scratches, or tears. • If the plastic tip is damaged [C], replace the float valve [B]. Push the rod [D] in the other end of the float valve needle and then release it [E]. If it does not spring out, replace the float valve. the tapered portion [A] of the pilot screw [B] for • Check wear or damage. If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it. that the vacuum piston moves smoothly in the car• Check buretor body. The surface of the piston must not be excessively worn. If the vacuum piston does not move smoothly, or if it is very loose in the carburetor body, replace both the body and the vacuum piston. FUEL SYSTEM 3-25 Air Cleaner Air Cleaner Element Removal • Remove: Air Cleaner Cover (see Frame chapter) Clips [A] Air Cleaner Housing Cap [B] • Remove: Thumbscrews [A] • Metal mesh [B] with element After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner ducts to keep dirt out of the carburetor and engine. WARNING If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possibly causing an accident. CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. • Separate metal mesh [A] and element [B]. Air Cleaner Element Cleaning and Inspection to the Fuel System in the Periodic Maintenance • Refer chapter. Air Cleaner Draining to the Fuel System in the Periodic Maintenance • Refer chapter. Air Cleaner Housing Removal • Remove: Air Cleaner Cover (see Frame chapter) Air Cleaner Housing Cap Air Cleaner Element (Air Cleaner Element Removal) 3-26 FUEL SYSTEM Air Cleaner • Remove: Screws [A] Element Bracket [B] • Remove: Air Cleaner Housing Bolts (M5) [A] • Remove: Air Cleaner Housing Bolts [A] • Remove: Breather Hose [A] Air Vent Hose [B] Drain Hose [C] Air Cleaner Housing [D] FUEL SYSTEM 3-27 Air Cleaner Air Cleaner Housing Installation the fitting of the housing in the duct [A], and fit the • Insert projection [B] under the fitting in the groove [C] in the duct. • Tighten the clamp screws. • Install: Drain Tube [A] Grommets [B] Air Ducts [C] • Install: Breather Hose [A] • Air Vent Hose [B] Drain Hose [C] Insert the carburetor air vent tube [D] in the fitting [E] of the housing. a non-permanent locking agent to the air cleaner • Apply housing bolts (M5) [A] and tighten them. Torque - Air Cleaner Housing Bolts (M5): 5.9 N·m (0.60 kgf·m, 52 in·lb) • Tighten: Torque - Air Cleaner Housing Bolts (M6) [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Air Cleaner Element Air Cleaner Housing Cap 3-28 FUEL SYSTEM Fuel Tank Fuel Tank Removal • Remove: Rear Fender (see Frame chapter) Bolts [A] Seat Bracket [B] • Disconnect: Breather Hose [A] Fuel Hose [B] Fuel Pump Lead Connector [C] • Remove: Fuel Tank Bolts [A] Fuel Tank [B] Fuel Tank Installation the rubber dampers [A]. • Check If the dampers are damaged or deteriorated, them. replace FUEL SYSTEM 3-29 Fuel Tank • Install: Fuel Tank Cover [A] • • • Fuel Tank [B] Grommets and Collars Tighten the fuel tank bolts. Connect: Breather Hose [C] Fuel Pump Lead Connector [D] Fuel Hose [E] Be sure the fuel hose is clamped to the fuel pump fitting. Fuel Tank Cleaning the fuel tank and drain it (see Fuel Tank Re• Remove moval). some high flash-point solvent into the fuel tank and • Pour shake the tank to remove dirt and fuel deposits. WARNING Clean the tank in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash–point solvents to clean the tank. A fire or explosion could result. the solvent out the tank. • Pour Install the fuel tank (see Fuel Tank Installation). • Fuel Tap Removal • Remove: Fuel Hoses [A] Fuel Tap Mounting Bolts [B] • Remove: Fuel Tap Vacuum Hose [A] 3-30 FUEL SYSTEM Fuel Tank Fuel Tap Installation the fuel hoses to the fuel tap as follows. • Connect Fuel Filter Hose to Fitting [A] • Fuel Tank Hose to Fitting [B] Fuel Tap Vacuum Hose to Fitting [C] Be sure to clamp the fuel hoses to the fuel tap to prevent leakage. Fuel Tap Inspection sure the O-ring [A] is in good condition to prevent leak• Be age. grease to the lever [B]. • Apply Tighten: • Torque - Fuel Tap Plate Screws [C]: 0.80 N·m (0.080 kgf·m, 7 in·lb) Fuel Tap Cover Screws [D]: 1.0 N·m (0.10 kgf·m, 8 in·lb) FUEL SYSTEM 3-31 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Disconnect the battery (–) terminal. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. • Remove: Seat Bracket • • Fuel Hose [A] Fuel Pump Lead Connector [B] Breather Hose [C] Unscrew the fuel pump bolts [D], and take out the fuel pump assembly and gasket. Do not contact the fuel filter with the fuel tank. Discard the fuel pump gasket. Pump Filter Cleaning WARNING Clean the pump filter in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the pump filter. the fuel pump [A] along with the pump filter [B]. • Remove Prepare a • vent. container [C] filled with a high-flash point soland shake the fuel filter only in the solvent to remove • Dip dirt and fuel deposits from the filter. the pump and filter by lightly applying compressed air. • Dry Install the fuel pump (see Fuel Pump Installation). • 3-32 FUEL SYSTEM Fuel Pump Fuel Pump Installation the pump filter (see Pump Filter Cleaning). • Clean Remove dirt or dust from the fuel pump by lightly applying • compressed air. Replace the fuel pump gasket [A] with a new one. • Install the fuel pump so that the fuel filter do not • contact with the fuel assembly tank. Fuel Pump Inspection • Refer to the Electrical System chapter. COOLING SYSTEM 4-1 Cooling System TABLE OF CONTENTS Exploded View......................................................................................................................... Coolant Flow Chart.................................................................................................................. Specifications .......................................................................................................................... Special Tools and Sealant ....................................................................................................... Coolant .................................................................................................................................... Coolant Deterioration Inspection........................................................................................ Coolant Level Inspection.................................................................................................... Coolant Draining ................................................................................................................ Coolant Filling .................................................................................................................... Pressure Testing ................................................................................................................ Water Pump............................................................................................................................. Water Pump Cover Removal ............................................................................................. Water Pump Cover Installation .......................................................................................... Impeller Removal ............................................................................................................... Water Pump Impeller Installation ....................................................................................... Water Pump Impeller Inspection ........................................................................................ Mechanical Seal Replacement .......................................................................................... Radiator ................................................................................................................................... Radiator Removal .............................................................................................................. Radiator Fan Removal ....................................................................................................... Radiator Fan Installation .................................................................................................... Radiator Inspection ............................................................................................................ Radiator Cleaning .............................................................................................................. Radiator Cap Inspection .................................................................................................... Thermostat .............................................................................................................................. Thermostat Removal.......................................................................................................... Thermostat Installation....................................................................................................... Thermostat Inspection ....................................................................................................... Radiator Fan Switch ................................................................................................................ Radiator Fan Switch Removal ........................................................................................... Radiator Fan Switch Installation ........................................................................................ Radiator Fan Switch Inspection ......................................................................................... Coolant Temperature Warning Light Switch ............................................................................ Coolant Temperature Warning Light Switch Removal ....................................................... Coolant Temperature Warning Light Switch Installation .................................................... Coolant Temperature Warning Light Switch Inspection ..................................................... Coolant Filter/Valve ................................................................................................................. Coolant Filter Cleaning ...................................................................................................... Coolant Valve Inspection ................................................................................................... 4- 2 4- 4 4- 6 4- 7 4- 8 4- 8 4- 8 4- 8 4- 8 4- 9 4-10 4-10 4-10 4-10 4-10 4-11 4-11 4-13 4-13 4-14 4-14 4-15 4-15 4-15 4-16 4-16 4-16 4-16 4-18 4-18 4-18 4-18 4-19 4-19 4-19 4-19 4-20 4-20 4-20 4 4-2 COOLING SYSTEM Exploded View COOLING SYSTEM 4-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Radiator Fan Switch 18 1.8 13 2 Water Pump Fitting Bolt 9.8 1.0 87 in·lb 3 Water Pump Impeller 7.8 0.80 69 in·lb 4 Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb 5 Coolant Temperature Warning Light Switch 7.8 0.80 69 in·lb 6 Radiator Fan Assembly Bolts 8.8 0.90 78 in·lb 7 Radiator Mounting Bolts 8.8 0.90 78 in·lb 8 Water Pump Cover Bolts 8.8 0.90 78 in·lb 9 Coolant Drain Plug 8.8 0.90 78 in·lb 10. Thermostat 11. Coolant Valve 12. Coolant Filter SS: Apply silicone sealant (Kawasaki Bond: 56019–120). Remarks SS 4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump (coupled with the oil pump) turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is below 69.5 ~ 72.5 C (157 ~ 162 F) , the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 69.5 ~ 72.5 C (157 ~ 162 F), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 96 ~ 100 C (205 ~ 212 F), the radiator fan switch conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the temperature is below 91 ~ 95 C (195 ~ 203 F), the fan switch opens and the radiator fan stops. In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies. The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contract, and the stored coolant flows back to the radiator from the reserve tank. The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 93 ~ 123 kPa (0.95 ~ 1.25 kgf/cm², 14 ~ 18 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 93 ~ 123 kPa (0.95 ~ 1.25 kgf/cm², 14 ~ 18 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator. COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator 2. Water Pump 3. Radiator Cap 4. Thermostat 5. Coolant Temperature Switch Warning Black Painted Arrow: Hot Coolant White Painted Arrow: Cold Coolant Light 6. Reserve Tank 7. Cylinder, Cylinder Head 8. Carburetor 9. Radiator Fan 10. Radiator Fan Switch 4-6 COOLING SYSTEM Specifications Item Standard Service Limit Permanent type of antifreeze (soft water – – – Coolant provided when shipping: Type and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green – – – Mixed ratio Soft water 50%, coolant 50% – – – Freezing point –35 C (–31 F) – – – Total amount 2.5 L (2.64 US qt) (reserve tank full level – – – including radiator and engine) Radiator cap: Relief pressure 93 ~ 123 kPa (0.95 ~ 1.25 kgf/cm², – – – 14 ~ 18 psi) Thermostat: Valve opening temperature 69.5 ~ 72.5 C (157 ~ 162 F) – – – Valve full opening lift 8 mm or more @ 85 C (185 F) – – – Coolant Filter/Valve: Coolant valve closing temperature 80 C (176 F) or more @ 24.5 kPa (for reference) (0.25 kgf/cm², 3.6 psi) – – – COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver Set : 57001–1129 Bearing Remover Head, f10 x f12 : 57001–1266 Bearing Remover Shaft, f9 : 57001–1265 Kawasaki Bond (Silicone Sealant) : 56019–120 4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection inspect the coolant in the reserve tank [A]. • Visually If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for cooling system leak. It may be caused by exhaust gas leaking into the cooling system. Coolant Level Inspection NOTE Check the level when the engine is cold (room or ambient temperature). the coolant level in the reserve tank with the vehi• Check cle held perpendicularly. Reserve Tank [A] F (full) Mark [B] L (low) Mark [C] If the coolant level is lower than the L mark, Remove the upper front cover and reserve tank cap [A], then add coolant to the F mark [B]. CAUTION For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attach the aluminum engine parts. In an emergency, soft water can be added. But the diluted coolant must be returned to the correct mixture ration within a few days. If coolant must be added often, or the reserve tank has run completely dry; there is probably leakage in the cooling system. Check the system for leaks. Coolant Draining to the Cooling System in the Periodic Maintenance • Refer chapter. Coolant Filling to the Cooling System in the Periodic Maintenance • Refer chapter. COOLING SYSTEM 4-9 Coolant Pressure Testing the upper front cover and radiator cap, then in• Remove stall a cooling system pressure tester [A] on the radiator filler neck. NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leakage. up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kgf/cm², 18 psi). CAUTION During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). the gauge for at least 6 seconds. • Watch If the pressure holds steady, the system is alright. If the pressure drops soon, check for leaks. 4-10 COOLING SYSTEM Water Pump Water Pump Cover Removal the coolant (see Cooling System in Periodic Main• Drain tenance chapter). • Remove: Foot Guards (Left Side) Cooling Hoses [A] Water Pump Cover Bolts [B] Water Pump Cover [C] Water Pump Cover Installation • Install: Knock Pins [A] • New Gasket Tighten: Torque - Water Pump Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Impeller Removal the coolant (see Cooling System in Periodic Main• Drain tenance chapter). the water pump cover (see Water Pump Cover • Remove Removal). • Loosen the water pump impeller [A] counterclockwise. Water Pump Impeller Installation a small amount of coolant on the sliding surface [A] • Apply of the mechanical seal and the sealing seat. the impeller on the water pump shaft and tighten • Install the impeller. Torque - Water Pump Impeller: 7.8 N·m (0.80 kgf·m, 69 in·lb) COOLING SYSTEM 4-11 Water Pump Water Pump Impeller Inspection inspect the impeller [A]. • Visually If the surface is corroded or the blades are damaged, replace the impeller. Mechanical Seal Replacement • Remove: Water Pump Impeller (see Water Pump Impeller Re• moval) Alternator Cover (see Electrical System chapter) Take the bearing [A] out of the alternator cover, using the bearing remover. Special Tools - Bearing Remover Shaft, f9: 57001–1265 [B] Bearing Remover Head, f10 x f12: 57001–1266 [C] out the mechanical seal [A] and oil seal [B] from • Press the inside of the alternator cover with the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001–1129 CAUTION If either the mechanical seal, oil seal, or the ball bearing is removed, make sure to replace all of them simultaneously with a new one. Be careful not to block the inspection hole with the oil seal. If the inspection hole is blocked, the coolant may pass through the oil seal and flow into the crankcase. heat-resistance grease on the oil seal lip. • Apply outside the alternator cover, press and insert the oil • From seal [A] flush [B] in the direction as shown. Special Tool - Bearing Driver Set: 57001–1129 4-12 COOLING SYSTEM Water Pump inside the alternator cover, press and insert the ball • From bearing [A] until it is bottomed. Special Tool - Bearing Driver Set: 57001–1129 a suitable socket [A] and the bearing driver [B], • Using press and insert a new mechanical seal [C] until its flange stops at the step [D] of the hole. Special Tool - Bearing Driver Set: 57001–1129 the sliding surface of a new mechanical seal with • Clean a high flash-point solvent, and apply a little coolant to the • • sliding surface to give the mechanical seal initial lubrication. Apply coolant to the surfaces of the rubber seal and sealing seat [A], and press the rubber seal [B] and sealing seat into the impeller by hand until the seat bottoms out. Tighten the water pump impeller by turning the bolt clockwise. Torque - Water Pump Impeller: 7.9 N·m (0.80 kgf·m, 69 in·lb) COOLING SYSTEM 4-13 Radiator Radiator Removal WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES. the coolant (see Cooling System in the Periodic • Drain Maintenance chapter). • Remove: Front Fender (see Frame chapter) Radiator Cover (see Frame chapter) Radiator Screen Mounting Screws [A] Radiator Screen [B] (With the Shroud [C]) • Remove: Radiator Hoses [A] Radiator Fan Wire Connector [B] Radiator Fan Switch Connectors [C] • Remove: Radiator Mounting Bolts [A] Radiator [B] CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency. 4-14 COOLING SYSTEM Radiator Radiator Fan Removal • Remove: Radiator (see Radiator Removal) Radiator Fan Assembly Bolts [A] Fan Assembly [B] • Remove: Radiator Fan Mounting Nut [A] Radiator Fan [B] NOTE When removing and installing the fun motor tube [A], do not crush the tube. Radiator Fan Installation • Install: Radiator Fan • Radiator Fan Assembly Tighten: Torque - Radiator Fan Assembly Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) COOLING SYSTEM 4-15 Radiator Radiator Inspection the radiator core. • Check If there are obstructions to air flow, remove the radiator and remove obstructions. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one. Radiator Cleaning to the Cooling System in the Periodic Maintenance • Refer chapter. Radiator Cap Inspection the condition of the top and bottom valve seals of • Check the radiator cap. If any one of them shows visible damage, replace the cap. Bottom Valve Seal [A] Top Valve Seal [B] Valve Spring [C] • Install the cap [A] on a cooling system pressure tester [B]. NOTE Wet the cap sealing surfaces with water or coolant to prevent pressure leakage. the pressure gauge, slowly pump the pressure • Watching tester to build up the pressure. The relief valve opens, indicated by the gauge hand flicks downward. The relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second. Radiator Cap Relief Pressure Standard: 93 ~ 123 kPa (0.95 ~ 1.25 kgf/cm², 14 ~ 18 psi) If the cap cannot hold the specified pressure, or if it holds too much pressure, replace it with a new one. 4-16 COOLING SYSTEM Thermostat Thermostat Removal the coolant (see Cooling System in Periodic Main• Drain tenance chapter). • Remove: Front Fender (see Frame chapter) Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Installation • Be sure to install the O-ring [A] on the housing cover. the ground wire terminal [A] as shown. • Install Tighten: • Torque - Thermostat Housing Cover Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) coolant (see Cooling System in Periodic Mainte• Add nance chapter). Thermostat Inspection the thermostat, and inspect the thermostat valve • Remove [A] at room temperature. If the valve is open, replace the valve with a new one. COOLING SYSTEM 4-17 Thermostat check valve opening temperature, suspend the ther• To mostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth. NOTE The thermostat must be completely submerged and the thermostat and thermometer must not touch the container sides or bottom. raise the temperature of the water while stirring • Gradually the water gently for even temperature. If the measurement is out of the range, replace the thermostat. Thermostat Valve Opening Temperature 69.5 ~ 72.5 C (157 ~ 162 F) 4-18 COOLING SYSTEM Radiator Fan Switch Radiator Fan Switch Removal CAUTION The fan switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it. the coolant (see Cooling System in Periodic Main• Drain tenance chapter). the fan switch leads [A]. • Disconnect • Remove the radiator fan switch [B]. Radiator Fan Switch Installation • Tighten: Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb) the coolant (see Cooling System in Periodic Mainte• Fill nance chapter). Radiator Fan Switch Inspection • Refer to the Electrical System chapter. COOLING SYSTEM 4-19 Coolant Temperature Warning Light Switch Coolant Temperature Warning Light Switch Removal CAUTION The coolant temperature warning light switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it. the coolant (see Cooling System in Periodic Main• Drain tenance chapter). the switch lead [A]. • Disconnect Remove the switch [B]. • Coolant Temperature Warning Light Switch Installation silicone sealant to the threads of the switch and • Apply tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 Torque - Coolant Temperature Warning Light Switch: 7.8 N·m (0.80 kgf·m, 69 in·lb) the coolant (see Cooling System in Periodic Mainte• Fill nance chapter). Coolant Temperature Warning Light Switch Inspection • Refer to the Electrical System chapter. 4-20 COOLING SYSTEM Coolant Filter/Valve Coolant Filter Cleaning to the Cooling System in the Periodic Maintenance • Refer chapter. Coolant Valve Inspection the coolant (see Cooling System in Periodic Main• Drain tenance chapter). the coolant valve [A] on the engine left side. • Remove Inspect the valve at room temperature. • If the valve iscoolant closed, replace the valve with a new one. To check valve opening just blow through the valve. Valve Closing Temperature (for reference) Standard: 80 C (176 F) or more at 24.5 kPa (0.25 kgf/cm², 3.6 psi) ENGINE TOP END 5-1 Engine Top End TABLE OF CONTENTS Exploded View.................................... Specifications ..................................... Special Tools and Sealant .................. Camshaft Chain Tensioner ................. Camshaft Chain Tensioner Removal ..................................... Camshaft Chain Tensioner Installation .................................. Rocker Case....................................... Rocker Case Removal .................. Rocker Case Installation ............... Rocker Arm Removal.................... Rocker Arm Installation................. Rocker Arm Inspection.................. Rocker Shaft Diameter Measurement ............................. Camshaft ............................................ Camshaft Removal ....................... Camshaft Installation .................... Camshaft Assembly ...................... Cam Wear..................................... Camshaft Bearing Wear................ KACR Inspection........................... KACR Removal............................. KACR Installation.......................... Camshaft Chain Removal ............. Camshaft Chain Installation .......... Cylinder Head..................................... Cylinder Compression Measurement ............................. Cylinder Head Removal ................ Cylinder Head Installation ............. 5- 2 5- 8 5-10 5-12 5-12 5-12 5-13 5-13 5-14 5-15 5-15 5-16 5-16 5-17 5-17 5-17 5-18 5-18 5-19 5-20 5-20 5-21 5-21 5-22 5-27 5-27 5-28 5-28 Cylinder Head Cleaning ................ Cylinder Head Warp...................... Valves ................................................. Valve Clearance Inspection .......... Valve Clearance Adjustment......... Valve Removal .............................. Valve Installation ........................... Valve Guide Removal ................... Valve Guide Installation ................ Valve-to-Guide Clearance Measurement ............................. Valve Seat Inspection ................... Valve Seat Repair (Valve Lapping) Cylinder and Piston ............................ Cylinder Removal.......................... Piston Removal............................. Cylinder, Piston Installation........... Cylinder Wear ............................... Piston Wear .................................. Piston/Cylinder Clearance ............ Piston Ring, Piston Ring Groove Wear........................................... Piston Ring Groove Width............. Piston Ring Thickness ................. Piston Ring End Gap .................... Exhaust System.................................. Spark Arrester Cleaning................ Muffler and Exhaust Pipe Removal ..................................... Muffler and Exhaust Pipe Installation .................................. Exhaust System Inspection........... 5-28 5-29 5-30 5-30 5-30 5-30 5-30 5-31 5-31 5-31 5-32 5-32 5-37 5-37 5-37 5-37 5-39 5-40 5-40 5-40 5-40 5-41 5-41 5-42 5-42 5-42 5-43 5-43 5 5-2 ENGINE TOP END Exploded View ENGINE TOP END 5-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Rocker Case Bolts 55 mm (2.2 in.) 8.8 0.90 78 in·lb S 2 Rocker Case Bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb S 3 Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb 4 Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb S 5 Cylinder Head Bolts (M10), First Torque 25 2.5 18 S,MO 5 Cylinder Head Bolts (M10), Final Torque 49 5.0 36 S 6 Cylinder Head Bolts (M6) 9.8 1.0 87 in·lb 7 Cylinder Head Jacket Plugs 20 2.0 14 8 Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb 9 Valve Adjusting Screw Locknuts 12 1.2 104 in·lb 10 Rocker Shaft Bolts 8.8 0.90 78 in·lb 11 Water Pipe Bolts 9.8 1.0 87 in·lb G: Apply grease for oil seal and O-ring. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. SS: Apply silicone sealant (Kawasaki Bond: 56019–120) S: Follow the specific tightening sequence. 5-4 ENGINE TOP END Exploded View ENGINE TOP END 5-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb 2 Chain Tensioner Cap Bolt 22 2.2 16 3 Intermediate Shaft Sprocket Nut 44 4.5 33 4 Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb 5 Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb 6 Camshaft Sprocket Bolts 12 1.2 104 in·lb 7 Position Plate Bolts 8.8 0.90 78 in·lb 8 Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb 9 Cylinder Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb 10 Front Cylinder Camshaft Chain Guide Bolt 20 2.0 14 11 Rear Cylinder Camshaft Chain Guide Bolt 20 2.0 14 12. Clamp G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. O: Apply engine oil. MO: Apply molybdenum disulfide oil. R: Replacement parts Remarks L 5-6 ENGINE TOP END Exploded View ENGINE TOP END 5-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb 2 Muffler Cover Bolts 8.8 0.90 78 in·lb 3 Muffler Mounting Bolts 20 2.0 14 4 Exhaust Pipe Clamp Bolt 8.8 0.90 78 in·lb R: Replacement parts Remarks 5-8 ENGINE TOP END Specifications Item Rocker Case: Rocker arm inside diameter Rocker shaft diameter Camshafts: Cam height: Exhaust Inlet Camshaft bearing clearance: f18 f22 Camshaft journal diameter: f18 f22 Camshaft bearing inside diameter: f18 f22 Camshaft runout KACR (Kawasaki Automatic Compression Release): KACR operating engine speed Cylinder Head: Cylinder compression (usable range) Electric starter Cylinder head warp Valve: Valve clearance: Exhaust Inlet Valve head thickness: Exhaust Inlet Valve stem bend Valve stem diameter: Exhaust Inlet Valve guide inside diameter: Exhaust Inlet Standard Service Limit 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in.) 12.05 mm (0.474 in.) 11.973 ~ 11.984 mm (0.4714 ~ 0.4718 in.) 11.95 mm (0.470 in.) 35.363 ~ 35.477 mm (1.3932 ~ 1.3967 in.) 35.26 mm (1.388 in.) 35.622 ~ 35.736 mm (1.4024 ~ 1.4069 in.) 35.52 mm (1.398 in.) 0.016 ~ 0.052 mm (0.0006 ~ 0.0020 in.) 0.020 ~ 0.062 mm (0.0008 ~ 0.0024 in.) 0.14 mm (0.0055 in) 0.15 mm (0.0059 in.) 17.966 ~ 17.984 mm (0.7073 ~ 0.7080 in.) 17.94 mm (0.706 in.) 21.959 ~ 21.980 mm (0.8645 ~ 0.8653 in.) 21.93 mm (0.863 in.) 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in.) 18.08 mm (0.712 in.) 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in.) 22.08 mm (0.870 in.) TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.0039 in.) 760 ± 30 r/min (rpm) – – – 290 ~ 520 kPa (3.0 ~ 5.3 kgf/cm², 43 ~ 75 psi) @ 290 r/min (rpm) ––– – – – 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) 0.8 mm (0.031 in.) 0.5 mm (0.020 in.) ––– 0.05 mm (0.002 in.) – – – – – – 0.5 mm (0.020 in.) 0.3 mm (0.012 in.) TIR 0.05 mm (0.002 in.) 4.955 ~ 4.970 mm (0.1951 ~ 0.1957 in.) 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in.) 4.94 mm (0.1945 in.) 4.96 mm (0.1953 in.) 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) 5.08 mm (0.20 in.) 5.08 mm (0.20 in.) ENGINE TOP END 5-9 Specifications Item Valve/valve guide clearance (wobble method): Exhaust Inlet Valve seat cutting angle Valve seating surface: Outside diameter: Exhaust Inlet Width: Exhaust Inlet Valve spring free length: Exhaust Inlet Cylinder, Piston: Cylinder inside diameter Piston diameter Piston/cylinder clearance Piston ring/groove clearance: Top Second Piston ring groove width: Top Second Piston ring thickness: Top Second Piston ring end gap: Top Second Oil Standard 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in.) 0.03 ~ 0.11 mm (0.0012 ~ 0.0043 in.) 45 , 32 , 60 Service Limit 0.34 mm (0.0133 in.) 0.28 mm (0.0110 in.) – – – 25.2 ~ 25.4 mm (0.992 ~ 1.000 in.) 29.4 ~ 29.6 mm (1.157 ~ 1.165 in.) – – – – – – 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.) 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.) – – – – – – 41.3 mm (1.626 in.) 41.3 mm (1.626 in.) 39.5 mm (1.555 in.) 39.5 mm (1.555 in.) 81.994 ~ 82.006 mm (3.2281 ~ 3.2286 in.) 82.09 mm (3.232 in.) 81.949 ~ 81.964 mm (3.2263 ~ 3.2269 in.) 81.80 mm (3.220 in.) 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in.) – – – 0.040 ~ 0.080 mm (0.0016 ~ 0.0032 in.) 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in.) 0.18 mm (0.0071 in.) 0.17 mm (0.0067 in.) 1.030 ~ 1.050 mm (0.0405 ~ 0.0413 in.) 1.020 ~ 1.040 mm (0.0402 ~ 0.0409 in.) 1.13 mm (0.0445 in.) 1.12 mm (0.0441 in.) 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.) 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.) 0.9 mm (0.035 in.) 0.9 mm (0.035 in.) 0.20 ~ 0.30 mm (0.0079 ~ 0.0118 in.) 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in.) 0.60 mm (0.0236 in.) 0.75 mm (0.0295 in.) 1.00 mm (0.0394 in.) 5-10 ENGINE TOP END Special Tools and Sealant Outside Circlip Pliers : 57001–144 Valve Seat Cutter, 32 – f28 : 57001–1119 Compression Gauge : 57001–221 Valve Seat Cutter, 60 – f30 : 57001–1123 Valve Spring Compressor Assembly : 57001–241 Valve Seat Cutter Holder Bar : 57001–1128 Piston Pin Puller Assembly : 57001–910 Valve Seat Cutter, 45 – f30 : 57001–1187 Valve Seat Cutter, 45 – f27.5 : 57001–1114 Valve Seat Cutter, 32 – f33 : 57001–1199 ENGINE TOP END 5-11 Special Tools and Sealant Valve Spring Compressor Adapter, f22 : 57001–1202 Piston Pin Puller Adapter : 57001–1211 Valve Guide Arbor, f5 : 57001–1203 Filter Cap Driver: 57001–1454 Valve Guide Reamer, f5 : 57001–1204 Compression Gauge Adapter, M10 × 1.0 : 57001–1486 Valve Seat Cutter Holder, f5 : 57001–1208 Kawasaki Bond (Silicone Sealant) : 56019–120 5-12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only partway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in “Camshaft Chain Tensioner Installation”. Do not turn over the crankshaft while the tensioner is removed. This could upset the cam chain timing, and damage the valves. • Remove: Cap Bolt [A] and Washer Pin and Spring • Remove: Tensioner Mounting Bolts [A] Camshaft Chain Tensioner [B] Camshaft Chain Tensioner Installation the stopper [A] to release the ratchet and push the • Push push rod [B] into the tensioner body. • Tighten: Torque - Chain Tensioner Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Pin [A] and Spring [B] • Washer [C] and Chain Tensioner Cap Bolt [D] Tighten: Torque - Chain Tensioner Cap Bolt: 22 N·m (2.2 kgf·m, 16 ft·lb) ENGINE TOP END 5-13 Rocker Case Rocker Case Removal Front Rocker Case: Remove: Air Cleaner Cover (see Frame chapter) Front Fender (see Frame chapter) Side Inner Cover (see Frame chapter) Timing Inspection Plug [A] Valve Adjusting Caps Converter Intake Duct, Exhaust Duct (see Converter System) • Special Tool - Filler Cap Driver: 57001–1454 a wrench on the alternator bolt, turn the crankshaft • Using counterclockwise until “T-F” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rocker arms: the end of the compression stroke. CAUTION Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case. The rocker arms could bend the valves. • Remove: Front Camshaft Chain Tensioner (see Camshaft Chain • • • Tensioner Removal) Rocker Case Bolts [A] Front Rocker Case [B] Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame. Rear Rocker Case: Remove: Front Rocker Case (see this section) Converter Exhaust Joint Duct Using a wrench on the alternator bolt, turn the crankshaft counterclockwise (270 ) until “T-R” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rocker arms: the end of the compression stroke. CAUTION Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case. The rocker arms could bend the valves. 5-14 ENGINE TOP END Rocker Case • Remove: Rear Camshaft Chain Tensioner (see Camshaft Chain • Tensioner Removal) Rocker Case Bolts [A] Rear Rocker Case [B] Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame. Rocker Case Installation the rear camshaft and then the front camshaft (see • Install Camshaft Installation in this chapter). that the crankshaft is positioned at TDC and at the • Check end of the compression stroke. CAUTION Be sure to position the crankshaft is at TDC of the end of the compression stroke. The rocker arms could bend the valves. silicone sealant to the outer surface of the cap [A] • Apply and the cylinder head upper surface [B] as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 the rocker case bolts following the tightening se• Tighten quence shown. Torque - Rocker Case Bolts [1 ~ 4, L=55 mm (2.2 in.) with washers]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Rocker Case Bolts [5 ~ 6, L=130 mm (5.1 in.)]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Rocker Case Bolts [A] [L=30 mm (1.2 in.), L=25 mm (1.0 in.)]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Check the valve clearance and adjust it if necessary. ENGINE TOP END 5-15 Rocker Case grease to the O-ring [A]. • Apply Tighten: • Torque - Valve Adjusting Cap Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Rocker Arm Removal • Remove: Rocker Case Rocker Shaft Bolts [A] (see Rocker Case Removal) Rocker Shaft [B] Washers Mark and record the rocker arm location so it can be installed in the original position. The rocker arms come off with the rocker shafts. Rocker Arm Installation molybdenum disulfide oil: • Apply Rocker Shaft [A] • • • Hole in Rocker Arm [B] Apply grease to the O-rings [C]. Install: Wave Washers [D] (as shown) Rocker Arms (as shown) Rocker Shafts and O-rings Tighten: Torque - Rocker Shaft Bolts [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb) 5-16 ENGINE TOP END Rocker Case Rocker Arm Inspection the area [A] on the rocker arm where the cam • Inspect rubs. • • If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes. Inspect the end of the valve clearance adjusting screws [B] where it contacts the valve stem. If the end of the adjusting screw is mushroomed or damaged in any way, or if the screw will not turn smoothly, replace it. Also inspect the end of the valve stem. Measure the inside diameter [C] of the rocker arm with a dial bore gauge. If the rocker arm inside diameter is larger than the service limit, replace it. Also check the rocker shaft diameter (see Rocker Shaft Diameter Measurement). Rocker Arm Inside Diameter Standard: 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in.) Service Limit: 12.05 mm (0.474 in.) Rocker Shaft Diameter Measurement the diameter [A] of the rocker shaft where the • Measure rocker arm pivots on it with a micrometer. If the rocker shaft diameter is smaller than the service limit, replace it. Also check the rocker arm inside diameter (see Rocker Arm Inspection). Rocker Shaft Diameter Standard: 11.973 ~ 11.984 mm (0.4714 ~ 0.4718 in.) Service Limit: 11.95 mm (0.470 in.) ENGINE TOP END 5-17 Camshaft Camshaft Removal • Remove: Both Camshaft Chain Tensioners (see Camshaft Chain • Tensioner Removal) Both Rocker Cases (see Rocker Case Removal) Both Camshafts [A] Support the chain using a suitable tool. Camshaft Installation a wrench on the alternator bolt, turn the crankshaft • Using clockwise until “T-R” mark [A] is aligned with the notch [B] in the inspection window. rear camshaft [A] has a groove [B]. • The First, • install the rear camshaft. the arrow [A] of the rear camshaft sprocket upward • Face (left side view). the rear camshaft chain with the rear camshaft • Engage sprocket. the marks [B] on the weights with the rear cylinder • Align head upper surface. 5-18 ENGINE TOP END Camshaft a wrench on the alternator bolt, turn the crankshaft • Using clockwise 270 . Align the “T-F” mark [A] with the notch [B] in the inspection window. the arrow [A] of the front camshaft sprocket upward • Face (right side view). the front camshaft chain with the front camshaft • Engage sprocket. the marks [B] on the weights with the front cylinder • Align head upper surface. • Install: Rocker Cases (see Rocker Case Installation) • Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation) Check the valve clearance (see Valve Clearance Inspection). Camshaft Assembly the KACR unit [A] (sprocket) on the camshaft so • Install that the unit fits onto the camshaft pins [B]. a non-permanent locking agent to the camshaft • Apply sprocket bolts [C]. • Tighten: Torque - Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Cam Wear the camshaft. • Remove Measure height [A] of the cam with a micrometer. • If the camstheare worn past the service limit, replace the camshaft. Cam Height Exhaust Inlet Standard 35.363 ~ 35.477 mm (1.3932 ~ 1.3967 in.) 35.622 ~ 35.736 mm (1.4024 ~ 1.4069 in.) Service Limit 35.26 mm (1.388 in.) 35.52 mm (1.398 in.) ENGINE TOP END 5-19 Camshaft Camshaft Bearing Wear • • The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be measured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case. Install the rocker case, tightening the bolts in the correct sequence to the specified torque (see Rocker Case Installation). NOTE Do not turn the camshaft when the plastigage is between the journal and rocker case. the rocker case and measure the plastigage • Remove width [A] to determine the clearance between the journal and the rocker case. Measure the widest portion of the plastigage. Camshaft Bearing Clearance (f18) Standard: 0.016 ~ 0.052 mm (0.0006 ~ 0.0020 in.) Service Limit: 0.14 mm (0.0055 in.) Camshaft Bearing Clearance (f22) Standard: 0.020 ~ 0.062 mm (0.0008 ~ 0.0024 in.) Service Limit: 0.15 mm (0.0059 in.) If any clearance exceeds the service limit, measure the diameter of the camshaft journal. Camshaft Journal Diameter (f18) Standard: 17.966 ~ 17.984 mm (0.7073 ~ 0.7080 in.) Service Limit: 17.94 mm (0.706 in.) Camshaft Journal Diameter (f22) Standard: 21.959 ~ 21.980 mm (0.8645 ~ 0.8653 in.) Service Limit: 21.93 mm (0.863 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. If the clearance still remains out of the limit, replace the cylinder head and the rocker case. CAUTION The cylinder head and rocker case are machined as a set, and must be replaced as a set. 5-20 ENGINE TOP END Camshaft KACR Inspection The Kawasaki Automatic Compression Release (KACR) momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting. Due to the simplicity of the mechanism, no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism [A]: compression is not released during starting, and compression is released during running. (1) If compression is not released during starting, the weights are not returning to their rest position. Remove the camshaft (see Camshaft Removal). Remove the KACR unit. Visually inspect the spring. If damaged, deformed, or missing, replace the spring. Remove the spring and move the weights back and forth. If the weights do not move smoothly, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary. [A] Rest Position (compression is released) [B] Weights [C] Spring • • • • (2) If compression is released while the engine is running, the weights are not swinging out. Remove the spring and move the weights back and forth. If the weights do not move easily from the retracted position, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary. [A] Running Position (compression is not released) [B] Weights [C] Spring • KACR Removal • Remove: Camshaft (see Camshaft Removal) Camshaft Sprocket Bolts [A] KACR Unit [B] ENGINE TOP END 5-21 Camshaft • Remove: Circlips [A] Weights [B] Spring [C] NOTE Do not remove the shaft [A] and pin [B]. If the parts are removed, they cannot be reinstalled. KACR Installation • Install: Weights • • • Circlips Spring [A] Hook the spring from the outside with the open side of the hook inwards. Install: KACR Unit Hook the arms [B] on the pins. Apply a non-permanent locking agent to the camshaft sprocket bolts [C] and tighten them. Torque - Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Camshaft Chain Removal (left side view): • Remove Rear and Front Camshafts (see Camshaft Removal) Alternator Rotor (see Electrical System chapter) Oil Pump (see Engine Lubrication System chapter) Intermediate Shaft Chain Tensioner [A] Circlip [B] and Washer Special Tool - Outside Circlip Pliers: 57001–144 • Remove: Intermediate Shaft Chain Guides [C] Position Plate Bolts [D] and Position Plate 5-22 ENGINE TOP END Camshaft (right side view): • Remove Torque Converter (see Converter System chapter) • Using a M6 bolt [A], pull out the cover [B]. • Using an Allen wrench, hold the intermediate shaft [A]. (left side view): • Remove Intermediate Shaft Sprocket Nut [A] Intermediate Shaft Sprocket [B] Intermediate Shaft Drive Chain [C] Rear Camshaft Chain [D] Front Camshaft Chain Camshaft Chain Installation Rear Camshaft Chain: Align the key groove [A] on the crankshaft with the embossed line [B] on the crankcase (left side view). • ENGINE TOP END 5-23 Camshaft the arrow [A] of the rear camshaft sprocket upward. • Face Align marks [B] on the weights with the rear cylinder • head the upper surface [C]. Place the rear camshaft chain [D] onto the rear camshaft • sprocket. the camshaft and intermediate shaft chains on • Engage the intermediate shaft sprocket [A] (left side view). the punch mark [B] on the intermediate shaft • Align sprocket with the embossed mark [C] on the crankcase. the intermediate shaft and align the punch mark [A] • Install on the intermediate shaft with the punch mark [B] on the intermediate sprocket nut. an Allen wrench, hold the intermediate shaft. • Using Tighten: • Torque - Intermediate Shaft Sprocket Nut [A]: 44 N·m (4.5 kgf·m, 33 ft·lb) 5-24 ENGINE TOP END Camshaft Front Camshaft Chain: Rotate the crankshaft clockwise 270 . Align the key groove [A] on the crankshaft with the embossed line [B] on the crankcase. • • the intermediate shaft [A] to the right side of the • Move engine. the front camshaft chain [B] with the sprocket on • Engage the intermediate shaft. (left side view): • Install Position Plate [A] • Tighten: Torque - Position Plate Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Intermediate Shaft Chain Guide [A] (front) • Tighten: Torque - Intermediate Shaft Chain Guide Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) ENGINE TOP END 5-25 Camshaft • Install: Intermediate Shaft Chain Guide [A] (Rear) Washer [B] Circlip [C] Special Tool - Outside Circlip Pliers: 57001–144 the intermediate shaft chain tensioner [A] as fol• Install lows: the stopper [B] and push the push rod [C] into • Release the tensioner body. • Insert a wire [D] into the rod hole to hold the rod in place. • Install: Intermediate Shaft Chain Tensioner [A] Tighten: • Torque - Intermediate Shaft Chain Tensioner Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Remove the wire [C] to free the push rod. that the punch mark [A] on the intermediate shaft • Confirm sprocket (Right Side) is aligned with the embossed mark [B] on the crankcase. 5-26 ENGINE TOP END Camshaft the arrow mark [A] upward. • Face Align the [B] on the weights with the front cylinder • head uppermarks surface [C]. Place the front camshaft chain on the front camshaft • sprocket. grease to the O-ring [A] and install the cover [B] into • Apply the right side of the crankcase so that the tapped hole [C] faces outward. • Install: Both Rocker Cases (see Rocker Case Installation) • Both Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation) Check the valve clearances (see Valve Clearance Inspection). ENGINE TOP END 5-27 Cylinder Head Cylinder Compression Measurement NOTE Use the battery which is fully charged. up the engine thoroughly, and stop the engine. • Warm Remove spark plug (see Electrical System chapter). • Attach thethecompression • into the spark plug hole.gauge [A] and adapter [B] firmly Special Tools - Compression Gauge: 57001-221 Compression Gauge Adapter, M10 × 1.0: 57001-1486 the throttle wide open and crank the engine with the • Hold electric starter or the recoil starter several times. When the gauge stops rising, stop cranking and read the gauge. Cylinder Compression (Usable Range) Electric Starter: 290 ~ 520 kPa (3.0 ~ 5.3 kgf/cm², 43 ~ 75 psi) @290 r/min (rpm) The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Cylinder compression is higher than usable range Diagnosis Remedy (Action) Carbon accumulation on piston, cylinder Remove the carbon deposits head, and in combustion chamber possibly and replace damaged parts if due to damaged valve stem oil seal and/or necessary. damaged piston oil rings (This may be indicated by white exhaust smoke). Incorrect cylinder head gasket thickness. Cylinder compression is lower than usable range Replace the gasket with a standard part. Damaged or missing compression release Replace the spring. cam spring Compression release weights do not Replace the compression release move smoothly. unit. Gas leakage around cylinder head Replace damaged gasket and check cylinder head warp. Bad condition of valve seating Repair if necessary. Incorrect valve clearance. Adjust the valve clearance. Incorrect piston/cylinder clearance Piston Replace the piston and/or seizure. cylinder Inspect the cylinder and liner and replace/repair the cylinder and/or piston as necessary. Bad condition of piston ring and/or piston ring grooves Compression release weights do not move smoothly Replace the piston and/or the piston rings. Replace the compression release unit 5-28 ENGINE TOP END Cylinder Head Cylinder Head Removal the coolant (see Cooling System chapter). • Drain Remove: • Carburetor (see Fuel System chapter) Exhaust Pipe (see Exhaust Pipe Removal) Water Pipe [A] Spark Plug Cap [B] Rocker Case [C] Camshaft (see Camshaft Removal) Exhaust Pipe (see Exhaust System) • Remove: Cylinder Head Bolt (M6) [A] Cylinder Head Bolts (M10) [B] and Washers Cylinder Head [C] and Gasket Lift the cylinder head to clear the dowel pins in the cylinder, and slide the cylinder head out of the frame. Cylinder Head Installation • Install: Dowel Pins [A] • New Cylinder Head Gasket [B] Oil Pipe [C] Camshaft Chain Guides [D] Tighten: Torque - Front Cylinder Camshaft Chain Guide Bolt: 20 N·m (2.0 kgf·m, 14 ft·lb) molybdenum disulfide oil to the threads and seating • Apply surface of the cylinder head bolts and both sides of the • washers. Tighten the cylinder head bolts following the tightening sequence as shown. First Torque - Cylinder Head Bolts (M10) [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) Final Torque - Cylinder Head Bolts (M10) [A]: 49 N·m (5.0 kgf·m, 36 ft·lb) • Tighten the cylinder head bolts (M6). Torque - Cylinder Head Bolts (M6) [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Cylinder Head Cleaning the cylinder head (see Cylinder Head Removal). • Remove Scrape the out of the combustion chamber and • exhaust portcarbon with a suitable tool. Wash the head with a high flash-point solvent. • Blow out any particles which may obstruct the oil passage • in the cylinder head using compressed air. ENGINE TOP END 5-29 Cylinder Head Cylinder Head Warp the cylinder head (see Cylinder Head Cleaning). • Clean Lay a straightedge across the lower surface of the cylinder • head. a thickness gauge [A] to measure the space between • Use the straightedge [B] and the head at several locations. Cylinder Head Warp Service Limit: 0.05 mm (0.002 in.) If the cylinder head is warped more than the service limit, replace it. If the cylinder head is warped less than the service limit, repair the head by lapping the lower surface with emery paper secured to a surface plate (first No. 200, then No. 400). 5-30 ENGINE TOP END Valves Valve Clearance Inspection to the Engine Top End in the Periodic Maintenance • Refer chapter. Valve Clearance Adjustment to the Engine Top End in the Periodic Maintenance • Refer chapter. Valve Removal the cylinder head (see Cylinder Head Removal). • Remove Mark and record the valve location so it can be installed • in the original position. Using the valve spring compressor assembly, remove the valve. Special Tools - Valve Spring Compressor Assembly: 57001–241 [A] Valve Spring Compressor Adapter, f22: 57001–1202 [B] Valve Installation the valve stem oil seal. • Replace If a new valve is to be used, check the valve-to-guide • • • clearance (see this chapter). If there is too little clearance, ream the valve guide (see Valve Guide Installation). If there is too much clearance, install a new valve guide (see Valve Guide Removal and Valve Guide Installation). Check the valve seat (see Valve Seat Inspection). Apply a thin coat of molybdenum disulfide grease to the valve stem. Install each spring so that the closed coil end faces downwards. The green paint on the spring faces upwards. Valve Stem [A] Oil Seal [B] Spring Seat [C] Spring [D] Retainer [E] Split Keepers [F] Closed Coil End [G] ENGINE TOP END 5-31 Valves Valve Guide Removal • Remove: Valve (see Valve Removal) • Valve Stem Oil Seal Hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Special Tool - Valve Guide Arbor, f5 : 57001-1203 Valve Guide Installation oil the valve guide outer surface. • Lightly Using the valve guide arbor, drive the valve guide until its • flange touches the cylinder head. Special Tool - Valve Guide Arbor, f5 : 57001–1203 the valve guide with the valve guide reamer [A] , if • Ream may be necessary to ream the guide even if the old guide is reused. Special Tool - Valve Guide Reamer, f5 : 57001-1204 Valve-to-Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Move [C] the stem back and forth to measure valve/valve guide clearance. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide. • • • NOTE The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard Service Limit Exhaust: 0.09 ~ 0.17 mm 0.34 mm (0.0035 ~ 0.0067 in.) (0.0133 in.) Inlet: 0.03 ~ 0.11 mm 0.28 mm (0.0012 ~ 0.0043 in.) (0.0110 in.) 5-32 ENGINE TOP END Valves Valve Seat Inspection the valve (see Valve Removal). • Remove Check the valve seating surface [A] between the valve [B] • and valve seat [C]. • Coat the valve seat with machinist’s dye. Push the valve into the guide. Rotate the valve against the seat with a lapping tool. Pull the valve out, and check the seating pattern on the valve head. It must be the correct width and even all the way around. Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter of the valve seating pattern is too large or too small, repair the seat (see Valve Seat Repair). Valve Seating Surface Outside Diameter Exhaust: 25.2 ~ 25.4 mm (0.992 ~ 1.000 in.) Inlet: 29.4 ~ 29.5 mm (1.157 ~ 1.165 in.) NOTE The valve stem and guide must be in good condition, or this check will not be valid. • If the valve seating pattern is not correct, repair the seat (see Valve Seat Repair). Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with vernier calipers. If the width is too wide, too narrow or uneven, repair the seat (see Valve Seat Repair). [F] Good [G] Too Wide [H] Too Narrow [J] Uneven Valve Seating Surface Width Exhaust: 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.) Inlet: 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.) Valve Seat Repair (Valve Lapping) • Using the valve seat cutters [A], repair the valve seat. Special Tools - Valve Seat Cutters: Exhaust Valves: Valve Seat Cutter, 45 - f27.5: 57001-1114 Valve Seat Cutter, 32 - f28: 57001-1119 Valve Seat Cutter, 60 - f30: 57001-1123 Inlet Valves: Valve Seat Cutter, 45 - f30: 57001-1187 Valve Seat Cutter, 32 - f33: 57001-1199 Valve Seat Cutter, 60 - f30: 57001-1123 Holder & Bar: Valve Seat Cutter Holder, f5: 57001-1208 [B] Valve Seat Cutter Holder Bar: 57001-1128 [C] If the manufacturer’s instructions are not available, use the following procedure. ENGINE TOP END 5-33 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve seat for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil. NOTE Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles. 4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion. NOTE Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil. 5. After use, wash it with washing oil and apply thin layer of engine oil before storing. Marks Stamped on the Cutter: The marks stamped on the back of the cutter [A] represent the following. 60 ........................... Cutter angle [B] 37.5f ........................ Outer diameter of cutter [C] Operating Procedures: Clean the seat area carefully. Coat the seat with machinist’s dye. Fit a 45 cutter into the holder and slide it into the valve guide. Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. • • • • CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. 5-34 ENGINE TOP END Valves Widened Width [A] of engagement by machining with 45 cutter Ground Volume [B] by 32 cutter 32 [C] Correct Width [D] Ground Volume [E] by 60 cutter 60 [F] the outside diameter of the seating surface with • Measure vernier calipers. If the outside diameter of the seating surface is too small, repeat the 45 grind [A] until the diameter is within the specified range. Original Seating Surface [B] NOTE Remove all pittings of flaws from 45 ground surface. After grinding with 45 cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface distinct and 32 and 60 grinding operation easier. When the valve guide is replaced, be sure to grind with 45 cutter for centering and good contact. If the outside diameter [A] of the seating surface is too large, make the 32 grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. Grind the seat at a 32 angle [B] until the seat O.D. is within the specified range. To make the 32 grind, fit a 32 cutter into the holder, and slide it into the valve guide. Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. • CAUTION The 32 cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. • After making the 32 grind, return to the seat O.D. measurement step above. To measure the seat width, use vernier calipers to measure the width of the 45 angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45 grind until the seat is slightly too wide, and then return to the seat O.D. measurement step above. ENGINE TOP END 5-35 Valves • If the seat width is too wide, make the 60 [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60 angle until the seat width is within the specified range. To make the 60 grind, fit 60 cutter into the holder, and slide it into the valve guide. Turn the holder, while pressing down lightly. After making the 60 grind, return to the seat width measurement step above. Correct Width [B] the valve to the seat, once the seat width and O.D. • Lap are within the ranges specified above. • • • Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. Repeat the process with a fine grinding compound. [A] Lubber [B] Valve Seat [C] Valve The seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. Be sure to remove all grinding compound before assembly. When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment). 5-36 ENGINE TOP END Valves ENGINE TOP END 5-37 Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Oil Pipe [A] Chain Guide [B] Cylinder Bolts [C] Cylinder [D] Cylinder Base Gasket Piston Removal the cylinder block (see Cylinder Removal). • Remove Place a piece of clean cloth under the piston and remove • the piston pin snap rings [A] from the outside of each piston. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. the piston pin puller assembly (special tool), re• Using move the piston pins. Special Tools - Piston Pin Puller Assembly [A]: 57001-910 Piston Pin Puller Adapter [B]: 57001-1211 • Remove the piston. spread the ring opening with your thumbs and • Carefully then push up on the opposite side of the ring [A] to remove • it. Remove the 3-piece oil ring with your thumbs in the same manner. Cylinder, Piston Installation NOTE If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston rings. 5-38 ENGINE TOP END Cylinder and Piston NOTE The oil ring rails have no “top” or “bottom”. the oil ring expander [A] in the bottom piston ring • Install groove so the ends [B] butt together. the oil ring steel rails, one above the expander and • Install one below it. Spread the rail with your thumbs, but only enough to fit the rail over the piston. Release the rail into the bottom piston ring groove. not mix up the top ring and second ring. • Do Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces • up. piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 ~ 40 [F] of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Oil Ring Steel Rails [C] Oil Ring Expander [D] F mark [E] must be faced toward Front Side for front and rear pistons Opening Positions [G] a new piston pin snap ring into the side of the piston • Fit so that the ring opening [A] does not coincide with the slit • [B] of the piston pin hole. When installing the piston pin snap ring, compress it only enough to install it and no more. Apply engine oil to the cylinder bore and, piston skirt. ENGINE TOP END 5-39 Cylinder and Piston • Install: Dowel Pins [A] New Cylinder Base Gasket [B] • Install: Cylinder • Clamp [A] (rear only) Tighten: Torque - Cylinder Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Chain Guide [C] Oil Pipe [D] Cylinder Wear there is a difference in cylinder wear in different di• Since rections, take a side-to-side and a front-to-back measurement at each of the three locations (total of six measurements) shown in the figure. If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. 10 mm (0.4 in.) [A] 60 mm (2.4 in.) [B] 20 mm (0.8 in.) [C] Standard: 81.994 ~ 82.006 mm (3.2281 ~ 3.2286 in.), and less than 0.01 mm (0.0004 in.) difference between any two measurements. Service Limit: 82.09 mm (3.232 in.), or more than 0.05 mm (0.0020 in.) difference between any two measurements. 5-40 ENGINE TOP END Cylinder and Piston Piston Wear the outside diameter [A] of each piston 5 mm • Measure (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the piston. Piston Diameter Standard: 81.949 ~ 81.964 mm (3.2263 ~ 3.2269 in.) Service Limit: 81.80 mm (3.220 in.) Piston/Cylinder Clearance the piston diameter from the cylinder inside di• Subtract ameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in.) Piston Ring, Piston Ring Groove Wear for uneven groove wear by inspecting the ring seat• Check ing. • The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard: Top: 0.040 ~ 0.080 mm (0.0016 ~ 0.0032 in.) Second: 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in.) Service Limit: 0.18 mm (0.0071 in.) 0.17 mm (0.0067 in.) If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both. Piston Ring Groove Width the piston ring groove width. • Measure Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard Top: 1.030 ~ 1.050 mm (0.0405 ~ 0.0413 in.) Second: 1.020 ~ 1.040 mm (0.0402 ~ 0.0409 in.) Service Limit 1.13 mm (0.0445 in.) 1.12 mm (0.0441 in.) If the width of any of the two grooves is wider than the service limit at any point, replace the piston. ENGINE TOP END 5-41 Cylinder and Piston Piston Ring Thickness the piston ring thickness. • Measure Use a micrometer to measure at several points around the ring. Piston Ring Thickness Standard Top: 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.) Second: 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.) Service Limit 0.9 mm (0.035 in.) 0.9 mm (0.035 in.) If any of the measurements is less than the service limit on either of the rings, replace all the rings. NOTE When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Piston Ring End Gap the piston ring [A] inside the cylinder, using the pis• Place ton to locate the ring squarely in place. Set it close to the • bottom of the cylinder, where cylinder wear is low. Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap Standard Top: 0.20 ~ 0.30 mm (0.0079 ~ 0.0118 in.) Second: 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.) 0.20 ~ 0.70 mm Oil: (0.0079 ~ 0.0276 in.) Service Limit 0.60 mm (0.0236 in.) 0.75 mm (0.0295 in.) 1.00 mm (0.0394 in.) If the end gap of either ring is greater than the service limit, replace all the rings. 5-42 ENGINE TOP END Exhaust System This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. Spark Arrester Cleaning to the Engine Top End in the Periodic Maintenance • Refer chapter. Muffler and Exhaust Pipe Removal • Remove: Rear Fender (see Frame chapter) Battery and Battery Case (see Electrical System) Left Side Inner Cover Rocker Case Bolts [A] Cable Holder [B] Rear Exhaust Pipe Nuts [A] • Remove: Front Exhaust Pipe Nuts [A] ENGINE TOP END 5-43 Exhaust System • Remove: Muffler Clamp Bolt [A] Muffler Mounting Bolts [B] Muffler [C] and Rear Exhaust Pipe Front Exhaust Pipe [D] Muffler and Exhaust Pipe Installation the exhaust pipe cover [A] or muffler cover [B] were • Ifremoved, tighten them. Torque - Exhaust Pipe Cover Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Muffler Cover Bolts [D]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Exhaust Pipe Clamp Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) the exhaust pipe holder gaskets [E] and clamp • Replace gasket [F] with new ones. (But do not tighten the following nuts and bolts.): • Install Front Exhaust Pipe [G], Clamp [H], Muffler and Nuts • Rear Exhaust Pipe [I] and Nuts Muffler Mounting Bolts [J] Tighten: Exhaust Pipe Holder Nuts evenly Muffler Clamp Bolt Torque - Muffler Mounting Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb) Rocker Case with Cable Holder Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Exhaust System Inspection removing the exhaust system, check for signs of • Before leakage at the exhaust pipe gasket in the cylinder head • • • and at the muffler clamp. If there are signs of leakage around the exhaust pipe gasket, it should be replaced. If the muffler-to-exhaust pipe joint leaks, tighten the clamp. Remove the exhaust pipe and muffler (see Exhaust Pipe and Muffler Removal). Inspect the gasket for damage and signs of leakage. If the gasket is damaged or has been leaking, replace it. Check the exhaust pipe and muffler for dents, cracks, rust and holes. If the exhaust pipe or muffler is damaged or has holes, it should be replaced for best performance and least noise. CONVERTER SYSTEM 6-1 Converter System TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Special Tools ........................................................................................................................... Torque Converter..................................................................................................................... Torque Converter Cover Removal ..................................................................................... Torque Converter Cover Installation .................................................................................. Converter Exhaust Duct Removal...................................................................................... Converter Exhaust Duct Installation................................................................................... Converter Intake Duct Removal......................................................................................... Converter Intake Duct Installation...................................................................................... Drive Belt ................................................................................................................................. Drive Belt Removal ............................................................................................................ Drive Belt Installation ......................................................................................................... Drive Belt Inspection .......................................................................................................... Drive Belt Deflection Inspection ......................................................................................... Drive Belt Deflection Adjustment ....................................................................................... Drive Pulley ............................................................................................................................. Drive Pulley Removal......................................................................................................... Drive Pulley Disassembly .................................................................................................. Drive Pulley Inspection ...................................................................................................... Spider Shoe Side Clearance Adjustment........................................................................... Drive Pulley Assembly ....................................................................................................... Drive Pulley Installation...................................................................................................... Driven Pulley ........................................................................................................................... Driven Pulley Removal....................................................................................................... Driven Pulley Disassembly ................................................................................................ Driven Pulley Inspection .................................................................................................... Driven Pulley Assembly ..................................................................................................... Driven Pulley Installation.................................................................................................... High Altitude Setting Information ............................................................................................. Specifications..................................................................................................................... 6- 2 6- 6 6- 7 6- 8 6- 8 6- 8 6- 9 6- 9 6-10 6-10 6-11 6-11 6-11 6-11 6-11 6-12 6-13 6-13 6-14 6-15 6-17 6-18 6-20 6-21 6-21 6-21 6-22 6-24 6-26 6-27 6-27 6 6-2 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 6-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Drive Pulley Bolt 93 9.5 69 2 Driven Pulley Nut 93 9.5 69 3 Drive Pulley Cover Bolts 13 1.3 113 in·lb 4 Ramp Weight Nuts 6.9 0.70 61 in·lb 5 Spider 275 28 203 G: Apply grease for oil seal and O-ring. Lh: Left-hand Threads M: Apply molybdenum disulfide grease. R: Replacement Parts Remarks Lh, R Lh 6-4 CONVERTER SYSTEM Exploded View CONVERTER SYSTEM 6-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Converter Cover Bolts 8.8 0.90 78 in·lb 2 Joint Duct Bolts 8.8 0.90 78 in·lb G: Apply grease for oil seal and O-ring. S: Follow the specific tightening sequence. Remarks S 6-6 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt: Belt deflection 22 ~ 27 mm (0.87 ~ 1.06 in.) Belt height (Parallel portion) 1.16 ~ 3.48 mm (0.046 ~ 0.137 in.) – – – 0.64 mm (0.0252 in.) Drive Pulley: Cover bushing inside diameter 27.985 ~ 28.085 mm (1.1018 ~ 1.1057 in.) 28.12 mm (1.107 in.) Sheave bushing inside diameter 37.985 ~ 38.085 mm (1.4955 ~ 1.4994 in.) 38.12 mm (1.501 in.) Shoe side clearance 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.) – – – Spring free length 60.4 mm (2.38 in.) – – – Driven Pulley: Sheave bushing inside diameter 40.000 ~ 40.039 mm (1.5748 ~ 1.5763 in.) 40.079 mm (1.5779 in.) Spring free length 99.5 mm (3.92 in.) – – – CONVERTER SYSTEM 6-7 Special Tools Circlip Pliers : 57001–154 Drive Pulley Holder : 57001–1473 Flywheel & Pulley Holder : 57001–1343 Drive Pulley Wrench : 57001–1474 Drive & Driven Pulley Holder : 57001–1412 Spring Holder Set : 57001–1483 Drive Pulley Puller Bolt : 57001–1429 Drive Pulley Holder : 57001–1520 Pulley Holder Attachment : 57001–1472 6-8 CONVERTER SYSTEM Torque Converter WARNING Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death. The pulleys of the belt drive torque converter are precision balanced components designed to operate within certain rpm limits. Disassembly/assembly and servicing procedures of the pulley assemblies must be followed closely. Modifications to the engine or pulleys that increase rpm may cause failure. Torque Converter Cover Removal the ignition switch OFF. • Turn • Remove: Clamp Screw [A] and Clamp [B] Joint Duct [C] • Remove: Torque Converter Cover Bolts [A] Torque Converter Cover [B] Torque Converter Cover Installation the trim seal into the converter cover. • Fit Set trim seal juncture in area [A] when insert trim seal in the cover. 10 mm [B] CONVERTER SYSTEM 6-9 Torque Converter the cover bolts following the tightening sequence • Tighten as shown. Torque - Converter Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Converter Exhaust Duct Removal • Remove: Clamp Screw [A] • Clamp [B] Remove the idle adjuster from the converter exhaust duct. the duct mounting bolt [A] and collar. • Remove Remove the converter exhaust duct. • Converter Exhaust Duct Installation the converter exhaust duct, collar and tighten the • Install duct mounting bolt. the converter exhaust duct [A] in the joint duct [B] • Install as shown. • • • • When installing converter exhaust duct, fit to aligning mark. Converter Exhaust Duct Aligning Mark [C] Joint Duct Aligning Mark [D] When installing joint duct, do not twist and deformation. Install the joint duct to the converter cover. Install the clamp and tighten the clamp screw. Install the idle adjuster to the converter exhaust duct. Adjust the idle speed (see Periodic Maintenance chapter). 6-10 CONVERTER SYSTEM Torque Converter Converter Intake Duct Removal • Remove: Seat and Air Cleaner Cover (see Frame chapter) • Front Fender (see Frame chapter) Remove the duct mounting bolt [A], collar and damper. the converter intake duct [A] from the joint duct • Remove [B]. • Remove the converter intake duct. Converter Intake Duct Installation grease to the O-ring [A]. • Apply Install the joint duct and tighten the joint duct bolts [B]. • Torque - Joint Duct Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) the converter intake duct [A] in the joint duct [B] as • Install shown. • • When installing converter intake duct, fit to aligning mark. Converter Intake Duct Aligning Mark [C] Joint duct Aligning Mark [D] Install the damper and collar. Tighten the duct mounting bolt. CONVERTER SYSTEM 6-11 Drive Belt Drive Belt Removal • Remove the drive pulley [A] (see Drive Pulley Removal). NOTE Before removing the drive belt, observe the direction of the informations [A] (Such as manufacturers name and arrow marks) printed on the belt so that it may be reinstalled on the pulleys as originally. • Lift the drive belt [B] off the driven pulley [C]. Drive Belt Installation NOTE Be sure the printed information faces the same direction so the belt rotates in the same direction as originally installed. When installing a new belt, install it so the printed information [A] can be read from beside the vehicle. is basically the reverse of removal. • Installation Loop the belt over the driven pulley [C]. • Install the drive[B]pulley (see Drive Pulley Installation). • the transmission in neutral, and rotate the driven pul• Put ley to allow the belt to return to the top [A] of the sheaves, before measuring belt deflection. Drive Belt Inspection to the Converter System in the Periodic Mainte• Refer nance chapter. Drive Belt Deflection Inspection to the Converter System in the Periodic Mainte• Refer nance chapter. 6-12 CONVERTER SYSTEM Drive Belt Drive Belt Deflection Adjustment to the Converter System in the Periodic Mainte• Refer nance chapter. CONVERTER SYSTEM 6-13 Drive Pulley Drive Pulley Removal • Remove: Torque Converter Cover (see Torque Converter Cover • • Removal) Be sure to remove the three cover bolts [A] in the positions shown and install the drive pulley holder [B] in the position shown. Note the holder’s relative position to the arrow mark [C]. Tighten the three bolts. Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 113 in·lb) CAUTION Be sure to install three bolts in the specified positions shown. Otherwise, the tapped holes will be damaged. Special Tool - Drive Pulley Holder: 57001–1520 the drive pulley bolt [D] (left-hand threads), hold• Loosen ing the drive pulley with the drive pulley holder. the drive pulley bolt, two washers and the • Remove stepped washer, but do not remove the drive pulley holder yet. NOTE The drive pulley bolt has left-hand threads. Turn the wrench clockwise for loosening. the drive pulley [A] from the crankshaft by screw• Remove ing the drive pulley puller bolt [B] clockwise, while holding the drive pulley with the drive pulley holder [C]. Special Tool - Drive Pulley Puller Bolt: 57001–1429 6-14 CONVERTER SYSTEM Drive Pulley Drive Pulley Disassembly the drive pulley holder [A] and drive & driven pulley • Hold holder [B] in a vise so that the upper surface on the holder is 7 mm (0.28 in.) [C] above the vise. Special Tools - Drive & Driven Pulley Holder: 57001–1412 Drive Pulley Holder: 57001–1473 the pulley onto the pulley holder. • Set Remove: • Drive Pulley Cover Bolts [A] Drive Pulley Cover [B] • Remove: Spring [A] Spacer the drive pulley wrench [A] on the spider [B] and • Put tighten the bolt [C]. Special Tool - Drive Pulley Wrench: 57001–1474 the wrench clockwise and remove the spider with the • Turn movable sheave. NOTE The spider has left-hand threads. clockwise for loosening. Turn the wrench CONVERTER SYSTEM 6-15 Drive Pulley • Remove: Spider [A] Shoes [B] Nuts [C] Ramp Weight Pin [D] Ramp Weight [E] Movable Sheave [F] Fixed Sheave [G] Drive Pulley Inspection If the sheave surfaces [A] appear damaged, replace the sheaves. If the cover bushing is damaged or worn, replace the drive pulley cover. Cover Bushing Inside Diameter [A] Standard: 27.985 ~ 28.085 mm (1.1018 ~ 1.1057 in.) Service Limit: 28.12 mm (1.107 in.) 6-16 CONVERTER SYSTEM Drive Pulley If the sheave bushing is damaged or worn, replace it. Sheave Bushing Inside Diameter [A] Standard: 37.985 ~ 38.085 mm (1.4955 ~ 1.4994 in.) Service Limit: 38.12 mm (1.501 in.) • If the spider shoes [A] are damaged, replace them. Check the spider shoe side clearance (see Spider Shoe Side Clearance Inspection). If the ramp weights [A] in the movable sheave are damaged or worn, replace them. If the pins [B] are damaged or worn, replace them. If the rollers [A] are damaged or worn, replace the spider [B]. If the washers [C] are damaged or worn, replace the spider. CONVERTER SYSTEM 6-17 Drive Pulley If the spring is worn or damaged, replace the spring. Spring Free Length [A] Standard: 60.4 mm (2.38 in.) Spider Shoe Side Clearance Adjustment • Remove: Drive Pulley (see Drive Pulley Removal) • Drive Pulley Cover and Spring (see Drive Pulley Disassembly) Temporarily install: Dowel Pins (2) Drive Pulley Cover Two Bolts (at dowel pins) the movable sheave clockwise. • Turn the resulting clearance [A] between the shoe [B] • Measure and the post [C] on the movable sheave at all four arms. Shoe Side Clearance Standard: 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.) If any of the measurements are greater than the maximum, replace all shoes with standard shoes (see Drive Pulley Disassembly). 6-18 CONVERTER SYSTEM Drive Pulley the movable sheave clockwise. • Turn Measure the resulting clearance [A] between the shoe [B] • and the post [C] on the movable sheave at two positions as shown. Arrow Mark [D] If the clearance is not within the specified range, adjust it according to following chart. Clearance Measurement Less than 0.15 mm (0.0059 in.) 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.) (standard clearance) Over 0.30 mm (0.0118 in.) Present Shoes Part Number Thickness 49048-1087 7.2 mm (0.283 in.) 49048-1088 7.3 mm (0.287 in.) no change 49048-1089 7.4 mm (0.291 in.) 49048-1090 49048-1091 49048-1092 49048-1093 49048-1094 49048-1095 7.5 mm (0.295 in.) 7.6 mm (0.299 in.) 7.7 mm (0.303 in.) 7.8 mm (0.307 in.) 7.9 mm (0.311 in.) 8.0 mm (0.315 in.) that the movable sheave [A] moves smoothly, after • Check the shoe side clearance adjustment. The movable sheave must move freely towards the fixed sheave [B]. If the movable sheave does not move smoothly, readjust the shoe side clearance. Drive Pulley Assembly the ramp weight [A] as shown. • Install Tighten: • Torque - Ramp Weight Nuts [B]: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Check that the ramp weights swing smoothly. CONVERTER SYSTEM 6-19 Drive Pulley the fixed sheave [A] with the drive pulley holder [B] • Hold in a vise. Special Tool - Drive Pulley Holder: 57001–1473 the threads of the fixed sheave and spider. • Clean Install: • Movable Sheave Spider [A] and Shoes [B] Align the arrow [C] on the spider with the arrow [D] on the movable sheave. Insert the guides so that the rubber side (small diameter) faces inward. the drive pulley wrench [A] on the spider [B] and • Put tighten the bolt [C]. Special Tool - Drive Pulley Wrench: 57001–1474 • Turn the wrench counterclockwise for tightening. Torque - Spider: 275 N·m (28 kgf·m, 203 ft·lb) • Remove the drive pulley wrench. the spacer. • Install Put the [A] in the groove of the spider. • Align thespring • Install: arrows [B] on the drive pulley cover and spider. • Dowel Pins [C] • Drive Pulley Cover Tighten: Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 113 in·lb) the surface of the sheaves with an oil-less cleaning • Clean fluid. 6-20 CONVERTER SYSTEM Drive Pulley Drive Pulley Installation the following portions with an oil-less cleaning fluid • Clean such as trichloroethylene or acetone. Fixed Sheave Tapered Portion [A] Crankshaft Tapered Portion [B] WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings. the drive pulley, stepped washer and two washers • Install on the drive pulley bolt as shown. Crankcase Side [A] Stepped Washer [B] Two Washer [C] Bolt Head [D] the drive pulley cover and be sure to install the drive • Install pulley holder [A] along with three cover bolts [B] in the • position shown. Note the holder’s relative position to the arrow mark [C]. Tighten the three cover bolts to the specified torque. Special Tool - Drive Pulley Holder: 57001–1520 • Tighten: Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 113 in·lb) Drive Pulley Bolt [D] (New, left-hand threads): 93 N·m (9.5 kgf·m, 69 ft·lb) CONVERTER SYSTEM 6-21 Driven Pulley Driven Pulley Removal • Remove: Torque Converter Cover (see Torque Converter Cover • Removal) Drive Pulley (see Drive Pulley Removal) Drive Belt (see Drive Belt Removal) Using a flywheel & pulley holder [A] and pulley holder attachments [B], remove the driven pulley nut [C] and washers. (Nut has R/H threads.) Special Tools - Flywheel & Pulley Holder: 57001–1343 Pulley Holder Attachment: 57001–1472 • Remove: Driven Pulley Driven Pulley Disassembly • Hold the drive & driven pulley holder [A] in a vise. Special Tool - Drive & Driven Pulley Holder: 57001–1473 the guide bar [B] of the spring holder set into the • Screw holder. Special Tool - Spring Holder Set: 57001–1483 the driven pulley [C] on the guide bar. • Put Tighten the nut [D], and compress the spring with the • spring holder [E] of the spring holder set. Special Tool - Spring Holder Set: 57001–1483 • Remove the circlip [A] with circlip pliers [B]. Special Tool - Circlip Pliers: 57001–154 • Remove the nut and spring holder [C]. • Remove: Spring Seats [A] Spring [B] Thrust Plate [C] 6-22 CONVERTER SYSTEM Driven Pulley match–marks [A] and [B] on the sheaves so that it • Make can be installed later in the same position. Movable Sheave [C] Fixed Sheave [D] off the molybdenum disulfide grease. • Wipe Remove • driver [B].the four pins [A] with a thin standard tip screw• Remove the movable sheave from the fixed sheave. • Remove: Spacer(s) [A] (for Drive Belt Deflection Adjustment) Driven Pulley Inspection If the sheave surfaces [A] appear damaged, replace the sheaves. CONVERTER SYSTEM 6-23 Driven Pulley the sheave with uneven wear on the belt con• Replace tacting surfaces. Sheave Surface [A] Straight Edge [B] If the sheave bushings [A] are damaged or worn, replace the movable sheave. Sheave Bushing Inside Diameter Standard: 40.000 ~ 40.039 mm (1.5748 ~ 1.5763 in.) Service Limit: 40.079 mm (1.5779 in.) seals for damage. • Inspect If seals are damaged, replace the movable sheave. If the splines [A] are damaged or worn, replace the fixed sheave. If the spring is damaged or worn, replace the spring. Spring Free Length [A] Standard: 99.5 mm (3.92 in.) If the spring coils are distorted, replace the spring. 6-24 CONVERTER SYSTEM Driven Pulley Driven Pulley Assembly off any grease or dirt on the movable and fixed • Clean sheaves, and dry them with a clean cloth. • Install: Spacers [A] (for Drive Belt Deflection Adjustment) grease to the oil seal lips [A]. • Apply Press oil seals [B] in the movable sheave assembly • so thatthe the oil seal surface is flush [C] with the sleeve end. [D] molybdenum disulfide grease to the inner sur• Apply faces of the bushings. the match–marks on the sheaves, made when • Align disassembled, and the opening [A] and hole [B] will be matched easily. molybdenum disulfide grease to the seating surface • Apply [A] of the pins, and insert them into the holes in the movable sheave. CONVERTER SYSTEM 6-25 Driven Pulley the movable sheave onto the fixed sheave, and ap• Draw ply molybdenum disulfide grease of 1 g (0.035 oz) to all openings [A]. NOTE Do not heap up the grease out of the openings. that the O-rings [A] are in good condition. • Check If any of the O-rings are damaged, replace them. • Apply grease to the O-rings. • Hold the drive pulley holder in a vise. Special Tool - Drive Pulley Holder: 57001- 1473 the guide bar of the spring holder set into the • Screw holder. Special Tool - Spring Holder Set: 57001-1483 the driven pulley [A] onto the guide bar. • Put Put the thrust plate [B] so that the alloy side (gray) faces • the movable sheave. Install: • Spring Seat [C]: 18.5 mm (0.728 in.) Spring [D] Spring Seat [E]: 9.3 mm (0.366 in.) Circlip [F] the nut [A], and compress the spring with the • Tighten spring holder [B]. Special Tool - Spring Holder Set: 57001-1483 • Install the circlip [C] with the circlip pliers [D]. Special Tool - Circlip Pliers: 57001-154 the driven pulley from the spring holder set. • Remove the surface of the sheaves with an oil-less cleaning • Clean fluid. 6-26 CONVERTER SYSTEM Driven Pulley Driven Pulley Installation the transmission driven shaft [A]. • Clean Install: • Driven Pulley NOTE When engaging the spline on the driven pulley with the spline [B] on the shaft, do not damage the pulley’s spline. If any damage occurs, remove it with a file. the driven shaft and driven pulley ends to open the • Clean air vent passage. Wipe off any extra grease. Wipe off any protruding grease [A]. the washers [A] on the shaft as shown. • Install Crankcase Side [B] Bolt Head [C] a flywheel & pulley holder [A] and pulley holder at• Using tachments [B], tighten the driven pulley nut [C]. Special Tools - Flywheel & Pulley Holder: 57001–1343 Pulley Holder Attachment: 57001–1472 Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb) CONVERTER SYSTEM 6-27 High Altitude Setting Information Specifications Carburetor Altitude Main Jet 0 ~ 500 m Front: #135 P/No. (92063-1014) (STD) (0 ~ 1 600 ft) Rear: #140 P/No. (92063-1013) (STD) 500 ~ 1 500 m Front: #132 P/No. (92063-1076) (1 600 ~ 4 900 ft) Rear: #138 P/No. (92063-1015) 1 500 ~ 2 500 m Front: #130 P/No. (92063-1075) (4 900 ~ 8 200 ft) Rear: #135 P/No. (92063-1014) 2 500 ~ 3 500 m Front: #128 P/No. (92063-1074) (8 200 ~ 11 500 ft) Rear: #130 P/No. (92063-1075) 3 500 ~ 4 500 m Front: #120 P/No. (92063-1073) (11 500 ~ 14 800 ft) Rear: #125 P/No. (92063-1069) There is not high altitude setting for belt converter. ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Special Tools and Sealant ....................................................................................................... Engine Oil Flow Chart.............................................................................................................. Engine Oil and Oil Filter........................................................................................................... Oil Level Inspection............................................................................................................ Engine Oil Change............................................................................................................. Oil Filter Change ................................................................................................................ Oil Screen Removal ........................................................................................................... Oil Screen Cleaning ........................................................................................................... Oil Pressure Measurement ................................................................................................ Oil Pressure Relief Valve......................................................................................................... Oil Pressure Relief Valve Removal .................................................................................... Oil Pressure Relief Valve Installation ................................................................................. Oil Pressure Relief Valve Inspection.................................................................................. Oil Pump.................................................................................................................................. Oil Pump Removal ............................................................................................................. Oil Pump Installation .......................................................................................................... Oil Pipe .................................................................................................................................... Oil Pipe Removal ............................................................................................................... Oil Pipe Installation ............................................................................................................ 7- 2 7- 4 7- 5 7- 6 7- 7 7- 7 7- 7 7- 7 7- 7 7- 8 7- 8 7- 9 7- 9 7- 9 7- 9 7-10 7-10 7-10 7-12 7-12 7-13 7 7-2 ENGINE LUBRICATION SYSTEM Exploded View ENGINE LUBRICATION SYSTEM 7-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Oil Filter 18 1.8 13 R 2 Oil Pressure Switch 15 1.5 11 SS 3 Oil Pipe Bolts 8.8 0.90 78 in·lb 4 Engine Drain Plug 20 2.0 14 5 Oil Pressure Relief Valve 15 1.5 11 6 Oil Pump Bolts 8.8 0.90 78 in·lb 7 Chain Guide Bolts 8.8 0.90 78 in·lb 8 Oil Pump Drive Chain Tensioner Bolt 25 2.5 18 9 Oil Filter Mounting Bolt 25 2.5 18 1.5 0.15 13 in·lb 10 Oil Pressure Switch Terminal Bolt G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. O: Apply engine oil. SS: Apply silicone sealant (Kawasaki Bond: 56019–120). R: Replacement Parts L L (15 mm) 7-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Grade API SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 1.7 L (1.80 US qt) (when filter is not removed) 1.9 L (2.01 US qt) (when filter is removed) 2.2 L (2.33 US qt) (when engine is completely dry) Oil Pressure Measurement: Oil Pressure @ 4 500 r/min (rpm), oil temp. 110 C (230 F) 480 kPa (4.9 kgf/cm², 69.7 psi) ENGINE LUBRICATION SYSTEM 7-5 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm² : 57001–164 Oil Pressure Gauge Adapter, PT 1/8 : 57001–1033 Kawasaki Bond (Silicone Sealant) : 56019–120 7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Pressure Switch 5. Oil Filter 6. Oil Pipe 7. Crankshaft 8. Rear Cylinder Head 9. Rear Camshaft 10. Transmission Idle Shaft 11. Transmission Drive Shaft 12. Front Cylinder Head 13. Front Camshaft ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection the vehicle so that it is level, both side-to-side and • Park front-to-rear. the oil has just been changed, start the engine, and run • Ifit for several minutes to fill the oil filter. CAUTION Allow the engine to idle for several minutes so that oil may reach all parts of the engine. Racing a "dry" engine may cause severe damage. the engine and wait several minutes for all the oil to • Stop drain back to the sump. the oil filler cap [A], wipe its dipstick [B] dry, and • Unscrew tighten it into the filler opening. the oil filler cap and check the oil level. The oil • Unscrew level should be between the upper (H) level line [C] and lower (L) level line [D]. If the level is too high, suck the excess oil out the filler hole with a syringe or other suitable device. If the level is too low, add oil through the filler hole. Use the same type and make of oil that is already in the engine. Engine Oil Change to the Engine Lubrication System in the Periodic • Refer Maintenance chapter. Oil Filter Change to the Engine Lubrication System in the Periodic • Refer Maintenance chapter. Oil Screen Removal the crankcase (see Crankshaft/Transmission chap• Split ter). • Pull the oil screen [A] out of the crankcase. 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Cleaning the oil screen [A] thoroughly whenever it is removed • Clean for any reason. the oil screen with a high flash-point solvent and • Clean remove any particles stuck to it. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents. NOTE While cleaning the screen, check for any metal particles that might indicate internal engine damage. the screen carefully for any damage, holes, broken • Check wires, or gasket pulling off. If the screen is damaged, replace it. Oil Pressure Measurement NOTE Measure the oil pressure after the engine is warmed up. the oil pressure switch, and attach the oil pres• Remove sure gauge [A] and adapter [B]. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter: 57001–1033 Oil Pressure Standard: 480 kPa (4.9 kgf/cm², 69.7 psi) @ 4 500 r/min (rpm), 110 C (230 F) of oil temp. • • If the oil pressure is much lower than the standard, inspect the relief valve, oil pump, and/or crankshaft bearing insert wear. If the oil pressure is much higher than the standard, inspect the oil filter, oil screen, and other areas of the lubrication system for clogging. Stop the engine. Remove the oil pressure gauge and adapter. WARNING Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed. silicone sealant to the oil pressure switch, • Apply tighten it. and Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15 kgf·m, 13 in·lb) ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal the crankcase (see Crankshaft / Transmission chap• Split ter). • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation crankcase assembly (See Crankshaft / Transmission • See chapter). a non-permanent locking agent to the threads of oil • Apply pressure relief valve, and tighten it. Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb) Oil Pressure Relief Valve Inspection the relief valve. • Remove a wooden stick, push the inner valve to make sure • Using that the valve [A] moves smoothly and that it returns to its original position by the force of the spring [B]. NOTE The relief valve cannot be disassembled and it must be inspected in the assembled state. If the valve movement is not smooth, wash the relief valve with high flash-point solvent, and use compressed air to remove any foreign particles from it. WARNING Clean the oil pressure relief valve in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents. If the valve does not move smoothly even after washing it, replace the relief valve. The oil pressure relief valve is precision made with no allowance for replacement of individual parts. 7-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Alternator Rotor and Starter Clutch Gear (see Electrical System chapter) Oil Pump Drive Chain Tensioner Bolt [A] Chain Guide Bolts [B] and Collar Chain Guides [C] • Remove: Oil Pump Bolts [A] Oil Pump Drive Chain [B] and Oil Pump Assembly [C] • Remove: Circlip [A] Inner Rotor [B] Outer Rotor [C] Oil Pump Drive Shaft [D] Oil Pump Cover [E] Oil Pump Installation engine oil: • Apply Oil Pump Shaft • Inner and Outer Rotors Install: Oil Pump Drive Shaft Oil Pump Cover Inner Rotor Outer Rotor New Circlip ENGINE LUBRICATION SYSTEM 7-11 Oil Pump to see that the dowel pins [A] are in place. • Check Apply engine oil to the oil pump hole [B]. • the oil pump drive chain [A] with the oil pump as• Install sembly [B]. • Tighten: Torque - Oil Pump Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Upper Chain Guide [A] (Face the tab [B] downward.) • Lower Chain Guide [C] and Collar [D] Tighten: Torque - Chain Guide Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) grease to the O-ring [A]. • Apply Install: • Pin [B] • Spring [C] O-ring Oil Pump Drive Chain Tensioner Bolt [D] Tighten: Torque - Oil Pump Drive Chain Tensioner Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) 7-12 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal Engine Left Side Oil Pipe: Remove: Alternator Cover (see Electrical System chapter) Oil Pipe Bolts [A] Oil Pipe [B] Oil Pump (see Oil Pump Removal) Oil Pipe Bolts [C] Oil Pipe [D] • Engine Right Side Oil Pipe: Remove: Drive Pulley (see Torque Converter chapter) Plate Bolts [A] Plate [B] • • Remove: Oil Pipe Bolt [A] Oil Pipe [B] Engine Inside Oil Pipe: Remove: Cylinder Head (see Engine Top End chapter) Oil Pipe [A] • ENGINE LUBRICATION SYSTEM 7-13 Oil Pipe Oil Pipe Installation the O-ring [A] with new ones. • Replace Apply engine • Tighten: oil to the O-rings before installation. • Torque - Oil Pipe Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation TABLE OF CONTENTS Exploded View......................................................................................................................... Engine Removal/Installation .................................................................................................... Engine Removal................................................................................................................. Engine Installation.............................................................................................................. 8888- 2 4 4 5 8 8-2 ENGINE REMOVAL/INSTALLATION Exploded View ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Engine Mounting Bracket Bolts 52 5.3 38 2 Engine Mounting Nut 62 6.3 46 Remarks 8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Remove: Engine Oil (drain) Coolant (drain) and Coolant Hose Front Fender and Rear Fender (see Frame chapter) Side Inner Covers (see Frame chapter) Muffler and Exhaust Pipe (see Engine Top End chapter) Carburetor (see Fuel System chapter) Intake and Exhaust Converter Duct Alternator Lead Connector Crankshaft Sensor Lead Connector Foot Guards and Guard (see Frame chapter) Cable Holder [A] and Reverse Lock Cable [B] (see Crankshaft/Transmission chapter) Oil Pressure Switch Lead Connector Spark Plug Caps • Remove: Starter Motor Cable Battery Negative Cable Neutral Switch Lead Connector Reverse Switch Lead Connector Boot (roll up forward) [A] Engine Mounting Bolts [B] Engine Mounting Bracket [C] a tape to protect the frame. • Put • Move the engine forward to remove the drive shaft [A]. • Remove the engine as shown. ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Installation • Roll up the boot [A] toward the engine. the drive shaft in the rear propeller shaft joint [A]. • Insert Tighten: • Torque - Engine Mounting Bracket Bolts: 52 N·m (5.3 kgf·m, 38 ft·lb) Engine Mounting Nut: 62 N·m (6.3 kgf·m, 46 ft·lb) CRANKSHAFT / TRANSMISSION 9-1 Crankshaft / Transmission TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Special Tools and Sealant ....................................................................................................... Crankcase ............................................................................................................................... Crankcase Disassembly .................................................................................................... Crankcase Assembly ......................................................................................................... Crankshaft/Connecting Rod .................................................................................................... Crankshaft Removal .......................................................................................................... Crankshaft Installation ....................................................................................................... Connecting Rod Removal .................................................................................................. Connecting Rod Installation ............................................................................................... Crankshaft/Connecting Rod Cleaning................................................................................ Connecting Rod Bend........................................................................................................ Connecting Rod Twist ........................................................................................................ Connecting Rod Big End Side Clearance .......................................................................... Connecting Rod Big End Bearing/Crankpin Wear ............................................................. Crankshaft Runout ............................................................................................................. Crankshaft Main Bearing/Journal Wear ............................................................................. Transmission ........................................................................................................................... Shift Lever Removal........................................................................................................... Shift Lever Installation........................................................................................................ Shift Control Cables Removal............................................................................................ Shift Control Cables Installation......................................................................................... Reverse Lock Cable Removal ........................................................................................... Reverse Lock Cable Installation ........................................................................................ Transmission Removal ...................................................................................................... Transmission Installation ................................................................................................... Shift Fork Bending ............................................................................................................. Shift Fork/Gear and Shifter Groove Wear.......................................................................... Transmission and Shift Mechanism Inspection.................................................................. Ball Bearing, Needle Bearing, and Oil Seal............................................................................. Ball and Needle Bearing Replacement .............................................................................. Ball and Needle Bearing Wear........................................................................................... Oil Seal Inspection ............................................................................................................. 9- 2 9- 6 9- 8 9- 9 9- 9 9-10 9-13 9-13 9-13 9-13 9-13 9-14 9-14 9-14 9-15 9-15 9-17 9-17 9-18 9-18 9-18 9-19 9-19 9-20 9-20 9-21 9-22 9-24 9-24 9-25 9-27 9-27 9-27 9-27 9 9-2 CRANKSHAFT / TRANSMISSION Exploded View CRANKSHAFT / TRANSMISSION 9-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Connecting Rod Big End Cap Nuts 34 3.5 25 MO 2 Engine Drain Plug 20 2.0 14 3 Crankcase Bolts (M8) 75 mm (2.95 in.) 20 2.0 14 S 4 Crankcase Bolts (M8) 110 mm (4.33 in.) 20 2.0 14 L(1), S 5 Crankcase Bolts (M6) 40 mm (1.57 in.) 9.8 1.0 87 in·lb 6 Crankcase Bolts (M6) 65 mm (2.56 in.) 9.8 1.0 87 in·lb 7 Position Plate Mounting Screws 4.9 0.50 43 in·lb 8. Do not apply a non-permanent locking agent to this area (2 ~ 3 mm, 0.08 ~ 0.12 in.). 9. About 12 mm (0.47 in.) 10. White Mark: Face the mark backwards and align it with the crankcase mark. 11. Face the seal of the bearing to the left side (outward). G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Three Bond 1215, Gray). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. O: Apply engine oil. S: Follow the specific tightening sequence. L 9-4 CRANKSHAFT / TRANSMISSION Exploded View CRANKSHAFT / TRANSMISSION 9-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Shift Shaft Lever Nut 8.8 0.90 78 in·lb 2 Shift Shaft Positioning Bolt 25 2.5 18 3 Shift Shaft Spring Bolt 25 2.5 18 4 Shift Shaft Cover Bolt 8.8 0.90 78 in·lb 5 Neutral Position Switch 15 1.5 11 6 Reverse Position Switch 15 1.5 11 7 Shift Shaft Lever Bolt 14 1.4 10 8 Reverse Cable Bracket Mounting Bolts 8.8 0.90 78 in·lb 9 Reverse Cable Locknut 12 1.2 104 in·lb 10 Cable Holder Mounting Bolts 9.8 1.0 87 in·lb 11. Do not apply a non-permanent locking agent to this end. G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfige oil. O: Apply engine oil. R: Replacement Parts Remarks L 9-6 CRANKSHAFT / TRANSMISSION Specifications Item Crankshaft, Connecting Rods: Connecting rod bend Connecting rod twist Standard Service Limit – – – TIR 0.2/100 mm (0.008/3.94 in.) TIR 0.2/100 mm (0.008/3.94 in.) – – – Connecting rod big end side clearance 0.16 ~ 0.46 mm (0.0063 ~ 0.0181 in.) 0.7 mm (0.028 in.) Connecting rod big end bearing, insert / crankpin clearance 0.028 ~ 0.052 mm (0.0011 ~ 0.0020 in.) Crankpin diameter: 39.984 ~ 40.000 mm (1.5742 ~ 1.5748 in.) 39.984 ~ 39.992 mm (1.5742 ~ 1.57449 in.) 39.993 ~ 40.000 mm (1.57452 ~ 1.5748 in.) 0.09 mm (0.0035 in.) 39.97 mm (1.5736 in.) – – – – – – 43.000 ~ 43.016 mm (1.6929 ~ 1.6939 in.) 43.000 ~ 43.008 mm (1.6929 ~ 1.69323 in.) 43.009 ~ 43.016 mm (1.69326 ~ 1.6935 in.) – – – – – – – – – Brown 1.482 ~ 1.486 mm (0.05835 ~ 0.05850 in.) Yellow 1.486 ~ 1.490 mm (0.05850 ~ 0.05866 in.) Green 1.490 ~ 1.494 mm (0.05866 ~ 0.05882 in.) Connecting rod big end bearing insert selection: – – – – – – – – – Marking: None Connecting rod big end inside diameter: Marking: None Connecting rod big end bearing insert thickness: Con-rod Big End Bore Diameter Marking None None Crankpin Diameter Marking None None Crankshaft runout Bearing Insert Size Color Brown Part Number 92028-1963 Yellow 92028-1962 Green 92028-1961 TIR 0.04 mm (0.0016 in.) or less TIR 0.10 mm (0.0039 in.) Crankshaft main journal diameter: f42 Side 41.984 ~ 42.000 mm (1.6529 ~ 1.6535 in.) 41.96 mm (1.652 in.) 42.025 ~ 42.041 mm (1.6545 ~ 1.6552 in.) 42.08 mm (1.6567 in.) Crankshaft main bearing bore diameter: f42 Side CRANKSHAFT / TRANSMISSION 9-7 Specifications Item Transmission Shift fork ear thickness Shifter groove width Standard 5.9 ~ 6.0 mm (0.2322 ~ 0.2362 in.) 6.05 ~ 6.15 mm (0.2382 ~ 0.2421 in.) Service Limit 5.8 mm (0.228 in.) 6.25 mm (0.246 in.) 9-8 CRANKSHAFT / TRANSMISSION Special Tools and Sealant Outside Circlip Pliers : 57001–144 Three Bond : 1215 (Gray) Bearing Driver Set : 57001–1129 CRANKSHAFT / TRANSMISSION 9-9 Crankcase Crankcase Disassembly • Remove: Engine (see Engine Removal/Installation chapter) Starter Motor (see Electrical System chapter) Oil Filter (see Engine Lubrication System chapter) Cylinder Blocks and Pistons (see Engine Top End chapter) Intermediate Shaft and Chain (see Engine Top End chapter) Right Crankcase Bolts (M6) [A] Right Crankcase Bolts (M8) [B] • Remove: Shift Shaft Positioning Bolt [A], Washer, Spring, and Steel Ball Left Crankcase Bolts (M6) [B] Left Crankcase Bolts (M8) [C] the teeth on the sprockets [A] by taping for protect• Wrap ing the bushing in the crankcase. the pry points [B], split the crankcase halves. • Using • Lift off the left crankcase half. 9-10 CRANKSHAFT / TRANSMISSION Crankcase Crankcase Assembly CAUTION The right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. NOTE Be certain that all parts are cleaned thoroughly before assembly. Blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crankshaft. WARNING Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or low flash-point solvents to clean parts. A fire or explosion could result. a small amount of engine oil to the transmission • Apply gears, bearings and shift fork. sure the mating surfaces of the crankcase halves are • Be clean and dry. and insert the new ball bearings until they are bot• Press tomed. Special Tool - Bearing Driver Set: 57001–1129 • • • [A] Ball Bearing [B] Ball Bearing (sealed side towards crankcase) Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole. [C] Needle Bearing [D] Needle Bearing (Insert it from outside.) Apply engine oil to the bearings. Install: Oil Pressure Relief Valve [E] (see Engine Lubrication System chapter) • Install: Rear Cylinder Camshaft Chain Guide [A] • Tighten: Torque - Rear Cylinder Camshaft Chain Guide Bolt [B]: 20 N·m (2.0 kgf·m, 14 ft·lb) CRANKSHAFT / TRANSMISSION 9-11 Crankcase and insert the new ball bearings [A] until they are • Press bottomed. Special Tool - Bearing Driver Set: 57001–1129 and insert the new needle bearings so that the • Press bearing surfaces are flush with the end of the hole. • • • • [B] Needle Bearing [C] Needle Bearing (Insert it from outside.) Apply engine oil to the bearings. Install the position plates [D]. Apply a non-permanent locking agent to the position plate mounting screws [E]. Tighten: Torque - Position Plate Mounting Screws: 4.9 N·m (0.50 kgf·m, 43 in·lb) the lip [A] of the oil seal [B] and press the seal 3 • Grease mm (0.12 in.) [C] inwards from the end of the boss. sure the following parts are in place in the right • Be crankcase half. Crankshaft Transmission Shafts and Shift Rod [A] Oil Tube [B] Oil Screen [C] O-ring (Apply Grease) [D] Dowel Pins [E] liquid gasket • Apply crankcase half. [A] to mating surface of the left Sealant - Three Bond: 1215 (Gray) • Apply after, must be assembled with in 20 min. 9-12 CRANKSHAFT / TRANSMISSION Crankcase a non-permanent locking agent to the area [C] (12 • Apply mm, 0.47 in.) except for the tip [D] (2 ~ 3 mm, 0.08 ~ 0.12 • in.). Left Crankcase Bolt (M8) [3] Tighten the right and left crankcase bolts (M8) following the tightening sequence [1 ~ 8]. Torque - Crankcase Bolts (M8): 20 N·m (2.0 kgf·m, 14 ft·lb) • [1, 2, 5, 6] L = 75 mm (2.95 in.) [3, 4, 7, 8] L = 110 mm (4.33 in.) Tighten: Torque - Crankcase Bolts (M6): 9.8 N·m (1.0 kgf·m, 87 in·lb) [A] L = 40 mm (1.57 in.) [B] L = 65 mm (2.56 in.) the breather tube [A] on the crankcase fitting. • Install Align the white line on the tube with the mark [B] on the crankcase. Face the open end of the clamp [C] towards the left side [D] as shown. grease to the steel ball [A] and spring [B]. • Apply Install: • Steel Ball • Spring Gasket [C] Shift Shaft Positioning Bolt [D] Tighten: Torque - Shift Shaft Positioning Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) • Check: Crankshaft and driven shaft turn freely. If any of the shafts do not turn freely, split the crankcase to locate the problem. CRANKSHAFT / TRANSMISSION 9-13 Crankshaft/Connecting Rod Crankshaft Removal the crankcase (see Crankcase Disassembly). • Split Remove • press. the crankshaft [A] from the crankcase using a Crankshaft Installation left shaft [A] of the crankshaft is longer than the right • The shaft [B]. engine oil to the both main journals. • Apply Insert right crankshaft tapered end (the shorter end) • into thetheright crankcase using a press. Connecting Rod Removal the crankshaft (see Crankshaft Removal). • Remove Remove the connecting rods [A] from the crankshaft. • NOTE Mark and record the locations of the connecting rods and their big end caps [B] so that they can be installed in their original positions. Remove the connecting rod big end nuts, and take off the rod and cap with the bearing inserts. Connecting Rod Installation CAUTION If the connecting rods, bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling the engine to be sure the correct bearing inserts are installed. molybdenum disulfide oil: • Apply Inner Surface [A] of Bearing Inserts the “OUT” marks [B] of both connecting rods to• Face wards the outsides of the crankshaft. the connecting rod cap so that the grooves [C] of the • Fit cap and connecting rod are on the same side. 9-14 CRANKSHAFT / TRANSMISSION Crankshaft/Connecting Rod molybdenum disulfide oil: • Apply Threads [A] of Connecting Rod Big End Cap Bolts • Seating Surface [B] of Connecting Rod Big End Cap Nuts [C] Tighten: Torque - Connecting Rod Big End Cap Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Crankshaft/Connecting Rod Cleaning removing the connecting rods from the crankshaft, • After clean them with a high flash-point solvent. the crankshaft oil passages with compressed air to • Blow remove any foreign particles or residue that may have accumulated in the passages. Connecting Rod Bend the connecting rod big end bearing inserts, and • Remove reinstall the connecting rod big end cap. an arbor [A] of the same diameter as the connect• Select ing rod big end, and insert the arbor through the connect- • • • ing rod big end. Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end. On a surface plate, set the big-end arbor on a V block [C]. With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend. If connecting rod bend exceeds the service limit, the connecting rod must be replaced. Connecting Rod Bend Service Limit: TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist the big-end arbor [A] still on the V block [C], hold the • With connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist. If connecting rod twist exceeds the service limit, the connecting rod must be replaced. Connecting Rod Twist Service Limit: TIR 0.2/100 mm (0.008/3.94 in.) CRANKSHAFT / TRANSMISSION 9-15 Crankshaft/Connecting Rod Connecting Rod Big End Side Clearance the side clearance of the connecting rod big end • Measure [A]. Insert a thickness gauge [B] between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.16 ~ 0.46 mm (0.0063 ~ 0.0181 in.) Service Limit: 0.7 mm (0.028 in.) If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again. If clearance is too large after connecting rod replacement, the crankshaft also must be replaced. Connecting Rod Big End Bearing/Crankpin Wear the bearing insert/crankpin [A] clearance with • Measure plastigage [B]. Tighten the big end nuts to the specified torque. Torque - Connecting Rod Big End Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) NOTE Do not move the connecting rod and crankshaft during clearance measurement. Connecting Rod Big End Bearing, Insert/Crankpin Clearance Standard: 0.028 ~ 0.052 mm (0.0011 ~ 0.0020 in.) Service Limit: 0.09 mm (0.0035 in.) If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.052 mm (0.0020 in.) and the service limit 0.09 mm (0.0035 in.), replace the bearing inserts [A] with inserts painted green [B]. Check insert/crankpin clearance with plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the crankpin. Crankpin Diameter Standard: 39.984 ~ 40.000 mm (1.5742 ~ 1.5748 in.) Service Limit: 39.97 mm (1.5736 in.) If the crankpin has worn past the service limit, replace the crankshaft with a new one. 9-16 CRANKSHAFT / TRANSMISSION Crankshaft/Connecting Rod If the measured crankpin diameter [A] is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it. Crankpin Diameter Marks None: 39.984 ~ 39.992 mm (1.5742 ~ 1.57449 in.) : 39.993 ~ 40.000 mm (1.57452 ~ 1.5748 in.) Crankpin Diameter Mark [B]: “ ” mark or no mark the connecting rod big end inside diameter, and • Measure mark each connecting rod big end in accordance with the • inside diameter. Tighten the big end nuts to the specified torque. Torque - Connecting Rod Big End Cap Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) NOTE The mark already on the big end should almost coincide with the measurement because of little wear. Connecting Rod Big End Inside Diameter Marks None: 43.000 ~ 43.008 mm (1.6929 ~ 1.69323 in.) : 43.009 ~ 43.016 mm (1.69326 ~ 1.6935 in.) Diameter Mark [A]: “ ” mark or no mark the proper bearing insert [A] in accordance with the • Select combination of the connecting rod and crankshaft coding. Size Color [B] Big End Bearing Insert Selection • Con-rod Big End Bore Diameter Marking Crankpin Diameter Mark None None None None Bearing Insert Size Color Part Number Brown 92028-1963 Yellow 92028-1962 Green 92028-1961 Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage. CRANKSHAFT / TRANSMISSION 9-17 Crankshaft/Connecting Rod Crankshaft Runout the crankshaft runout. • Measure If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.04 mm (0.0016 in.) or less Service Limit: TIR 0.10 mm (0.0039 in.) Crankshaft Main Bearing/Journal Wear • Measure the diameter [A] of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 41.984 ~ 42.000 mm (1.6529 ~ 1.6535 in.) Service Limit: 41.96 mm (1.652 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. the main • Measure crankcase halves. bearing bore diameter [A] in the Crankcase Main Bearing Bore Diameter Standard: 42.025 ~ 42.041 mm (1.6545 ~ 1.6552 in.) Service Limit: 42.08 mm (1.6567 in.) If there is any signs of seizure, damage, or excessive wear, replace the crankcase halves as a set. 9-18 CRANKSHAFT / TRANSMISSION Transmission Shift Lever Removal • Remove: Seat and Rear Fender (see Frame chapter) • • Air Cleaner Cover and Right Side Inner Cover (see Frame chapter) Battery and Rear Ignition Coil (see Electrical System chapter) Make sure that the shift control grip is in neutral position. Make sure that the shift lever is in neutral position. Neutral position is the shift control cable lower ends [A] and reverse cable bracket mounting bolt [B] aligned state. At neutral position. 1 mm [A] the cable holder mounting bolts [A]. • Remove Remove • lever. the shift control cables [B] from the shift shaft the shift shaft lever bolt [C]. • Remove Remove the shift shaft lever [D] from the shift shaft. • Shift Lever Installation the shift shaft lever to the shift shaft. • Install When installing shift shaft lever, align the mark [A] on the • shaft end with the slit [B] of the shift shaft lever. Tighten the shift shaft lever bolt. Torque - Shift Shaft Lever Bolt: 14 N·m (1.4 kgf·m, 10 ft·lb) the shift control cables to the shift shaft lever. • Install Install cable holder and tighten the cable holder • mountingthebolts. Torque - Cable Holder Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) the shift control cables free play (see Periodic • Adjust Maintenance chapter). CRANKSHAFT / TRANSMISSION 9-19 Transmission Shift Control Cables Removal • Remove: Seat (see Frame chapter) Battery and Rear Ignition Coil [A] (see Electrical System chapter) Loosen the adjusting nuts [B]. Remove the cable holder mounting bolts [C]. Remove the shift control cables [D] from the shift shaft lever. Remove the shift control cables from the cable holder [E]. • • • • • Remove the band [A] and clamp [B]. the shift control grip screws [A]. • Remove Remove the shift control cables from the shift control grip. • Shift Control Cables Installation sure that the shift lever is in neutral position. • Make Neutral position is the shift control cable lower ends [A] • • and reverse cable bracket mounting bolt [B] aligned state. Lubricate the shift control cables before installation. Route the shift control cables correctly according to the Appendix chapter. WARNING Operation with an improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition. the shift control cables free play (see Periodic • Adjust Maintenance chapter). 9-20 CRANKSHAFT / TRANSMISSION Transmission Reverse Lock Cable Removal • Remove: Right Foot Guard (see Frame chapter) • Converter Cover (see Converter System chapter) Remove the reverse lock cable locknut [A]. the cotter pin [A], washer [B] and pin [C]. • Remove Remove the reverse lock cable from the lever [D]. • the locknuts [A] and remove the reverse lock ca• Loosen ble from the frame. Reverse Lock Cable Installation the reverse lock cable before installation. • Lubricate the reverse lock cable to the frame. • Install Tighten locknuts temporarily. • Install thethereverse cable [A] to the lever. • Replace the cotter lock pin with a new one. • Install the pin, washer and cotter pin. • CRANKSHAFT / TRANSMISSION 9-21 Transmission the reverse lock cable in the reverse lock cable • Install bracket [A]. • Tighten the reverse lock cable locknut [B]. Torque - Reverse Lock Cable Locknut: 12 N·m (1.2 kgf·m, 104 in·lb) • Tighten the locknuts securely. Transmission Removal the shift lever (see Shift Lever Removal). • Remove Split the crankcase (see Crankcase Disassembly). • Remove: • Reverse Lock Cable Bracket Mounting Bolts [A] Reverse Lock Cable Bracket [B] Shift Shaft Cover Bolt [C] Shift Shaft Cover [D] • Remove: Shift Shaft Spring Bolt [A] Shift Shaft [B] • Remove: Reverse Idle Shaft [A] Spacer [B] Reverse Drive Gear [C], Needle Bearing and Spacer Shifter [D] Shift Rod [E] 9-22 CRANKSHAFT / TRANSMISSION Transmission • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Spacer [A] Idle Gear Assembly [B] and Spacer Washer and Spacer [C] High Gear [D] • Remove: Needle Bearings [A] Remove • press. the driven shaft [B] from the crankcase using a Transmission Installation the driven shaft in the crankcase until it is bottomed • Insert using a press. • Apply engine oil to the needle bearings and install them. • Install: Spacer and Idle Gear Assembly [A] Spacer [B] High Gear [C] CRANKSHAFT / TRANSMISSION 9-23 Transmission • Install: Spacer Toothed Washer [A] Circlip Special Tool - Outside Circlip Pliers: 57001–144 engine oil: • Apply Shift Rod [A] and Shift Fork Ear [B] • Needle Bearing [C] Install: Shift Rod with Shifter Spacer [D] Needle Bearing • Install: Reverse Drive Gear [A] Spacer [B] • Install: Reverse Idle Shaft [A] 9-24 CRANKSHAFT / TRANSMISSION Transmission molybdenum disulfide oil to the shift shaft [A]. • Apply Install: • Shift Shaft Spring Bolt [B] • • Spring [C] Guide [D] Apply a non-permanent locking agent: Shift Shaft Spring Bolt Tighten: Torque - Shift Shaft Spring Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) a new bushing [A] and oil seal [B] are installed in • When the shift shaft cover [C], press and insert the new bushing and oil seal so that their surfaces are flush with the end of the each hole. • Install: Shift Shaft Cover • Tighten: Torque - Shift Shaft Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Shift Fork Bending inspect the shift fork. • Visually If the fork is bent, replace the shift rod with a new one. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. [A] 90 Shift Fork/Gear and Shifter Groove Wear the thickness of the shift fork ears [A], and mea• Measure sure the width [B] of the gear groove and shifter. If the thickness of a shift fork ear is less than the service limit, the shift rod must be replaced. Shift Fork Ear Thickness Standard: 5.9 ~ 6.0 mm (0.2322 ~ 0.2362 in.) Service Limit: 5.8 mm (0.228 in.) If the groove is worn over the service limit, the shifter must be replaced. Shifter Groove Width Standard: 6.05 ~ 6.15 mm (0.2382 ~ 0.2421 in.) Service Limit: 6.25 mm (0.2460 in.) CRANKSHAFT / TRANSMISSION 9-25 Transmission Transmission and Shift Mechanism Inspection inspect: • Visually Gears Dogs of Gear and Shifter If they are damaged or worn excessively, replace them. 9-26 CRANKSHAFT / TRANSMISSION Transmission 1. Driven Shaft 2. Spacer (17.3 x 30 x 2.0) 3. Reverse Gear (12T) 4. Spacer (21.2 x 29 x 1.6) 5. Shifter 6. Snap Ring 7. Washer T=1.5 8. Spacer (28 × 39 × 8) 9. Drive Hi Gear (27T) 10. Reverse Idle Shaft 11. Reverse Driven Gear (16T) 12. Reverse Driven Output Gear (14T) 13. Idle Shaft 14. Spacer (20.3 × 33 × 2.0) 15. Driven Output Gear (20T) 16. Driven Hi Gear (29T) 17. Needle Bearing 18. Spacer (25 × 32 × 13) CRANKSHAFT / TRANSMISSION 9-27 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. a press or puller, remove the ball bearing and/or • Using three needle bearings. NOTE In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93 C (200 F) max., and tapping the bearing in or out. CAUTION Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil. a press and the bearing driver set [A], install the • Using new ball bearing until it stops at the bottom of its housing. Three new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole. Special Tool - Bearing Driver Set: 57001–1129 Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection. Removal may damage them. the ball bearings. • Check Since the ball bearings are made to extremely close toler- • ances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. Spin [A] the bearing by hand to check its condition. If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it. Check the needle bearings. The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a needle bearing, replace it. Oil Seal Inspection the oil seals. • Inspect Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged. WHEELS / TIRES 10-1 Wheels / Tires TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Special Tool ............................................................................................................................. Wheel Alignment ..................................................................................................................... Toe-in Inspection................................................................................................................ Toe-in Adjustment .............................................................................................................. Wheels (Rims) ......................................................................................................................... Wheel Removal.................................................................................................................. Wheel Installation............................................................................................................... Wheel (Rim) Inspection...................................................................................................... Wheel (Rim) Replacement................................................................................................. Tires......................................................................................................................................... Tire Removal...................................................................................................................... Tire Installation................................................................................................................... Tire Inspection ................................................................................................................... Front Hub................................................................................................................................. Front Hub Removal............................................................................................................ Front Hub Installation......................................................................................................... Front Hub Disassembly/Assembly ..................................................................................... Rear Hub ................................................................................................................................. Rear Hub Removal ............................................................................................................ Rear Hub Installation ......................................................................................................... Rear Hub Disassembly/Assembly...................................................................................... 10- 2 10- 4 10- 5 10- 6 10- 6 10- 7 10- 8 10- 8 10- 8 10- 8 10- 9 10-10 10-10 10-10 10-11 10-12 10-12 10-12 10-12 10-13 10-13 10-13 10-13 10 10-2 WHEELS / TIRES Exploded View WHEELS / TIRES 10-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Wheel Nuts 78 8.0 58 2 Front Axle Nuts 52 5.3 38 3 Tie-rod End Nuts 42 4.3 31 4 Tie-rod Adjusting Locknuts 22 2.2 16 5 Rear Axle Nuts 265 27 195 6. Tie-rod: Install the width across flats side to the knuckle arm. W: Apply water or soap and water solution. R: Replacement parts Remarks 10-4 WHEELS / TIRES Specifications Item Standard Service Limit Wheel Alignment: Toe-in of front wheels: 10 ± 10 mm (0.39 ± 0.39 in.) – – – AT 22 × 7-10 – – – Tires: Standard tire: Front HOLESHOT XC, Tubeless Rear AT 22 × 11-10 – – – HOLESHOT XCT, Tubeless Tire air pressure (when cold): Front 28 kPa (0.28 kgf/cm², 4.0 psi) – – – Rear 35 kPa (0.35 kgf/cm², 5.0 psi) – – – 250 kPa (2.5 kgf/cm², 36 psi) – – – Maximun tire air pressure (to seat beads, when cold) Tire tread depth: Front ––– 3 mm (0.12 in.) Rear ––– 3 mm (0.12 in.) WHEELS / TIRES 10-5 Special Tool Jack : 57001–1238 10-6 WHEELS / TIRES Wheel Alignment Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is the greater than B (Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs. Caster and camber are build-in and require no adjustment. A (Rear ) – B (Front) = Amount of Toe-in (Distance A and B are measured at axle height with the vehicle sitting on the ground, or at 1G.) Toe-in Inspection a heavy coat of chalk or a paint line near the center • Apply of the front tires. a needle nose scriber, make a thin mark near the • Using center of the chalk coating while turning the wheel. the front wheels on the ground, set the handlebar • With straight ahead. the level of the axle height, measure the distance be• Attween the scribed or painted lines for both front and rear • of the front tires. Subtract the measurement of the front from the measurement of the rear to get the toe-in. If the toe-in is not in the specified range, go on to the Toe-in Adjustment procedure. Toe-in of Front Wheels Standard: 10 ± 10 mm (0.39 ± 0.39 in.) at 1G WHEELS / TIRES 10-7 Wheel Alignment Toe-in Adjustment the locknuts [A] [B] and turn the adjusting tie–rods • Loosen [C] the same number of turns on both sides to achieve the specified toe-in. NOTE The locknut [A] on the tie-rod has left-hand threads. Turn the locknut clockwise for loosening. The toe-in will be near the specified value, if the tie-rod length [D] is 386 ~ 389 mm (15.2 ~ 15.3 in.) on each tie-rod. CAUTION Adjust the tie-rod length so that the visible thread length [E] is even on both ends of the tie-rod. Uneven thread length could cause tie-rod end damage. the toe-in. • Check Tighten: • Torque - Tie-Rod Adjusting Locknuts: 22 N·m (2.2 kgf·m, 16 ft·lb) • Test ride the vehicle. 10-8 WHEELS / TIRES Wheels (Rims) Wheel Removal the wheel nuts [A]. • Loosen Support vehicle on a stand or a jack so that the wheels • are off thetheground. Special Tool - Jack: 57001-1238 • Remove: Wheel Nuts Wheel Wheel Installation the wheel so that the air valve [A] is toward the • Position outside of the vehicle. • Tighten the wheel nuts in a criss-cross pattern. Torque - Wheel Nuts: 78 N·m (8.0 kgf·m, 58 ft·lb) Wheel (Rim) Inspection both sides of the rim for dents [A]. If the rim is • Examine dented, replace it. If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary. WHEELS / TIRES 10-9 Wheels (Rims) Wheel (Rim) Replacement the wheel (see Wheel Removal). • Remove Disassemble tire from the rim (see Tire Removal). • Remove the airthevalve and discard it. CAUTION Replace the air valve whenever the tire is replaced. Do not reuse the air valve. Plastic Cap [A] Valve Core [B] Stem Seal [C] Valve Stem [D] Valve Seat [E] Valve Opened [F] a new air valve in the new rim. • Install Remove the valve cap, lubricate the stem with a soap and water solution, and pull the stem [A] through the rim from the inside out until it snaps into place. CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber. the tire on the new rim (see Tire Installation). • Mount Install the wheel (see Wheel Installation). • 10-10 WHEELS / TIRES Tires Tire Removal the wheel. • Remove Unscrew the valve core to deflate the tire. • Use a proper valve core tool [A]. the tire beads and rim flanges on both sides of • Lubricate the wheel with a soap and water solution, or water [A]. This helps the tire beads slip off the rim flanges. CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire. the tire from the rim using a suitable commer• Remove cially available tire changer. NOTE The tires cannot be removed with hand tools because they fit the rims tightly. Tire Installation the rim (see Wheel (Rim) Inspection). • Inspect • Replace the air valve with a new one. CAUTION Replace the air valve with whenever the tire is replaced. Do not reuse the air valve. the tire for wear and damage (see Tire Inspection). • Check Lubricate the tire beads and rim flanges with a soap and • water solution, or water. WARNING Do not use the lubricant other than a water and soap solution, or water to lubricate the tire beads and rim because it may cause tire separation. WHEELS / TIRES 10-11 Tires the wheel rim [A] on a suitable stand [B] to pre• Support vent the tire from slipping off. • Inflate the tire until the tire beads seat on the rim. Maximum Tire Air Pressure (to seat beads when cold) Front and Rear: 250 kPa (2.5 kgf/cm², 36 psi) WARNING Do not inflate the tire to more than the maximum tire air pressure. Overinflation can explode the tire with possibility of injury and loss of life. to see that rim lines [A] on both sides of the tire are • Check parallel with the rim flanges [B]. • • • If the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate the tire. After the beads are properly seated, check for air leaks. Apply a soap and water solution around the tire bead and check for bubbles. Deflate the tire to the specified pressure. Check the tire pressure using an air pressure gauge. NOTE Kawasaki provides the air pressure gauge (P/N 52005 -1082) with the owner’s tool kit. Tire Air Pressure (when cold) Front: 28 kPa (0.28 kgf/cm², 4.0 psi) Rear: 35 kPa (0.35 kgf/cm², 5.0 psi) the wheel (see Wheel Installation). • Install Wipe off the soap and water solution on the tire and dry • the tire before operation. WARNING Do not operate the vehicle with the water and soap still around the tire beads. They will cause tire separation, and a hazardous condition may result. Tire Inspection to the Wheels/Tires in Periodic Maintenance chap• Refer ter. 10-12 WHEELS / TIRES Front Hub Front Hub Removal • Remove: Cotter Pin [A] • Loosen the axle nut [B]. the wheel (see Wheel Removal). • Remove Remove caliper [A] by taking off the mounting bolts, • and let thethecaliper hang free. the axle nut [B] and pull off the front hub [C] and • Remove brake disc. • Separate the brake disc from the front hub. Front Hub Installation the brake disc (see Brakes chapter). • Install Tighten: • Torque - Front Axle Nut: 52 N·m (5.3 kgf·m, 38 ft·lb) • Insert a new cotter pin [A] and bend it over the nut [B]. 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 up to next alignment. It should be within 30 degree. Loosen once and tighten again when the slot goes past the nearest hole. Front Hub Disassembly/Assembly not press the hub bolts [A] out. • Do If any hub bolt is damaged, replace the hub [B] and bolts as a unit. WHEELS / TIRES 10-13 Rear Hub Rear Hub Removal • Remove: Cotter Pin [A] • Loosen the axle nut [B]. • Remove: Wheel (see Wheel Removal) Axle Nut [A] Rear Hub [B] Rear Hub Installation • Tighten: Torque - Rear Axle Nuts: 265 N·m (27 kgf·m, 195 ft·lb) • Insert a new cotter pin [A] and bend it over the nut [B]. 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 up to next alignment. It should be within 30 degree. Loosen once and tighten again when the slot goes past the nearest hole. Rear Hub Disassembly/Assembly not press the hub bolts [A] out. • Do If any hub bolt is damaged, replace the hub [B] and bolts as a unit. FINAL DRIVE 11-1 Final Drive TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Special Tools ........................................................................................................................... Output Bevel Gears ................................................................................................................. Output Drive Bevel Gear Removal..................................................................................... Output Drive Bevel Gear Installation.................................................................................. Output Drive Bevel Gear Disassembly .............................................................................. Output Drive Bevel Gear Assembly ................................................................................... Output Driven Bevel Gear Removal................................................................................... Output Driven Bevel Gear Installation................................................................................ Output Driven Bevel Gear Disassembly ............................................................................ Output Driven Bevel Gear Assembly ................................................................................. Output Bevel Gears Adjustment ........................................................................................ Bevel Gears Inspection...................................................................................................... Cam Damper Inspection .................................................................................................... Propeller Shaft......................................................................................................................... Propeller Shaft Removal .................................................................................................... Propeller Shaft Installation ................................................................................................. Propeller Shaft Joint Boot Inspection................................................................................. Propeller Shaft Inspection.................................................................................................. Rear Axle................................................................................................................................. Rear Axle Removal ............................................................................................................ Rear Axle Installation ......................................................................................................... Ball Bearing Wear .............................................................................................................. Rear Axle Runout Inspection ............................................................................................. Final Gear Case ...................................................................................................................... Final Gear Case Oil Level Inspection ................................................................................ Final Gear Case Oil Change.............................................................................................. Final Gear Case Removal ................................................................................................. Final Gear Case Installation............................................................................................... Final Gear Case Disassembly .......................................................................................... Final Gear Case Assembly ................................................................................................ Oil Seal Installation ............................................................................................................ Final Bevel Gear Adjustment ............................................................................................. Pinion Gear Unit Disassembly ........................................................................................... Pinion Gear Unit Assembly ................................................................................................ Bevel Gear Inspection........................................................................................................ Bearing and Oil Seal................................................................................................................ Ball or Needle Bearing Inspection...................................................................................... Oil Seal Inspection ............................................................................................................. 11- 2 11- 6 11- 7 11- 9 11- 9 11- 9 11-10 11-12 11-13 11-14 11-14 11-16 11-17 11-22 11-22 11-23 11-23 11-23 11-23 11-23 11-24 11-24 11-24 11-25 11-25 11-26 11-26 11-26 11-26 11-27 11-28 11-29 11-30 11-30 11-33 11-34 11-34 11-36 11-36 11-36 11 11-2 FINAL DRIVE Exploded View FINAL DRIVE 11-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Output Driven Bevel Gear Housing Bolts 26 2.7 20 2 Output Drive Bevel Gear Housing Bolts 26 2.7 20 3 Bearing Holder 137 14 101 L 4 Bevel Gear Holder Nut 157 16 116 L 5 Bearing Holder 120 12 89 L 6 Output Shaft Holder Nut 157 16 116 L 7 Output Drive Bevel Gear Cover Bolts 8.8 0.90 78 in·lb G: Apply L: Apply M: Apply MO: Apply grease for oil seal and O-ring. a non-permanent locking agent. molybdenum disulfide grease. molybdenum disulfide oil. 11-4 FINAL DRIVE Exploded View FINAL DRIVE 11-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Oil Filler Cap 29 3.0 22 2 Oil Drain Plug 20 2.0 14 3 Pinion Gear Bearing Holder 137 14 101 L 4 Pinion Gear Bearing Holder Nut 157 16 116 L 5 Final Gear Case Left Cover Bolts 49 5.0 36 L 6 Final Gear Case Bolts 42 4.3 31 S 7 Final Gear Case Right Cover Bolts (M8) 24 2.4 17 L, S 8 Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L, S 9 Final Gear Case Right Cover Bolts (M12) 94 9.6 69 L, S G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. MF: Apply MOBIL FLUID 424 or equivalent oil. S: Follow the specific tightening sequence. 11-6 FINAL DRIVE Specifications Item Standard Service Limit Output Bevel Gear Case Output bevel gear backlash 0.05 ~ 0.11 mm (0.0020 ~ 0.0043 in.) – – – (at output drive shaft spline) Rear Axle Shaft Rear axle shaft runout TIR 1 mm (0.04 in.) or less TIR 2 mm (0.08 in.) Final Gear Case: Gear case oil: Type MOBIL Fluid 424 or – – – CITGO TRANSGARD TRACTOR HYDRAULIC FLUID Oil level Filler opening bottom – – – Capacity 900 mL (0.95 US qt) – – – 0.07 ~ 0.14 mm (0.003 ~ 0.006 in.) – – – Final bevel gear backlash (at pinion gear spline) FINAL DRIVE 11-7 Special Tools Bearing Puller : 57001–135 Damper Spring Compressor Set : 57001–1475 Outside Circlip Pliers : 57001–144 Holder & Guide Arbor : 57001–1476 Oil Seal & Bearing Remover : 57001–1058 Socket Wrench, Hex 50 : 57001–1478 Bearing Driver Set : 57001–1129 Output Shaft Holder & Spacer : 57001–1479 Socket Wrench : 57001–1363 Pinion Gear Holder : 57001–1480 11-8 FINAL DRIVE Special Tools Nut Holding Bolts : 57001–1481 Pinion Gear Holder : 57001–1485 Socket Wrench : 57001–1482 Oil Seal Driver: 57001–1487 Socket Wrench, Hex 41 : 57001–1484 Hexagon Wrench, Hex 41 : 57001–1491 FINAL DRIVE 11-9 Output Bevel Gears Output Drive Bevel Gear Removal • Remove: Oil Pipe (see Engine Lubrication System chapter) Output Drive Bevel Gear Cover Bolts [A] Output Drive Bevel Gear Cover [B] • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001–144 • Remove: Output Drive Idle Gear [B] • Remove: Output Drive Bevel Gear Housing Bolts [A] Output Drive Bevel Gear Housing [B] Output Drive Bevel Gear Installation the output drive bevel gear housing. • Install • Tighten: Torque - Output Drive Bevel Gear Housing Bolts: 26 N·m (2.7 kgf·m, 20 ft·lb) • Install: Output Drive Idle Gear New Circlip Special Tool - Outside Circlip Pliers: 57001–144 11-10 FINAL DRIVE Output Bevel Gears grease: • Apply O-rings [A] • Install: Output Drive Bevel Gear Cover [B] Tighten: • Torque - Output Drive Bevel Gear Cover Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Output Drive Bevel Gear Disassembly • Remove: Output Drive Bevel Gear Housing [A] (see Output Drive • • Bevel Gear Removal) Look through the hole [B] in the housing. Turn the bevel gear [C] until the groove of the output drive bevel gear holder nut is seen. the nut holding bolts [A] (4) securely into the • Tighten grooves [B] of the bevel gear holder nut [C] in the output drive bevel gear housing. Special Tool - Nut Holding Bolts: 57001–1481 [D] Output Drive Bevel Gear Housing [E] Outer Ball Bearing [F] Inner Ball Bearing [G] Bearing Holder [H] Output Drive Bevel Gear FINAL DRIVE 11-11 Output Bevel Gears the output drive bevel gear housing [A] in a vise. • Hold Loosen the bevel gear [B] using an Allen wrench about • four rotations. one nut holding bolt, and look at through the • Remove hole. If the groove of the bevel gear holder nut is not seen, loosen the other three bolts. the gear shaft end using a copper mallet until the • Drive grooves of the bearing holder nut can be seen again. the nut holding bolts (4) securely into the • Retighten groove of the bevel gear holder nut in the output drive bevel gear housing. Special Tool - Nut Holding Bolts: 57001–1481 the above procedure, and remove the bevel gear • Repeat from the housing. the bearing holder [A] using the hexagon wrench • Remove [B]. Special Tool - Hexagon Wrench, Hex 41: 57001–1491 If the holder seems too difficult to break free, apply heat to softer the locking agent. • Remove: Outer Ball Bearing [A] Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058 11-12 FINAL DRIVE Output Bevel Gears • Remove: Output Drive Bevel Gear Holder Nut Inner Ball Bearing [A] Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058 Output Drive Bevel Gear Assembly • Press the new inner ball bearing until it is bottomed. Special Tool - Bearing Driver Set [A]: 57001-1129 a non-permanent locking agent to the threads of • Apply the bearing holder [A] and tighten it so that the deep side [B] faces outward. Torque - Bearing Holder: 120 N·m (12 kgf·m, 89 ft·lb) • Press the output drive bevel gear until it is bottomed. FINAL DRIVE 11-13 Output Bevel Gears a non-permanent locking agent to the threads of • Apply the bevel gear holder nut [A] and tighten it so that the projection side [B] faces outward. Special Tool - Socket Wrench: 57001-1482 [C] Torque - Bevel Gear Holder Nut: 157 N·m (16 kgf·m, 116 ft·lb) • Press the new outer ball bearing until it is bottomed. Output Driven Bevel Gear Removal • Remove: Swingarm (see Suspension chapter) and Propeller Shaft (see this chapter) or Engine (see Engine Removal/Installation chapter) Output Driven Bevel Gear Housing Bolts [A] Output Driven Bevel Gear Housing [B] lightly the front end [A] of the output driven bevel gear • Tap shaft using a plastic mallet. The output driven bevel gear shaft assembly comes off with the housing. 11-14 FINAL DRIVE Output Bevel Gears Output Driven Bevel Gear Installation grease: • Apply O-ring [A] the output driven bevel gear shaft assembly. • Install Tighten: • Torque - Output Driven Bevel Gear Housing Bolts: 26 N·m (2.7 kgf·m, 20 ft·lb) Output Driven Bevel Gear Disassembly • Remove: Output Driven Bevel Gear Housing Assembly (see Out• put Driven Bevel Gear Removal) Hold the holder in a vise, and set the housing assembly [A] on the holder. Special Tools - Damper Spring Compressor Set [B]: 57001-1475 Holder & Guide Arbor [C]: 57001-1476 • Tighten the nuts [D] and compress the damper spring [E]. • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001–144 • Remove: Circlip [A] Spring Holder [B] Spring [C] Cam Damper [D] Output Driven Bevel Gear [E] FINAL DRIVE 11-15 Output Bevel Gears the housing assembly [A] with the output shaft holder • Hold [B] & spacer [C] in a vise. Special Tool - Output Shaft Holder & Spacer: 57001-1479 • Remove: Oil Seal [D] • Remove: Output Shaft Holder Nut [A] Special Tool - Socket Wrench [B]: 57001-1482 the housing assembly [A] with the holder [B] in a • Hold vise. Special Tool - Holder & Guide Arbor : 57001-1476 • Remove: Bearing Holder [C] Special Tool - Socket Wrench [D], Hex 50: 57001-1478 • If the holder seems too difficult to break free, apply heat to softer the locking agent. Remove: Ball Bearing Special Tool - Oil Seal & Bearing Remover: 57001-1058 11-16 FINAL DRIVE Output Bevel Gears Output Driven Bevel Gear Assembly • Press the new ball bearing until it is bottomed. Special Tool - Bearing Driver Set [A]: 57001-1129 the housing assembly [A] with the holder [B] in a • Hold vise. Special Tool - Holder & Guide Arbor: 57001-1476 a non-permanent locking agent to the threads of • Apply the bearing holder [C] and tighten it. Special Tool - Socket Wrench, Hex 50: 57001-1478 Torque - Bearing Holder: 137 N·m (14 kgf·m, 101 ft·lb) the housing assembly [A] with the output shaft holder • Hold [B] & spacer [C] in a vise. Special Tool - Output Shaft Holder & Spacer: 57001-1479 the output shaft [D] in the housing. • Insert Apply a non-permanent locking agent to the threads of • the output shaft holder nut [E] and tighten it so that the projection side [F] faces outward. Special Tool - Socket Wrench: 57001-1482 Torque - Output Shaft Holder Nut: 157 N·m (16 kgf·m, 116 ft·lb) • Apply grease to the oil seal and press it. the holder [A] in a vise, and set the housing assembly • Hold [B] on the holder. Special Tool - Holder & Guide Arbor: 57001-1476 • Install: Output Driven Bevel Gear [C] Cam Damper [D] Spring [E] Spring Holder [F] Circlip [G] FINAL DRIVE 11-17 Output Bevel Gears • Install: Guide Bars [A] Damper Spring Compressor Set [B] Special Tools - Holder & Guide Arbor: 57001-1476 Damper Spring Compressor Set: 57001-1475 the nuts [C] and compress the damper spring. • Tighten Install: • Circlip Special Tool - Outside Circlip Pliers: 57001-144 Output Bevel Gears Adjustment The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. When replacing any one of the backlash-related parts, be sure to check and adjust the backlash and tooth contact. First adjust the backlash, and then tooth contact by replacing shims. These two adjustments are of critical importance and must be carried out in the correct sequence, using the procedures shown. 11-18 FINAL DRIVE Output Bevel Gears Output Bevel Gear (Backlash-related Parts) 1. Ball Bearings 2. Drive Bevel Gear Shims 3. Output Drive Bevel Gear 4. Bearing Housings 5. Output Driven Bevel Gear 6. Output Driven Shaft 7. Driven Bevel Gear Shims FINAL DRIVE 11-19 Output Bevel Gears Drive Bevel Gear Shims for Tooth Contact Adjustment Thickness 0.15 mm (0.006 in.) 0.2 mm (0.008 in.) 0.5 mm (0.020 in.) 0.8 mm (0.031 in.) 1.0 mm (0.039 in.) 1.2 mm (0.047 in.) Part Number 92180-1311 92180-1312 92180-1313 92180-1314 92180-1351 92180-1352 Driven Bevel Gear Shims for Backlash Adjustment Thickness 0.15 mm (0.006 in.) 0.2 mm (0.008 in.) 0.5 mm (0.020 in.) 0.8 mm (0.031 in.) 1.0 mm (0.039 in.) 1.2 mm (0.047 in.) Part Number 92180-1307 92180-1308 92180-1309 92180-1310 92180-1349 92180-1350 Bevel Gear Backlash Adjustment The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position. Remove the output drive idle gear (see Output Drive Bevel Gear Removal). • up a dial gauge [A] against the output drive shaft • Set spline groove to check gear backlash. • To measure the backlash, turn the shaft clockwise and counterclockwise slightly so as not to move the mate gear. A rod can be inserted through the lower hole of the housing and into contact with driven gear. This may help to hold it still. The difference between the highest and lowest gauge reading is the amount of backlash. If the backlash is not within the limit, replace the shim(s) at the driven bevel gear. Change the thickness a little at a time. Recheck the backlash, and readjust as necessary. Output Bevel Gear Backlash Standard: 0.05 ~ 0.11 mm (0.0020 ~ 0.0043 in.) (at output drive shaft spline) 11-20 FINAL DRIVE Output Bevel Gears Tooth Contact Adjustment Tooth contact location is influenced by drive gear position more than by driven gear position. Clean any dirt and oil off the bevel gear teeth. Apply checking compound to 4 or 5 teeth on the output driven bevel gear. • • NOTE Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. The checking compound must be smooth and firm with the consistency of tooth paste. Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears. the output driven shaft for 3 or 4 turns in the drive • Turn and reverse (coast) directions, while creating a drag on • the drive bevel gear shaft. Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and a little closer to the toe of the tooth. If the tooth contact pattern is incorrect, replace the shim(s) at the drive bevel gear and shim(s) at the driven bevel gear, following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary. NOTE If the backlash is out of the standard range after changing shims, correct the backlash before checking the tooth contact pattern. FINAL DRIVE 11-21 Output Bevel Gears Example 1: Decrease the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or increase the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below. Repeat in 0.1 mm (0.004 in.) steps if necessary. Example 2: Increase the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or decrease the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below. Repeat in 0.1 mm (0.004 in.) steps if necessary. 11-22 FINAL DRIVE Output Bevel Gears Bevel Gears Inspection check the bevel gears [A] for scoring, chipping, • Visually or other damage. Replace the bevel gears as a set if either gear is damaged. Cam Damper Inspection inspect: • Visually Bevel Gear Cam [A] Cam Follower [B] Spring [C] Shaft [D] Replace any part if it appears damaged. FINAL DRIVE 11-23 Propeller Shaft Propeller Shaft Removal the final gear case oil (see Final Drive in the Periodic • Drain Maintenance chapter). • Remove: Swingarm [A] (see Suspension chapter) Propeller Shaft [B] Propeller Shaft Installation the old grease off the front and rear end splines • Wipe [A] of the propeller shaft [B] and apply new molybdenum • • disulfide grease in those. Be sure to install the spring [C] on the pinion gear nut of the final gear case. Install the propeller shaft while aligning the splines. Propeller Shaft Joint Boot Inspection to the Final Drive in the Periodic Maintenance chap• Refer ter. Propeller Shaft Inspection the propeller shaft (see Propeller Shaft Re• Remove moval). that the universal joint [A] works smoothly without • Check rattling or sticking. • • If it does rattle or stick, the universal joint is damaged. Replace the propeller shaft with a new one. Visually inspect the splines [B] on the propeller shaft. If they are badly worn, chipped, or loose, replace the propeller shaft. Also, inspect the splines on the rear end of the output shaft and the pinion gear joint in the final gear case. If splines are badly worn, chipped, or loose, replace the output shaft and the pinion gear joint. 11-24 FINAL DRIVE Rear Axle Rear Axle Removal the final gear case oil (see Final Drive in the Periodic • Drain Maintenance chapter). • Remove: Rear Wheels (see Wheels/Tires chapter) Rear Hub (see Wheels/Tires chapter) Rear Bottom Guard [A] (see Frame chapter) Cap [B] Final Gear Case Left Cover Bolts [C] Final Gear Case Left Cover Bracket [D] Final Gear Case Left Cover [E] [A] the right end of the rear axle [B] and pull it out from • Tap the left. The left axle bearing comes off with the axle. Rear Axle Installation the rear axle from the left side with the left bearing • Install installed, while aligning the splines. grease: • Apply O-ring [A] Oil Seal Lips in Final Gear Case Left Cover • Install: Final Gear Case Left Cover [A] • Final Gear Case Left Cover Bracket [B] Apply a non-permanent locking agent to the cover bolts, and tighten them. Torque - Final Gear Case Left Cover Bolts : 49 N·m (5.0 kgf·m, 36 ft·lb) • Install the cap [C]. FINAL DRIVE 11-25 Rear Axle Ball Bearing Wear CAUTION Do not remove the bearing [A] for inspection. Removal may damage it. the ball bearing. • Check Since the ball bearing is made to extremely close tolerances, the wear must be judged by feel rather than measurement. Spin the bearing by hand to check its condition. If the bearing is noisy, does not spin smoothly, or has any rough spots, replace the rear axle shaft. Rear Axle Runout Inspection inspect the axle for damage. • Visually If the axle is damaged or bent, replace it. the rear axle in an alignment jig or on V blocks, and • Set place a dial gauge [A] against the middle point. the axle slowly. The difference between the highest • Turn and lowest dial gauge readings is the axle runout (TIR). If the runout exceeds the service limit, replace the axle. Rear Axle Shaft Runout Standard: TIR 1 mm (0.04 in.) or less Service Limit: TIR 2 mm (0.08 in.) 11-26 FINAL DRIVE Final Gear Case Final Gear Case Oil Level Inspection the vehicle so that it is level, both side-to-side and • Park front-to-rear. • Remove the filler cap. CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case. the oil level. The oil level should come to the bot• Check tom of the filler opening [A]. • • If it is insufficient, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. Apply grease to the O-ring. Be sure the O-ring is in place. Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb) Final Gear Case Oil Change to the Final Drive in the Periodic Maintenance chap• Refer ter. Final Gear Case Removal • Remove: Lower Rear Shock Absorber Mounting Bolts, Nuts and Washers (see Suspension chapter) Rear Brake Cable Ends [A] (see Brake chapter) Final Gear Case Breather Hose [B] Rear Bottom Guard (see Frame chapter) FINAL DRIVE 11-27 Final Gear Case • Remove: Brake Cable Mount Bolts [A] Brake Cam Lever Cover and Cable Mount [B] • Remove: Final Gear Case Bolts [A] (10) Final Gear Case [B] Final Gear Case Installation • Install: Spring [A] • Dowel Pins [B] New Gasket [C] (see Brake System chapter) Insert the pinion gear shaft of the final gear case in the plate assembly. Align the splines by rotating the axle shaft. the final gear case bolts following the tightening • Tighten sequence [110]. Torque - Final Gear Case Bolts: 42 N·m (4.3 kgf·m, 31 ft·lb) 11-28 FINAL DRIVE Final Gear Case Final Gear Case Disassembly • Remove: Final Gear Case (see Final Gear Case Removal) Final Gear Case Right Cover Bolts [A] Final Gear Case Right Cover Bracket [B] Final Gear Case Right Cover [C] • Remove: Shim(s) [A] Ring Gear [B] • Remove: Pinion Gear Bearing Holder [A] Hold the final gear case [A] in a vise, and remove the bearing holder using the socket wrench [B]. Special Tool - Socket Wrench, Hex 50: 57001-1478 If the holder seems too difficult to break free, apply heat to softer the locking agent. FINAL DRIVE 11-29 Final Gear Case • Remove: Pinion Gear Unit [A] Shim(s) Final Gear Case Assembly check the pinion gear and ring gear for scoring, • Visually chipping, or other damage. • Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact. Install: Shim(s) Pinion Gear Unit Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced (see Final Bevel Gear Adjustment). a non-permanent locking agent to the pinion gear • Apply bearing holder [A], and tighten it. Special Tool - Socket Wrench, Hex 50: 57001-1478 Torque - Pinion Gear Bearing Holder: 137 N·m (14 kgf·m, 101 ft·lb) • Inspect: Ball Bearing [A] (see Bearing and Oil Seal section) • Oil Seals [B] (see Bearing and Oil Seal section) If they are damaged, replace the final gear case right cover [C]. Apply grease to the oil seal lips and O-ring [D]. 11-30 FINAL DRIVE Final Gear Case • Install: Final Gear Case Right Cover [A] • Final Gear Case Right Cover Bracket [B] Apply a non-permanent locking agent to the cover bolts, and tighten them following the tightening sequence [1 ~ 8]. Torque - Final Gear Case Right Cover Bolts (M8): 24 N·m (2.4 kgf·m, 17 ft·lb) Final Gear Case Right Cover Bolts (M10): 49 N·m (5.0 kgf·m, 36 ft·lb) Final Gear Case Right Cover Bolts (M12): 94 N·m (9.6 kgf·m, 69 ft·lb) • Install: Final Gear Case Left Cover Rear Axle (see Rear Axle Installation) Oil Seal Installation the oil seals in the right and left covers to the spec• Press ified positions as shown. [A] Left Cover [B] Outside Oil Seal [C] 31.5 ~ 32.5 mm (1.24 ~ 1.28 in.) [D] Inside Oil Seal [E] 21.3 ~ 22.3 mm (0.84 ~ 0.88 in.) Use the oil seal driver [A] for the outside oil seals of the right and left covers. Special Tool - Oil Seal Driver: 57001–1487 Final Bevel Gear Adjustment • The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears. First, adjust backlash, and then tooth contact by replacing shims. The amount of backlash is influenced by the ring gear position more than by the pinion gear position. Tooth contact locations is influenced by the pinion gear position more than by the ring gear position. FINAL DRIVE 11-31 Final Gear Case Final Gear Case (Backlash-related Parts) 1. Pinion Gear 2. Pinion Gear Bearing Holder 3. Gear Case Right Cover 4. Ball Bearings 5. Ring Gear 6. Pinion Gear Shim(s) 7. Ring Gear Shim(s) 11-32 FINAL DRIVE Final Gear Case 6. Pinion Gear Shims for Tooth Contact Adjustment Thickness 0.15 mm (0.006 in.) 0.2 mm (0.008 in.) 0.5 mm (0.020 in.) 0.8 mm (0.031 in.) 1.0 mm (0.039 in.) 1.2 mm (0.047 in.) Part Number 92180-1320 92180-1319 92180-1321 92180-1322 92180-1345 92180-1346 7. Ring Gear Shims for Backlash Adjustment Thickness 0.15 mm (0.006 in.) 0.2 mm (0.008 in.) 0.5 mm (0.020 in.) 0.8 mm (0.031 in.) 1.0 mm (0.039 in.) 1.2 mm (0.047 in.) Part Number 92180-1318 92180-1316 92180-1317 92180-1315 92180-1343 92180-1344 Backlash Adjustment Clean any dirt and oil off the bevel gear teeth. Install the pinion gear assembly with the primary shim 1.0 mm (0.039 in.) thickness. Assemble the final gear case (see Final Gear Case Assembly). Install the ring gear with the primary shim 1.0 mm (0.039 in.) thickness. Check the backlash during tightening the cover bolts, and stop to tighten them immediately if the backlash disappears. Then, change the ring gear shim to a thinner one. • • • install the rear axle in the gear case and hold • Temporarily, it with a vise so that the ring gear is lower than the pinion • • gear. Mount a dial gauge [A] so that the tip of the gauge is against the splined portion [B] of the pinion gear joint. To measure the backlash, move the pinion gear shaft back and forth [C] while holding the rear axle steady. The difference between the highest and the lowest gauge reading is the amount of backlash. Measure backlash at three locations equally spaced on the splines. Final Bevel Gear Backlash : 0.07 ~ 0.14 mm (0.003 ~ 0.006 in.) at pinion gear spline • If the backlash is not within the limit, replace the ring gear shim(s). To increase backlash, decrease the thickness of the shim(s). To decrease backlash, increase the thickness of the shim(s). Change the thickness a little at a time. Recheck the backlash, and readjust as necessary. FINAL DRIVE 11-33 Final Gear Case Tooth Contact Adjustment Clean any dirt and oil off the bevel gear teeth. Apply checking compound to 4 or 5 teeth of the pinion gear. • • NOTE Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. The checking compound must be smooth and firm, with the consistency of tooth paste. Special compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact. the final gear case (see Final Gear Case As• Assemble sembly). the pinion gear for one revolution in the drive and • Turn reverse (coast) direction, while creating drag on the ring • • gear. Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary. NOTE If the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern. Pinion Gear Unit Disassembly • Remove: Pinion Gear Unit [A] (see Final Gear Case Disassembly) Hold the pinion gear bearing holder nut [B] with the socket • wrench [C] in a vise, and loosen the pinion gear shaft using the pinion gear holder [D]. Special Tools - Socket Wrench: 57001-1363 Pinion Gear Holder: 57001-1480 • Remove the ball bearing [E] as necessary. Special Tool - Bearing Puller: 57001-135 11-34 FINAL DRIVE Final Gear Case Pinion Gear Unit Assembly • • • • The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set. Visually inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a bearing, replace the bearing. Be sure to check and adjust the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced. Press the bearing [A] on the pinion gear until it is bottomed. Install the pinion gear bearing holder nut [B] so that the projection [C] faces outward. a non-permanent locking agent to the pinion gear • Apply bearing holder nut [A], and tighten it. Special Tools - Socket Wrench [B]: 57001-1363 Pinion Gear Holder [C]: 57001-1480 Torque - Pinion Gear Bearing Holder Nut: 157 N·m (16 kgf·m, 116 ft·lb) Bevel Gear Inspection check the bevel gears [A] for scoring, chipping, • Visually or other damage. Replace the bevel gears as a set if either gear is damaged. FINAL DRIVE 11-35 Final Gear Case 11-36 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close tolerances, the clearance cannot normally be measured. CAUTION Do not remove any bearings for inspection except the right rear axle bearing. each bearing in the case or hub back and forth [A] • Turn while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. the needle bearings [A] in the final gear case. • Check The rollers in the needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If the bearing is damaged, replace the rear final gear case. Oil Seal Inspection the oil seals [A]. • Inspect Replace any if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged. BRAKES 12-1 Brakes TABLE OF CONTENTS Exploded View.................................... Specifications ..................................... Special Tool ........................................ Brake Fluid ......................................... Brake Fluid Recommendation....... Brake Fluid Level Inspection......... Brake Fluid Change ...................... Brake Line Air Bleeding ................ Master Cylinder .................................. Master Cylinder Removal.............. Master Cylinder Installation........... Master Cylinder Disassembly ....... Master Cylinder Assembly ............ Master Cylinder Inspection (Visual Inspection).................................. Calipers .............................................. Caliper Removal ........................... Caliper Installation ........................ Caliper Disassembly ..................... Caliper Assembly .......................... Piston and Cylinder Damage ........ Caliper Holder Shaft Wear Inspection................................... Brake Pads ......................................... Brake Pad Removal ...................... Brake Pad Installation ................... Brake Pad Wear Inspection .......... 12- 2 12- 6 12- 7 12- 8 12- 8 12- 8 12- 8 12- 8 12- 9 12- 9 12- 9 12- 9 12-10 12-10 12-11 12-11 12-11 12-12 12-12 12-13 12-13 12-14 12-14 12-14 12-14 Brake Discs ........................................ Disc Cleaning................................ Disc Removal................................ Disc Installation............................. Disc Wear ..................................... Disc Runout .................................. Brake Hoses ....................................... Brake Hose Inspection.................. Brake Hose Replacement ............. Rear Brake Lever, Pedal and Cables . Brake Pedal Position Inspection ... Brake Pedal Position Adjustment.. Rear Brake Lever Free Play Inspection................................... Brake Pedal Free Play Inspection. Rear Brake Lever and Pedal Free Play Adjustment ......................... Brake Pedal Removal ................... Brake Pedal Installation ................ Brake Cable Removal ................... Brake Cable Installation ................ Brake Cable Lubrication................ Brake Pedal Shaft Removal.......... Brake Pedal Shaft Installation....... Internal Wet Brake.............................. Internal Wet Brake Disassembly... Internal Wet Brake Assembly........ 12-15 12-15 12-15 12-15 12-15 12-16 12-17 12-17 12-17 12-18 12-18 12-18 12-18 12-18 12-18 12-18 12-19 12-19 12-20 12-20 12-20 12-20 12-21 12-21 12-22 12 12-2 BRAKES Exploded View BRAKES 12-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Reservoir Cap Screws 1.5 0.15 13 in·lb 2 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb 3 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb 4 Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb 5 Brake Switch Mounting Bolt 1.2 0.12 10 in·lb 6 Brake Hose Banjo Bolts 25 2.5 18 7 Caliper Mounting Bolts 25 2.5 18 8 Bleed Valves 7.9 0.80 69 in·lb 9 Disc Mounting Bolts 37 3.8 27 B: Apply brake fluid. L: Apply a non-permanent locking agent. Si: Apply silicone grease. Remarks L 12-4 BRAKES Exploded View BRAKES 12-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Parking Brake Lever Screw – – – L 2 Gasket Screws – – – L 3 Brake Pedal Bolt 8.8 0.90 78 in·lb G: Apply grease. L: Apply a non-permanent locking agent. MF: Apply MOBIL FLUID 424 or equivalent oil. 12-6 BRAKES Specifications Item Standard Service Limit Brake Fluid: Type DOT 3 or DOT 4 – – – Pad lining thickness 4.0 mm (0.16 in.) 1 mm (0.04 in.) Disc thickness 3.3 ~ 3.7 mm (0.130 ~ 0.146 in.) 3 mm (0.12 in.) Disc runout TIR 0.2 mm (0.008 in.) or less Front Disc Brake: TIR 0.3 mm (0.012 in.) Rear Brake Lever, Pedal and Cables: Rear brake pedal position 35 ~ 40 mm (1.38 ~ 1.57 in.) – – – above footboad Rear brake lever free play 1 ~ 2 mm (0.04 ~ 0.08 in.) – – – Rear brake pedal free play 15 ~ 25 mm (0.6 ~ 1.0 in.) – – – BRAKES 12-7 Special Tool Inside Circlip Pliers : 57001–143 12-8 BRAKES Brake Fluid WARNING When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. 4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. 5. Don’t change the fluid in the rain or when a strong wind is blowing. 6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning of these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake. 7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash-point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily. 8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. 9. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE. Brake Fluid Recommendation Use extra heavy-duty brake fluid only from a container marked DOT3 or DOT4. Recommended Disc Brake Fluid Type : DOT 3 or DOT 4 Brake Fluid Level Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brakes in the Periodic Maintenance chapter. Brake Line Air Bleeding • Refer to the Brakes in the Periodic Maintenance chapter. BRAKES 12-9 Master Cylinder Master Cylinder Removal • Remove: Brake Hose Banjo Bolt [A] Master Cylinder Clamp Bolts [B] Master Cylinder [C] CAUTION Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. Master Cylinder Installation master cylinder clamp must be installed with the "UP" • The mark [A] upwards. the upper clamp bolt first, and then the lower • Tighten clamp bolt. There will be a gap at the lower part of the clamp after tightening. Torque - Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) a new flat washer on each side of the brake hose • Use fitting, and tighten the banjo bolt. Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) the brake line after master cylinder installation (see • Bleed Brakes in the Periodic Maintenance chapter). the brake for good braking power, no braking brag, • Check and no fluid leakage. WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc. The brakes will not function on the first application of the lever if this is not done. Master Cylinder Disassembly • Remove: Master Cylinder (see Master Cylinder Removal) Brake Lever Pivot Nut [A] Brake Lever Pivot Bolt [B] Brake Lever [C] Dust Cover [D] Circlip [E] Piston [F] Spring [G] Special Tool - Inside Circlip Pliers: 57001–143 CAUTION Do not remove the secondary cup [H] from the piston since removal will damage it. 12-10 BRAKES Master Cylinder Master Cylinder Assembly assembly, clean all parts including the master • Before cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake. care not to scratch the piston or the inner wall of the • Take cylinder. brake fluid to the removed parts and to the inner • Apply wall of the cylinder. • Tighten: Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52 in·lb) Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb) Master Cylinder Inspection (Visual Inspection) • Refer to the Brakes in the Periodic Maintenance chapter. BRAKES 12-11 Calipers Caliper Removal the front wheel (see Wheels/Tires chapter). • Remove Loosen the bolt [A] at the brake hose lower end, • and tighten itbanjo loosely. Unscrew the caliper bolts [B]. • Detach the caliper [C]mounting from the disc. • Unscrew the banjo bolt and remove the brake hose [D] • from the caliper. CAUTION Immediately wash away any brake fluid that spills. NOTE If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Disassembly). Caliper Installation the caliper and brake hose lower end. • Install Replace the washers that are on each side of hose fitting • with new ones. Tighten: Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) the fluid level in the brake reservoir. • Check Bleed the brake line (see Brakes in the Periodic Mainte• nance chapter). the brake for good braking power, no brake drag, • Check and no fluid leakage. WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc. The brakes will not function on the first application of the lever if this is not done. 12-12 BRAKES Calipers Caliper Disassembly • Remove: Caliper (see Caliper Removal) • Pads (see Brake Pad Removal) Anti-rattle Spring Using compressed air, remove the piston. Cover the caliper opening with a clean, heavy cloth [A]. Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper. WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers. NOTE If compressed air is not available, do as follows with the brake hose connected to the caliper. Prepare a container for brake fluid. Remove the pads and spring (see Brake Pad Removal). Pump the brake lever to remove the caliper piston. • Remove: Dust Seal [A] Fluid Seal [B] Bleed Valve [C] and Rubber Cap [D] Boots [E] and Caliper Holder [F] Caliper Assembly the fluid seal [A] with a new one. • Replace Apply brake fluid to the fluid seal, and install it into the • cylinder by hand. Replace the dust seal [B] with a new one if it is damaged. Apply brake fluid to the dust seal, and install it into the cylinder by hand. BRAKES 12-13 Calipers brake fluid to the outside of the pistons [A], and • Apply push them into the cylinder by hand. Take care that nei- • • • ther the cylinder nor the piston skirt gets scratched. Replace the rubber boots [B] if they are damaged. Apply a thin coat of silicone grease to the caliper holder shafts [C] and holder holes [D] (Silicone grease is a special high temperature, water-resistant grease). Install: Caliper Holder [E] Bleed Valve [F] and Rubber Cap Torque - Bleed Valve: 7.9 N·m (0.80 kgf·m, 69 in·lb) the anti-rattle spring [A] in the caliper as shown. • Install Install the pads (see Brake Pad Installation). • Piston and Cylinder Damage inspect the pistons [A] and cylinder surfaces. • Visually Replace the caliper if the cylinder and piston are badly scored or rusty. Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [B]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature. Check to see that the caliper holder shafts are not badly worn or stepped, and that the rubber friction boots are not damaged. If the rubber friction boot is damaged, replace the rubber friction boot. If caliper holder shaft is damaged, replace the caliper holder shaft and rubber friction boot as a unit. • 12-14 BRAKES Brake Pads Brake Pad Removal the front wheel (see Wheels/Tires chapter). • Remove Detach the from the disc (see Caliper Removal). • Draw out thecaliper clip [A], and remove the pad holder pin [B]. • the pad [A] on the outside. • Remove Push the [B] towards the piston, and remove the • pad [C] onholder the piston side. Brake Pad Installation the caliper piston in by hand as far as it will go. • Push Be sure • Install: that the anti-rattle spring is in place. • Brake Pads Pad Holder Pin and Clip The clip must be “outside” of the pads. WARNING Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc. The brake will not function on the first application if this is not done. Brake Pad Wear Inspection • Refer to the Brakes in the Periodic Maintenance chapter. BRAKES 12-15 Brake Discs Disc Cleaning Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone. WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings. Disc Removal • Remove: Front Hub (see Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Brake Disc [B] Disc Installation disc must be installed with the marked side [A] facing • The toward the steering knuckle. a non-permanent locking agent: • Apply Disc Mounting Bolts • Tighten: Torque - Disc Mounting Bolts: 37 N·m (3.8 kgf·m, 27 ft·lb) installing the discs, check the disc runout. Com• After pletely clean off any grease that has gotten on either side of the disc with a high flash-point solvent. Do not use one which will leave an oily residue. Disc Wear the thickness of each disc at the point [A] where • Measure it has worn the most. Replace the disc if it has worn past the service limit. Disc Thickness Standard: 3.3 ~ 3.7 mm (0.130 ~ 0.146 in.) Service Limit: 3 mm (0.12 in.) 12-16 BRAKES Brake Discs Disc Runout up the vehicle so that the wheels are off the ground. • Jack Remove • one side.the front wheels and turn the handlebar fully to up a dial gauge against the disc [A], and measure the • Set disc runout. If the runout exceeds the service limit, replace the disc. Disc Runout Standard: Service Limit: TIR 0.2 mm (0.008 in.) or less TIR 0.3 mm (0.012 in.) BRAKES 12-17 Brake Hoses Brake Hose Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Hose Replacement • Refer to the Brakes in the Periodic Maintenance chapter. 12-18 BRAKES Rear Brake Lever, Pedal and Cables Brake Pedal Position Inspection that the brake pedal [B] is in the correct position as • Check shown. [A] Converter Cover Pedal Position [C] Standard: 35 ~ 40 mm (1.38 ~ 1.57 in.) If it is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment the locknut [A], and turn the adjusting bolt [B] until • Loosen the brake pedal is correctly positioned. the locknut. • Tighten Check the brake pedal free play (see Brakes in the Peri• odic Maintenance chapter). Rear Brake Lever Free Play Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Pedal Free Play Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Rear Brake Lever and Pedal Free Play Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Brake Pedal Removal • Remove: Right Foot (see Frame chapter) the locknut and the adjusting bolt. • Loosen Remove brake switch spring [A]. • Loosen thethebrake pedal bolt [B]. • Remove: • Washers [C] Brake Pedal [D] BRAKES 12-19 Rear Brake Lever, Pedal and Cables Brake Pedal Installation grease to the tip of the brake pedal shaft. • Apply Install brake pedal. • Align thethepunch [A] on the brake pedal shaft with the • punch mark [B] mark on the brake pedal. the washers [A]. • Install Tighten: • Torque - Brake Pedal Bolt [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) the brake switch spring [C]. • Install Adjust • tion). the brake pedal position (see Brake Pedal Posi- Brake Cable Removal • Remove: Right Foot Guard (see Frame chapter) Unscrew the adjusters [A] at the rear ends of the cables, • and pull the cables out of the joints [B]. Remove the • mount [D]. circlip [C] and pull the cables out of the cable the knurled locknut [B] at the rear brake lever and • Loosen screw in the adjuster [C]. up the slots [A] in the brake lever, knurled locknut, • Line and adjuster, and then free the cable from the lever. • Remove the brake lever cable from the frame. 12-20 BRAKES Rear Brake Lever, Pedal and Cables • Remove: Swingarm (see Suspension chapter) • Remove: Circlip [A] Cotter Pin, Washer and Pin [B] Brake Pedal Cable [C] Brake Cable Installation the brake cable front ends. • Grease Replace cotter pin with a new one. • Route thethebrake cables according to the Cable, Wire, and • Hose Routing section in Appendix chapter. Install the parts removed appropriate chapter). • Adjust the brake pedal and(seerearthebrake lever. • Brake Cable Lubrication Whenever the brake cable is removed, lubricate the cable as follows: Lubricate the cable with a penetrating rust inhibitor. • Brake Pedal Shaft Removal • Remove: Swingarm (see Suspension chapter) • • Brake Pedal (see Brake Pedal Removal) Brake Cable (see Brake Cable Removal) Reverse Lock Cable (see Crankcase/Transmission chapter) Remove the brake return spring [A] with pliers. Remove the brake pedal shaft [B]. Brake Pedal Shaft Installation grease to the tip of the brake pedal shaft [A]. • Apply • Install: Brake Return Spring • • Brake Pedal Shaft Hook the brake return spring end [B] to the projection [C], turn the spring clockwise and hook the other end of the spring [D] to the brake pedal shaft [E] with pliers. Install: Brake Cable (see Brake Cable Installation) Reverse Lock Cable (see Crankcase/Transmission chapter) Brake Pedal (see Brake Pedal Installation) Swingarm (see Suspension chapter) BRAKES 12-21 Internal Wet Brake Internal Wet Brake Disassembly • Remove: Rear Final Gear Case (see Final Drive chapter) Gasket Screws [A] Gasket [B] Dowel Pins [C] • Remove: Steel Pressure Plates [A] and Steel Plates Friction Plates [B] Pins [C] and Springs • Remove: Brake Cam Plate [A] • Remove: Steel Balls [A] 12-22 BRAKES Internal Wet Brake • Remove: Brake Cam Lever Bolt and Nut [A] Brake Camshaft [B] Brake Cam Lever [C] Internal Wet Brake Assembly [A] MOBIL FLUID 424 or equivalent oil to the brake • Apply camshaft and the inside of the collar. the brake cam lever inserting the camshaft in the • Install swingarm. the punch mark [A] on the brake cam lever with the • Align punch mark [B] on the brake camshaft. • Install the brake cam lever bolt and nut, and tighten them. • Install: Steel Balls Brake Cam Plate [A] Fit the cam plate and brake camshaft [B] as shown. BRAKES 12-23 Internal Wet Brake • Install: Steel Pressure Plate [A] and Pins [B] (as shown) • Install: Steel Pressure Plates [A] Friction Plates [B] Steel Plate [C] Springs [D] • Install: Dowel Pins [A] • • New Gasket [B] Apply a non-permanent locking agent to the gasket screws [C], and tighten them. Install: Rear Final Gear Case (see Final Drive chapter) SUSPENSION 13-1 Suspension TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Special Tools ........................................................................................................................... Shock Absorbers ..................................................................................................................... Front Shock Absorber Inspection....................................................................................... Front Shock Absorber Preload Adjustment........................................................................ Front Shock Absorber Removal......................................................................................... Front Shock Absorber Installation...................................................................................... Rear Shock Absorber: .......................................................................................................... Compression Damping Adjustment ................................................................................... Rear Shock Absorber Removal ......................................................................................... Rear Shock Absorber Installation ...................................................................................... Rear Shock Absorber Preload Adjustment ........................................................................ Rear Shock Absorber Inspection ....................................................................................... Rear Shock Absorber Scrapping ....................................................................................... Suspension Arms .................................................................................................................... Suspension Arm Removal ................................................................................................. Suspension Arm Installation .............................................................................................. Suspension Arm Disassembly ........................................................................................... Suspension Arm Assembly ................................................................................................ Swingarm................................................................................................................................. Swingarm Removal............................................................................................................ Swingarm Installation......................................................................................................... Swingarm Disassembly...................................................................................................... Swingarm Assembly .......................................................................................................... Swingarm Bearing Inspection ............................................................................................ Swingarm Bearing Lubrication ........................................................................................... 13- 2 13- 4 13- 5 13- 6 13- 6 13- 6 13- 6 13- 7 13- 7 13- 7 13- 8 13- 8 13- 8 13- 9 13- 9 13-10 13-10 13-10 13-10 13-11 13-12 13-12 13-12 13-13 13-14 13-15 13-15 13 13-2 SUSPENSION Exploded View SUSPENSION 13-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb Remarks 1 Front Shock Absorber Mounting Nuts 42 4.3 31 2 Rear Shock Absorber Mounting Nuts 62 6.3 46 3 Suspension Arm Pivot Bolts 42 4.3 31 4 Steering Knuckle Joint Nuts 29 3.0 21 5 Swingarm Pivot Right Shaft 152 15.5 112 L 6 Swingarm Pivot Left Shaft 20 2.0 14 L 7 Swingarm Pivot Left Nut 152 15.5 112 G: Apply grease. L: Apply a non-permanent locking agent. AG: Apply grease (Amoco rykon premium grease No. 2 EP Green). MF: Apply MOBIL FLUID 424 or equivalent oil. R: Replacement parts 13-4 SUSPENSION Specifications Item Standard Front Shock Absorbers: Spring preload setting position Service Limit (Usable Range) No. 2 1 ~ 5 Rear Shock Absorber: Spring preload adjustment (Adjusting nut position from the center of the mounting hole upper) (Adjustable Range) 94.2 mm (3.71 in.) 93.2 ~ 104.3 mm (3.67 ~ 4.11 in.) Gas Reservoir: Compression damping Adjustment (from the seated position adjuster tuned fully clockwise) Gas pressure (Adjust Range) 14 clicks counter-clockwise 980 kPa (10 kgf/cm², 142 psi) 19 clicks – – – SUSPENSION 13-5 Special Tools Inside Circlip Pliers : 57001–143 Hook Wrench : 57001–1101 Outside Circlip Pliers : 57001–144 Bearing Driver Set : 57001–1129 Oil Seal & Bearing Remover : 57001–1058 Jack : 57001–1238 13-6 SUSPENSION Shock Absorbers Front Shock Absorber Inspection Since the front shock absorbers are sealed units which cannot be disassembled, only external checks are necessary. If one unit is damaged, replace both shock absorbers as a set. If only one unit is replaced and the two are not balanced, vehicle instability at high speed may result. Front Shock Absorber Preload Adjustment The spring adjusting sleeve [A] on the rear shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions. If the spring action feels too soft or too stiff, adjust it in accordance with the following table. Spring Action Position 1 2 (STD) 3 4 5 Spring Force ¯ Stronger Setting Soft Load Light Terrain Smooth Speed Low ¯ Hard ¯ Heavy ¯ Rough ¯ High the adjusting sleeve on shock absorber to the de• Turn sired position with the hook wrench [A]. Owner’s Tool - 92110–1129 Front Shock Absorber Removal the vehicle on a stand or a jack so that the rear • Support wheels are off the ground. Special Tool - Jack: 57001–1238 holding the rear wheels, remove the lower and up• While per shock absorber mounting bolts [A], nuts, and wash- • ers. Remove the front shock absorber [B]. SUSPENSION 13-7 Shock Absorbers Front Shock Absorber Installation plenty of grease to the inside of the bushing, sleeve • Apply and oil seals. • Install: Rubber Bushing [A] • Bushing [B] Sleeve [C] Oil Seals [D] Tighten: Torque - Front Shock Absorber Mounting Nuts: 42 N·m (4.3 kgf·m, 31 ft·lb) Rear Shock Absorber: To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Compression Damping Adjustment the compression damping adjuster [A] on the rear • Turn shock absorber gas reservoir with a flat-bead screwdriver. If the damping feels too soft or too stiff, adjust it in accordance with the following table. Seated position : adjuster turned fully clockwise [A]. Compression Damping Standard: 14 clicks NOTE Always make any damping adjustments in small steps and test their effects before using them in competition. 13-8 SUSPENSION Shock Absorbers Rear Shock Absorber Removal • Remove: Seat (see Frame chapter) • Rear Fender (see Frame chapter) Support the vehicle on a stand or a jack so that the rear wheels are off the ground. Special Tool - Jack: 57001–1238 holding the rear wheels, remove the lower and up• While per shock absorber mounting bolts [A], nuts, and wash- • ers. Remove the rear shock absorber [B]. Rear Shock Absorber Installation plenty of grease to the inside of the needle bearing, • Apply sleeve and oil seals. • Install: Oil seals [A] • Needle Bearing [B] Sleeve [C] Collars [D] Rubber Bushing [E] Tighten: Torque - Rear Shock Absorber Mounting Nuts [F]: 62 N·m (6.3 kgf·m, 46 ft·lb) Rear Shock Absorber Preload Adjustment • Remove: Rear Shock Absorber (see Rear Shock Absorber Re• moval) Loosen the locknut and turn out the adjusting nut to free the spring. Special Tools - Hook Wrench [A]: 57001–1101 SUSPENSION 13-9 Shock Absorbers the spring free length. • Measure To adjust the spring preload, turn in the adjusting nut [A] • to the desired position and tighten the locknut [B]. Adjusting nut position [C] Spring Preload Setting Position Standard: 94.2 mm (3.71 in.) Usable Range: 93.2 mm (3.67 in.) to 104.3 mm (4.11 in.) Torque - Rear Shock Absorber Spring Locknut: 30 N·m (3.1 kgf·m, 22 ft·lb) If the spring action feels too soft or too stiff, adjust it in accordance with the following table. Spring Action Position 94.2 mm (3.71 in.) ¯ 104.3 mm (4.11 in.) Spring Force Weak Setting Load Terrain Speed Soft Light Smooth Low ¯ Stronger ¯ Hard ¯ Heavy ¯ Rough ¯ High Rear Shock Absorber Inspection the upper pivot. • Check If the sleeve, needle bearing and oil seals is damaged, • replace them. Oil Seal [A] Needle Bearing [B] Sleeve [C] Rubber Bushing [D] Check the lower pivot. If bushing are worn, cracked, hardened, or otherwise damaged, replace them. Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas, do not incinerate the reservoir tank without first releasing the gas or it may explode. the shock absorber (see Rear Shock Absorber • Remove Removal). the valve cap [A] and release the nitrogen gas • Remove completely from the gas reservoir. • Remove the valve. WARNING Since the high pressure gas is dangerous, do not point the valve toward your face or body. 13-10 SUSPENSION Suspension Arms Suspension Arm Removal • Remove: Brake Hose Banjo Bolt (Caliper side) Front Wheel (see Wheels/Tires chapter) Knuckle Joint Nuts and Cotter Pin [A] Knuckle Joints [B] (from Knuckle) Tie-Rod End Nut [C] Suspension Arm Pivot Bolts [D] Suspension Arms [E] Suspension Arm Installation • Tighten: Torque - Suspension Arm Pivot Bolts: 42 N·m (4.3 kgf·m, 31 ft·lb) Knuckle Joint Nuts: 29 N·m (3.0 kgf·m, 21 ft·lb) Tie-Rod End Nut: 42 N·m (4.3 kgf·m, 31 ft·lb) Suspension Arm Disassembly • Remove: Oil Seals [A] Sleeve [B] Collars [C] SUSPENSION 13-11 Suspension Arms • Remove: Circlip [A] • Snap Ring [B] Press out the ball joint bearing [C] and needle bearing [D]. Knuckle joint [E] Special Tools - Inside Circlip Pliers: 57001–143 Outside Circlip Pliers: 57001–144 Suspension Arm Assembly the following parts as shown. • Install Front Side [A] Needle Bearing [B] [C] = 7.5 ± 0.1 mm (0.295 ± 0.004 in.) Oil seals [D] Sleeve [E] • Rear Side [F] Ball Joint Bearing [G] [H] = 13.5 ± 0.1 mm (0.531 ± 0.004 in.) Circlips [J] Oil seals [K] Apply grease to oil seals. Collars [L] 13-12 SUSPENSION Swingarm Swingarm Removal the vehicle on a stand or a jack so that the rear • Support wheels are off the ground. Special Tool - Jack: 57001–1238 • Remove: Rear Final Gear Case (see Final Drive chapter) Swingarm Pivot Left Nut [A] Swingarm Pivot Left Shaft [B] • Loosen: Boot Clamp Screw [A] Remove: • Boot Swingarm Pivot Right Shaft [B] Swingarm [C] Swingarm Installation molybdenum disulfide grease to the spline of the • Apply output shaft [A]. • Fit the propeller shaft on the output shaft. a non-permanent locking agent: • Apply Swingarm Pivot Shaft [A], [B] • Tighten: Torque - Swingarm Pivot Right Shaft: 152 N·m (15.5 kgf·m, 112 ft·lb) • Tighten: Torque - Swingarm Pivot Left Shaft [B]: 20 N·m (2.0 kgf·m, 14 ft·lb) Swingarm Pivot Left Nut [C]: 152 N·m (15.5 kgf·m, 112 ft·lb) • Fit the boot on the swingarm, and tighten the clamp screw. SUSPENSION 13-13 Swingarm Swingarm Disassembly • Remove: Collars [A] O-ring [B] • Remove: Oil Seal [A] • Remove: Tapered Roller Bearing [A] • Remove: Outer Race [A] 13-14 SUSPENSION Swingarm • Remove: Ball Bearing [A] Special Tool - Oil Seal & Bearing 57001–1058 Remover • Remove: Oil Seal [A] • Remove: Collar [A] Oil Seal [B] Swingarm Assembly grease: • Apply Inside [A] of Oil Seals Apply MOBIL FLUID 424 or Equivalent: • Surface of Collar [B] Install the following parts as shown. • Brake Lever Oil Seal [C] [D] = 14.5 ± 0.1 mm (0.571 ± 0.004 mm) Collar (level with surface) Propeller Shaft Oil Seal [E] [F] = 25 ± 0.1 mm (0.984 ± 0.004 mm) Ball Bearing [G] (level with surface) [B]: SUSPENSION 13-15 Swingarm Amoco Rykon Premium Grease No.2 EP Green: • Apply Inside of Oil Seals [A] • O-rings [B] Install the following parts as shown. Tapered Roller Bearing [C] Oil Seal (level with surface) O-ring Collar [D] Special Tool - Bearing Driver Set: 57001-1129 Swingarm Bearing Inspection the final gear case (see Final Drive chapter). • Remove Move the up and down to check for abnormal • friction, andswingarm push and pull it back and forth to check for • bearing play. If abnormal friction is felt, the bearings are damaged. Replace the oil seals and both left and right bearings. The play developed during use may indicate bearing damage. In this case, remove the swingarm and inspect the bearings. Replace both left and right bearings, if either of the bearings is damaged. Swingarm Bearing Lubrication the swingarm. • Remove Using a high solvent, wash the bearings clean • of grease, andflash-point dry them. Inspect the bearings and oil seals for abrasion, color • change, or other damage. grease to the outer races [A], and pack the tapered • Apply roller bearings [B] with the same grease. Amoco Rykon Premium Grease No. 2 EP (green) • Apply to the inside of the oil seals. • Install the swingarm (see Swingarm Installation). STEERING 14-1 Steering TABLE OF CONTENTS Exploded View......................................................................................................................... Specifications .......................................................................................................................... Steering ................................................................................................................................... Steering Stem Removal ..................................................................................................... Steering Stem Installation .................................................................................................. Knuckle Removal ............................................................................................................... Knuckle Installation ............................................................................................................ Tie-Rod Removal ............................................................................................................... Tie-Rod Installation ............................................................................................................ Tie-Rod End Removal........................................................................................................ Tie-Rod End Installation..................................................................................................... Steering Maintenance.............................................................................................................. Steering Inspection ............................................................................................................ Steering Stem Straightness ............................................................................................... Steering Lubrication ........................................................................................................... Steering Stem Clamp Inspection ....................................................................................... Steering Stem Bearing Inspection ..................................................................................... Steering Knuckle Bearing Inspection ................................................................................. Tie-Rod End and Steering Knuckle Joint Inspection.......................................................... Handlebar ................................................................................................................................ Handlebar Removal ........................................................................................................... Handlebar Installation ........................................................................................................ 14- 2 14- 4 14- 5 14- 5 14- 6 14- 7 14- 7 14- 7 14- 7 14- 8 14- 8 14- 9 14- 9 14- 9 14- 9 14- 9 14-10 14-10 14-10 14-11 14-11 14-11 14 14-2 STEERING Exploded View STEERING 14-3 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Handlebar Holder Bolts 29 3.0 22 2 Tie-Rod Adjusting Locknuts 22 2.2 16 3 Tie-Rod End Nuts 42 4.3 31 4 Steering Stem Clamp Bolts 25 2.5 18 5 Steering Stem Bearing Joint Bolts 21 2.1 15 6 Steering Stem Bottom End Nut 40 4.1 30 7 Suspension Arm Pivot Bolts 42 4.3 31 8 Knuckle Joint Nuts 29 3.0 22 9 Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb L: Apply a non-permanent locking agent. G: Apply grease for oil seal and O-ring. AD: Apply adhesive agent. AG: Apply grease (Amoco rykon premium grease No. 2 EP Green). S: Follow the specific tightening sequence. Remarks S L 14-4 STEERING Specifications Item Standard Service Limit 387.4 ± 1.5 mm (15.3 ± 0.06 in.) – – – Tie-Rods: Tie-rod length STEERING 14-5 Steering Steering Stem Removal • Remove: Front Fender (see Frame chapter) Front Wheels (see Wheels/Tires chapter) Cotter Pins [A] Tie-Rod End Nuts [B] and Tie-Rod End Steering Stem Bearing Housing Bolts [C] (right and left) CAUTION Do not loosen the tie-rod adjusting locknuts [D], or the toe-in of the front wheels will be changed. Handlebar Assembly [A] (see Handlebar Removal) Screws [B] Clamp [C] • Remove: Air Cleaner Duct [A] Converter Intake Duct [B] Nuts [C] and Clamp Steering Clamp Bolts [D], and Plate Steering Clamps [E] and Collars Grease Seals [F] (upper and lower) the steering stem out of the frame. • Pull Remove: • Cotter Pin [A] Steering Stem Bottom End Nut [B] Collar [C] Steering Stem Bearing [D] 14-6 STEERING Steering Steering Stem Installation grease up the seal grooves [A] in the steering stem • Full bearing [B]. • Install: Collar Tighten: • Torque - Steering Stem Bottom End Nut: 40 N·m (4.1 kgf·m, 30 ft·lb) both ends of the cotter pin [A] as shown. • Bend Steering Stem Bottom End Nut [B] a non-permanent locking agent: • Apply Steering Stem Bearing Joint Bolts [A] Amoco Rykon Premium Grease No.2 EP (Green): • Apply Inside of Grease Seals [A] • • Steering Stem [B] Install: Grease Seals Steering Clamps [C] and Collars [D] Plate [E], and Steering Stem Clamp Bolts [F] Clamp [G] Nuts [H] and Washers Tighten: Torque - Steering Stem Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Tie-Rod End Nuts: 42 N·m (4.3 kgf·m, 31 ft·lb) • Inspect the toe-in (see Wheels/Tires chapter). STEERING 14-7 Steering Knuckle Removal • Remove: Front Wheel and Hub (see Wheels/Tires chapter) Brake Caliper (see Brakes chapter) Cotter Pin and [A] Tie-Rod End [B] CAUTION Do not loosen the tie-rod adjusting locknuts [C], or the toe-in of the front wheels will be changed. • Remove: Cotter Pins and Knuckle Joint Nuts [D] • Brake Hose Clamp (upper knuckle joint) Remove the knuckle [E] from the suspension arms. Knuckle Installation the spherical bearing [A]. • Inspect If roughness, excessive play, or seizure is found, replace • • • • the knuckle joint [B]. Clean the shanks [C] of the knuckle joint. Check that the joint boot [D] is not torn, worn, deteriorated, or is leaking grease. Install the knuckle. Tighten: Torque - Knuckle Joint Nut: 29 N·m (3.0 kgf·m, 22 ft·lb) Tie-Rod End Nut: 42 N·m (4.3 kgf·m, 31 ft·lb) Tie-Rod Removal • Remove: Front Wheel (see Wheels/Tires chapter) Cotter Pins and Tie-Rod End Nuts [A] Tie-Rod [B] CAUTION When removing the tie-rod, be careful not to bend it. Do not loosen the tie-rod adjusting locknuts [C], or the toe-in of the front wheels will be changed. Tie-Rod Installation right and left tie-rods are identical. • The Tighten: • Torque - Tie-Rod End Nuts: 42 N·m (4.3 kgf·m, 31 ft·lb) Wheel Nuts: 52 N·m (5.3 kgf·m, 38 ft·lb) • Inspect the toe-in (see Wheels/Tires chapter). 14-8 STEERING Steering Tie-Rod End Removal the tie-rod (see Tie-Rod Removal). • Remove Holding the across flats [A] on the tie-rod, loosen • the locknut [B]width and unscrew the tie-rod end [C]. NOTE The locknut near the flattened area on the tie-rod has left-hand threads. Turn the wrench clockwise (as viewed from the joint end) for loosening. CAUTION Do not remove the grease seal. It is packed with grease. Tie-Rod End Installation • Check that the seal lip [A] is on the shank [B]. the tie-rod ends so that width across flats on the • Install tie-rod face to the knuckle arm, the tie-rod has the correct length [A], and both visible thread lengths [B] are approximately equal. Tie-Rod Length Standard: 387.4 ± 1.5 mm (15.3 ± 0.06 in.) • Tighten: Torque - Tie-Rod Adjusting Locknuts: 22 N·m (2.2 kgf·m, 16 ft·lb) STEERING 14-9 Steering Maintenance Steering Inspection • Refer to the Steering in the Periodic Maintenance chapter. Steering Stem Straightness the steering stem (see Steering Stem Removal). • Remove Check the steering stem for straightness. • Use a straightedge along the stem. If the steering stem is bent, replace the steering stem. Steering Lubrication the steering stem clamps. • Lubricate Remove the steering stem (see Steering Stem Removal). Wipe all the old grease off the steering stem, bearing sleeves, and out of the grease seals. Apply Amoco Rykon Premium Grease No. 2 EP (Green) to the steering stem [A], grease seals [B], and mating surface [C] of the clamp. the steering stem bearing [A]. • Lubricate Remove the steering stem bearing. Pack the grease seal lips with grease. Steering Stem Clamp Inspection the steering stem clamps [A]. • Inspect If roughness, excessive play, or seizure is found, replace both clamps. 14-10 STEERING Steering Maintenance Steering Stem Bearing Inspection the spherical bearing [A]. • Inspect If roughness, excessive play, or seizure is found, replace • the steering stem bearing. Inspect the upper and lower grease seals [B]. If damage, wear or deterioration is found, replace the steering stem bearing. Steering Knuckle Bearing Inspection CAUTION Do not remove any bearings for inspection. the steering knuckle (see Steering Knuckle Re• Remove moval). the bearing seal [B] for tears or leakage. • Examine If the seal is torn or is leaking, replace the bearing. [A] the bearing back and forth while checking for • Turn roughness or binding. If roughness or binding is found, replace the bearing. Tie-Rod End and Steering Knuckle Joint Inspection each spherical bearing [A]. • Inspect If roughness, excessive play, or seizure is found, replace • the tie-rod end, or steering knuckle joint. Inspect each grease seal [B]. If damage, wear or deterioration is found, replace the tie -rod end, or steering knuckle joint. STEERING 14-11 Handlebar Handlebar Removal • Remove: Throttle Case Front Brake Master Cylinder Left-hand Switch Housing Rear Brake Lever Assembly Handlebar Cover and Indicator Unit [A] as a set Handlebar Holder Bolts [A] Handlebar Holders [B] Handlebar [C] Handlebar Installation the handlebar so that the angle of the handlebar • Install matches the angle of the steering stem as shown. [A] : Parallel the handlebar holder [A]. • Install Tighten • bolts [C].the holder front bolts [B] first and then the rear Torque - Handlebar Holder Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb) If the holder is correctly installed, there will be no gap at the front and an even gaps [D] at the rear after tightening. Be sure the indicator unit lead place under the handlebar [E]. 14-12 STEERING Handlebar the left switch housing [C] on the handlebar [B] so • Install that the opening angle is 40 [A] or less. NOTE Do not open the housing more than 40 , the built-in parts in the housing may be damaged. • Install: Rear Brake Lever Assembly [A] Left Switch Housing [B] Shift Grip [C] [D] = 2 ~ 3 mm (0.08 ~ 0.12 in.) FRAME 15-1 Frame TABLE OF CONTENTS Exploded View......................................................................................................................... Seat ......................................................................................................................................... Seat Removal .................................................................................................................... Seat Installation ................................................................................................................. Fenders ................................................................................................................................... Front Fender Removal ....................................................................................................... Front Fender Installation .................................................................................................... Rear Fender Removal........................................................................................................ Rear Fender Installation..................................................................................................... Covers ..................................................................................................................................... Side Inner Cover Removal................................................................................................. Side Inner Cover Installation.............................................................................................. Air Cleaner Cover Removal ............................................................................................... Air Cleaner Cover Installation ............................................................................................ Radiator Cover Removal.................................................................................................... Guards..................................................................................................................................... Front Guard Removal ........................................................................................................ Front Guards Installation.................................................................................................... Engine Bottom Guard Removal ......................................................................................... Engine Bottom Guard Installation ...................................................................................... Rear Bottom Guard Removal............................................................................................. Rear Bottom Guard Installation.......................................................................................... Foot Guard and Stay ............................................................................................................... Foot Guard and Stay Removal .......................................................................................... Foot Guard and Stay Installation ....................................................................................... 15- 2 15- 6 15- 6 15- 6 15- 7 15- 7 15- 7 15- 8 15- 8 15- 9 15- 9 15- 9 15- 9 15- 9 15-10 15-11 15-11 15-11 15-11 15-11 15-11 15-11 15-12 15-12 15-12 15 15-2 FRAME Exploded View 1. Canada Model FRAME 15-3 Exploded View AD: Apply adhesive agent to outside. 15-4 FRAME Exploded View FRAME 15-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Engine Mounting Bracket Bolts 52 5.3 38 2 Engine Mounting Nut 62 6.3 46 3 Footrest Mounting Bolts 44 4.5 33 AD: Apply adhesive agent. Remarks 15-6 FRAME Seat Seat Removal down the seat latch [A], and then remove the seat • Push [B] by pulling it up to the rear. Seat Installation the front seat hooks [A] into the button [B] on the air • Slip cleaner cover and the brace [C] on the frame. the stoppers [D] into the holes [E] in the frame. • Put Push • down the rear part of the seat until the lock [F] clicks. FRAME 15-7 Fenders Front Fender Removal • Remove: Seat (see Seat Removal) Air Cleaner Cover (see Air Cleaner Cover Removal) Screw and Collar [A] Upper Front Cover [B] • Remove: Screws and Collars [A] (both side) Screws and Collars [B] • Remove Bolts [A] (both side) Screws and Collar [B] (both side) Headlight Connector [C] (both side) Front Fender Front Fender Installation • Install: Grommets [A] Clamp Nut [B] Damper [C] Stay [D] Front Fender Upper Front Cover Air Cleaner Cover (see Air Cleaner Cover Installation) Seat (see Seat Installation) 15-8 FRAME Fenders Rear Fender Removal • Remove: Seat (see Seat Removal) Bolts and Collars [A] (both side) Bolts and Plats [B] (both side) • Remove: Bolts and Collars [A] Tank Cap Cover [B] • Remove: Fuel Tank Cap [A] • Rear Fender Install the fuel tank cap at once. Rear Fender Installation the fuel tank cap. • Remove • Install: Rear Fender • Fuel Tank Cap Install the removed parts. FRAME 15-9 Covers Side Inner Cover Removal • Remove: Air Cleaner Cover (see Air Cleaner Cover Removal) Screws and Collars [A] Side Inner Cover [B] Side Inner Cover Installation • Install: Collars [A] Screws [B] Air Cleaner Cover (see Air Cleaner Cover Installation) Air Cleaner Cover Removal • Remove: Seat (see Seat Removal) Knobs [A] Air Cleaner Cover [B] Air Cleaner Cover Installation the tabs [A] of the cover into the recesses (both • Insert sides). • Install the removed parts. 15-10 FRAME Covers Radiator Cover Removal • Remove: Screws and Collars [A] Quick Rivet [B] Radiator Cover [C] FRAME 15-11 Guards Front Guard Removal • Remove: Front Guard Bolts [A] Front Guard [B] Front Guards Installation the front guard. • Install Tighten the front guard bolts. • Engine Bottom Guard Removal • Remove: Bolts [A] Engine Bottom Guard [B] Engine Bottom Guard Installation • Confirm: Damper [C] • Install: Engine Bottom Guard Bolts Rear Bottom Guard Removal • Remove: Bolts (M6) [A] Bolts (M8) [B] Rear Bottom Guard [C] Rear Bottom Guard Installation • Confirm: Dampers [D] Install: • Rear Bottom Guard Bolts (M8) Bolts (M6) 15-12 FRAME Foot Guard and Stay Foot Guard and Stay Removal • Remove: Screws and Collars [A] Foot Guards [B] • Remove: Bolt and Nut [A] • Bolts [B] Guard Stays [C] Footrest [D] For left side, remove guard [E]. Foot Guard and Stay Installation left side, install the guard and tighten it. • For Install [A] and foot stay [B]. • Tightenthethefootrest footrest mounting bolt [C] and the bolts [D]. • Torque - Footrest Mounting Bolt : 44 N·m (4.5 kgf·m, 33 ft·lb) • Install the foot guard [E] and tighten the screws [F]. ELECTRICAL SYSTEM 16-1 Electrical System TABLE OF CONTENTS Exploded View.................................... Specifications ..................................... Special Tools ...................................... Parts Location..................................... Precautions......................................... Electrical Wiring.................................. Wiring Inspection .......................... Battery ................................................ Battery Removal ........................... Battery Installation ........................ Electrolyte Filling .......................... Initial Charge ................................ Precautions ................................... Interchange ................................... Charging Condition Inspection...... Refreshing Charge ....................... Charging System ................................ Alternator Cover Removal............. Alternator Cover Installation.......... Alternator Rotor Removal ............ Alternator Rotor Installation .......... Alternator Stator Removal............. Alternator Stator Installation.......... Regulator/Rectifier Output Voltage Inspection................................... Alternator Inspection ..................... Regulator/Rectifier Inspection....... Ignition System ................................... Spark Plug Removal ..................... Spark Plug Installation .................. Spark Plug Cleaning/Inspection.... Spark Plug Gap Inspection ........... Ignition Coil Removal .................... Ignition Coil Installation ................. Ignition Coil Inspection.................. Ignition Coil Primary Peak Voltage Inspection................................... Crankshaft Sensor Removal ......... Crankshaft Sensor Installation ...... Crankshaft Sensor Inspection....... Crankshaft Sensor Peak Voltage Inspection................................... 16- 4 16-10 16-12 16-13 16-14 16-16 16-16 16-17 16-17 16-17 16-17 16-19 16-19 16-20 16-21 16-21 16-23 16-23 16-24 16-25 16-26 16-26 16-26 16-27 16-28 16-29 16-32 16-32 16-33 16-33 16-33 16-33 16-34 16-34 16-36 16-36 16-37 16-37 16-38 Alternator Rotor Inspection ........... Ignition Timing Test ....................... Vehicle-down Sensor Outline........ Vehicle-down Sensor Removal ..... Vehicle-down Sensor Installation .. Vehicle-down Sensor Inspection... Electric Starter System ....................... Starter Motor Removal.................. Starter Motor Installation............... Starter Motor Disassembly............ Starter Motor Assembly ................ Commutator Cleaning/Inspection.. Armature Inspection...................... Starter Motor Brush Length........... Brush Assembly Inspection........... Brush Plate and Terminal Bolt Inspection................................... Starter Relay Inspection................ Starter Circuit Relay Inspection .... Starter Motor Clutch Removal....... Starter Motor Clutch Installation.... Starter Motor Clutch Inspection .... Torque Limiter Inspection.............. Lighting System .................................. Headlight Beam Vertical Adjustment ................................. Headlight Bulb Replacement ........ Taillight Bulb Replacement............ Radiator Fan System.......................... Radiator Fan Circuit Inspection..... Radiator Fan Motor Inspection...... Fuel Pump/Fuel Reserve Switch ........ Fuel Pump Inspection ................... Fuel Reserve Switch Inspection (1)............................................... Fuel Reserve Switch Inspection (2)............................................... Indicator Unit ...................................... Indicator Unit Removal.................. Indicator Unit Installation............... Indicator Unit Inspection ............... Switches ............................................. 16-38 16-39 16-39 16-40 16-40 16-41 16-45 16-45 16-45 16-46 16-47 16-48 16-49 16-50 16-50 16-50 16-50 16-51 16-52 16-53 16-53 16-54 16-55 16-55 16-55 16-57 16-60 16-60 16-60 16-61 16-61 16-62 16-62 16-64 16-64 16-64 16-64 16-67 16 16-2 ELECTRICAL SYSTEM Brake Light Switch Adjustment ..... Radiator Fan Switch Inspection .... Coolant Temperature Warning Light Switch Inspection .............. Switch Inspection .......................... Fuses.................................................. 16-67 16-67 16-68 16-68 16-70 30 A Main Fuse Removal.............. Radiator Fan Fuse Removal ......... Main Fuse Inspection.................... Radiator Fan Fuse Inspection....... Wiring Diagram................................... 16-70 16-70 16-70 16-71 16-72 16-4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-5 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Battery Cable Bolts 5.9 0.60 52 in·lb 2 Starter Motor Mounting Bolts 8.8 0.90 78 in·lb 3 Starter Motor Terminal Nut 4.9 0.50 43 in·lb 4 Starter Motor Terminal Locknut 6.9 0.70 61 in·lb 5 Starter Motor Bolts 4.9 0.50 43 in·lb 6 Starter Motor Clutch Bolts 34 3.5 25 7 Alternator Stator Bolts 13 1.3 113 in·lb 8 Crankshaft Sensor Mounting Bolts 5.9 0.60 52 in·lb 9 Alternator Cover Plugs 18 1.8 13 10 Alternator Rotor Bolt 127 13 94 11 Alternator Bolt Cover Bolts 8.8 0.90 78 in·lb 12 Alternator Cover Bolts 8.8 0.90 78 in·lb G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. O: Apply engine oil. R: Replacement Parts Remarks L 16-6 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-7 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Spark Plugs 13 1.3 113 in·lb 2 Ignition Coil Mounting Bolts 5.5 0.55 48 in·lb 3 Igniter Mounting Bolts 2.3 0.23 20 in·lb 4 Oil Pressure Switch 15 1.5 11 5 Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb 6 Neutral Position Switch 15 1.5 11 7 Reverse Position Switch 15 1.5 11 8 Fuel Pump Mounting Bolts 2.0 0.20 17 in·lb 9 Regulator/Rectifier Bolts 8.8 0.90 78 in·lb 10. Vehicle Down Sensor G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond : 56019–120). Remarks SS 16-8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16-9 Exploded View No. Fastener Torque N·m kgf·m ft·lb 1 Radiator Fan Switch 18 1.8 13 2 Coolant Temperature Warning Light Switch 6.9 0.70 61 in·lb SS: Apply silicone sealant (Kawasaki Bond: 56019-120). Remarks SS 16-10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery: Type Sealed Battery – – – Capacity 12 V 12 Ah – – – Alternator type Three-phase AC – – – Charging voltage 14 ~ 15 V – – – Alternator output voltage 36 ~ 54 V 3 000 r/min (rpm) – – – Stator coil resistance 0.33 ~ 0.49 – – – Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.) – – – Spark plug cap resistance 3.75 ~ 6.25 k – – – 3 needle arcing distance 7 mm (0.28 in.) or more – – – Primary winding resistance 0.09 ~ 0.13 – – – Secondary winding resistance 3.8 ~ 5.8 k – – – Primary peak voltage 50 V or more – – – Crankshaft sensor resistance 110 ~ 140 – – – Crankshaft sensor peak voltage 1.8 V or more – – – Detection method Magnetic flux detection method – – – Detection angle More than 65 ± 5 for each bank – – – Detection time Within 0.5 ~ 1.0 sec. – – – Output voltage in the text – – – Charging System: (Regulator/rectifier output voltage) Ignition System: Spark plug: Ignition coil: Vehicle-down Sensor Electric Starter System: Starter motor: Commutator diameter 28 mm (1.10 in.) 27 mm (1.06 in.) Brush length 12 mm (0.47 in.) 4 mm (0.16 in.) 17.7 ~ 22.6 kPa – – – Fuel Pump: Fuel pump pressure (0.18 ~ 0.23 kgf/cm², 2.6 ~ 3.3 psi) Switches: Brake light switch timing ON after 10 mm (0.4 in.) – – – of pedal travel Radiator fan switch resistance: Rising temperature From OFF to ON at 96 ~ 100 C (205 ~ 212 F) – – – ELECTRICAL SYSTEM 16-11 Specifications Item Falling temperature Standard From ON to OFF at 91 ~ 95 C Service Limit – – – (196 ~ 203 F) ON: Less than 0.5 OFF: More than 1 M Coolant temperature warning light switch resistance: Rising temperature From OFF to ON at 112 ~ 118 C – – – (234 ~ 244 F) Falling temperature From ON to OFF at 108 ~ 111 C (226 ~ 232 F) ON: less than 0.5 OFF: More than 1 M – – – 16-12 ELECTRICAL SYSTEM Special Tools Hook Wrench : 57001–1101 Hand Tester : 57001–1394 Timing Light : 57001–1241 Flywheel Puller Assembly : 57001–1405 Compression Gauge Gasket : 57001–1314 Needle Adapter Set : 57001–1457 ELECTRICAL SYSTEM 16-13 Parts Location Light/Dimmer Switch [A] Engine Stop Switch [B] Starter Button [C] Reverse Power Assist Switch (Override) [D] Rear Brake Light Switch [E] Ignition Switch [F] Indicator Unit [G] Front Brake Light Switch [H] Battery [A] Fuel Pump, Fuel Reserve Switch [B] (in fuel tank) Main Fuse 30 A [C] Starter Relay [D] Vehicle Down Sensor [E] Igniter [F] Ignition Coil (Rear) [G] Rear Brake Light Switch [H] Water Temperature Switch [A] Radiator Fan Switch [B] Ignition Coil (Front) [C] Spark Plug [D] Starter Motor [E] Oil Pressure Warning Light Switch [F] Crankshaft Sensor [G] Alternator [H] Reverse Position Switch [A] Neutral Position Switch [B] Regulator/Rectifier [C] Starter Circuit Relays [D] Radiator Fan Fuse [E] 16-14 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be taken when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition before condemning other parts of an electrical system. A fully charged battery is required for conducting accurate electrical system tests. The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. To prevent damaging electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. Because of the high current, never keep the starter button depressed when the starter motor will not turn over, or the current may burn out the starter motor windings. Only use an illumination bulb rated for the voltage or wattage specified in the wiring diagram, or the handle cover could be warped by excessive heat radiated from the bulb. Take care not to short the leads that are directly connected to the battery positive (+) terminal to chassis ground. Troubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail again. Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Defective wires and bad connections will affect electrical system operation. Measure coil and winding resistance when the part is cold (at room temperature). Color Codes: BK BL BR CH DG Black Blue Brown Chocolate Dark green G GY LB LG O Green Gray Light blue Light green Orange P PU R W Y Pink Purple Red White Yellow ELECTRICAL SYSTEM 16-15 Precautions Electrical Connectors: Female Connectors [A] Male Connectors [B] 16-16 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection inspect the wiring for signs of burning, fraying, • Visually etc. • • If any wiring is defective, replace the damaged wiring. Pull each connector [A] apart and inspect for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. Use the wiring diagram to find the ends of the lead which is suspected of being a problem. Connect the hand tester between the ends of the leads. Special Tool - Hand Tester: 57001–1394 Set the tester to the x 1 range. If the tester does not read 0 , the lead is defective. Replace the lead or the wiring harness [B] if necessary. ELECTRICAL SYSTEM 16-17 Battery Battery Removal off the ignition switch. • Turn Remove seat (see Frame chapter) • Loosen thethebolts [A] of the battery holder [B]. • Remove the battery with the holder and the case. • Disconnect the battery (–) cable [C] first, and • then the positive (+) cablenegative [D]. Take out the battery [E]. • Battery Installation off the ignition switch. • Turn Put the with the case and the holder in place. • Connectbattery • ble. the positive cable first and then the negative caa light coat of grease on the terminals to prevent cor• Put rosion. • Tighten the battery holder bolts. Electrolyte Filling sure that the model name [A] of the electrolyte con• Make tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name : KMX 14–BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type. This is to prevent overfilling of the electrolyte, shorting the battery life, and deterioration of the battery performance. to see that there is no peeling, tears or holes in the • Check seal sheet on the top of the battery. the battery on a level surface. • Place Remove the seal sheet. • CAUTION Do not remove the aluminum seal sheet [A] sealing the filler ports [B] until just before use. NOTE A battery whose seal sheet has any peeling, tears, holes, or from which the air-sucking sound was not heard requires a refreshing charge (initial charge). 16-18 ELECTRICAL SYSTEM Battery the electrolyte container out of the vinyl bag. • Take Detach the seal caps [A] from the container. • NOTE Do not discard the seal caps because it is used as the battery plugs later. Do not peel back or pierce the seals [B] on the container. the electrolyte container upside down aligning the • Place six seals with the six battery filler ports. the container down strongly enough to break the • Push seals. Now the electrolyte should start to flow into the battery. NOTE Do not tilt the container as the electrolyte flow may be interrupted. sure air bubbles [A] are coming up from all six filler • Make ports. Leave the container this way for 5 minutes or longer. NOTE If no air bubbles are coming up from a filler port, tap [B] the bottom of the bottle two or three times. Never remove the container from the battery. CAUTION Fill the electrolyte into the battery until the container is completely emptied. certain that all the electrolyte has flowed out. • Be the bottom the same way as above if there is any • Tap electrolyte left in the container. pull the container gently out of the battery. • Now Let the battery sit for 20 minutes. During this time, the • electrolyte permeates the special separators and the gas generated by chemical reaction is released. ELECTRICAL SYSTEM 16-19 Battery the seal caps [A] tightly into the filler ports until the seal • Fit caps are at the same level as the top of the battery. NOTE Do not hammer. Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the battery, never remove it, nor add any water or electrolyte. Initial Charge While an sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use. However, if a battery shows a terminal voltage of higher than 12.6 V after 10 minutes of filling (Note 1), no initial charge is necessary. Condition requiring initial charge Charging method 1.4 A x 2 ~ 3 hours At low temperatures (lower than 0 C) Battery has been stored in high temperature and humidity. Seal has been removed, or broken - peeling, tear or hole. (If you did not hear the air-sucking sound "Shoosh" as you removed the seal.) Battery as old as 2 years or more after manufacture. Battery manufacturing date is printed on battery top. Example) 12 10 99 T1 Day Month Year Mfg. location 1.4 A x 15 ~ 20 hours Note 1 : Terminal voltage — To measure battery terminal voltage, use a digital voltmeter. Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the sealing plug to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Refreshing Charge). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. 16-20 ELECTRICAL SYSTEM Battery CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal caps during refresh charge. If by chance an excessive amount of gas is generated due to overcharging, the safety valve operates to keep the battery safe. 3) When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative lead removed. Give a refresh charge once a month during storage. 4) Battery life If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it. (Provided, however, the vehicle’s starting system has no problem.) WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medical attention if severe. Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electrical system. Therefore, replace a sealed battery only on a vehicle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened. ELECTRICAL SYSTEM 16-21 Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage. Remove the battery (see Battery Removal). • CAUTION Be sure to disconnect the negative (-) lead first. • Measure the battery terminal voltage. NOTE Measure with a digital voltmeter [A] which can be read to one decimal place voltage. If the reading is below the specified, refreshing charge is required. Battery Terminal Voltage Standard: 12.6 V or more Refreshing Charge the battery [A] (see Battery Removal). • Remove Refresh-charge by following method according to the bat• tery terminal voltage. WARNING This battery is sealed type. Never remove seal sheet [B] even at charging. Never add water. Charge with current and time as stated below. Terminal Voltage: 11.5 ~ less than 12.5 V Standard Charge 1.4 A x 5 ~ 10 h (see following chart) Quick Charge 6.0 A x 1.0 h CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do the standard charge later on. Terminal Voltage : less than 11.5 V Charging Method: 1.4 A x 20 h 16-22 ELECTRICAL SYSTEM Battery NOTE Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current [D], decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery. Battery [A] Battery Charger [B] Standard Value [C] battery condition after refreshing charge. • Determine Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria 12.6 V or higher 12.0 ~ 12.5 V or lower 12.0 V or lower Judgement Good Charge insufficient ® Recharge Unserviceable ® Replace ELECTRICAL SYSTEM 16-23 Charging System Alternator Cover Removal the coolant (see Cooling System chapter). • Drain Remove: • Bolts [A] and Alternator Bolt Cover [B] Water Pump Cover [C] and Impeller (see Cooling System chapter) • Remove: Torque Converter Cover (see Converter System chap• ter) Remove the three bolts of the drive pulley cover, except for at the dowel pin parts [A] as shown. [B] Arrow and tighten the drive pulley holder [A] and the three • Install bolts [B]. Special Tool - Drive Pulley Holder: 57001–1520 [C] Arrow the drive pulley with the drive pulley holder, • Holding loosen the alternator rotor bolt [A]. • Remove: Alternator Rotor Bolt 16-24 ELECTRICAL SYSTEM Charging System • Remove: Collar [A] Install the M6 bolt [B] to the collar, and remove it. an oil pan under the engine left side. • Place Remove: • Alternator and Crankshaft Sensor Lead Connectors (disconnect) Alternator Cover Bolts [A] Alternator Cover [B] Clamp [C] Alternator Cover Installation sure all of the old gasket has been removed from the • Be alternator cover and the left crankcase sealing surfaces. that the dowel pins [A] are in place, and fit a new • Check gasket on the crankcase. • Check that the bearing [B] is in place. the grommets [A] into the notch in the cover. • Fit Grease • Tighten the alternator cover oil seal. • Torque - Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) ELECTRICAL SYSTEM 16-25 Charging System that the O-ring [A] in the collar [B] is in good con• Check dition. grease to the O-ring. • Apply Install collar on the alternator cover. • Install the the alternator rotor bolt [C]. • • Hold the drive pulley with the drive pulley holder [A]. Special Tool - Drive Pulley Holder: 57001-1520 • Tighten: Torque - Alternator Rotor Bolt: 127 N·m (13 kgf·m, 94 ft·lb) Alternator Bolt Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Add engine oil. Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Ball Bearing [A] • Thread the flywheel puller [A] onto the alternator rotor. Special Tool - Flywheel Puller: 57001–1405 the flywheel puller, turn the rotor puller until the • Holding alternator rotor is forced off the end of the crankshaft. CAUTION If the rotor is difficult to remove, turn the puller while tapping the end of the puller. Do not strike the alternator rotor. Striking the rotor can cause the magnets to lose magnetism. 16-26 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation [A] the inside of the rotor and the end of the crank• Clean shaft. the rotor onto the crankshaft so that woodruff key [B] • Fit fits in the groove [C] in the hub of the rotor. the torque limiter [A]. • Install Install the alternator rotor [B] while turning the starter • clutch gear [C]. Alternator Stator Removal • Remove: Alternator Cover (see Alternator Cover Removal) Crankshaft Sensor [A] (see Crankshaft Sensor Removal) Bolts [B] and Alternator Stator [C] Alternator Stator Installation • Tighten: Torque - Alternator Stator Bolts: 13 N·m (1.3 kgf·m, 113 in·lb) • Install: Crankshaft Sensor (see Crankshaft Sensor Installation) Fit the lead grommets into the notch on the alternator • cover. Grommets [A] for Alternator Leads Grommets [B] for Crankshaft Sensor Leads ELECTRICAL SYSTEM 16-27 Charging System Regulator/Rectifier Output Voltage Inspection the seat (see Frame chapter). • Remove Check the condition (see Battery section). • Warm up thebattery • conditions. engine to obtain actual alternator operating that the ignition switch is turned off, and connect a • Check hand tester to the battery terminals. Special Tool - Hand Tester : 57001–1394 the engine and note the voltage readings at various • Start engine speeds with the headlight turned on and then off. The readings should show nearly battery voltage when the engine speed is low, and as the engine speed increases, the readings should also increase. Regulator/Rectifier Output Voltage Tester Range 25 V DC Connections Tester (+) to Tester (–) to Battery (+) Battery (–) off the ignition switch, • Turn tester. Reading 14 ~ 15 V and disconnect the hand If the regulator/rectifier output voltage is between the values given in the table, the charging system is working normally. If the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open. If the battery voltage does not increase as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective. 16-28 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures: short, open, or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output. To check the alternator output voltage, perform the following procedures. Remove the rear fender (see Frame chapter). Disconnect the alternator connector [A]. Connect a hand tester as shown in the table. Start the engine. Run it at the rpm given in the table. Note the voltage readings (total 3 measurements). • Alternator Output Voltage Connections Reading Tester Range Tester (+) to Tester (–) to @3 000rpm 250 V AC One yellow lead Another yellow lead 36 ~ 54 V If the output voltage is within the values in the table, the alternator is operating correctly, and the regulator/rectifier is damaged. A much lower reading indicates that the alternator is defective. the stator coil resistance as follows: • Check Stop the engine. Disconnect the alternator connector. Connect a hand tester as shown in the table. Note the readings (total 3 measurement). Stator Coil Resistance Tester Range x1 • Connections Tester (+) to One yellow lead Tester (–) to Reading Another yellow lead 0.33 ~ 0.49 If there is more resistance than shown in the table, or no reading (infinity) for any two leads, the stator has an open and must be replaced. Much less resistance means the stator is shorted and must be replaced. Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground. Any reading less than infinity (¥) indicates a short, necessitating stator replacement. If the stator coils have normal resistance, but the voltage check shows the alternator to be defective; then the rotor magnetism has probably weakened, and the rotor must be replaced. Special Tool - Hand Tester : 57001–1394 ELECTRICAL SYSTEM 16-29 Charging System Regulator/Rectifier Inspection • Remove: Connectors [A] (disconnect) Bolts [B] and Regulator/Rectifier [C] Rectifier Circuit Check: Check conductivity of the following pair of terminals. • Rectifier Circuit Inspection Tester connection W/R-Y1, W/R-Y2, W/R-Y3 BK-Y1, BK-Y2, BK-Y3 The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and must be replaced. NOTE The actual meter reading varies with the meter and the individual rectifier. Generally speaking the lower reading should be from zero to one half of the scale. Regulator Circuit Check: To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ~ 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of a test light. to be sure the rectifier circuit is correct before con• Check tinuing. Regulator Circuit Test-1st Step: Connect the test light and the 12 V battery to the regulator/rectifier as shown. Check Y1, Y2, and Y3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. If the test light does not turn on, continue the test. • • 16-30 ELECTRICAL SYSTEM Charging System Regulator Circuit Test-2nd Step: Connect the test light and a 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step". Apply 12 V to the BR terminal. Check Y1, Y2, and Y3 terminals. If the test light turns on, the regulator/rectifier is defective. If the test light does not turn on, continue the test. • • • Regulator Circuit Test-3rd Step: Connect the test light and a 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step". Momentarily apply 24 V to the BR terminal by adding a 12 V battery. Check Y1, Y2, and Y3 terminals. • • • CAUTION Do not apply more than 24 V to the regulator/rectifier. Do not leave the 24 V applied for more than a few seconds, or the unit will be damaged. If the test light did not light when the 24 V was applied momentarily to the BR terminal, the regulator/rectifier is defective. If the regulator/rectifier passes all of the tests described, it may still be defective. If the charging system still does not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit. ELECTRICAL SYSTEM 16-31 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load 16-32 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent igniter damage. Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the diodes and igniter. Use the standard regulator/rectifier, or the igniter will be damaged. Spark Plug Removal Front Side: Remove: Spark Plug Cap [A] Spark Plug [B] • Rear Side: Remove: Rear Fender (see Frame chapter) Air Cleaner Cover (see Frame chapter) Inner Side Cover (see Frame chapter) Clamp Screws [A] and Clamps Converter Exhaust Joint Duct [B] • ELECTRICAL SYSTEM 16-33 Ignition System • Remove: Spark Plug Cap [A] Spark Plug [B] Spark Plug Installation • Tighten: Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 113 in·lb) the spark plug caps securely. • Fit Pull up the spark pug caps lightly to make sure of the • installation of the spark plug caps. Spark Plug Cleaning/Inspection to the Spark Plug Inspection in the Periodic Main• Refer tenance chapter. Spark Plug Gap Inspection to the Spark Plug Inspection in the Periodic Main• Refer tenance chapter. Ignition Coil Removal Front Side: Remove: Spark Plug Cap [A] Primary Lead Connectors [B] Bolt [C] Ignition Coil [D] • Rear Side: Remove: Rear Fender (see Frame chapter) Air Cleaner Cover (see Frame chapter) Inner Side Cover (see Frame chapter) Converter Exhaust Joint Duct (see Spark Plug Removal (Rear Side)) Spark Plug Cap [A] Primary Lead Connectors [B] Bolt [C] Ignition Coil [D] • 16-34 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation the primary leads to the ignition coil terminals as • Connect shown. Front Side: G/W Lead ® (+) Mark [A] BK/Y Lead ® (–) Mark Rear Side: BL/W Lead ® (+) Mark [A] BK/Y Lead ® (–) Mark Ignition Coil Inspection the ignition coil. • Remove Measure the arcing distance with a coil tester [A] to check • the condition of the ignition coil [B]. Connect the ignition (with the spark plug cap left at• tached at the end of coil the spark plug lead) to the tester in the manner prescribed by the manufacturer and measure the arcing distance. Ignition Coil Arcing Distance 7 mm or more WARNING To avoid extremely high voltage shocks, do not touch the ignition coil body or leads. • If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective. To determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil. Remove the cap by turning it counterclockwise. If the arcing distance is as before, the trouble is with the ignition coil. If the arcing distance is normal, the trouble is with the spark plug cap. If a coil tester is not available, the coil can be checked for a broken or badly shorted winding with a hand tester. Special Tool - Hand Tester : 57001–1394 NOTE The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. ELECTRICAL SYSTEM 16-35 Ignition System the primary winding resistance [A] as follows: • Measure Connect the tester between the coil terminals. • Set the tester to the x 1 range. Measure the secondary winding resistance [B] as follows: Remove the plug cap by turning it counterclockwise. Connect the tester between the spark plug lead and terminal. Set the tester to the x 1 k range. Ignition Coil Winding Resistance Primary windings : 0.09 ~ 0.13 Secondary windings : 3.8 ~ 5.8 k If the hand tester does not read as specified, replace the coil. To install the plug cap, turn it clockwise. 16-36 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE Be sure the battery is fully charged. the spark plug cap (see Spark Plug Removal), • Remove but do not remove the spark plug. the primary peak voltage as follows. • Measure Connect a commercially peak voltage adapter [A] to the hand tester [B] (250 V DC range). Install the needle adapters [C] on the peak voltage adapter leads. Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 Recommended Tool - Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI Insert the needle adapter inside the seal of the G/W (front) or BL/W (rear) lead in the ignition coil [D] until the needle reaches the terminal in the ignition coil. Install a new spark plug [E] into the spark plug cap, and ground it to the engine. WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. Turn the ignition switch ON, rotate the engine for 4 ~ 5 • seconds with the transmission in neutral to measure the • primary peak voltage. Repeat the measurements 5 times for one ignition coil. Ignition Coil Primary Peak Voltage Standard: 50 V or more the test for the other ignition coil. • Repeat If the reading is less than the specified value, check the following. Ignition Coils (see Ignition Coil Inspection) Crankshaft Sensor (see Crankshaft Sensor Inspection) If the ignition coils and crankshaft sensor are normal, see the Ignition System Troubleshooting chart. Crankshaft Sensor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Crankshaft Sensor Mounting Bolts [A] Plate [B] Crankshaft Sensor [C] ELECTRICAL SYSTEM 16-37 Ignition System Crankshaft Sensor Installation • Install: Stator Coil Leads [A] • Plate [B] Crankshaft Sensor [C] Tighten: Torque - Crankshaft Sensor Mounting Bolts: 5.9 N·m (0.6 kgf·m, 52 in·lb) the lead grommets into the notch on the alternator • Fit cover. Grommets [A] for Alternator Leads Grommets [B] for Crankshaft Sensor Leads Crankshaft Sensor Inspection the rear fender (see Frame chapter). • Remove the crankshaft sensor lead connector [A]. • Disconnect Measure the crankshaft sensor resistance. • Connect a hand tester between the BK/W lead and the BL lead. Set the tester to the x 10 range. Crankshaft Sensor Resistance 110 ~ 140 If the tester does not read as specified, replace the crankshaft sensor. 16-38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE Be sure the battery is fully charged. the spark plug caps, but do not remove the spark • Remove plugs. • Disconnect: Crankshaft Sensor Wire Connector [A] the hand tester [B] to the 10 V DC range. • Set Connect the peak voltage adapter [C] to the hand tester • and crankshaft sensor leads in the connector. Special Tool - Hand Tester: 57001–1394 Recommended Tool - Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI Connections: Crankshaft Sensor Wire ¬ Blue ¬ Black/White Adapter Red Black Hand Tester ® (+) ® (–) Turn the ignition switch on, and rotate the engine for 4 ~ 5 • seconds with the transmission gear in neutral to measure the pickup coil peak voltage. • Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage Standard: 1.8 V or more If the peak voltage is lower than the standard, inspect the crankshaft sensor. Alternator Rotor Inspection the timing projection [A] for damage such as chip• Check ping or grooving. If the timing projection on the rotor is visibly damaged, replace the alternator rotor. ELECTRICAL SYSTEM 16-39 Ignition System Ignition Timing Test the ignition timing inspection plug. • Remove Attach a timing [A] and a tachometer in the manner • prescribed by thelightmanufacturer. Special Tool - Timing Light : 57001–1241 the engine and aim the timing light at the timing mark • Start on the alternator rotor. the engine at the speeds specified and note the align• Run ment of the timing marks. [A] F or R mark Ignition Timing Engine speed r/min (rpm) Slot [B] aligned with: 1 100 and below Advanced mark [C] on alternator rotor 5 000 and above Advanced mark [D] on alternator rotor NOTE Do not mix up the timing marks with mark [A]. If the ignition timing is incorrect, replace the igniter and the crankshaft sensor. Vehicle-down Sensor Outline This sensor has a weight [A] with two magnets inside, and sends a signal to the igniter. But when the vehicle banks 60 ~ 70 or more to either side (in fact falls down), the weight turns and shuts off the voltage in the vehicle-down sensor circuit. The igniter senses this change, and stops the fuel pump and the ignition system. Hall IC [B] 16-40 ELECTRICAL SYSTEM Ignition System Vehicle-down Sensor [A] Ground Terminal [B] BK/Y Output Terminal [C] Y/G Power Source Terminal [D] BR Constant Voltage Circuit [E] Hall IC (Integrated Circuit) [F] Vehicle-down Sensor Circuit [G] Front [H] Vehicle-down Sensor Removal CAUTION Never drop the down-sensor, especially on a hard surface. Shock to the sensor can damage it. • Remove: Rear Fender (see Frame chapter) Fuel Tank (see Fuel System chapter) Vehicle-down Sensor Lead Connector [A] Screws [B] Vehicle-down Sensor [C] Vehicle-down Sensor Installation the vehicle-down sensor [A] so that the sensor lead • Install faces backwards [B], and the arrow mark [C] on the sen- • sor points upward. Tighten the screws securely. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations, like leaning over in a turn, with the potential for an accident resulting in injury or death. Ensure that the down sensor is held in place by the sensor brackets. ELECTRICAL SYSTEM 16-41 Ignition System Vehicle-down Sensor Inspection NOTE Be sure the battery is fully charged. Vehicle-down Sensor Power Source Voltage: Remove: Seat (see Frame chapter) Vehicle-down Sensor Lead Connector • • Connect: Vehicle-down Sensor Lead Connector [A] (harness side) Digital Volt Meter [B] I. Connections to Connector (12 V circuit) Meter (+) ® Connector BR Lead [C] Meter (–) ® Connector BK/Y Lead [D] Turn the ignition switch ON, and measure the power source voltage. • Vehicle-down Sensor Power Source Voltage Standard: Battery Voltage (12.5 V or more) the ignition switch OFF. • Turn If there is no battery voltage, check the following: Main Fuse 30A Ignition Switch Wiring for Vehicle-down Sensor Power Source II. Connections to Connector (5 V circuit) Meter (+) ® Connector Y/G Lead [E] Meter (–) ® Connector BK/Y Lead [D] Turn the ignition switch ON, and measure the power source voltage. • Vehicle-down Sensor Power Source Voltage Standard: about 5 V the ignition switch OFF. • Turn If there is no standard voltage, check the following: Igniter Wiring for Vehicle-down Sensor Power Source 16-42 ELECTRICAL SYSTEM Ignition System Vehicle-down Sensor Output Voltage: Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). Connect the vehicle-down sensor [A] to the connector of the harness. Hold the sensor almost vertical [B] with the arrow mark pointed up. Connect: Vehicle-down Sensor Lead Connector [C] Digital Volt Meter [D] Needle Adapters [E] • • • • Special Tool - Needle Adapter Set: 57001–1457 Connection to Connector (5 V circuit) Meter (+) ® Connector Y/G Lead [F] Meter (–) ® Connector BK/Y Lead [G] Turn the ignition switch ON, and measure the output voltage with the connector joined. • Vehicle-down Sensor Power Output Voltage Standard: 0.4 ~ 1.4 V (with sensor arrow mark pointed up) the sensor 60 ~ 70 or more [H] right or left, and mea• Tilt sure the output voltage. The time lag is from 0.5 to 1 second. Vehicle-down Sensor Power Output Voltage Standard: 3.7 ~ 4.4 V (with sensor tilted 60 ~ 70 or more, right or left) If the output voltage is out of the specified, replace the vehicle-down sensor. ELECTRICAL SYSTEM 16-43 Ignition System Ignition System Troubleshooting 16-44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Reverse Switch 2. Fuel Pump 3. Reverse Power Assist Switch (Override) 4. Engine Stop Switch 5. Ignition Switch 6. Reset Connector 7. Vehicle-down Sensor 8. Crankshaft Sensor 9. Igniter 10. Ignition Coils 11. Spark Plugs 12. Battery 13. Main Fuse 30A ELECTRICAL SYSTEM 16-45 Electric Starter System Starter Motor Removal • Remove: Converter Intake Duct [A] Joint Duct [B] and Collars • Remove: Starter Motor Cable [A] Starter Motor Mounting Bolts [B] Clamp [C] Starter Motor [D] CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged. Starter Motor Installation installing the starter motor, clean the starter mo• When tor lugs [A] and crankcase [B] where the starter motor is grounded. • If the O-ring [A] shows wear or damage, or if it is hardened, replace it with a new one. Apply a small amount of engine oil to the O-ring. 16-46 ELECTRICAL SYSTEM Electric Starter System • Install: Starter Motor [A] • Clamp [B] (as shown) Starter Motor Cable [C] Tighten: Torque - Starter Motor Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Starter Motor Terminal Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) grease to the O-ring [D] in the joint duct [E]. • Apply Install: • Joint Duct and Collars [F] • Clamp [G] (as shown) Tighten: Torque - Joint Duct Bolts [H]: 8.8 N·m (0.90 kgf·m, 78 in·lb) Starter Motor Disassembly • Remove: Starter Motor Bolts [A] Left End Cover [B] Right End Cover [C] Yoke [D] remove the brush plate assembly [A], remove the ter• To minal nut [B]. ELECTRICAL SYSTEM 16-47 Electric Starter System the brush spring [A] with needle nose pliers, and pull • Hold the brush [B] off the holder. Starter Motor Assembly the O-rings. • Replace Install the plate assembly to the right end cover • so that thebrush projection [A] on the brush plate fits into the • • groove on the right end cover. Install the O-ring, insulators [B], and washer [C] in that order on the terminal bolt. Tighten: Torque - Starter Motor Terminal Locknut: 6.9 N·m (0.70 kgf·m, 61 in·lb) the washers [A]. • Install Install the armature [B] between the brushes. • the yoke [A] onto the right end cover [B] aligning • Install the marks [C] on the yoke and right end cover. 16-48 ELECTRICAL SYSTEM Electric Starter System • Install the washers [A]. • Install the plate [A] on the left end cover [B]. the mark [A] on the left end cover with the mark [B] • Align on the yoke. • Tighten: Torque - Starter Motor Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Commutator Cleaning/Inspection the commutator surface [A] if necessary with fine • Smooth emery cloth [B], and clean out the grooves. ELECTRICAL SYSTEM 16-49 Electric Starter System the diameter [A] of the commutator [B]. • Measure Replace the starter motor with a new one if the commutator diameter is less than the service limit. Commutator Diameter Standard: 28 mm (1.10 in.) Service Limit: 27 mm (1.06 in.) Armature Inspection the x 1 range, measure the resistance between • Using any two commutator segments [A]. • • If there is a high resistance or no reading (¥) between any two segments, a winding is open. Replace the starter motor. Using the highest range, measure the resistance between the segments and the shaft [B]. If there is any reading at all, the armature has a short. Replace the starter motor. Special Tool - Hand Tester: 57001–1394 NOTE Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one. 16-50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Brush Length • Measure the overall length [A] of each brush. Starter Motor Brush Length Standard: 12 mm (0.47 in.) Service Limit: 4 mm (0.16 in.) If any is worn down to the service limit, replace the brush plate assembly. Brush Assembly Inspection the x 1 range, measure the resistance as shown. • Using [A] Terminal Bolt and Positive Brush [B] Brush Plate and Negative Brush If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assembly. Special Tool - Hand Tester: 57001–1394 Brush Plate and Terminal Bolt Inspection the highest range, measure the resistance as fol• Using lows: [A] Terminal Bolt and Right – Hand End Cover [B] Terminal Bolt and Brush Plate If there is any reading, the brush holder assembly has a short. Replace the brush plate assembly. Special Tool - Hand Tester: 57001–1394 Starter Relay Inspection • Remove: Seat (see Frame chapter) Starter Relay [A] ELECTRICAL SYSTEM 16-51 Electric Starter System the hand tester [A] and a 12 V battery [B] to the • Connect starter relay [C] as shown. If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Hand Tester Range: x 1 Criteria : range When battery is connected Þ 0 When battery is disconnected Þ ¥ Special Tool - Hand Tester: 57001–1394 Starter Circuit Relay Inspection • Remove: Seat (see Frame chapter) Rear Fender (see Frame chapter) Starter Circuit Relays [A] (Brake and Neutral Switch Circuit) The starter circuit relays for the brake and neutral switch circuits are identical. the hand tester [A] and a 12 V battery [B] to the • Connect starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Hand Tester Range: x 1 Criteria: When battery is connected Þ 0 When battery is disconnected Þ ¥ Relay Coil Terminals [1] and [2] Relay Switch Terminals [3] and [4] 16-52 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Engine Stop Switch 2. Starter Button 3. Front Brake Light Switch 4. Parking Brake Light Switch 5. Rear Brake Light Switch 6. Starter Circuit (Brake) 7. Ignition Switch 8. Starter Motor 9. Starter Relay 10. Main Fuse 30A Starter Motor Clutch Removal the alternator rotor (see Alternator Rotor Re• Remove moval). the rotor with the flywheel holder and take out the • Hold starter motor clutch bolts [A]. Special Tool - Flywheel Holder: 57001–1313 Relay 11. Battery 12. Starter Circuit (Neutral) 13. Neutral Switch Relay ELECTRICAL SYSTEM 16-53 Electric Starter System • Take out the one-way clutch [A]. Starter Motor Clutch Installation the one-way clutch so that the flange [A] fits on the • Install recess [B] of the race. a non-permanent locking agent: • Apply Starter Motor Clutch Bolts • Tighten: Torque - Starter Motor Clutch Bolts : 34 N·m (3.5 kgf·m, 25 ft·lb) Starter Motor Clutch Inspection • Remove: Alternator Rotor (see Alternator Rotor Removal) the starter clutch gear into the starter motor clutch. • Fit If the alternator rotor turns counterclockwise [A] freely from the starter clutch gear, but not clockwise [B], the clutch is operating correctly. If the clutch does not operate correctly, or if it makes noise, disassemble it and examine each part visually. Replace any worn or damaged parts. NOTE Examine the starter clutch gear [A]. Replace it if it is worn or damaged. 16-54 ELECTRICAL SYSTEM Electric Starter System Torque Limiter Inspection • Remove: Alternator Rotor (see Alternator Rotor Removal) the torque limiter [A] and visually inspect it. • Remove If the limiter has wear, discoloration, or other damage, replace it as a unit. ELECTRICAL SYSTEM 16-55 Lighting System Headlight Beam Vertical Adjustment the adjusting screw [A] on each headlight rim in or • Turn out to adjust the headlight vertically. NOTE On high beam, the brightest point should be slightly below horizontal with the vehicle on its wheels and the rider seated. Adjust both headlights to the same angle. Headlight Bulb Replacement • Remove: Front Fender (see Frame chapter) Mounting Screws [A] Headlight Unit [B] • Remove: Headlight Bolts [A] and Washer Vertical Adjustment Screw [B], Spring, and Nut Headlight Body [C] • Remove: Headlight Connector [A] Dust Cover [B] 16-56 ELECTRICAL SYSTEM Lighting System the holder [A] and turn it counterclockwise. • Push Remove: • Holder Headlight Bulb [B] the new bulb [A] by aligning the projection [B] with • Insert the notch [C] in the headlight unit. the bulb holder [A] in, turn it clockwise, and release • Push it. It should lock in position. the dust cover [A]. • Fit Face the TOP mark [B] upward. ELECTRICAL SYSTEM 16-57 Lighting System • Install: Grommet [A] Vertical Adjustment Screw, Spring and Nut [B] Damper, Collar and Bolt [C] Taillight Bulb Replacement • Remove: Rear Fender (see Frame chapter) Tail Light Connector [A] Screws and Collars [B] Tail Light Assembly [C] with Cover • Remove Screw [A] Screw and Collar [B] Tail Light Cover [C] the screws [A]. • Remove Remove the taillight lens [B] from the taillight assembly. • 16-58 ELECTRICAL SYSTEM Lighting System the bulb [A] in, turn it counterclockwise, and pull it • Push out. • Be sure the socket is clean. the new bulb by aligning the pins [A] with the • Insert grooves [B] in the walls of the socket. the bulb in, turn it clockwise, and release it. It should • Push lock in position. ELECTRICAL SYSTEM 16-59 Lighting System Lighting System Circuit 1. Reverse Switch 2. Reverse Indicator Light (LED) 3. Front Brake Light Switch 4. Parking Brake Light Switch 5. Rear Brake Light Switch 6. Headlight (Right) 7. Headlight (Left) 8. Reset Connector 9. Light/Dimmer Switch 10. Ignition Switch 11. Main Fuse 30A 12. Battery 13. Tail/Brake Light 16-60 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection the leads from the radiator fan switch [A]. • Disconnect Using an auxiliary wire [B], connect the radiator fan switch • leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the following. Leads and Connectors Main Fuse and Fan Fuse Fan Motor Radiator Fan Motor Inspection the connector [A] in the fan lead. • Disconnect Using two auxiliary wires, supply battery [B] voltage to the • fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Motor Leads BL: Battery (+) BK: Battery (–) Radiator Fan Circuit 1. Radiator Fan Fuse 20A 2. Radiator Fan Switch 3. Radiator Fan 4. Main Fuse 30A 5. Battery ELECTRICAL SYSTEM 16-61 Fuel Pump/Fuel Reserve Switch Fuel Pump Inspection Fuel Pump Supply Voltage Inspection: Turn the ignition switch OFF. Remove: Seat Fuel Pump Lead Connector [A] Connect a hand tester [B] with suitable leads as shown. Hand Tester (+) ® Fuel Pump Connector (BR) Terminal Hand Tester (–) ® Fuel Pump Connector (BK/R) Terminal Turn the ignition switch ON, and run the engine with the transmission in neutral. Measure the fuel pump supply voltage. • • • • • Fuel Pump Supply Voltage Standard: near the Battery Voltage If the reading is not as specified, replace the igniter. If the reading is as specified, check the fuel pump. Fuel Pump Operational Inspection: Remove: Fuel Pump (see Fuel System chapter) Prepare a container filled with kerosene. Prepare the rubber hoses, and connect them to the pump fitting. Connect a suitable pressure gauge to the outlet hose as shown. Fuel Pump [A] Pressure Gauge [B] Outlet Hose [C] Kerosene [D] Battery [E] (12V) Connect the pump leads to the battery using auxiliary wires as shown. Battery (+) ® Fuel Pump Connector (BR) Terminal Battery (–) ® Fuel Pump Connector (BK/R) Terminal If the pump does not operate, the pump is defective. Replace the fuel pump. If the pump operates is normal, close the outlet hose while operating the fuel pump. When the pump stops, read the pressure gauge. If the pressure gauge reading is out of the specified pressure, the pump is defective. Replace the fuel pump. • • • • • • Fuel Pump Pressure Standard: 17.7 ~ 22.6 kPa (0.18 ~ 0.23 kgf/cm², 2.6 ~ 3.3 psi) • Install the fuel pump and tighten it. Torque - Fuel Pump Mounting Bolts : 2 N·m (0.2 kgf·m, 17 in·lb) 16-62 ELECTRICAL SYSTEM Fuel Pump/Fuel Reserve Switch Fuel Reserve Switch Inspection (1) the fuel tank with fuel. • Fill Close surely. • Removethethefuelfueltanktankcap(see System chapter). • Connect the test light [A] (12FuelV 3.4 a socket with • leads) and the 12 V battery [B] to theWfuelbulb pump connector [C]. Connections: Battery (+) ® 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) ® BL Lead Terminal Battery (–) ® BK/Y Lead Terminal Special Tool - Needle Adapter Set: 57001-1457 If the test light turn on, the reverse switch is defective. Replace the fuel pump. Fuel Reserve Switch Inspection (2) • Remove: Fuel Pump (see Fuel System chapter) Connect (12 V 3.4 W bulb in a socket with • leads) andthethetest12 light V battery to the fuel pump connector as shown. 12 V Battery [A] Test Light [B] Fuel Pump Connector [C] Fuel Reserve Switch [D] If the test light doesn’t light, replace the fuel pump. NOTE It may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed. Leave the fuel reserve switch with leads for inspection connected for 3 minute. ELECTRICAL SYSTEM 16-63 Fuel Pump/Fuel Reserve Switch Fuel Pump/Fuel Reserve Switch Circuit 1. Indicator Unit 2. Fuel Level Sensor 3. Fuel Pump 4. Igniter 5. Reset Connector 6. Main Fuse 30 A 7. Battery 8. Ignition Switch 16-64 ELECTRICAL SYSTEM Indicator Unit Indicator Unit Removal • Remove: Air Cleaner Cover (see Frame chapter) Indicator Unit Lead Connector [A] Handlebar Cover and Indicator Unit [B] • Remove: Bolts [A] • Handle Holders [B] Handlebar Assembly Remove the indicator unit from handlebar cover. CAUTION Do not drop the indicator unit. Indicator Unit Installation • Install: Indicator Unit Lead Connector • Handlebar Assembly Be sure the indicator unit lead [A] placed under the handlebar [B]. Install the removed parts. CAUTION Do not drop the indicator unit. Indicator Unit Inspection • Remove: Indicator Unit (see Indicator Unit Removal) ELECTRICAL SYSTEM 16-65 Indicator Unit Check1. Indicator Light Inspection Using the auxiliary leads connect a 12 V battery to the indicator unit connector as follows: • Fuel Indicator Light [A]: Battery Positive (+) Terminal to Terminal [1] Battery Positive (–) Negative to Terminal [2] If indicator light does not go on, replace the indicator unit. Check2. LED (light Emitting Diode) Light Inspection Using the auxiliary leads, connect a 12 V battery to the indicator unit connector as follows: • Neutral Indicator Light (LED) [B]: Battery Positive (+) Terminal to Terminal [1] Battery Positive (–) Negative to Terminal [3] Reverse Indicator Light (LED) [C]: Battery Positive (+) Terminal to Terminal [1] Battery Positive (–) Negative to Terminal [4] Water Temperature Warning Light (LED) [D]: Battery Positive (+) Terminal to Terminal [1] Battery Positive (–) Negative to Terminal [5] Oil Pressure Warning Light (LED) [E]: Battery Positive (+) Terminal to Terminal [1] Battery Positive (–) Negative to Terminal [6] Belt Indicator Light (LED) [F]: Battery Positive (+) Terminal to Terminal [1] Battery Positive (–) Negative to Terminal [7] If each LED light does not go on, replace the indicator unit. 16-66 ELECTRICAL SYSTEM Indicator Unit Indicator Unit Circuit 1. Indicator Unit 2. Neutral Switch 3. Reverse Switch 4. Fuel Reserve Switch 5. Igniter 6. Oil Pressure Switch 7. Water Temperature Switch 8. Ignition Switch 9. Main Fuse 30A 10. Battery ELECTRICAL SYSTEM 16-67 Switches Brake Light Switch Adjustment to the Brake Light Switch Inspection in the Periodic • Refer Maintenance chapter. Radiator Fan Switch Inspection • Remove: Radiator Fan Switch (see Cooling System chapter) the fan switch [A] in a container of coolant so that • Suspend the temperature sensing projection and threaded portion • are submerged. Suspend an accurate thermometer [B] in the coolant. NOTE The switch and thermometer must not touch the container sides or bottom. the container over a source of heat and gradu• Place ally raise the temperature of the coolant while stirring the • coolant gently. Using the hand tester, measure the internal resistance of the switch across the terminals at the temperatures shown in the table. If the hand tester does not show the specified values, replace the switch. Radiator Fan Switch Resistance Rising temperature: From OFF to ON at 96 ~ 100 C (205 ~ 212 F) Falling temperature: From ON to OFF at 91 ~ 95 C (196 ~ 203 F) ON: Less than 0.5 OFF: More than 1 M 16-68 ELECTRICAL SYSTEM Switches Coolant Temperature Warning Light Switch Inspection • Remove: Coolant Temperature Warning Light Switch (see Cooling • • System chapter) Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged. Suspend an accurate thermometer [B] in the coolant. NOTE The switch and thermometer must not touch the container sides or bottom. the container over a source of heat and gradu• Place ally raise the temperature of the coolant while stirring the • coolant gently. Using the hand tester, measure the internal resistance of the switch across the connector and the body at the temperatures shown in the table. If the hand tester does not show the specified values, replace the switch. Coolant Temperature Warning Light Switch Resistance Rising temperature: From OFF to ON at 112 ~ 118 C (234 ~ 244 F) Falling temperature: From ON to OFF at 108 ~ 111 C (226 ~ 232 F) ON: Less than 0.5 OFF: More than 1 M Switch Inspection the hand tester, check to see that only the con• Using nections shown in the table have continuity (about zero ohms). For the handlebar switches, ignition switch, refer to tables in the Wiring Diagram. If the switch has an open or short, repair or replace it with a new one. ELECTRICAL SYSTEM 16-69 Switches Neutral Switch Connection [A] Neutral Switch Reverse Switch Connections [B] Reverse Switch Oil Pressure Switch Connections* *: Engine lubrication system is in good condition. 16-70 ELECTRICAL SYSTEM Fuses 30 A Main Fuse Removal • Remove: Seat (see Frame chapter) • Starter Relay and 30A Main Fuse Connector [A] Pull out the main fuse [B] from the starter relay with a needle nose pliers. Radiator Fan Fuse Removal • Remove: Seat (see Frame chapter) • Fuse Case Cover [A] Pull out the fuse from the fuse case. Spare Fuse [B] Main Fuse Inspection the fuse element. • Inspect If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Housing [A] Fuse Element [B] Terminals [C] Blown Element [D] CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components. ELECTRICAL SYSTEM 16-71 Fuses Radiator Fan Fuse Inspection the fuse (see Radiator Fan Fuse Removal). • Remove Inspect the element. • If it is blownfuse out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Fuse Element [A] Blown Element [B] CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components. 16-72 ELECTRICAL SYSTEM Wiring Diagram ELECTRICAL SYSTEM 16-73 Wiring Diagram APPENDIX 17-1 Appendix TABLE OF CONTENTS Troubleshooting Guide ............................................................................................................ Cable, Wire, and Hose Routing ............................................................................................... 17- 2 17- 6 17 17-2 APPENDIX Troubleshooting Guide NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Starter motor not rotating: Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn’t turn over: Starter motor clutch trouble Engine won’t turn over: Valve seizure Rocker arm seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure No fuel flow: Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded: Fuel level too high Float valve worn or stuck open Starting technique faulty (When flooded, crank the engine with the throttle fully opened to allow more air to reach the engine.) Fuel/air mixture incorrect: Pilot screw and/or idle adjusting screw maladjusted Pilot jet or air passage clogged Air cleaner clogged, poorly sealed, or missing Starter jet clogged No spark; spark weak: Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Crankshaft Sensor trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off) Poor Running at Low Speed: Spark weak: Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Igniter trouble Pickup coil trouble Ignition coil trouble Battery voltage low Fuel/air mixture incorrect: Pilot screw and/or idle adjusting screw maladjusted Pilot jet or air passage clogged Starter plunger stuck open Air cleaner clogged, poorly sealed, or missing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance APPENDIX 17-3 Troubleshooting Guide Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off) Other: Carburetor vacuum piston doesn’t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Final gear case oil viscosity too high Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble Igniter trouble Ignition coil trouble Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle jet worn Main air jet clogged Bleed holes of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged, poorly sealed, or missing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston rings bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.) Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off) Knocking: Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble Miscellaneous: Throttle valve won’t fully open Carburetor vacuum piston doesn’t slide smoothly Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Final gear case oil viscosity too high Overheating: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect Igniter trouble Fuel/air mixture incorrect: Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed, or missing Air cleaner duct loose Air cleaner clogged Compression high: Carbon built up in combustion chamber Compression release cam (K.A.C.R.) sticks close Engine load faulty: Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Final gear case overheating: Insufficient oil Bevel gears maladjusted Coolant incorrect: Coolant level too low Coolant deteriorated 17-4 APPENDIX Troubleshooting Guide Thick coolant Cooling system component incorrect: Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling: Cooling system component incorrect: Radiator fan switch trouble Thermostat trouble Converter Operation Faulty: Belt slipping: Belt dirty, worn, or wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low: Drive pulley spring broken or weak Converter engagement speed too high: Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn’t move smoothly Drive pulley movable sheave doesn’t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly: Drive pulley spring weak Driven pulley spring weak or incorrectly installed (too loose) Shifting too slowly: Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn’t move smoothly Drive pulley movable sheave doesn’t move smoothly Drive pulley spring incorrect installed (too tight) Driven pulley movable sheave doesn’t move smoothly Gear Shifting Faulty: Doesn’t go into gear: Shift shaft bent or seized Gear stuck on the shaft Shift control grip damaged Shift control cable maladjusted Reverse lock maladjusted Jumps out of gear: Shifter groove worn Gear dogs worn Shift block worn Shift fork worn Shift shaft spring weak or broken Shift control cable maladjusted Drive shaft, output shaft, and/or gear splines worn Overshifts: Shift shaft spring weak or broken Shift control cable maladjusted Abnormal Engine Noise: Knocking: Igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston holes worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise: Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn, broken, or stuck Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, guides worn Loose alternator rotor Abnormal Drive Train Noise: Converter noise: Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn APPENDIX 17-5 Troubleshooting Guide Drive pulley weight or roller worn Wear guides worn Transmission noise: Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Final gear case noise: Insufficient lubricant Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Abnormal Frame Noise: Shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Rear brake noise: Foreign matter in hub Brake not properly adjusted Other noise: Bracket, nut, bolt, etc. not properly mounted or tightened Exhaust Smokes Excessively: White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level too high Black Smoke: Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke: Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and/or Stability Unsatisfactory Handlebar hard to turn: Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Damage tie-rod end Handlebar shakes or excessively vibrates: Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem clamp bolt loose Handlebar pulls to one side: Frame bent Wheel maladjustment Suspension arm bent or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory: Too hard: Tire air pressure too high Shock absorber maladjusted Too soft: Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Brake Doesn’t Hold Front brake: Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad overworn or worn unevenly Oil, grease on pads and disc Disc worn or warped Brake overheated Rear Brake: Brake not properly adjusted Plates worn Brake parts worn or damaged Battery Discharged: Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte level too low) Battery leads making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Regulator/rectifier trouble Alternator trouble Wiring faulty Battery Overcharged: Regulator/rectifier trouble Battery trouble 17-6 APPENDIX Cable, Wire, and Hose Routing 1. Tube 2. Clamp 3. Align the white paint mark on the tube with the adjustment mark on the crankcase. 4. Electric Starter APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Cooling Hoses 2. Clamps (Install the clamps with the tabs direction as shown.) 3. Coolant Valve 4. Position the white marks on the tube as shown. 5. Damper 6. Clamps 17-8 APPENDIX Cable, Wire, and Hose Routing 1. Clamp 2. Engine Ground Lead 3. Install the clamp on the engine ground lead. APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Water Pipe 2. White Paint 3. Clamps 4. Cooling Hoses 5. Coolant Filter Body 6. Coolant Filter 7. Carburetor 8. Mark 9. Cooling Hose 10. Assemble Angle (about 45 , [4] and [9] hoses) 11. Cooling Hose 17-10 APPENDIX Cable, Wire, and Hose Routing 1. White Paint 2. Water Pipe 3. Clamp 4. Cooling Hose 5. To Carburetor 6. Carburetor Overflow Tube 7. Exhaust Pipe Cover 8. Tube 9. Breather 10. Pump Cover 11. Mark 12. To Radiator 13. Duct 14. Face the clamp screw as shown. APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Air Cleaner Duct 2. Clamps 3. Clamps 4. Boots 5. Clamp 6. Vent Hose 7. To Crankcase 8. Coolant Valve 9. Coolant Tube 10. Starter Cable 11. Carburetor 12. Clamps 13. Air Vent Tube 17-12 APPENDIX Cable, Wire, and Hose Routing 1. Clamps 2. Bands 3. Ignition Coil (Rear) 4. Clamp 5. Clamp 6. Clamp 7. Drain Plug 8. Drain Hose 9. Vent Hose 10. Align the mark. 11. Fit the projection and groove of the each ducts. APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Coolant Temperature Warning Switch 2. Reserve Tank 3. Reserve Tank Breather Hose 4. Cooling Hose 5. Clamp 6. Radiator Hose Light 7. Radiator 8. Forward 9. Face the reserve tank breather hose as shown. 10. Fan Motor Breather Hose 11. Fan Motor Lead 17-14 APPENDIX Cable, Wire, and Hose Routing 1. Radiator Hose 2. Cooling Hose 3. Reserve Tank 4. Radiator Fan Switch 5. Fan Motor Lead 6. Fan Motor Breather Hose 7. Clamp 8. Clamp 9. Face the white paint upward. 10. To Thermostat 11. To Water Pump 12. To Fan Motor 13. To Final Gear Case APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Fuel Tap 2. Fuel Tap Vacuum Hose 3. Clamp 4. Fuel Hose 5. Fuel Filter 6. To Fuel Tank 7. Face the clamp as shown. 17-16 APPENDIX Cable, Wire, and Hose Routing 1. Front Brake Switch Lead 2. Throttle Cable 3. Front Brake Hose 4. Indicator Unit Lead 5. Ignition Switch Lead 6. Brake Switch Lead 7. Left Handlebar Switch Lead 8. Parking Brake Cable 9. Choke Cable 10. Shift Control Cable 11. Shift Control Cable APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Throttle Cable 2. Choke Cable 3. Shift Control Cable 4. Clamp the choke cable only with the band. 5. Band 6. To Front Side of Shift Control Grip 17-18 APPENDIX Cable, Wire, and Hose Routing 1. Final Gear Case Breather Hose 2. Band 3. Reverse Lock Cable 4. Clamp 5. Rear Brake Cable 6. Parking Brake Cable 7. Clamp 8. Band (With the Rear Brake Light Switch) 9. Through the parking brake cable upper side on the cross pipe. 10. Shift Control Cable 11. To Rear Side of Shift Control Grip APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Head Light Lead 2. Horn Connector 3. Clamp 4. Clamp 5. Convertor Duct 6. Indicator Unit Lead Connector 7. Rear Brake Switch Lead Connector 8. Front Brake Switch Lead Connector 9. Ignition Switch Lead Connector 10. Left Handlebar Switch Lead Connector 11. Reverse Power Assist Switch Lead Connector 12. Clamp 13. Clamp 14. Radiator Fan Connector 15. Ground (Tighten with the thermostat cover bolt.) 16. Water Temperature Warning Switch Lead 17. Radiator Fan Switch Lead 17-20 APPENDIX Cable, Wire, and Hose Routing 1. Left Head Light Lead Connector 2. Radiator Fan Connector 3. Radiator Fan Switch Connector 4. Water Temperature Warning Switch Lead 5. Ground (Tighten with the thermostat cover bolt.) 6. Clamp 7. Ignition Coil (Front) 8. Clamp 9. Band 10. Regulator/Rectifier 11. Clamp 12. Starter Circuit Relays 13. Clamp APPENDIX 17-21 Cable, Wire, and Hose Routing 1. To Engine Ground 2. Main Harness 3. Clamp (Main Harness Accessory) 4. Fuel Tank Breather Hose 5. To Tail/Brake Light 6. Vehicle-down Sensor 7. Starter Relay/Main Fuse 8. To Regulator/Rectifier 9. To Reverse/Neutral Switch 10. Battery 11. Fuse Case (For Radiator Fan) 12. Spare Fuse 13. Reset Connectors 17-22 APPENDIX Cable, Wire, and Hose Routing 1. To Tail/Brake Light 2. Clamp 3. Run the main harness under the seat bracket. 4. Clamp (With the Fuel Hose) 5. Igniter 6. Ignition Coil (Rear) 7. Band (Face the end of the band upward.) 8. Clamp 9. Clamp 10. Clamp 11. To Right Headlight 12. Rear Brake Light Switch 13. Band (With the Final Gear Case Breather Hose) APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp 3. Fuel Tank Breather Hose 4. Fuel Hose 5. Clamp the fuel hose and main harness. 6. Through the hoses above the main harness. 7. Clamp 17-24 APPENDIX Cable, Wire, and Hose Routing 1. Through the brake hose to the clamp. (Left Side Only) 2. Through the brake hose to the clamp on the left side suspension arm. 3. Fit the grommet to the frame clamp. MODEL APPLICATION Year Model 2004 KSV700–A1 Beginning Frame No. JKASV700AAB600001 or JKASV6A1 4B500001 :This digit in the frame number changes from one machine to another. Part No. 99924-1315-01 Printed in Japan
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