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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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- Read OWNER'S MANUAL before operating.

KFX 700V FORCE

Quick Reference Guide

General Information 1

Periodic Maintenance 2

Fuel System 3

Cooling System 4

Engine Top End 5

Converter System 6

Engine Lubrication System 7

Engine Removal/Installation 8

Crankshaft / Transmission 9

Wheels / Tires 10

Final Drive 11

Brakes 12

Suspension 13

Steering 14

Frame 15

Electrical System 16

Appendix 17

This quick reference guide will assist

you in locating a desired topic or pro-

cedure.

•Bend the pages back to match the

black tab of the desired chapter num-

ber with the black tab on the edge at

each table of contents page.

•Refer to the sectional table of con-

tents for the exact pages to locate

the specific topic required.

KFX 700 V FORCE

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.

LIST OF ABBREVIATIONS

Aampere(s) lb pounds(s)

ABDC after bottom dead center mmeter(s)

AC alternating current min minute(s)

ATDC after top dead center Nnewton(s)

BBDC before bottom dead center Pa pascal(s)

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

Cdegree(s) Celcius rrevolution

DC direct current rpm revolution(s) per minute

Ffarad(s) TDC top dead center

Fdegree(s) Fahrenheit TIR total indicator reading

ft foot, feet Vvolt(s)

ggram(s) Wwatt(s)

hhour(s) ohm(s)

Lliter(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 opti-

mum 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 know-

ingly 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 follow-

ing 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 de-

vices or elements of design in order to perform maintenance.

2. Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are ex-

ceeded.

b.Use of replacement parts or accessories which adversely affect the performance

or durability of the vehicle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

d.Permanently removing, disconnecting, or rendering inoperative any component or

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,

THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING

$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 in-

formation to make it useful to the owner who de-

sires to perform his own basic maintenance and

repair work. A basic knowledge of mechanics,

the proper use of tools, and workshop proce-

dures must be understood in order to carry out

maintenance and repair satisfactorily. When-

ever the owner has insufficient experience or

doubts his ability to do the work, all adjust-

ments, maintenance, and repair should be car-

ried out only by qualified mechanics.

In order to perform the work efficiently and

to avoid costly mistakes, read the text, thor-

oughly familiarize yourself with the procedures

before starting work, and then do the work care-

fully in a clean area. Whenever special tools or

equipment are specified, do not use makeshift

tools or equipment. Precision measurements

can only be made if the proper instruments are

used, and the use of substitute tools may ad-

versely affect safe operation.

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 Vehi-

cle 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 care-

fully. Don’t take shortcuts.

•Remember to keep complete records of main-

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In this manual, the product is divided into

its major systems and these 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 Ta-

ble of Contents.

For example, if you want ignition coil informa-

tion, use the Quick Reference Guide to locate

the Electrical System chapter. Then, use the

Table of Contents on the first page of the chap-

ter to find the Ignition Coil section.

Whenever you see these WARNING and

CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance

practices.

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in

addition to WARNING and CAUTION) which will

help you distinguish different types of informa-

tion.

NOTE

This note symbol indicates points of par-

ticular interest for more efficient and con-

venient operation.

•Indicates a procedural step or work to be

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 inspec-

tion in the procedural step or sub-step it fol-

lows.

In most chapters an exploded view illustration

of the system components follows the Table of

Contents. In these illustrations you will find the

instructions indicating which parts require spec-

ified tightening torque, oil, grease or a locking

agent during assembly.

GENERAL INFORMATION 1-1

General Information

TABLE OF CONTENTS

Before Servicing ...................................................................................................................... 1- 2

Model Identification.................................................................................................................. 1- 5

General Specifications............................................................................................................. 1- 6

Unit Conversion Table .............................................................................................................1-9

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly oper-

ation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustra-

tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever

necessary. This section explains the items that require particular attention during the removal and

reinstallation or disassembly and reassembly of general parts.

Especially note the following:

(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 instal-

lation 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 assem-

bled 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 com-

monly 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 dam-

age.

(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 dam-

ages 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 re-

moval 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. Pos-

itive 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. There-

fore, always replace these parts with new ones every time they are removed. Although the pre-

viously 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 in-

structed 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 dete-

riorated 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 1 985 mm (78.15 in.)

Overall width 1 195 mm (47.05 in.)

Overall height 1 170 mm (46.06 in.)

Wheelbase 1 285 mm (50.60 in.)

Ground clearance:

Rear final gear case 160 mm (6.30 in.)

Center of frame 245 mm (9.65 in.)

Seat height 850 mm (33.46 in.)

Dry mass 234 kg (516 lb)

Curb mass: Front 115 kg (254 lb)

Rear 135 kg (298 lb)

Fuel tank capacity 12 L (3.2 US gal)

Performance:

Minimum turning radius 3.2 m (10.50 ft)

Engine:

Type 4-stroke, SOHC, V2-cylinders

Cooling system Liquid-cooled

Bore and stroke 82.0 × 66.0 mm (3.23 × 2.60 in.)

Displacement 697 mL (42.5 cu in.)

Compression ratio 9.9 : 1

Maximum horsepower 36.3 kW (49.4 PS) @6 500 r/min (rpm), (US) -

Maximum torque 59.2 N·m (6.04 kgf·m, 43.67 ft·lb) @5 000 r/min (rpm)

Carburetion system Carburetor, Keihin CVKR–D32

Starting system Electric Starter

Ignition system Digital DC-CDI

Timing advance Electronically advanced

Ignition timing From 5 BTDC @1 100 r/min (rpm)

to 28 BTDC @5 000 r/min (rpm)

Spark plug NGK CR7E

Valve timing:

Inlet Open 20 BTDC

Close 44 ABDC

Duration 244

Exhaust: Open 44 BBDC

Close 20 ATDC

Duration 244

Lubrication system Forced lubrication (wet sump)

Engine oil: Type API SF or SG

API SH or SJ with JASO MA class

Viscosity SAE 10W-40

Capacity 2.2 L (2.33 US qt)

GENERAL INFORMATION 1-7

General Specifications

Items KSV700-A1

Drive Train:

Primary reduction system:

Type Belt converter

Reduction ratio 3.122 ~0.635

Transmission:

Type 1-speed and reverse

Gear ratios:

Forward: 2.416 (29/27 × 27/20 × 20/12)

Reverse 4.285 (16/12 × 20/14 × 27/20 × 20/12)

Final drive system:

Type Shaft 2WD

Reduction ratio 4.375 (35/8)

Overall drive ratio:

Forward: 32.999 ~6.711

Reverse 58.527 ~11.904

Final gear case oil: Type MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR

HYDRAULIC FLUID

Capacity 900 mL (0.95 US qt)

Frame:

Type Double cradle, tubular steel

Caster (rake angle) 4.5

Camber –0.5

King pin angle 12.5

Trail 20 mm (0.79 in.)

Tread: Front 1 000 mm (39.37 in.)

Rear 900 mm (35.43 in.)

Front tire: Type Tubeless

Size AT22 × 7 – 10

Rear tire: Type Tubeless

Size AT22 × 11 – 10

Suspension:

Front: Type Double A-arms

Wheel travel 236 mm (9.29 in.)

Rear: Type Swingarm

Wheel travel 200 mm (7.87 in.)

Brake:

Front Disc × 2

Rear Enclosed wet multi-plate

Electrical Equipment:

Battery 12 V 14 Ah

Headlight: Type Semi-sealed beam

Bulb 12 V 45/45 W × 2

1-8 GENERAL INFORMATION

General Specifications

Items KSV700-A1

Tail/brake light Alternator:

Bulb 12 V 5/21 W

Alternator: Type Three - phase AC

Rated output 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 Symbol Power

mega M× 1 000 000

kilo k× 1 000

centi c×0.01

milli m× 0.001

micro m× 0.000001

Units of Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)

L × 0.2200 = gal (imp)

L × 1.057 = qt (US)

L × 0.8799 = qt (imp)

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (imp)

mL × 0.06102 = cu in

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kg·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kg·m × 9.807 = N·m

kg·m × 7.233 = ft·lb

kg·m × 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kg/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kg/cm² × 98.07 = kPa

kg/cm² × 14.22 = psi

cm Hg × 1.333 = kPa

Units of Speed:

km/h × 0.6214 = mph

Units of Power:

kW × 1.360 = PS

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

TABLE OF CONTENTS

Periodic Maintenance Chart ............... 2- 3

Torque and Locking Agent.................. 2- 5

Specifications ..................................... 2-11

Special Tools ...................................... 2-13

Periodic Maintenance Procedures...... 2-14

Fuel System..................................... 2-14

Throttle Lever Free Play

Inspection................................... 2-14

Throttle Lever Free Play

Adjustment ................................. 2-14

Choke Lever Free Play Check ...... 2-15

Choke Lever Free Play

Adjustment ................................. 2-15

Idle Speed Inspection ................... 2-15

Idle Speed Adjustment.................. 2-16

Fuel System Cleanliness

Inspection................................... 2-16

Air Cleaner Element Cleaning and

Inspection................................... 2-16

Air Cleaner Draining...................... 2-17

Fuel Hoses and Connections

Inspection................................... 2-17

Fuel Hose and Fuel Filter

Replacement .............................. 2-18

Cooling System................................ 2-19

Radiator Cleaning ......................... 2-19

Radiator Hose and Connection

Inspection................................... 2-19

Coolant Change ............................ 2-20

Coolant Filter Cleaning ................. 2-22

Engine Top End ............................... 2-22

Valve Clearance Inspection .......... 2-22

Valve Clearance Adjustment......... 2-23

Spark Arrester Cleaning................ 2-24

Converter System ............................ 2-24

Drive Belt Inspection ..................... 2-24

Drive Belt Deflection Inspection .... 2-25

Drive Belt Deflection Adjustment .. 2-26

Engine Lubrication System.............. 2-27

Engine Oil Change........................ 2-27

Oil Filter Change ........................... 2-27

Crankshaft/Transmission ................. 2-28

Shift Control Grip Free Play

Inspection................................... 2-28

Shift Control Grip Free Play

Adjustment ................................. 2-28

Wheels/Tires.................................... 2-29

Tire Inspection .............................. 2-29

Final Drive........................................ 2-29

Final Gear Case Oil Change......... 2-29

Propeller Shaft Joint Boot

Inspection................................... 2-30

Brakes.............................................. 2-30

Front Brake Pad Wear Inspection. 2-30

Front Brake Hoses and

Connections Inspection.............. 2-30

Front Brake Hose Replacement.... 2-30

Brake Fluid Level Inspection......... 2-31

Brake Fluid Change ...................... 2-31

Brake Line Air Bleeding ................ 2-32

Master Cylinder Inspection (Visual

Inspection).................................. 2-33

Caliper Fluid Seal Replacement ... 2-34

Caliper Dust Seal and Friction

Boot Replacement...................... 2-34

Rear Brake Plates Replacement... 2-34

Rear Brake Lever Free Play

Inspection................................... 2-34

Rear Brake Pedal Free Play

Inspection................................... 2-34

Rear Brake Lever and Pedal Free

Play Adjustment ......................... 2-35

Suspension...................................... 2-35

Knuckle Joint Inspection ............... 2-35

Steering ........................................... 2-36

Steering Inspection ....................... 2-36

Tie Rod End Inspection................. 2-36

Electrical System ............................. 2-37

Spark Plug Cleaning / Inspection.. 2-37

Spark Plug Gap Inspection ........... 2-37

Brake Light Switch Inspection....... 2-37

Brake Light Timing Adjustment ..... 2-37

General Lubrication ......................... 2-37

Lubrication .................................... 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.

FirstFREQUENCY

Service Regular Service

OPERATION

After 10

hrs. or

100 km

(60 mi.)

of use

Every

days

or 200

(120

mi.) of

use

Every

days

or 600

(360

mi.) of

use

Every 90

days, 1

700 km (1

100 mi.) or

when belt

indicator

light turns

on (100

hrs of use)

whichever

comes first

Every

year

of use

See

page

ENGINE

Converter drive belt wear – inspect * •2–24

Converter drive belt deflection - inspect * •2–25

Air cleaner – inspect * • • 2–16

Throttle lever play – inspect • • 2–15

Cable adjustment* • • 2–28

Idle speed – inspect •2–15

Valve clearance – inspect •2–22

Fuel system cleanliness – inspect * • • 2–16

Engine oil – change * • • 2–27

Oil filter – replace * • • 2–27

Spark plug – clean and gap • • 2–37

Spark arrester – clean •2–24

Fuel hoses and connections – inspect •2–17

Fuel hose and fuel filter replace 4 years 2–18

Radiator – clean* • • 2–19

Radiator hoses, and connections –

check* •2–19

Coolant – change* 2 years 2–20

Coolant filter of carburetor – clean •2–22

CHASSIS

Joint boots – inspect * • •

2–30

2–35

2–36

Rear brake pedal and lever play – inspect

*• • 2–34

Rear brake plates – change * every 9 600 km (6 000 mi.) 2–34

Bolts and nuts – tighten • • 2–39

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FirstFREQUENCY

Service Regular Service

OPERATION

After 10

hrs. or

100 km

(60 mi.)

of use

Every

days

or 200

(120

mi.) of

use

Every

days

or 600

(360

mi.) of

use

Every 90

days, 1

700 km (1

100 mi.) or

when belt

indicator

light turns

on (100

hrs of use)

whichever

comes first

Every

year

of use

See

page

Front brake pad wear – inspect * • • 2–30

Brake light switch – inspect * • • 2–37

Steering – inspect • • 2–36

Tire wear – inspect * •2–29

Final gear case oil – change • • 2–29

General lubrication * •2–37

Front brake fluid level – inspect • • 2–31

Front brake fluid – change •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 •2–30

Front brake hose – replace 4 years 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

Fuel System:

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 L

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 7in·lb

Fuel Tap Cover Screws 1.0 0.10 8in·lb

Fuel Pump Bolts 2.0 0.20 17 in·lb

Cooling System

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 SS

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

Engine Top End:

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

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 L

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 System:

Converter Cover Bolts 8.8 0.90 78 in·lb S

Driven Pulley Nut 93 9.5 69

Ramp Weight Nuts 6.9 0.70 61 in·lb

Spider 275 28 203 Lh

Drive Pulley Cover Bolts 13 1.3 113 in·lb

Drive Pulley Bolt 93 9.5 69 R, Lh

JointDuctBolts 8.8 0.90 78 in·lb

Engine Lubrication System:

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 L (15mm)

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Chain Guide Bolts 8.8 0.90 78 in·lb

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Torque

Fastener N·m kgf·m ft·lb Remarks

Oil Pump Drive Chain Tensioner Bolt 25 2.5 18

Engine Removal/Installation

Engine Mounting Bracket Bolts 52 5.3 38

Engine Mounting Nuts 62 6.3 46

Crankshaft/Transmission:

Crankcase Bolts (M8) 20 2.0 14 S, L (1)

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 L

Shift Shaft Cover Bolts 8.8 0.90 78 in·lb

Connecting Rod Big End Cap Nuts 34 3.5 25 MO

Engine Drain Plug 20 2.0 14

Position Plate Mounting Screws 4.9 0.50 43 in·lb L

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

Wheels/Tires:

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

Final Drive:

(Output Bevel Gears)

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

(Final Gear Case)

Oil Filler Cap 29 3.0 22

Oil Drain Plug 20 2.0 14

Final Gear Case Bolts 42 4.3 31 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

Brakes:

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

Brake Pedal Bolt 8.8 0.90 78 in·lb

Suspension:

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:

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

Frame:

Engine Mounting Bracket Bolts 52 5.3 38

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Torque

Fastener N·m kgf·m ft·lb Remarks

Engine Mounting Nut 62 6.3 46

Footrest Mounting Bolts 44 4.5 33

Electrical System:

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 L

Reverse Position Switch 15 1.5 11

Neutral Position Switch 15 1.5 11

Oil Pressure Switch 15 1.5 11 SS

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 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

54T 2.2 ~2.6 0.22 ~0.27 19 ~23 in·lb

69T 12 ~15 1.2 ~1.5 104 ~130 in·lb

67T 7.8 ~9.8 0.80 ~1.0 69 ~87 in·lb

64T 3.9 ~4.9 0.40 ~0.50 35 ~43 in·lb

87T 18 ~22 1.8 ~2.2 13 ~16

84T 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

53.4 ~4.9 0.35 ~0.50 30 ~43 in·lb

65.9 ~7.8 0.60 ~0.80 52 ~69 in·lb

814 ~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 2~3mm(0.08~0.12in.) –––

Air cleaner element oil High-quality foam air filter oil –––

Engine Top End:

Valve clearance:

Exhaust 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) –––

Inlet 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) –––

Converter System:

Belt height (Parallel portion) 1.16 ~ 3.48 mm (0.0457 ~ 0.1370 in.) 0.64 mm

(0.0251 in.)

Belt deflection 22 ~ 27 mm (0.87 ~ 1.06 in.) –––

Engine Lubrication System:

Engine oil:

Type API SF or SG –––

API SH or SJ with JASO MA class –––

Viscosity SAE10W-40 –––

Capacity 1.7L(1.80USqt) –––

(When filter is not removed)

1.9L(2.01USqt) –––

(When filter is removed)

2.2L(2.33USqt) –––

(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 AT 22 X 7-10 –––

CARLISLE, HOLE SHOT XC –––

Rear AT 22 x 11-10 –––

CARLISLE, HOLE SHOT XCT –––

Final Drive:

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) –––

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.) –––

Electrical System:

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 –––

PERIODIC MAINTENANCE 2-13

Special Tools

Oil Filter Wrench :

57001–1249

Carburetor Drain Plug Wrench, Hex 3 :

57001–1269

Flywheel & Pulley Holder :

57001–1343

Pulley Holder Attachment :

57001–1472

Filler Cap Driver:

57001–1454

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Throttle Lever Free Play Inspection

•Check that the throttle lever [A] moves smoothly from full

open to close, and the throttle closes 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 ~3mm(0.08~0.12in.)

Throttle Lever Free Play Adjustment

•Slide the rubber cover off the adjuster at the throttle case.

•Loosen the locknut [A] and turn the throttle cable upper

adjuster [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

•Check if the choke lever [A] returns properly and if the

inner cable slides smoothly.

•Make sure that the choke lever returns to its released po-

sition all the way.

•To determine the amount of choke cable play at the lever,

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

•Loosen the locknut [A] of the choke cable.

•Turn the adjuster [B] until the cable has proper amount of

play.

•Tighten the locknut securely.

Idle Speed Inspection

•Start the engine and warm it up thoroughly.

•With the engine idling, turn the handlebar to both sides to

check for any changes in the idle speed.

If handlebar movement changes the idle speed, the throt-

tle cable may be improperly adjusted incorrectly routed,

or damaged. Be sure to correct any of these conditions

before riding.

WARNING

Operation with improperly adjusted, incorrectly

routed, or damaged cables could result in an

unsafe riding condition.

•Check idle speed with a suitable tachometer.

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

•Start the engine and warm it up thoroughly.

•Turn the idle adjusting screw [A] until the idle speed is

correct.

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 ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

•Turn the fuel tap to the OFF position.

•Place the suitable container under the drain plugs [A].

•Turn out the carburetor drain plug a few turns and drain

the fuel system.

Special Tool - Carburetor Drain Plug Wrench, Hex 3:

57001–1269

•Check to see if water or dirt comes out.

•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 any-

where 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.

•Remove the air cleaner element (see Fuel System chap-

ter).

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

•Clean the element [A] in a bath of high-flash point solvent.

•Squeeze it dry in a clean towel [A]. Do not wring the ele-

ment or blow it dry; the element can be damaged.

•Inspect the element for damage.

If it is torn, punctured, or hardened, replace it.

•After cleaning, saturate the element with a high-quality

foam-air-filter oil, squeeze out the excess oil, then wrap

it in a clean rag and squeeze it as dry as possible. Be

careful not to tear the element.

Air Cleaner Draining

•If any water or oil accumulates in the tube, drain it by

taking off the tube plug [A]. After draining, be sure to install

the tube plug and clamp firmly.

Fuel Hoses and Connections Inspection

•Remove the air cleaner cover (see Frame chapter)

•Turn the fuel tap to the OFF position.

•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, kink-

ing, flattening or twisting, and route the fuel hose with a

minimum of bending so that the fuel flow will not be ob-

structed.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel Hose and Fuel Filter Replacement

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

•Remove the air cleaner cover (see Frame chapter).

•Turn the fuel tap to the OFF position.

•Remove:

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, kink-

ing, flattening or twisting, and route the fuel hose with a

minimum of bending so that the fuel flow will not be ob-

structed.

•Fit the fuel hose [A] onto the pipe fully and install the

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 ac-

cordance 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 sur-

face.

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.

•Place a container under the drain plug [A] at the bottom

of the water pump [B], then remove the drain plug.

•Remove the radiator cap [A] in two steps. First turn the

cap counterclockwise to the first step. Then push and turn

it further in the same direction and remove the cap.

•The coolant will drain from the radiator and engine.

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

•Install the cooling hose [A].

•Tighten the drain plug.

Torque - Coolant Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•Support the vehicle on a stand or the jack so that the front

wheels are off the ground. This makes air bleeding easier.

•Fill the radiator up to the radiator filler neck [B] with

coolant.

NOTE

Pour in the coolant slowly so that the air in the engine

and radiator can escape.

•Fill the reserve tank up to the full level line with coolant,

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: 2.5L(2.64USqt)

NOTE

Choose a suitable mixture ratio by referring to the

coolant manufacturer’s directions.

•Bleed the air from the cooling system as follows.

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 en-

gine 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

•Drain the coolant (see Coolant change).

•Remove the filter [A] from the cooling hoses [B] of carbu-

retor system.

•Blow [C] off dirt and sediment on the filter with com-

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 alter-

nator 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

•Measure the clearance for all four valves, one at a time

between the end of the valve stem and the adjusting

screw [A] with the thickness gauge [B].

Valve Clearance (when cold)

Exhaust: 0.20 ~ 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

•Remove the valve adjusting caps.

•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)

•Recheck the clearance.

If the clearance is incorrect, repeat the adjustment proce-

dure.

If the clearance is correct, perform the adjustment proce-

dure 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.

•Remove the drain plug [A] on the muffler.

•In an open area away from combustible materials, start

the engine with the transmission in neutral.

•Raise and lower engine speed while tapping on the muf-

fler with a rubber 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, odor-

less, poisonous gas. Breathing exhaust gas leads

to carbon monoxide poisoning, asphyxiation, and

death.

•Stop the engine.

•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 transmis-

sion 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.

•Remove the torque converter cover (see Converter Sys-

tem chapter).

•Measure the height [A] of the belt paralle portion at sev-

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

•Check the belt [A] for abnormal wear [B].

Measure the width [C] of the belt at abnormal wear point.

If any measurements exceed 0.5 mm (0.02 in.), replace

the belt.

•Check the belt for cracks, breaks, or peeling.

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

•Remove the torque converter cover (see Converter Sys-

tem chapter).

•Put the transmission in neutral and rotate the driven pulley

by hand to make sure the belt is shifted all the way to the

top of the driven pulley.

•Measure the belt deflection [A] as shown:

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 re-

moving 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

•Disassemble the driven pulley (see Converter System

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. Thickness

92026-1569 0.6 mm (0.024 in.)

92026-1617 0.8 mm (0.032 in.)

92026-1565 1.0 mm (0.039 in.)

92026-1570 1.4 mm (0.055 in.)

•Assemble the driven pulley (see Converter System chap-

ter).

•With the transmission in neutral, rotate the driven pulley

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

thedrivenpulleynut.

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

•Support the vehicle so that it is level side to side and front

to back after warming up the engine.

•Remove the engine drain plug [A] to drain the oil.

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: API SF or SG

API SH or SJ with JASO MA class

Viscosity: SAE 10W-40

Amount: 1.7L(1.80USqt)

(When filter is not removed)

1.9L(2.01USqt)

(When filter is removed)

2.2L(2.33USqt)

(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

•Drain the engine oil.

•Remove the oil filter [A] with the oil filter wrench [B].

Special Tool - Oil Filter Wrench : 57001–1249

•Replace the filter with a new one.

•When installing the oil filter, be careful of the following.

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

•Measure the distance the shift control grip moves with the

push button depressed.

•Check the shift control cable free play of both directions.

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

•Remove the battery with the battery case (see Electrical

System).

•Make sure that the shift control grip is in neutral position.

•Make sure that the gear change lever is in neutral posi-

tion.

Neutral position is the shift cable lower ends [A] and re-

verse lock cable bracket bolt [B] aligned state.

Drive Position [C]

Reverse Position [D]

•Turn the adjusting nuts [A] at shift control cable lower end

make the inner cables [B] tight with no free play.

•Turn the shift control grip from “N” to “D” and to “R” respec-

tively and make sure the change lever [C] works correctly.

•Tighten the all adjusting nuts securely.

•Slide back the rubber covers.

•Loosen the locknuts [A] and turn the shift cable upper

adjusters [B] to obtain the specified free play.

•Tighten the locknuts securely and re install the rubber

covers.

PERIODIC MAINTENANCE 2-29

Periodic Maintenance Procedures

Wheels/Tires

Tire Inspection

•Examine the tire for damage and wear.

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 re-

moval, 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, re-

place the tire.

Tire Tread Depth

Service Limit:

Front: 3mm(0.12in.)

Rear: 3mm(0.12in.)

Standard Tire

Front: AT22x7-10CARLISLE, HOLE SHOT XC

Rear: AT 22 x 11 - 10 CARLISLE, HOLE SHOT XCT

Final Drive

Final Gear Case Oil Change

•Warm up the oil by running the vehicle so that the oil will

pick up any sediment and drain easily. Then stop the

vehicle.

•Park the vehicle so that it is level, both side-to-side 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 care-

ful that no oil gets on the tire or rim because oil will

deteriorate the tire. Clean off any oil that inadver-

tently gets on them with a high-flash point solvent.

•After the oil has completely drained out, install the drain

plug with a new aluminum gasket.

Torque - Oil Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)

•Fill the final gear case up to the bottom of filler opening

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

•Visually inspect the rear propeller shaft joint boot [A] in

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

•Check the lining thickness [A] of the pads in each caliper.

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

•Inspect the brake hose and fittings for deterioration,

cracks and signs of leakage.

Thehighpressureinsidethebrakelinecancausefluidto

leak [A] or the hose to burst if the line is not properly main-

tained. Bend and twist the rubber hose while examining

it.

Replace the hose if any cracks [B] or bulges [C] are no-

ticed.

•Tighten any loose fittings.

Front Brake Hose Replacement

•Pump the brake fluid out of the line as explained in the

Brake Fluid Change.

•Remove the banjo bolts at both ends of the brake hose,

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.

•Use a new flat washer for each side of the hose fittings.

•Install the new brake hose in its place (see Appendix

chapter), and 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

•Position the reservoir horizontal, and check that the fluid

level in the reservoir is higher than the lower level line [A].

If the fluid level is lower than the lower level line, check

for fluid leakage of the brake line, and add the fluid as

follows:

Remove the reservoir cap, and fill the reservoir to the up-

per level line [A] in the reservoir with the same type and

brand of the fluid that is already in the reservoir. And then

install the reservoir cap.

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

•Remove the reservoir cap and the rubber cap on the bleed

valve.

•Attach a clear plastic hose to the bleed valve on the

caliper, and run the other end of the hose into a container.

•Fill the reservoir with new brake fluid.

•Change the brake fluid as follows:

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 sys-

tem must be bled.

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Repeat this operation until fresh brake fluid comes out into

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)

•Apply the brake lever forcefully for a few seconds, and

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 dan-

gerous to operate the vehicle under such condi-

tions, bleed the air from the brake line immediately.

Brake Line Air Bleeding

•Bleed the air whenever brake parts are replaced or re-

assembled.

•Remove the reservoir cap and fill the reservoir with new

brake fluid.

•Slowly pump the brake lever several times until no air

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

•Attach a clear plastic hose to the bleed valve on the

caliper, and run the other end of the hose into a container.

•Bleed the brake line and the caliper as follows:

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 en-

tered 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)

•Apply the brake lever forcefully for a few seconds, and

check for fluid leakage around the fittings.

Master Cylinder Inspection (Visual Inspection)

•Disassemble the master cylinder (see Brakes chapter).

•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, re-

place 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 as-

sembly 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 condi-

tions: (a) fluid leakage around the pad; (b) brakes over-

heat; (c) there is a large difference in inner and outer pad

wear; (d) the seal is stuck to the piston.

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

•Disassemble the brake caliper (see Brakes chapter).

•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

•Disassemble the internal wet brake (see Brakes chapter).

•Replace the steel pressure plates, steel plates and friction

plates in accordance with the specified interval.

Rear Brake Lever Free Play Inspection

•Check the rear brake lever free play [A].

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 ~2mm(0.04~0.08in.)

Rear Brake Pedal Free Play Inspection

•Check the brake pedal free play [A].

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 adjust-

ments 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.

•Turn the brake lever adjuster [A] at the rear end of the

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.

•Operate the pedal a few times to see that it returns to its

rest position immediately upon release.

•Rotate the rear wheels to check for brake drag.

•Check braking effectiveness.

If there is any doubt as to the conditions of the brake,

check the brake parts for wear or damage.

Suspension

Knuckle Joint Inspection

•Visually inspect the boot [A] of knuckle joint.

If damage, wear or deterioration is found, replace the

knuckle joint.

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering

Steering Inspection

•Turn the handlebar left and right, and check the steering

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 steer-

ing action which must be taken into account.

•Check the steering action again.

If steering stem bearing lubrication does not remedy the

problem, inspect the steering stem for straightness, steer-

ing 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, steer-

ing stem bearings, tie-rod bearings, and steering knuckle

joints.

TieRodEndInspection

•Visually inspect the grease seal [A] of tie rod end.

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

•Remove the spark plug (see Electrical System chapter).

•Clean the spark plug, preferably in a sandblasting device,

and then clean off any abrasive particles. The plug may

also be cleaned using a wire brush or other suitable tool.

If the spark plug electrodes are corroded or damaged,

or if the insulator is cracked, replace the plug. Use the

standard spark plug or its equivalent.

Spark Plug Gap Inspection

•Measure the gap [A] with a wire-type thickness gauge.

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

•Turn on the ignition switch.

•Check the operation of the rear brake light switch by de-

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

•Remove the foot guard (see Frame chapter).

•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 in-

side the switch, be sure that the switch body does

not turn during adjustment.

General Lubrication

Lubrication

•Before lubricating each part, clean off any rusty spots with

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 lubri-

cation.

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.

•With the cable disconnected at the both ends, the cable

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

•Check the tightness of the bolts and nuts listed here in

accordance with the Periodic Maintenance Chart. Also,

check to see that each cotter pin is in place and in good

condition.

If there are loose fasteners, retorque them to the speci-

fied torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not listed in the appropriate

chapter, see the Basic Torque Table (see Torque and

Locking Agent). For each fastener, first loosen it by 1/2

turn, then tighten it.

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.................................... 3- 2

Specifications ..................................... 3- 6

Special Tools ...................................... 3- 7

Throttle Lever and Cable .................... 3- 8

Throttle Lever Free Play

Inspection................................... 3- 8

Throttle Lever Free Play

Adjustment ................................. 3- 8

Throttle Case

Removal/Disassembly................ 3- 8

Throttle Case

Assembly/Installation ................. 3- 8

Throttle Cable Installation ............. 3- 9

Throttle Case Inspection ............... 3- 9

Throttle Cable Lubrication............. 3-10

Throttle Cable Inspection .............. 3-10

Choke Lever and Cable...................... 3-11

Choke Lever Free Play Check ...... 3-11

Choke Lever Free Play

Adjustment ................................. 3-11

Choke Lever and Cable Removal . 3-11

Choke Lever and Cable

Installation .................................. 3-12

Choke Cable Lubrication............... 3-12

Choke Cable Inspection................ 3-12

Carburetor .......................................... 3-13

Idling Speed Inspection................. 3-13

Idle Speed Adjustment.................. 3-13

Pilot Screw Adjustment ................. 3-13

Service Fuel Level Inspection ....... 3-13

Service Fuel Level Adjustment ..... 3-14

Carburetor Synchronization

Inspection................................... 3-15

Carburetor Synchronization

Adjustment ................................. 3-16

Fuel System Cleanliness

Inspection................................... 3-16

Carburetor Removal...................... 3-16

Carburetor Installation................... 3-17

Carburetor Disassembly ............... 3-18

Carburetor Assembly .................... 3-20

Carburetor Separation .................. 3-21

Carburetor Joining ........................ 3-21

Carburetor Cleaning...................... 3-22

Carburetor Inspection ................... 3-23

Air Cleaner.......................................... 3-25

Air Cleaner Element Removal....... 3-25

Air Cleaner Element Cleaning and

Inspection................................... 3-25

Air Cleaner Draining...................... 3-25

Air Cleaner Housing Removal....... 3-25

Air Cleaner Housing Installation.... 3-27

Fuel Tank............................................ 3-28

Fuel Tank Removal ....................... 3-28

Fuel Tank Installation .................... 3-28

Fuel Tank Cleaning ....................... 3-29

Fuel Tap Removal ......................... 3-29

Fuel Tap Installation ...................... 3-30

Fuel Tap Inspection....................... 3-30

Fuel Pump .......................................... 3-31

Fuel Pump Removal ..................... 3-31

Pump Filter Cleaning .................... 3-31

Fuel Pump Installation .................. 3-32

Fuel Pump Inspection ................... 3-32

3-2 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Throttle Limiter Screw 3.7 0.38 33 in·lb

2Throttle Limiter Locknut 3.7 0.38 33 in·lb

3Throttle Case Assembly Screws 3.7 0.38 33 in·lb

4Choke Lever Mounting Screw 3.5 0.36 31 in·lb

5Left 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.

3-4 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-5

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Air Cleaner Housing Bolts (M5) 5.9 0.60 52 in·lb L

2Air Cleaner Housing Bolts (M6) 8.8 0.90 78 in·lb

3Air Cleaner Element Bracket Screws 4.9 0.50 43 in·lb

4Fuel Tap Plate Screws 0.80 0.080 7in·lb

5Fuel Tap Cover Screws 1.0 0.10 8in·lb

6Fuel 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

3-6 FUEL SYSTEM

Specifications

Item Standard Service Limit

Throttle Case and Cable:

Throttle lever free play 2~3 mm (0.08 ~ 0.12 in.) –––

Choke Lever and Cable:

Choke lever free play about 3 mm (0.12 in.) –––

Carburetor:

Make/Type KEIHIN, CVKR-D32 –––

Main jet: Front #135 –––

Rear #140 –––

Main air jet: #80 –––

Needle jet: #6 –––

Jet needle NBZH –––

Pilot jet #40 –––

Pilot air jet #130 –––

Pilot screw 1 1/2 turns out –––

Carburetor synchronization

vacuum

less than 2.7 kPa (2 cmHg) –––

difference between carburetors

Starter jet #95 –––

Idle speed 1100 ± 50 r/min (rpm) –––

Service fuel level 12 ± 1 mm (0.47 ± 0.04 in.) –––

below the punch mark

Float height 4.0 ± 1 mm (0.16 ± 0.04 in.) –––

Optional parts:

Main jet:

*Altitude:

0~500 m (0 ~ 1600 ft):

Front #135 (92063-1014) –––

Rear #140 (92063-1013) –––

500 ~1500 m (1600 ~ 4900 ft):

Front #132 (92063-1076) –––

Rear #138 (92063-1015) –––

1500 ~2500 m (4900 ~ 8200 ft):

Front #130 (92063-1075) –––

Rear #135 (92063-1014) –––

2500 ~3500 m (8200 ~ 11500 ft):

Front #128 (92063-1074) –––

Rear #130 (92063-1075) –––

3500 ~4500 m (11500 ~ 14800 ft):

Front #120 (92063-1073) –––

Rear #125 (92063-1069) –––

Air Cleaner:

Air cleaner element oil 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

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Throttle Lever Free Play Adjustment

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Throttle Case Removal/Disassembly

•Remove the throttle case screws [A] and pull the case

open.

•Slide the cable adjuster dust cover out of place.

•Remove the rubber cover [A].

•Pull the cable tip [A] out of the throttle lever catch with the

throttle lever opened.

•Loosen the locknut [B] and unscrew the adjuster [C].

•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

•Lubricate the throttle case and cable before assembly/in-

stallation.

•Be certain that the return spring is correctly installed on

the throttle lever [A].

•Instal the throttle case so that fit the projection on the

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

•Swing the throttle control lever so that the carburetor throt-

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 throt-

tle limiter and adjustment procedure of it.

WARNING

Operation with an improperly assembled throttle

case could result in an unsafe riding condition.

•Check the throttle lever free play (see Fuel System in Pe-

riodic Maintenance chapter).

•Slide back the cable adjuster dust cover to the original

position.

Throttle Cable Installation

•Lubricate the throttle cable before installation.

•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.

•Check the throttle cable (see Fuel System in Periodic

Maintenance chapter).

Throttle Case Inspection

•With the throttle cable disconnected from the throttle

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 ca-

ble 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

•With the throttle cable disconnected at both ends, the ca-

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

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Choke Lever Free Play Adjustment

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Choke Lever and Cable Removal

•Remove the air cleaner housing (see Air Cleaner Housing

Removal).

•Remove the carburetor from the carburetor holder.

•Remove the cooling hoses and fuel hose.

•Remove the screws [A] and holder plates.

•Pull out the starter plungers.

•Hold the starter plunger springs compressed, and free the

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]

•Free the choke cable upper end [A] from the choke lever

[B].

3-12 FUEL SYSTEM

Choke Lever and Cable

•Pull off the retaining clip [A].

•Pull the cable out of the vehicle.

Choke Lever and Cable Installation

•Lubricate the choke cable before installation.

•Install the wave washer, plain washer and screw in that

order.

•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

•With the choke cable disconnected at both ends, the ca-

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

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Idle Speed Adjustment

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Pilot Screw Adjustment

•Adjust the pilot screw if necessary.

•Remove the converter exhaust joint duct (see Converter

System chapter).

•Turn the carburetor pilot screw [A] all the way in until it

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 ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

•Remove the carburetor (see Carburetor Removal).

3-14 FUEL SYSTEM

Carburetor

•Set the carburetor [A], fuel level gauge [B], and fuel [C] as

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 carbu-

retor drain screw.

Special Tool - Carburetor Drain Plug Wrench, Hex 3:

57001–1269

•Wait until the fuel level in the gauge settles.

•Hold the gauge vertically and lower it slowly so that the

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 remeasure-

ment.

•Read the fuel level [G].

If the fuel level is incorrect, adjust it.

Service Fuel Level

Standard: 12 ± 1 mm (0.47 ± 0.04 in.) below the punch

mark

•Tighten the drain screw.

•Repeat the same procedure for the other carburetor.

Service Fuel Level Adjustment

WARNING

Gasoline is extremely flammable and can be ex-

plosive 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.

•Remove the carburetors, and drain the fuel.

•Remove the float chamber.

•Remove the screw [A].

•Slide out the pivot pin [B] and remove the float [C].

FUEL SYSTEM 3-15

Carburetor

•Bend the tang [A] on the float arm very slightly to change

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 de-

creasing 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

•Check idle speed.

•Remove:

Converter Exhaust Joint Duct (see Converter System

chapter)

Fuel Tap Vacuum Hose [A]

Caps [B] on the Carburetor Holder

•Connect the battery wires to the battery.

•Attach a suitable vacuum gauge [A] to the fitting on the

carburetor 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

•Remove the air cleaner cover (see Frame chapter).

•Turn the adjust screw [A] to synchronize the carburetors.

If the carburetor 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

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

•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]

•Loosen the clamp screws [A] on the carburetor holders.

•Remove the carburetor out of the frame.

FUEL SYSTEM 3-17

Carburetor

•Remove the throttle cable cover screw [A] and throttle

cable cover [B].

•Loosen the nut [A] on the throttle cable.

•Remove the throttle cable lower end [B].

•Remove the screws [A] and holder plates [B].

•Pull out of the starter plungers.

Carburetor Installation

•Check fuel leakage from the carburetors.

WARNING

Fuel spilled from the carburetors is hazardous.

•Adjust the idle speed (see Fuel System in Periodic Main-

tenance chapter).

•Check the throttle cable (see Fuel System in Periodic

Maintenance chapter).

3-18 FUEL SYSTEM

Carburetor

Carburetor Disassembly

•Remove the carburetors (see Carburetor Removal).

WARNING

Gasoline is extremely flammable and can be ex-

plosive 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.

•Remove the upper chamber cover [A], spring [B], and vac-

uum piston [C].

CAUTION

During carburetor disassembly, be careful not to

damage the diaphragm. Never use a sharp edge to

remove the diaphragm.

•Remove the jet needle [D] from the vacuum piston. These

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.

•Install the float valve needle in the valve seat and hook

the needle hanger [A] onto the float tang.

•Insert the float pivot pin [B] into the pivot post and the float.

•Tighten the screw [C].

•Set the float to the standard height (see Service Fuel

Level Adjustment).

•Insert the jet needle [A] into the hole in the center of the

vacuum piston [B], and place the spring seat [C] over the

needle.

•Slip the needle through the hole in the center of the vac-

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 bind-

ing in the carburetor bore.

FUEL SYSTEM 3-21

Carburetor

•Fit the projection [A] of the vacuum piston diaphragm in

the recess [B] of the body.

•After installing the upper chamber cover, check to make

sure that the vacuum piston moves smoothly in the car-

buretor body.

Carburetor Separation

•Remove:

Carburetor (see Carburetor Removal)

Carburetor Joining Bolts [A] and Nuts

•Separate the carburetors.

Carburetor Joining

•The center lines of the carburetor bores must be parallel

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.

•Visually synchronize the throttle (butterfly) valves.

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 Adjust-

ment).

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 any-

where near the working area; this includes any ap-

pliance 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 carbu-

retor, 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 carbure-

tor with a cleaning solution. This will prevent dam-

age or deterioration of the parts.

The carburetor body has plastic parts that can-

not be removed. Do not use a strong carburetor

cleaning solution which could attack these parts;

instead, use a mild high flash-point cleaning solu-

tion safe for plastic parts.

Do not use wire or any other hard instrument to

clean carburetor parts, especially jets, as they may

be damaged.

•Disassemble the carburetor and clean all the metal parts

in a carburetor cleaning solution.

•Rinse the parts in water and dry them with compressed

air.

•Blow through the air and fuel passages with compressed

air.

•Remove the float valve, spray cleaning solution from the

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 ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

•Remove the carburetor (see Carburetor Removal).

•Before disassembling the carburetors, check the fuel level

(see Fuel Level Inspection).

•Turn the throttle cable pulley [A] to check that the throttle

butterfly valve [B] moves smoothly and return back with

the spring tension.

If the throttle valve does not move smoothly, replace the

carburetor.

•Disassemble the carburetors (see Carburetor Disassem-

bly).

•Clean the carburetor (see Carburetor Cleaning).

•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 condi-

tion, replace them.

3-24 FUEL SYSTEM

Carburetor

•Check the plastic tip [A] of the float valve needle. It should

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.

•Check the tapered portion [A] of the pilot screw [B] for

wear or damage.

If the pilot screw is worn or damaged on the tapered por-

tion, it will prevent the engine from idling smoothly. Re-

place it.

•Check that the vacuum piston moves smoothly in the car-

buretor body. The surface of the piston must not be ex-

cessively 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 car-

buretor and engine.

WARNING

If dirt or dust is allowed to pass through into the

carburetors, the throttle may become stuck, possi-

bly causing an accident.

CAUTION

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

•Separate metal mesh [A] and element [B].

Air Cleaner Element Cleaning and Inspection

•Refer to the Fuel System in the Periodic Maintenance

chapter.

Air Cleaner Draining

•Refer to the Fuel System in the Periodic Maintenance

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

•Insert the fitting of the housing in the duct [A], and fit the

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.

•Apply a non-permanent locking agent to the air cleaner

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

•Check the rubber dampers [A].

If the dampers are damaged or deteriorated, replace

them.

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

•Remove the fuel tank and drain it (see Fuel Tank Re-

moval).

•Pour some high flash-point solvent into the fuel tank and

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.

•Pour the solvent out the tank.

•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

•Connect the fuel hoses to the fuel tap as follows.

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

•Be sure the O-ring [A] is in good condition to prevent leak-

age.

•Apply grease to the lever [B].

•Tighten:

Torque - Fuel Tap Plate Screws [C]: 0.80 N·m (0.080 kgf·m,

7in·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 sur-

face. Such a shock to the pump can damage it.

WARNING

Gasoline is extremely flammable and can be explo-

sive 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 any-

where near the working area. Because of the dan-

ger of highly flammable liquids, do not use gasoline

or low-flash point solvent to clean the pump filter.

•Remove the fuel pump [A] along with the pump filter [B].

•Prepare a container [C] filled with a high-flash point sol-

vent.

•Dip and shake the fuel filter only in the solvent to remove

dirt and fuel deposits from the filter.

•Dry the pump and filter by lightly applying compressed air.

•Install the fuel pump (see Fuel Pump Installation).

3-32 FUEL SYSTEM

Fuel Pump

Fuel Pump Installation

•Clean the pump filter (see Pump Filter Cleaning).

•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 assembly so that the fuel filter do not

contact with the fuel tank.

Fuel Pump Inspection

•Refer to the Electrical System chapter.

COOLING SYSTEM 4-1

Cooling System

TABLE OF CONTENTS

Exploded View......................................................................................................................... 4- 2

Coolant Flow Chart.................................................................................................................. 4- 4

Specifications .......................................................................................................................... 4- 6

Special Tools and Sealant ....................................................................................................... 4- 7

Coolant .................................................................................................................................... 4- 8

Coolant Deterioration Inspection........................................................................................ 4- 8

Coolant Level Inspection.................................................................................................... 4- 8

Coolant Draining ................................................................................................................ 4- 8

Coolant Filling .................................................................................................................... 4- 8

Pressure Testing ................................................................................................................ 4- 9

Water Pump............................................................................................................................. 4-10

Water Pump Cover Removal ............................................................................................. 4-10

Water Pump Cover Installation .......................................................................................... 4-10

Impeller Removal ............................................................................................................... 4-10

Water Pump Impeller Installation ....................................................................................... 4-10

Water Pump Impeller Inspection ........................................................................................ 4-11

Mechanical Seal Replacement .......................................................................................... 4-11

Radiator ................................................................................................................................... 4-13

Radiator Removal .............................................................................................................. 4-13

Radiator Fan Removal ....................................................................................................... 4-14

Radiator Fan Installation .................................................................................................... 4-14

Radiator Inspection ............................................................................................................ 4-15

Radiator Cleaning .............................................................................................................. 4-15

Radiator Cap Inspection .................................................................................................... 4-15

Thermostat .............................................................................................................................. 4-16

Thermostat Removal.......................................................................................................... 4-16

Thermostat Installation....................................................................................................... 4-16

Thermostat Inspection ....................................................................................................... 4-16

Radiator Fan Switch ................................................................................................................ 4-18

Radiator Fan Switch Removal ........................................................................................... 4-18

Radiator Fan Switch Installation ........................................................................................ 4-18

Radiator Fan Switch Inspection ......................................................................................... 4-18

Coolant Temperature Warning Light Switch ............................................................................ 4-19

Coolant Temperature Warning Light Switch Removal ....................................................... 4-19

Coolant Temperature Warning Light Switch Installation .................................................... 4-19

Coolant Temperature Warning Light Switch Inspection ..................................................... 4-19

Coolant Filter/Valve ................................................................................................................. 4-20

Coolant Filter Cleaning ...................................................................................................... 4-20

Coolant Valve Inspection ................................................................................................... 4-20

4-2 COOLING SYSTEM

Exploded View

COOLING SYSTEM 4-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Radiator Fan Switch 18 1.8 13

2Water Pump Fitting Bolt 9.8 1.0 87 in·lb

3Water Pump Impeller 7.8 0.80 69 in·lb

4Thermostat Housing Cover Bolts 8.8 0.90 78 in·lb

5Coolant Temperature Warning Light Switch 7.8 0.80 69 in·lb SS

6Radiator Fan Assembly Bolts 8.8 0.90 78 in·lb

7Radiator Mounting Bolts 8.8 0.90 78 in·lb

8Water Pump Cover Bolts 8.8 0.90 78 in·lb

9Coolant 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).

4-4 COOLING SYSTEM

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and cor-

rosion. 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 op-

erates 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 Warning Light

Switch

6. Reserve Tank

7. Cylinder, Cylinder Head

8. Carburetor

9. Radiator Fan

10. Radiator Fan Switch

Black Painted Arrow: Hot Coolant

White Painted Arrow: Cold Coolant

4-6 COOLING SYSTEM

Specifications

Item Standard Service Limit

Coolant provided when shipping:

Type Permanent type of antifreeze (soft water –––

and ethylene glycol plus corrosion and

rust inhibitor chemicals for aluminum

engines and radiators)

Color Green –––

Mixed ratio Soft water 50%, coolant 50% –––

Freezing point –35 C (–31 F) –––

Total amount 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 8mmormore@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 Shaft, f9:

57001–1265

Bearing Remover Head, f10 x f12 :

57001–1266

Kawasaki Bond (Silicone Sealant) :

56019–120

4-8 COOLING SYSTEM

Coolant

Coolant Deterioration Inspection

•Visually inspect the coolant in the reserve tank [A].

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

thecoolingsystem.

If the coolant gives off an abnormal smell, check for cool-

ing system leak. It may be caused by exhaust gas leaking

into the cooling system.

Coolant Level Inspection

NOTE

Check the level when the engine is cold (room or ambi-

ent temperature).

•Check the coolant level in the reserve tank with the vehi-

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 cor-

rect 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

•Refer to the Cooling System in the Periodic Maintenance

chapter.

Coolant Filling

•Refer to the Cooling System in the Periodic Maintenance

chapter.

COOLING SYSTEM 4-9

Coolant

Pressure Testing

•Remove the upper front cover and radiator cap, then in-

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.

•Build up pressure in the system carefully until the pres-

sure reaches 123 kPa (1.25 kgf/cm², 18 psi).

CAUTION

During pressure testing, do not exceed the pres-

sure for which the system is designed. The maxi-

mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

•Watch the gauge for at least 6 seconds.

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

•Drain the coolant (see Cooling System in Periodic Main-

tenance chapter).

•Remove:

Foot Guards (Left Side)

Cooling Hoses [A]

Water Pump Cover Bolts [B]

Water Pump Cover [C]

Water Pump Cover Installation

•Install:

KnockPins[A]

New Gasket

•Tighten:

Torque - Water Pump Cover Bolts: 8.8 N·m (0.90 kgf·m, 78

in·lb)

Impeller Removal

•Drain the coolant (see Cooling System in Periodic Main-

tenance chapter).

•Remove the water pump cover (see Water Pump Cover

Removal).

•Loosen the water pump impeller [A] counterclockwise.

Water Pump Impeller Installation

•Apply a small amount of coolant on the sliding surface [A]

of the mechanical seal and the sealing seat.

•Install the impeller on the water pump shaft and tighten

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

•Visually inspect the impeller [A].

If the surface is corroded or the blades are damaged, re-

place 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]

•Press out the mechanical seal [A] and oil seal [B] from

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.

•Apply heat-resistance grease on the oil seal lip.

•From outside the alternator cover, press and insert the oil

seal [A] flush [B] in the direction as shown.

Special Tool - Bearing Driver Set: 57001–1129

4-12 COOLING SYSTEM

Water Pump

•From inside the alternator cover, press and insert the ball

bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set: 57001–1129

•Using a suitable socket [A] and the bearing driver [B],

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

•Clean the sliding surface of a new mechanical seal with

a high flash-point solvent, and apply a little coolant to the

sliding surface to give the mechanical seal initial lubrica-

tion.

•Apply coolant to the surfaces of the rubber seal and seal-

ing seat [A], and press the rubber seal [B] and sealing

seat into the impeller by hand until the seat bottoms out.

•Tighten the water pump impeller by turning the bolt clock-

wise.

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 bat-

tery. The radiator fan may start even if the ignition

switch is off. NEVER TOUCH THE RADIATOR FAN

UNTIL THE RADIATOR FAN CONNECTOR IS DIS-

CONNECTED. TOUCHING THE FAN BEFORE THE

CONNECTOR IS DISCONNECTED COULD CAUSE

INJURY FROM THE FAN BLADES.

•Drain the coolant (see Cooling System in the Periodic

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 effi-

ciency.

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

•Check the radiator core.

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 de-

formed fins, replace the radiator with a new one.

Radiator Cleaning

•Refer to the Cooling System in the Periodic Maintenance

chapter.

Radiator Cap Inspection

•Check the condition of the top and bottom valve seals of

the radiator cap.

If any one of them shows visible damage, replace the cap.

Bottom Valve Seal [A]

Top Valve Seal [B]

ValveSpring[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.

•Watching the pressure gauge, slowly pump the pressure

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

•Drain the coolant (see Cooling System in Periodic Main-

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.

•Install the ground wire terminal [A] as shown.

•Tighten:

Torque - Thermostat Housing Cover Bolts [B]: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

•Add coolant (see Cooling System in Periodic Mainte-

nance chapter).

Thermostat Inspection

•Remove the thermostat, and inspect the thermostat valve

[A] at room temperature.

If the valve is open, replace the valve with a new one.

COOLING SYSTEM 4-17

Thermostat

•To check valve opening temperature, suspend the ther-

mostat [A] and an accurate thermometer [B] in a container

of water with the heat-sensitive portions [C] in almost the

same depth.

NOTE

The thermostat must be completely submerged and the

thermostat and thermometer must not touch the con-

tainer sides or bottom.

•Gradually raise the temperature of the water while stirring

the water gently for even temperature.

If the measurement is out of the range, replace the ther-

mostat.

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.

•Drain the coolant (see Cooling System in Periodic Main-

tenance chapter).

•Disconnect the fan switch leads [A].

•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)

•Fill the coolant (see Cooling System in Periodic Mainte-

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.

•Drain the coolant (see Cooling System in Periodic Main-

tenance chapter).

•Disconnect the switch lead [A].

•Remove the switch [B].

Coolant Temperature Warning Light Switch Installation

•Apply silicone sealant to the threads of the switch and

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)

•Fill the coolant (see Cooling System in Periodic Mainte-

nance chapter).

Coolant Temperature Warning Light Switch Inspection

•Refer to the Electrical System chapter.

4-20 COOLING SYSTEM

Coolant Filter/Valve

Coolant Filter Cleaning

•Refer to the Cooling System in the Periodic Maintenance

chapter.

Coolant Valve Inspection

•Drain the coolant (see Cooling System in Periodic Main-

tenance chapter).

•Remove the coolant valve [A] on the engine left side.

•Inspect the coolant valve at room temperature.

If the valve is 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.................................... 5- 2

Specifications ..................................... 5- 8

Special Tools and Sealant .................. 5-10

Camshaft Chain Tensioner ................. 5-12

Camshaft Chain Tensioner

Removal ..................................... 5-12

Camshaft Chain Tensioner

Installation .................................. 5-12

Rocker Case....................................... 5-13

Rocker Case Removal.................. 5-13

Rocker Case Installation ............... 5-14

Rocker Arm Removal.................... 5-15

Rocker Arm Installation................. 5-15

Rocker Arm Inspection.................. 5-16

Rocker Shaft Diameter

Measurement ............................. 5-16

Camshaft ............................................ 5-17

Camshaft Removal ....................... 5-17

Camshaft Installation .................... 5-17

Camshaft Assembly...................... 5-18

Cam Wear..................................... 5-18

Camshaft Bearing Wear................ 5-19

KACR Inspection........................... 5-20

KACR Removal............................. 5-20

KACR Installation.......................... 5-21

Camshaft Chain Removal ............. 5-21

Camshaft Chain Installation .......... 5-22

Cylinder Head..................................... 5-27

Cylinder Compression

Measurement ............................. 5-27

Cylinder Head Removal................ 5-28

Cylinder Head Installation ............. 5-28

Cylinder Head Cleaning ................ 5-28

Cylinder Head Warp...................... 5-29

Valves ................................................. 5-30

Valve Clearance Inspection .......... 5-30

Valve Clearance Adjustment......... 5-30

Valve Removal .............................. 5-30

Valve Installation ........................... 5-30

Valve Guide Removal ................... 5-31

Valve Guide Installation ................ 5-31

Valve-to-Guide Clearance

Measurement ............................. 5-31

Valve Seat Inspection ................... 5-32

Valve Seat Repair (Valve Lapping) 5-32

Cylinder and Piston ............................ 5-37

Cylinder Removal.......................... 5-37

Piston Removal............................. 5-37

Cylinder, Piston Installation........... 5-37

Cylinder Wear ............................... 5-39

Piston Wear .................................. 5-40

Piston/Cylinder Clearance ............ 5-40

Piston Ring, Piston Ring Groove

Wear........................................... 5-40

Piston Ring Groove Width............. 5-40

Piston Ring Thickness ................. 5-41

Piston Ring End Gap .................... 5-41

Exhaust System.................................. 5-42

Spark Arrester Cleaning................ 5-42

Muffler and Exhaust Pipe

Removal ..................................... 5-42

Muffler and Exhaust Pipe

Installation .................................. 5-43

Exhaust System Inspection........... 5-43

5-2 ENGINE TOP END

Exploded View

ENGINE TOP END 5-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Rocker Case Bolts 55 mm (2.2 in.) 8.8 0.90 78 in·lb S

2Rocker Case Bolts 130 mm (5.1 in.) 9.8 1.0 87 in·lb S

3Rocker Case Bolts 30 mm (1.2 in.) 9.8 1.0 87 in·lb

4Rocker Case Bolts 25 mm (1.0 in.) 9.8 1.0 87 in·lb S

5Cylinder Head Bolts (M10), First Torque 25 2.5 18 S,MO

5Cylinder Head Bolts (M10), Final Torque 49 5.0 36 S

6Cylinder Head Bolts (M6) 9.8 1.0 87 in·lb

7Cylinder Head Jacket Plugs 20 2.0 14

8Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb

9Valve 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

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Chain Tensioner Mounting Bolts 8.8 0.90 78 in·lb

2Chain Tensioner Cap Bolt 22 2.2 16

3Intermediate Shaft Sprocket Nut 44 4.5 33

4Intermediate Shaft Chain Guide Bolts 8.8 0.90 78 in·lb

5Intermediate Shaft Chain Tensioner Bolts 8.8 0.90 78 in·lb

6Camshaft Sprocket Bolts 12 1.2 104 in·lb L

7Position Plate Bolts 8.8 0.90 78 in·lb

8Cylinder Bolts 40 mm (1.6 in.) 9.8 1.0 87 in·lb

9Cylinder 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

5-6 ENGINE TOP END

Exploded View

ENGINE TOP END 5-7

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Exhaust Pipe Cover Bolts 8.8 0.90 78 in·lb

2Muffler Cover Bolts 8.8 0.90 78 in·lb

3Muffler Mounting Bolts 20 2.0 14

4Exhaust Pipe Clamp Bolt 8.8 0.90 78 in·lb

R: Replacement parts

5-8 ENGINE TOP END

Specifications

Item Standard Service Limit

Rocker Case:

Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in.) 12.05 mm (0.474 in.)

Rocker shaft diameter 11.973 ~ 11.984 mm (0.4714 ~ 0.4718 in.) 11.95 mm (0.470 in.)

Camshafts:

Cam height:

Exhaust 35.363 ~ 35.477 mm (1.3932 ~ 1.3967 in.) 35.26 mm (1.388 in.)

Inlet 35.622 ~ 35.736 mm (1.4024 ~ 1.4069 in.) 35.52 mm (1.398 in.)

Camshaft bearing clearance:

f18 0.016 ~ 0.052 mm (0.0006 ~ 0.0020 in.) 0.14 mm (0.0055 in)

f22 0.020 ~ 0.062 mm (0.0008 ~ 0.0024 in.) 0.15 mm (0.0059 in.)

Camshaft journal diameter:

f18 17.966 ~ 17.984 mm (0.7073 ~ 0.7080 in.) 17.94 mm (0.706 in.)

f22 21.959 ~ 21.980 mm (0.8645 ~ 0.8653 in.) 21.93 mm (0.863 in.)

Camshaft bearing inside

diameter:

f18 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in.) 18.08 mm (0.712 in.)

f22 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in.) 22.08 mm (0.870 in.)

Camshaft runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm

(0.0039 in.)

KACR (Kawasaki Automatic

Compression Release):

KACR operating engine

speed

760 ± 30 r/min (rpm) –––

Cylinder Head:

Cylinder compression

(usable range)

Electric starter 290 ~ 520 kPa (3.0 ~ 5.3 kgf/cm², –––

43 ~ 75 psi) @ 290 r/min (rpm)

Cylinder head warp ––– 0.05 mm (0.002 in.)

Valve:

Valve clearance:

Exhaust 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.) –––

Inlet 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.) –––

Valve head thickness:

Exhaust 0.8 mm (0.031 in.) 0.5 mm (0.020 in.)

Inlet 0.5 mm (0.020 in.) 0.3 mm (0.012 in.)

Valve stem bend ––– TIR 0.05 mm

(0.002 in.)

Valve stem diameter:

Exhaust 4.955 ~ 4.970 mm (0.1951 ~ 0.1957 in.) 4.94 mm (0.1945 in.)

Inlet 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in.) 4.96 mm (0.1953 in.)

Valve guide inside diameter:

Exhaust 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) 5.08 mm (0.20 in.)

Inlet 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in.) 5.08 mm (0.20 in.)

ENGINE TOP END 5-9

Specifications

Item Standard Service Limit

Valve/valve guide clearance

(wobble method):

Exhaust 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in.) 0.34 mm (0.0133 in.)

Inlet 0.03 ~ 0.11 mm (0.0012 ~ 0.0043 in.) 0.28 mm (0.0110 in.)

Valve seat cutting angle 45 ,32,60 –––

Valve seating surface:

Outside diameter:

Exhaust 25.2 ~ 25.4 mm (0.992 ~ 1.000 in.) –––

Inlet 29.4 ~ 29.6 mm (1.157 ~ 1.165 in.) –––

Width:

Exhaust 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.) –––

Inlet 0.5 ~ 1.0 mm (0.02 ~ 0.04 in.) –––

Valve spring free length:

Exhaust 41.3 mm (1.626 in.) 39.5 mm (1.555 in.)

Inlet 41.3 mm (1.626 in.) 39.5 mm (1.555 in.)

Cylinder, Piston:

Cylinder inside diameter 81.994 ~ 82.006 mm (3.2281 ~ 3.2286 in.) 82.09 mm (3.232 in.)

Piston diameter 81.949 ~ 81.964 mm (3.2263 ~ 3.2269 in.) 81.80 mm (3.220 in.)

Piston/cylinder clearance 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in.) –––

Piston ring/groove

clearance:

Top 0.040 ~ 0.080 mm (0.0016 ~ 0.0032 in.) 0.18 mm (0.0071 in.)

Second 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in.) 0.17 mm (0.0067 in.)

Piston ring groove width:

Top 1.030 ~ 1.050 mm (0.0405 ~ 0.0413 in.) 1.13 mm (0.0445 in.)

Second 1.020 ~ 1.040 mm (0.0402 ~ 0.0409 in.) 1.12 mm (0.0441 in.)

Piston ring thickness:

Top 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.) 0.9 mm (0.035 in.)

Second 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.) 0.9 mm (0.035 in.)

Piston ring end gap:

Top 0.20 ~ 0.30 mm (0.0079 ~ 0.0118 in.) 0.60 mm (0.0236 in.)

Second 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.) 0.75 mm (0.0295 in.)

Oil 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in.) 1.00 mm (0.0394 in.)

5-10 ENGINE TOP END

Special Tools and Sealant

Outside Circlip Pliers :

57001–144

Compression Gauge :

57001–221

Valve Spring Compressor Assembly :

57001–241

Piston Pin Puller Assembly :

57001–910

Valve Seat Cutter, 45 –f27.5 :

57001–1114

Valve Seat Cutter, 32 –f28 :

57001–1119

Valve Seat Cutter, 60 –f30 :

57001–1123

Valve Seat Cutter Holder Bar :

57001–1128

Valve Seat Cutter, 45 –f30 :

57001–1187

Valve Seat Cutter, 32 –f33 :

57001–1199

ENGINE TOP END 5-11

Special Tools and Sealant

Valve Spring Compressor Adapter, f22 :

57001–1202

Valve Guide Arbor, f5:

57001–1203

Valve Guide Reamer, f5:

57001–1204

Valve Seat Cutter Holder, f5:

57001–1208

Piston Pin Puller Adapter :

57001–1211

Filter Cap Driver:

57001–1454

Compression Gauge Adapter, M10 × 1.0 :

57001–1486

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. Ob-

serve 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 Ten-

sioner 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

•Push the stopper [A] to release the ratchet and push the

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

•Using a wrench on the alternator bolt, turn the crankshaft

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

•Install the rear camshaft and then the front camshaft (see

Camshaft Installation in this chapter).

•Check that the crankshaft is positioned at TDC and at the

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.

•Apply silicone sealant to the outer surface of the cap [A]

and the cylinder head upper surface [B] as shown.

Sealant - Kawasaki Bond (Silicone Sealant): 56019–120

•Tighten the rocker case bolts following the tightening se-

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

•Apply grease to the O-ring [A].

•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 in-

stalled in the original position.

The rocker arms come off with the rocker shafts.

Rocker Arm Installation

•Apply molybdenum disulfide oil:

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

•Inspect the area [A] on the rocker arm where the cam

rubs.

If the rocker arm is scored, discolored or otherwise dam-

aged, replace it. Also inspect the camshaft lobes.

•Inspect the end of the valve clearance adjusting screws

[B] where it contacts the valve stem.

If the end of the adjusting screw is mushroomed or dam-

aged in any way, or if the screw will not turn smoothly,

replace it. Also inspect the end of the valve stem.

•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

•Measure the diameter [A] of the rocker shaft where the

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

•Using a wrench on the alternator bolt, turn the crankshaft

clockwise until “T-R” mark [A] is aligned with the notch

[B] in the inspection window.

•The rear camshaft [A] has a groove [B].

•First, install the rear camshaft.

•Face the arrow [A] of the rear camshaft sprocket upward

(left side view).

•Engage the rear camshaft chain with the rear camshaft

sprocket.

•Align the marks [B] on the weights with the rear cylinder

head upper surface.

5-18 ENGINE TOP END

Camshaft

•Using a wrench on the alternator bolt, turn the crankshaft

clockwise 270 .

Align the “T-F” mark [A] with the notch [B] in the inspection

window.

•Face the arrow [A] of the front camshaft sprocket upward

(right side view).

•Engage the front camshaft chain with the front camshaft

sprocket.

•Align the marks [B] on the weights with the front cylinder

head upper surface.

•Install:

Rocker Cases (see Rocker Case Installation)

Camshaft Chain Tensioners (see Camshaft Chain Ten-

sioner Installation)

•Check the valve clearance (see Valve Clearance Inspec-

tion).

Camshaft Assembly

•Install the KACR unit [A] (sprocket) on the camshaft so

that the unit fits onto the camshaft pins [B].

•Apply a non-permanent locking agent to the camshaft

sprocket bolts [C].

•Tighten:

Torque - Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 104

in·lb)

Cam Wear

•Remove the camshaft.

•Measure the height [A] of the cam with a micrometer.

If the cams are worn past the service limit, replace the

camshaft.

Cam Height

Standard Service Limit

Exhaust 35.363 ~ 35.477 mm 35.26 mm

(1.3932 ~ 1.3967 in.) (1.388 in.)

Inlet 35.622 ~ 35.736 mm 35.52 mm

(1.4024 ~ 1.4069 in.) (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 mea-

sured. 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 In-

stallation).

NOTE

Do not turn the camshaft when the plastigage is be-

tween the journal and rocker case.

•Remove the rocker case and measure the plastigage

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 com-

pression pressure to escape, making it easy to turn over

the engine during starting.

Due to the simplicity of the mechanism, no periodic main-

tenance is needed. There are only two symptoms of prob-

lems with the KACR mechanism [A]: compression is not re-

leased 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 po-

sition, 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

•Remove (left side view):

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

•Remove (right side view):

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].

•Remove (left side view):

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 em-

bossed line [B] on the crankcase (left side view).

ENGINE TOP END 5-23

Camshaft

•Face the arrow [A] of the rear camshaft sprocket upward.

•Align the marks [B] on the weights with the rear cylinder

head upper surface [C].

•Place the rear camshaft chain [D] onto the rear camshaft

sprocket.

•Engage the camshaft and intermediate shaft chains on

the intermediate shaft sprocket [A] (left side view).

•Align the punch mark [B] on the intermediate shaft

sprocket with the embossed mark [C] on the crankcase.

•Install the intermediate shaft and align the punch mark [A]

on the intermediate shaft with the punch mark [B] on the

intermediate sprocket nut.

•Using an Allen wrench, hold the intermediate shaft.

•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 em-

bossed line [B] on the crankcase.

•Move the intermediate shaft [A] to the right side of the

engine.

•Engage the front camshaft chain [B] with the sprocket on

the intermediate shaft.

•Install (left side view):

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

•Install the intermediate shaft chain tensioner [A] as fol-

lows:

•Release the stopper [B] and push the push rod [C] into

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.

•Confirm that the punch mark [A] on the intermediate shaft

sprocket (Right Side) is aligned with the embossed mark

[B] on the crankcase.

5-26 ENGINE TOP END

Camshaft

•Face the arrow mark [A] upward.

•Align the marks [B] on the weights with the front cylinder

head upper surface [C].

•Place the front camshaft chain on the front camshaft

sprocket.

•Apply grease to the O-ring [A] and install the cover [B] into

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 Inspec-

tion).

ENGINE TOP END 5-27

Cylinder Head

Cylinder Compression Measurement

NOTE

Use the battery which is fully charged.

•Warm up the engine thoroughly, and stop the engine.

•Remove the spark plug (see Electrical System chapter).

•Attach the compression gauge [A] and adapter [B] firmly

into the spark plug hole.

Special Tools - Compression Gauge: 57001-221

Compression Gauge Adapter, M10 × 1.0:

57001-1486

•Hold the throttle wide open and crank the engine with the

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 us-

able range.

Problem Diagnosis Remedy (Action)

Cylinder

compression is

higher than usable

range

Carbon accumulation on piston, cylinder

head, and in combustion chamber possibly

due to damaged valve stem oil seal and/or

damaged piston oil rings (This may be

indicated by white exhaust smoke).

Remove the carbon deposits

and replace damaged parts if

necessary.

Incorrect cylinder head gasket thickness. Replace the gasket with a

standard part.

Damaged or missing compression release

cam spring

Replace the spring.

Compression release weights do not

move smoothly.

Replace the compression release

unit.

Cylinder

compression is

lower than usable

range

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

seizure.

Replace the piston and/or

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

Replace the piston and/or the

piston rings.

Compression release weights do not

move smoothly

Replace the compression release

unit

5-28 ENGINE TOP END

Cylinder Head

Cylinder Head Removal

•Drain the coolant (see Cooling System chapter).

•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 cylin-

der, 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)

•Apply molybdenum disulfide oil to the threads and seating

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

•Remove the cylinder head (see Cylinder Head Removal).

•Scrape the carbon out of the combustion chamber and

exhaust port 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

•Clean the cylinder head (see Cylinder Head Cleaning).

•Lay a straightedge across the lower surface of the cylinder

head.

•Use a thickness gauge [A] to measure the space between

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

•Refer to the Engine Top End in the Periodic Maintenance

chapter.

Valve Clearance Adjustment

•Refer to the Engine Top End in the Periodic Maintenance

chapter.

Valve Removal

•Remove the cylinder head (see Cylinder Head Removal).

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

•Replace the valve stem oil seal.

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 down-

wards.

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(seeValveRemoval)

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

•Lightly oil the valve guide outer surface.

•Using the valve guide arbor, drive the valve guide until its

flange touches the cylinder head.

Special Tool - Valve Guide Arbor, f5 : 57001–1203

•Ream the valve guide with the valve guide reamer [A] , if

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

•Remove the valve (see Valve Removal).

•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 dur-

ing the operation, wash off any ground particles sticking

to the cutter with washing oil.

5. After use, wash it with washing oil and apply thin layer of

engine oil before storing.

Marks Stamped on the Cutter:

The marks stamped on the back of the cutter [A] represent

the following.

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 cylin-

der 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]

•Measure the outside diameter of the seating surface with

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 machin-

ist’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 be-

low.

•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. mea-

surement step above.

•To measure the seat width, use vernier calipers to mea-

sure the width of the 45 angle portion of the seat at sev-

eral 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 de-

scribed 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 m ak e t h e 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 mea-

surement step above.

Correct Width [B]

•Lap the valve to the seat, once the seat width and O.D.

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 com-

pound 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 assem-

bly.

•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

•Remove the cylinder block (see Cylinder Removal).

•Place a piece of clean cloth under the piston and remove

the piston pin snap rings [A] from the outside of each pis-

ton.

CAUTION

Do not reuse snap rings, as removal weakens and

deforms them. They could fall out and score the

cylinder wall.

•Using the piston pin puller assembly (special tool), re-

move the piston pins.

Special Tools - Piston Pin Puller Assembly [A]: 57001-910

Piston Pin Puller Adapter [B]: 57001-1211

•Remove the piston.

•Carefully spread the ring opening with your thumbs and

then push up on the opposite side of the ring [A] to remove

it.

•Remove the 3-piece oil ring with your thumbs in the same

manner.

Cylinder, Piston Installation

NOTE

If a new piston or cylinder is used, check piston to cylin-

der 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”.

•Install the oil ring expander [A] in the bottom piston ring

groove so the ends [B] butt together.

•Install the oil ring steel rails, one above the expander and

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.

•Do not mix up the top ring and second ring.

•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.

•The piston ring openings must be positioned as shown in

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.

TopRing[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]

•Fit a new piston pin snap ring into the side of the piston

so that the ring opening [A] does not coincide with the slit

[B] of the piston pin hole.

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

•Since there is a difference in cylinder wear in different di-

rections, take a side-to-side and a front-to-back measure-

ment at each of the three locations (total of six measure-

ments) shown in the figure.

If any of the cylinder inside diameter measurements ex-

ceeds the service limit, replace the cylinder.

10 mm (0.4 in.) [A]

60 mm (2.4 in.) [B]

20 mm (0.8 in.) [C]

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

•Measure the outside diameter [A] of each piston 5 mm

(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 pis-

ton.

Piston Diameter

Standard: 81.949 ~81.964 mm (3.2263 ~ 3.2269 in.)

Service Limit: 81.80 mm (3.220 in.)

Piston/Cylinder Clearance

•Subtract the piston diameter from the cylinder inside di-

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

•Check for uneven groove wear by inspecting the ring seat-

ing.

The rings should fit perfectly parallel to groove surfaces.

If not, replace the piston and all the piston rings.

•With the piston rings in their grooves, make several mea-

surements with a thickness gauge [A] to determine piston

ring/groove clearance.

Piston Ring/Groove Clearance

Standard: Service Limit:

Top: 0.040 ~0.080 mm 0.18 mm

(0.0016 ~ 0.0032 in.) (0.0071 in.)

Second: 0.030 ~0.070 mm 0.17 mm

(0.0012 ~ 0.0028 in.) (0.0067 in.)

If the piston ring groove clearance is greater than the ser-

vice 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

•Measure the piston ring groove width.

Use a vernier caliper at several points around the piston.

Piston Ring Groove Width

Standard Service Limit

Top: 1.030 ~1.050 mm 1.13 mm

(0.0405 ~ 0.0413 in.) (0.0445 in.)

Second: 1.020 ~1.040 mm 1.12 mm

(0.0402 ~ 0.0409 in.) (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

•Measure the piston ring thickness.

Use a micrometer to measure at several points around

the ring.

Piston Ring Thickness

Standard Service Limit

Top: 0.97 ~0.99 mm 0.9 mm

(0.0382 ~ 0.0390 in.) (0.035 in.)

Second: 0.97 ~0.99 mm 0.9 mm

(0.0382 ~ 0.0390 in.) (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 un-

even groove wear. The rings should fit perfectly parallel

to the groove sides. If not, replace the piston.

Piston Ring End Gap

•Place the piston ring [A] inside the cylinder, using the pis-

ton to locate the ring squarely in place. Set it close to the

bottom of the cylinder, where cylinder wear is low.

•Measure the gap [B] between the ends of the ring with a

thickness gauge.

Piston Ring End Gap

Standard Service Limit

Top: 0.20 ~0.30 mm 0.60 mm

(0.0079 ~ 0.0118 in.) (0.0236 in.)

Second: 0.30 ~0.45 mm 0.75 mm

(0.0118 ~ 0.0177 in.) (0.0295 in.)

Oil: 0.20 ~0.70 mm 1.00 mm

(0.0079 ~ 0.0276 in.) (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 prop-

erly maintained to ensure its efficiency. In accordance with

the Periodic Maintenance Chart, clean the spark arrester.

Spark Arrester Cleaning

•Refer to the Engine Top End in the Periodic Maintenance

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

•If the exhaust pipe cover [A] or muffler cover [B] were

removed, 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)

•Replace the exhaust pipe holder gaskets [E] and clamp

gasket [F] with new ones.

•Install (But do not tighten the following nuts and bolts.):

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

•Before removing the exhaust system, check for signs of

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 gas-

ket, 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......................................................................................................................... 6- 2

Specifications .......................................................................................................................... 6- 6

Special Tools ........................................................................................................................... 6- 7

Torque Converter..................................................................................................................... 6- 8

Torque Converter Cover Removal ..................................................................................... 6- 8

Torque Converter Cover Installation .................................................................................. 6- 8

Converter Exhaust Duct Removal...................................................................................... 6- 9

Converter Exhaust Duct Installation................................................................................... 6- 9

Converter Intake Duct Removal......................................................................................... 6-10

Converter Intake Duct Installation...................................................................................... 6-10

Drive Belt ................................................................................................................................. 6-11

Drive Belt Removal ............................................................................................................ 6-11

Drive Belt Installation ......................................................................................................... 6-11

Drive Belt Inspection .......................................................................................................... 6-11

Drive Belt Deflection Inspection ......................................................................................... 6-11

Drive Belt Deflection Adjustment ....................................................................................... 6-12

Drive Pulley ............................................................................................................................. 6-13

Drive Pulley Removal......................................................................................................... 6-13

Drive Pulley Disassembly .................................................................................................. 6-14

Drive Pulley Inspection ...................................................................................................... 6-15

Spider Shoe Side Clearance Adjustment........................................................................... 6-17

Drive Pulley Assembly ....................................................................................................... 6-18

Drive Pulley Installation...................................................................................................... 6-20

Driven Pulley ........................................................................................................................... 6-21

Driven Pulley Removal....................................................................................................... 6-21

Driven Pulley Disassembly ................................................................................................ 6-21

Driven Pulley Inspection .................................................................................................... 6-22

Driven Pulley Assembly ..................................................................................................... 6-24

Driven Pulley Installation.................................................................................................... 6-26

High Altitude Setting Information ............................................................................................. 6-27

Specifications..................................................................................................................... 6-27

6-2 CONVERTER SYSTEM

Exploded View

CONVERTER SYSTEM 6-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Drive Pulley Bolt 93 9.5 69 Lh, R

2Driven Pulley Nut 93 9.5 69

3Drive Pulley Cover Bolts 13 1.3 113 in·lb

4Ramp Weight Nuts 6.9 0.70 61 in·lb

5Spider 275 28 203 Lh

G: Apply grease for oil seal and O-ring.

Lh: Left-hand Threads

M: Apply molybdenum disulfide grease.

R: Replacement Parts

6-4 CONVERTER SYSTEM

Exploded View

CONVERTER SYSTEM 6-5

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Converter Cover Bolts 8.8 0.90 78 in·lb S

2Joint Duct Bolts 8.8 0.90 78 in·lb

G: Apply grease for oil seal and O-ring.

S: Follow the specific tightening sequence.

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

Flywheel & Pulley Holder :

57001–1343

Drive & Driven Pulley Holder :

57001–1412

Drive Pulley Puller Bolt :

57001–1429

Pulley Holder Attachment :

57001–1472

Drive Pulley Holder :

57001–1473

Drive Pulley Wrench :

57001–1474

Spring Holder Set :

57001–1483

Drive Pulley Holder :

57001–1520

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 de-

signed to operate within certain rpm limits. Disas-

sembly/assembly and servicing procedures of the

pulley assemblies must be followed closely. Modi-

fications to the engine or pulleys that increase rpm

may cause failure.

Torque Converter Cover Removal

•Turn the ignition switch OFF.

•Remove:

Clamp Screw [A] and Clamp [B]

JointDuct[C]

•Remove:

Torque Converter Cover Bolts [A]

Torque Converter Cover [B]

Torque Converter Cover Installation

•Fit the trim seal into the converter cover.

Set trim seal juncture in area [A] when insert trim seal in

the cover.

10 mm [B]

CONVERTER SYSTEM 6-9

Torque Converter

•Tighten the cover bolts following the tightening sequence

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.

•Remove the duct mounting bolt [A] and collar.

•Remove the converter exhaust duct.

Converter Exhaust Duct Installation

•Install the converter exhaust duct, collar and tighten the

duct mounting bolt.

•Install the converter exhaust duct [A] in the joint duct [B]

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.

•Remove the converter intake duct [A] from the joint duct

[B].

•Remove the converter intake duct.

Converter Intake Duct Installation

•Apply grease to the O-ring [A].

•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)

•Install the converter intake duct [A] in the joint duct [B] as

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 direc-

tion so the belt rotates in the same direction as origi-

nally installed. When installing a new belt, install it so

the printed information [A] can be read from beside the

vehicle.

•Installation is basically the reverse of removal.

•Loop the belt [B] over the driven pulley [C].

•Install the drive pulley (see Drive Pulley Installation).

•Put the transmission in neutral, and rotate the driven pul-

ley to allow the belt to return to the top [A] of the sheaves,

before measuring belt deflection.

Drive Belt Inspection

•Refer to the Converter System in the Periodic Mainte-

nance chapter.

Drive Belt Deflection Inspection

•Refer to the Converter System in the Periodic Mainte-

nance chapter.

6-12 CONVERTER SYSTEM

Drive Belt

Drive Belt Deflection Adjustment

•Refer to the Converter System in the Periodic Mainte-

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 posi-

tions shown. Otherwise, the tapped holes will be

damaged.

Special Tool - Drive Pulley Holder: 57001–1520

•Loosen the drive pulley bolt [D] (left-hand threads), hold-

ing the drive pulley with the drive pulley holder.

•Remove the drive pulley bolt, two washers and the

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.

•Remove the drive pulley [A] from the crankshaft by screw-

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

•Hold the drive pulley holder [A] and drive & driven pulley

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

•Set the pulley onto the pulley holder.

•Remove:

Drive Pulley Cover Bolts [A]

Drive Pulley Cover [B]

•Remove:

Spring [A]

Spacer

•Put the drive pulley wrench [A] on the spider [B] and

tighten the bolt [C].

Special Tool - Drive Pulley Wrench: 57001–1474

•Turn the wrench clockwise and remove the spider with the

movable sheave.

NOTE

The spider has left-hand threads. Turn the wrench

clockwise for loosening.

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 dam-

aged 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 spi-

der.

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 Disas-

sembly)

•Temporarily install:

Dowel Pins (2)

Drive Pulley Cover

Two Bolts (at dowel pins)

•Turn the movable sheave clockwise.

•Measure the resulting clearance [A] between the shoe [B]

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 maxi-

mum, replace all shoes with standard shoes (see Drive

Pulley Disassembly).

6-18 CONVERTER SYSTEM

Drive Pulley

•Turn the movable sheave clockwise.

•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

Present Shoes

Part Number Thickness

Less than 0.15 mm

(0.0059 in.)

49048-1087 7.2 mm (0.283 in.)

49048-1088 7.3 mm (0.287 in.)

0.15 ~ 0.30 mm no change

(0.0059 ~ 0.0118 in.) 49048-1089 7.4 mm (0.291 in.)

(standard clearance)

49048-1090 7.5 mm (0.295 in.)

49048-1091 7.6 mm (0.299 in.)

Over 0.30 mm 49048-1092 7.7 mm (0.303 in.)

(0.0118 in.) 49048-1093 7.8 mm (0.307 in.)

49048-1094 7.9 mm (0.311 in.)

49048-1095 8.0 mm (0.315 in.)

•Check that the movable sheave [A] moves smoothly, after

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

•Install the ramp weight [A] as shown.

•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

•Hold the fixed sheave [A] with the drive pulley holder [B]

in a vise.

Special Tool - Drive Pulley Holder: 57001–1473

•Clean the threads of the fixed sheave and spider.

•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.

•Put the drive pulley wrench [A] on the spider [B] and

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.

•Install the spacer.

•Put the spring [A] in the groove of the spider.

•Align the arrows [B] on the drive pulley cover and spider.

•Install:

Dowel Pins [C]

Drive Pulley Cover

•Tighten:

Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 113

in·lb)

•Clean the surface of the sheaves with an oil-less cleaning

fluid.

6-20 CONVERTER SYSTEM

Drive Pulley

Drive Pulley Installation

•Clean the following portions with an oil-less cleaning fluid

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.

•Install the drive pulley, stepped washer and two washers

on the drive pulley bolt as shown.

Crankcase Side [A]

Stepped Washer [B]

Two Washer [C]

Bolt Head [D]

•Install the drive pulley cover and be sure to install the drive

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 at-

tachments [B], remove the driven pulley nut [C] and wash-

ers. (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

•Screw the guide bar [B] of the spring holder set into the

holder.

Special Tool - Spring Holder Set: 57001–1483

•Put the driven pulley [C] on the guide bar.

•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

•Make match–marks [A] and [B] on the sheaves so that it

can be installed later in the same position.

Movable Sheave [C]

Fixed Sheave [D]

•Wipe off the molybdenum disulfide grease.

•Remove the four pins [A] with a thin standard tip screw-

driver [B].

•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

•Replace the sheave with uneven wear on the belt con-

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.)

•Inspect seals for damage.

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

•Clean off any grease or dirt on the movable and fixed

sheaves, and dry them with a clean cloth.

•Install:

Spacers [A] (for Drive Belt Deflection Adjustment)

•Apply grease to the oil seal lips [A].

•Press the oil seals [B] in the movable sheave assembly

so that the oil seal surface is flush [C] with the sleeve end.

•Apply [D] molybdenum disulfide grease to the inner sur-

faces of the bushings.

•Align the match–marks on the sheaves, made when

disassembled, and the opening [A] and hole [B] will be

matched easily.

•Apply molybdenum disulfide grease to the seating surface

[A] of the pins, and insert them into the holes in the mov-

able sheave.

CONVERTER SYSTEM 6-25

Driven Pulley

•Draw the movable sheave onto the fixed sheave, and ap-

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.

•Check that the O-rings [A] are in good condition.

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

•Screw the guide bar of the spring holder set into the

holder.

Special Tool - Spring Holder Set: 57001-1483

•Put the driven pulley [A] onto the guide bar.

•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]

•Tighten the nut [A], and compress the spring with the

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

•Remove the driven pulley from the spring holder set.

•Clean the surface of the sheaves with an oil-less cleaning

fluid.

6-26 CONVERTER SYSTEM

Driven Pulley

Driven Pulley Installation

•Clean the transmission driven shaft [A].

•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.

•Clean the driven shaft and driven pulley ends to open the

air vent passage. Wipe off any extra grease.

Wipe off any protruding grease [A].

•Install the washers [A] on the shaft as shown.

Crankcase Side [B]

Bolt Head [C]

•Using a flywheel & pulley holder [A] and pulley holder at-

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......................................................................................................................... 7- 2

Specifications .......................................................................................................................... 7- 4

Special Tools and Sealant ....................................................................................................... 7- 5

Engine Oil Flow Chart..............................................................................................................7-6

Engine Oil and Oil Filter...........................................................................................................7-7

Oil Level Inspection............................................................................................................ 7-7

Engine Oil Change............................................................................................................. 7- 7

Oil Filter Change ................................................................................................................ 7- 7

Oil Screen Removal ........................................................................................................... 7- 7

Oil Screen Cleaning ........................................................................................................... 7- 8

Oil Pressure Measurement ................................................................................................ 7- 8

Oil Pressure Relief Valve......................................................................................................... 7- 9

Oil Pressure Relief Valve Removal .................................................................................... 7- 9

Oil Pressure Relief Valve Installation ................................................................................. 7- 9

Oil Pressure Relief Valve Inspection.................................................................................. 7- 9

Oil Pump.................................................................................................................................. 7-10

Oil Pump Removal ............................................................................................................. 7-10

Oil Pump Installation .......................................................................................................... 7-10

Oil Pipe .................................................................................................................................... 7-12

Oil Pipe Removal ............................................................................................................... 7-12

Oil Pipe Installation ............................................................................................................ 7-13

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 7-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Oil Filter 18 1.8 13 R

2Oil Pressure Switch 15 1.5 11 SS

3Oil Pipe Bolts 8.8 0.90 78 in·lb

4Engine Drain Plug 20 2.0 14

5Oil Pressure Relief Valve 15 1.5 11 L

6Oil Pump Bolts 8.8 0.90 78 in·lb

7Chain Guide Bolts 8.8 0.90 78 in·lb

8Oil Pump Drive Chain Tensioner Bolt 25 2.5 18

9Oil Filter Mounting Bolt 25 2.5 18 L(15mm)

10 Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

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

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

•Park the vehicle so that it is level, both side-to-side and

front-to-rear.

•If the oil has just been changed, start the engine, and run

it 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.

•Stop the engine and wait several minutes for all the oil to

drain back to the sump.

•Unscrew the oil filler cap [A], wipe its dipstick [B] dry, and

tighten it into the filler opening.

•Unscrew the oil filler cap and check the oil level. The oil

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

•Refer to the Engine Lubrication System in the Periodic

Maintenance chapter.

Oil Filter Change

•Refer to the Engine Lubrication System in the Periodic

Maintenance chapter.

Oil Screen Removal

•Split the crankcase (see Crankshaft/Transmission chap-

ter).

•Pull the oil screen [A] out of the crankcase.

7-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter

Oil Screen Cleaning

•Clean the oil screen [A] thoroughly whenever it is removed

for any reason.

•Clean the oil screen with a high flash-point solvent and

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.

•Check the screen carefully for any damage, holes, broken

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.

•Remove the oil pressure switch, and attach the oil pres-

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, in-

spect the oil filter, oil screen, and other areas of the lubri-

cation 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.

•Apply silicone sealant to the oil pressure switch, and

tighten it.

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

•Split the crankcase (see Crankshaft / Transmission chap-

ter).

•Remove the oil pressure relief valve [A].

Oil Pressure Relief Valve Installation

•See crankcase assembly (See Crankshaft / Transmission

chapter).

•Apply a non-permanent locking agent to the threads of oil

pressure relief valve, and tighten it.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11

ft·lb)

Oil Pressure Relief Valve Inspection

•Remove the relief valve.

•Using a wooden stick, push the inner valve to make sure

that the valve [A] moves smoothly and that it returns to its

original position by the force of the spring [B].

NOTE

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

•Apply engine oil:

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

•Check to see that the dowel pins [A] are in place.

•Apply engine oil to the oil pump hole [B].

•Install the oil pump drive chain [A] with the oil pump as-

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)

•Apply grease to the O-ring [A].

•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

•Replace the O-ring [A] with new ones.

•Apply engine oil to the O-rings before installation.

•Tighten:

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......................................................................................................................... 8- 2

Engine Removal/Installation .................................................................................................... 8-4

Engine Removal................................................................................................................. 8-4

Engine Installation..............................................................................................................8-5

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View

ENGINE REMOVAL/INSTALLATION 8-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Engine Mounting Bracket Bolts 52 5.3 38

2Engine Mounting Nut 62 6.3 46

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]

•Put a tape to protect the frame.

•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.

•Insert the drive shaft in the rear propeller shaft joint [A].

•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......................................................................................................................... 9- 2

Specifications .......................................................................................................................... 9- 6

Special Tools and Sealant ....................................................................................................... 9- 8

Crankcase ............................................................................................................................... 9- 9

Crankcase Disassembly .................................................................................................... 9- 9

Crankcase Assembly ......................................................................................................... 9-10

Crankshaft/Connecting Rod .................................................................................................... 9-13

Crankshaft Removal .......................................................................................................... 9-13

Crankshaft Installation ....................................................................................................... 9-13

Connecting Rod Removal .................................................................................................. 9-13

Connecting Rod Installation............................................................................................... 9-13

Crankshaft/Connecting Rod Cleaning................................................................................ 9-14

Connecting Rod Bend........................................................................................................ 9-14

Connecting Rod Twist ........................................................................................................ 9-14

Connecting Rod Big End Side Clearance.......................................................................... 9-15

Connecting Rod Big End Bearing/Crankpin Wear ............................................................. 9-15

Crankshaft Runout............................................................................................................. 9-17

Crankshaft Main Bearing/Journal Wear ............................................................................. 9-17

Transmission ........................................................................................................................... 9-18

Shift Lever Removal........................................................................................................... 9-18

Shift Lever Installation........................................................................................................ 9-18

Shift Control Cables Removal............................................................................................ 9-19

Shift Control Cables Installation......................................................................................... 9-19

Reverse Lock Cable Removal ........................................................................................... 9-20

Reverse Lock Cable Installation ........................................................................................ 9-20

Transmission Removal ...................................................................................................... 9-21

Transmission Installation ................................................................................................... 9-22

Shift Fork Bending ............................................................................................................. 9-24

Shift Fork/Gear and Shifter Groove Wear.......................................................................... 9-24

Transmission and Shift Mechanism Inspection.................................................................. 9-25

Ball Bearing, Needle Bearing, and Oil Seal............................................................................. 9-27

Ball and Needle Bearing Replacement .............................................................................. 9-27

Ball and Needle Bearing Wear........................................................................................... 9-27

Oil Seal Inspection ............................................................................................................. 9-27

9-2 CRANKSHAFT / TRANSMISSION

Exploded View

CRANKSHAFT / TRANSMISSION 9-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Connecting Rod Big End Cap Nuts 34 3.5 25 MO

2Engine Drain Plug 20 2.0 14

3Crankcase Bolts (M8) 75 mm (2.95 in.) 20 2.0 14 S

4Crankcase Bolts (M8) 110 mm (4.33 in.) 20 2.0 14 L(1), S

5Crankcase Bolts (M6) 40 mm (1.57 in.) 9.8 1.0 87 in·lb

6Crankcase Bolts (M6) 65 mm (2.56 in.) 9.8 1.0 87 in·lb

7Position Plate Mounting Screws 4.9 0.50 43 in·lb L

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.

9-4 CRANKSHAFT / TRANSMISSION

Exploded View

CRANKSHAFT / TRANSMISSION 9-5

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Shift Shaft Lever Nut 8.8 0.90 78 in·lb

2Shift Shaft Positioning Bolt 25 2.5 18

3Shift Shaft Spring Bolt 25 2.5 18 L

4Shift Shaft Cover Bolt 8.8 0.90 78 in·lb

5Neutral Position Switch 15 1.5 11

6Reverse Position Switch 15 1.5 11

7Shift Shaft Lever Bolt 14 1.4 10

8Reverse Cable Bracket Mounting Bolts 8.8 0.90 78 in·lb

9Reverse 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

9-6 CRANKSHAFT / TRANSMISSION

Specifications

Item Standard Service Limit

Crankshaft, Connecting Rods:

Connecting rod bend ––– TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting rod twist ––– 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.) 0.09 mm

(0.0035 in.)

Crankpin diameter: 39.984 ~ 40.000 mm (1.5742 ~ 1.5748 in.) 39.97 mm

(1.5736 in.)

Marking: None 39.984 ~39.992 mm (1.5742 ~ 1.57449 in.) –––

39.993 ~ 40.000 mm (1.57452 ~ 1.5748 in.) –––

Connecting rod big end

inside diameter: 43.000 ~ 43.016 mm (1.6929 ~ 1.6939 in.) –––

Marking: None 43.000 ~ 43.008 mm (1.6929 ~ 1.69323 in.) –––

43.009 ~ 43.016 mm (1.69326 ~ 1.6935 in.) –––

Connecting rod big end bearing

insert thickness:

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:

Con-rod Big End Crankpin

Bore Diameter Diameter Bearing Insert

Marking Marking Size Color Part Number

None Brown 92028-1963

None None Yellow 92028-1962

None Green 92028-1961

Crankshaft runout 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.)

Crankshaft main bearing bore

diameter:

f42 Side 42.025 ~ 42.041 mm (1.6545 ~ 1.6552 in.) 42.08 mm

(1.6567 in.)

CRANKSHAFT / TRANSMISSION 9-7

Specifications

Item Standard Service Limit

Transmission

Shift fork ear thickness 5.9 ~ 6.0 mm (0.2322 ~ 0.2362 in.) 5.8 mm

(0.228 in.)

Shifter groove width 6.05 ~ 6.15 mm (0.2382 ~ 0.2421 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 chap-

ter)

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]

•Wrap the teeth on the sprockets [A] by taping for protect-

ing the bushing in the crankcase.

•Using the pry points [B], split the crankcase halves.

•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 crank-

shaft.

WARNING

Clean the engine parts in a well-ventilated area, and

take care that there are no sparks or flame any-

where near the working area; this includes any ap-

pliance with a pilot light. Do not use gasoline or low

flash-point solvents to clean parts. A fire or explo-

sion could result.

•Apply a small amount of engine oil to the transmission

gears, bearings and shift fork.

•Be sure the mating surfaces of the crankcase halves are

clean and dry.

•Press and insert the new ball bearings until they are bot-

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 Sys-

tem 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

•Press and insert the new ball bearings [A] until they are

bottomed.

Special Tool - Bearing Driver Set: 57001–1129

•Press and insert the new needle bearings so that the

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)

•Grease the lip [A] of the oil seal [B] and press the seal 3

mm (0.12 in.) [C] inwards from the end of the boss.

•Be sure the following parts are in place in the right

crankcase half.

Crankshaft

Transmission Shafts and Shift Rod [A]

Oil Tube [B]

Oil Screen [C]

O-ring (Apply Grease) [D]

Dowel Pins [E]

•Apply liquid gasket [A] to mating surface of the left

crankcase half.

Sealant - Three Bond: 1215 (Gray)

•Apply after, must be assembled with in 20 min.

9-12 CRANKSHAFT / TRANSMISSION

Crankcase

•Apply a non-permanent locking agent to the area [C] (12

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=75mm(2.95in.)

[3,4,7,8]L=110mm(4.33in.)

•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.)

•Install the breather tube [A] on the crankcase fitting.

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.

•Apply grease to the steel ball [A] and spring [B].

•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

•Split the crankcase (see Crankcase Disassembly).

•Remove the crankshaft [A] from the crankcase using a

press.

Crankshaft Installation

•The left shaft [A] of the crankshaft is longer than the right

shaft [B].

•Apply engine oil to the both main journals.

•Insert the right crankshaft tapered end (the shorter end)

into the right crankcase using a press.

Connecting Rod Removal

•Remove the crankshaft (see Crankshaft Removal).

•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 crank-

shaft are replaced with new ones, select the bearing

insert and check clearance with a plastigage before

assembling the engine to be sure the correct bear-

ing inserts are installed.

•Apply molybdenum disulfide oil:

Inner Surface [A] of Bearing Inserts

•Face the “OUT” marks [B] of both connecting rods to-

wards the outsides of the crankshaft.

•Fit the connecting rod cap so that the grooves [C] of the

cap and connecting rod are on the same side.

9-14 CRANKSHAFT / TRANSMISSION

Crankshaft/Connecting Rod

•Apply molybdenum disulfide oil:

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

•After removing the connecting rods from the crankshaft,

clean them with a high flash-point solvent.

•Blow the crankshaft oil passages with compressed air to

remove any foreign particles or residue that may have

accumulated in the passages.

Connecting Rod Bend

•Remove the connecting rod big end bearing inserts, and

reinstall the connecting rod big end cap.

•Select an arbor [A] of the same diameter as the connect-

ing rod big end, and insert the arbor through the connect-

ing rod big end.

•Select an arbor of the same diameter as the piston pin

and 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 con-

necting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist

•With the big-end arbor [A] still on the V block [C], hold the

connecting rod horizontally and measure the amount that

the arbor [B] varies from being parallel with the surface

plate over a 100 mm (3.94 in.) length of the arbor to de-

termine the amount of connecting rod twist.

If connecting rod twist exceeds the service limit, the con-

necting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

CRANKSHAFT / TRANSMISSION 9-15

Crankshaft/Connecting Rod

ConnectingRodBigEndSideClearance

•Measure the side clearance of the connecting rod big end

[A].

Insert a thickness gauge [B] between the big end and ei-

ther 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 con-

necting 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

•Measure the bearing insert/crankpin [A] clearance with

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 bear-

ing inserts [A] with inserts painted green [B]. Check in-

sert/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

•Measure the connecting rod big end inside diameter, and

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

•Select the proper bearing insert [A] in accordance with the

combination of the connecting rod and crankshaft coding.

Size Color [B]

Big End Bearing Insert Selection

Crankpin

Diameter

Bearing Insert

Mark

Con-rod Big

End Bore

Diameter

Marking Size Color Part Number

None Brown 92028-1963

None None Yellow 92028-1962

None 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

•Measure the crankshaft runout.

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.

•Measure the main bearing bore diameter [A] in the

crankcase halves.

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.

1mm[A]

•Remove the cable holder mounting bolts [A].

•Remove the shift control cables [B] from the shift shaft

lever.

•Remove the shift shaft lever bolt [C].

•Remove the shift shaft lever [D] from the shift shaft.

Shift Lever Installation

•Install the shift shaft lever to the shift shaft.

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)

•Install the shift control cables to the shift shaft lever.

•Install the cable holder and tighten the cable holder

mounting bolts.

Torque - Cable Holder Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•Adjust the shift control cables free play (see Periodic

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].

•Remove the shift control grip screws [A].

•Remove the shift control cables from the shift control grip.

Shift Control Cables Installation

•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.

•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.

•Adjust the shift control cables free play (see Periodic

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].

•Remove the cotter pin [A], washer [B] and pin [C].

•Remove the reverse lock cable from the lever [D].

•Loosen the locknuts [A] and remove the reverse lock ca-

ble from the frame.

Reverse Lock Cable Installation

•Lubricate the reverse lock cable before installation.

•Install the reverse lock cable to the frame.

•Tighten the locknuts temporarily.

•Install the reverse lock cable [A] to the lever.

•Replace the cotter pin with a new one.

•Install the pin, washer and cotter pin.

CRANKSHAFT / TRANSMISSION 9-21

Transmission

•Install the reverse lock cable in the reverse lock cable

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

•Remove the shift lever (see Shift Lever Removal).

•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:

ReverseIdleShaft[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 the driven shaft [B] from the crankcase using a

press.

Transmission Installation

•Insert the driven shaft in the crankcase until it is bottomed

usingapress.

•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

•Apply engine oil:

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:

ReverseIdleShaft[A]

9-24 CRANKSHAFT / TRANSMISSION

Transmission

•Apply molybdenum disulfide oil to the shift shaft [A].

•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)

•When a new bushing [A] and oil seal [B] are installed in

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

•Visually inspect the shift fork.

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

•Measure the thickness of the shift fork ears [A], and mea-

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

•Visually inspect:

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.

•Using a press or puller, remove the ball bearing and/or

three needle bearings.

NOTE

In the absence of the above mentioned tools, satisfac-

tory results may be obtained by heating the case to ap-

proximately 93 C (200 F) max., and tapping the bearing

in or out.

CAUTION

Do not heat the case with a torch. This will warp the

case. Soak the case in oil and heat the oil.

•Using a press and the bearing driver set [A], install the

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. Re-

moval may damage them.

•Check the ball bearings.

Since the ball bearings are made to extremely close toler-

ances, the wear must be judged by feel rather than mea-

surement. Clean each bearing in a high flash-point sol-

vent, dry it (do not spin the bearing while it is dry), and oil

it with engine oil.

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 bear-

ing, replace it.

Oil Seal Inspection

•Inspect the oil seals.

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......................................................................................................................... 10- 2

Specifications .......................................................................................................................... 10- 4

Special Tool ............................................................................................................................. 10- 5

Wheel Alignment ..................................................................................................................... 10- 6

Toe-in Inspection................................................................................................................ 10- 6

Toe-in Adjustment .............................................................................................................. 10- 7

Wheels (Rims) ......................................................................................................................... 10- 8

Wheel Removal.................................................................................................................. 10- 8

Wheel Installation............................................................................................................... 10- 8

Wheel (Rim) Inspection...................................................................................................... 10- 8

Wheel (Rim) Replacement................................................................................................. 10- 9

Tires......................................................................................................................................... 10-10

Tire Removal...................................................................................................................... 10-10

Tire Installation................................................................................................................... 10-10

Tire Inspection ................................................................................................................... 10-11

Front Hub................................................................................................................................. 10-12

Front Hub Removal............................................................................................................ 10-12

Front Hub Installation......................................................................................................... 10-12

Front Hub Disassembly/Assembly ..................................................................................... 10-12

Rear Hub ................................................................................................................................. 10-13

Rear Hub Removal ............................................................................................................ 10-13

Rear Hub Installation ......................................................................................................... 10-13

Rear Hub Disassembly/Assembly...................................................................................... 10-13

10-2 WHEELS / TIRES

Exploded View

WHEELS / TIRES 10-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Wheel Nuts 78 8.0 58

2Front Axle Nuts 52 5.3 38

3Tie-rod End Nuts 42 4.3 31

4Tie-rod Adjusting Locknuts 22 2.2 16

5Rear 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

10-4 WHEELS / TIRES

Specifications

Item Standard Service Limit

Wheel Alignment:

Toe-in of front wheels: 10 ± 10 mm (0.39 ± 0.39 in.) –––

Tires:

Standard tire: Front AT 22 × 7-10 –––

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) –––

Maximun tire air pressure 250 kPa (2.5 kgf/cm², 36 psi) –––

(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 to-

gether 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 slip-

ping or scuffing action between the tires and the ground. If

toe-in is incorrect, the front wheels will be dragged along

the ground, scuffing and wearing the tread knobs.

Caster and camber are build-in and require no adjust-

ment.

A (Rear ) – B (Front) = Amount of Toe-in

(Distance A and B are measured at axle height with the

vehicle sitting on the ground, or at 1G.)

Toe-in Inspection

•Apply a heavy coat of chalk or a paint line near the center

of the front tires.

•Using a needle nose scriber, make a thin mark near the

center of the chalk coating while turning the wheel.

•With the front wheels on the ground, set the handlebar

straight ahead.

•At the level of the axle height, measure the distance be-

tween the scribed or painted lines for both front and rear

of the front tires.

•Subtract the measurement of the front from the measure-

ment 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

•Loosen the locknuts [A] [B] and turn the adjusting tie–rods

[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. Un-

even thread length could cause tie-rod end damage.

•Check the toe-in.

•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

•Loosen the wheel nuts [A].

•Support the vehicle on a stand or a jack so that the wheels

are off the ground.

Special Tool - Jack: 57001-1238

•Remove:

Wheel Nuts

Wheel

Wheel Installation

•Position the wheel so that the air valve [A] is toward the

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

•Examine both sides of the rim for dents [A]. If the rim is

dented, replace it.

If the tire is removed, inspect the air sealing surfaces [A]

of the rim for scratches or nicks. Smooth the sealing sur-

faces with fine emery cloth if necessary.

WHEELS / TIRES 10-9

Wheels (Rims)

Wheel (Rim) Replacement

•Remove the wheel (see Wheel Removal).

•Disassemble the tire from the rim (see Tire Removal).

Remove the air valve and discard it.

CAUTION

Replace the air valve whenever the tire is replaced.

Do not reuse the air valve.

Plastic Cap [A]

ValveCore[B]

Stem Seal [C]

Valve Stem [D]

Valve Seat [E]

Valve Opened [F]

•Install a new air valve in the new rim.

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 lu-

bricate the stem because they will deteriorate the

rubber.

•Mount the tire on the new rim (see Tire Installation).

•Install the wheel (see Wheel Installation).

10-10 WHEELS / TIRES

Tires

Tire Removal

•Remove the wheel.

•Unscrew the valve core to deflate the tire.

Use a proper valve core tool [A].

•Lubricate the tire beads and rim flanges on both sides of

the wheel with a soap and water solution, or water [A].

This helps the tire beads slip off the rim flanges.

CAUTION

Do not lubricate the tire beads and rim flanges with

engine oil or petroleum distillates because they will

deteriorate the tire.

•Remove the tire from the rim using a suitable commer-

cially available tire changer.

NOTE

The tires cannot be removed with hand tools because

they fit the rims tightly.

Tire Installation

•Inspect the rim (see Wheel (Rim) Inspection).

•Replace the air valve with a new one.

CAUTION

Replace the air valve with whenever the tire is re-

placed. Do not reuse the air valve.

•Check the tire for wear and damage (see Tire Inspection).

•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

•Support the wheel rim [A] on a suitable stand [B] to pre-

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.

•Check to see that rim lines [A] on both sides of the tire are

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)

•Install the wheel (see Wheel Installation).

•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 sep-

aration, and a hazardous condition may result.

Tire Inspection

•Refer to the Wheels/Tires in Periodic Maintenance chap-

ter.

10-12 WHEELS / TIRES

Front Hub

Front Hub Removal

•Remove:

Cotter Pin [A]

•Loosen the axle nut [B].

•Remove the wheel (see Wheel Removal).

•Remove the caliper [A] by taking off the mounting bolts,

and let the caliper hang free.

•Remove the axle nut [B] and pull off the front hub [C] and

brake disc.

•Separate the brake disc from the front hub.

Front Hub Installation

•Install the brake disc (see Brakes chapter).

•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

•Do not press the hub bolts [A] out.

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

•Do not press the hub bolts [A] out.

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......................................................................................................................... 11- 2

Specifications .......................................................................................................................... 11- 6

Special Tools ........................................................................................................................... 11- 7

Output Bevel Gears ................................................................................................................. 11- 9

Output Drive Bevel Gear Removal..................................................................................... 11- 9

Output Drive Bevel Gear Installation.................................................................................. 11- 9

Output Drive Bevel Gear Disassembly .............................................................................. 11-10

Output Drive Bevel Gear Assembly ................................................................................... 11-12

Output Driven Bevel Gear Removal................................................................................... 11-13

Output Driven Bevel Gear Installation................................................................................ 11-14

Output Driven Bevel Gear Disassembly ............................................................................ 11-14

Output Driven Bevel Gear Assembly ................................................................................. 11-16

Output Bevel Gears Adjustment ........................................................................................ 11-17

Bevel Gears Inspection...................................................................................................... 11-22

Cam Damper Inspection .................................................................................................... 11-22

Propeller Shaft......................................................................................................................... 11-23

Propeller Shaft Removal .................................................................................................... 11-23

Propeller Shaft Installation ................................................................................................. 11-23

Propeller Shaft Joint Boot Inspection................................................................................. 11-23

Propeller Shaft Inspection.................................................................................................. 11-23

Rear Axle................................................................................................................................. 11-24

Rear Axle Removal ............................................................................................................ 11-24

Rear Axle Installation ......................................................................................................... 11-24

Ball Bearing Wear .............................................................................................................. 11-25

Rear Axle Runout Inspection ............................................................................................. 11-25

Final Gear Case ...................................................................................................................... 11-26

Final Gear Case Oil Level Inspection ................................................................................ 11-26

Final Gear Case Oil Change.............................................................................................. 11-26

Final Gear Case Removal ................................................................................................. 11-26

Final Gear Case Installation............................................................................................... 11-27

Final Gear Case Disassembly .......................................................................................... 11-28

Final Gear Case Assembly ................................................................................................ 11-29

Oil Seal Installation ............................................................................................................ 11-30

Final Bevel Gear Adjustment ............................................................................................. 11-30

Pinion Gear Unit Disassembly ........................................................................................... 11-33

Pinion Gear Unit Assembly ................................................................................................ 11-34

Bevel Gear Inspection........................................................................................................ 11-34

Bearing and Oil Seal................................................................................................................ 11-36

Ball or Needle Bearing Inspection...................................................................................... 11-36

Oil Seal Inspection ............................................................................................................. 11-36

11-2 FINAL DRIVE

Exploded View

FINAL DRIVE 11-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Output Driven Bevel Gear Housing Bolts 26 2.7 20

2Output Drive Bevel Gear Housing Bolts 26 2.7 20

3Bearing Holder 137 14 101 L

4Bevel Gear Holder Nut 157 16 116 L

5Bearing Holder 120 12 89 L

6Output Shaft Holder Nut 157 16 116 L

7Output Drive Bevel Gear 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.

MO: Apply molybdenum disulfide oil.

11-4 FINAL DRIVE

Exploded View

FINAL DRIVE 11-5

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Oil Filler Cap 29 3.0 22

2Oil Drain Plug 20 2.0 14

3Pinion Gear Bearing Holder 137 14 101 L

4Pinion Gear Bearing Holder Nut 157 16 116 L

5Final Gear Case Left Cover Bolts 49 5.0 36 L

6Final Gear Case Bolts 42 4.3 31 S

7Final Gear Case Right Cover Bolts (M8) 24 2.4 17 L, S

8Final Gear Case Right Cover Bolts (M10) 49 5.0 36 L, S

9Final 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) –––

Final bevel gear backlash 0.07 ~0.14 mm (0.003 ~ 0.006 in.) –––

(at pinion gear spline)

FINAL DRIVE 11-7

Special Tools

Bearing Puller :

57001–135

Outside Circlip Pliers :

57001–144

Oil Seal & Bearing Remover :

57001–1058

Bearing Driver Set :

57001–1129

Socket Wrench :

57001–1363

Damper Spring Compressor Set :

57001–1475

Holder & Guide Arbor :

57001–1476

Socket Wrench, Hex 50 :

57001–1478

Output Shaft Holder & Spacer :

57001–1479

Pinion Gear Holder :

57001–1480

11-8 FINAL DRIVE

Special Tools

Nut Holding Bolts :

57001–1481

Socket Wrench :

57001–1482

Socket Wrench, Hex 41 :

57001–1484

Pinion Gear Holder :

57001–1485

Oil Seal Driver:

57001–1487

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

•Install the output drive bevel gear housing.

•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

•Apply grease:

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.

•Tighten the nut holding bolts [A] (4) securely into the

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

•Hold the output drive bevel gear housing [A] in a vise.

•Loosen the bevel gear [B] using an Allen wrench about

four rotations.

•Remove one nut holding bolt, and look at through the

hole.

If the groove of the bevel gear holder nut is not seen,

loosen the other three bolts.

•Drive the gear shaft end using a copper mallet until the

grooves of the bearing holder nut can be seen again.

•Retighten the nut holding bolts (4) securely into the

groove of the bevel gear holder nut in the output drive

bevel gear housing.

Special Tool - Nut Holding Bolts: 57001–1481

•Repeat the above procedure, and remove the bevel gear

from the housing.

•Remove the bearing holder [A] using the hexagon wrench

[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

•Apply a non-permanent locking agent to the threads of

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

•Apply a non-permanent locking agent to the threads of

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/In-

stallation chapter)

Output Driven Bevel Gear Housing Bolts [A]

Output Driven Bevel Gear Housing [B]

•Tap lightly the front end [A] of the output driven bevel gear

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

•Apply grease:

O-ring [A]

•Install the output driven bevel gear shaft assembly.

•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

•Hold the housing assembly [A] with the output shaft holder

[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

•Hold the housing assembly [A] with the holder [B] in a

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

•Hold the housing assembly [A] with the holder [B] in a

vise.

Special Tool - Holder & Guide Arbor: 57001-1476

•Apply a non-permanent locking agent to the threads of

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)

•Hold the housing assembly [A] with the output shaft holder

[B] & spacer [C] in a vise.

Special Tool - Output Shaft Holder & Spacer: 57001-1479

•Insert the output shaft [D] in the housing.

•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.

•Hold the holder [A] in a vise, and set the housing assembly

[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

•Tighten the nuts [C] and compress the damper spring.

•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 replac-

ing 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 Part Number

0.15 mm (0.006 in.) 92180-1311

0.2 mm (0.008 in.) 92180-1312

0.5 mm (0.020 in.) 92180-1313

0.8 mm (0.031 in.) 92180-1314

1.0 mm (0.039 in.) 92180-1351

1.2 mm (0.047 in.) 92180-1352

Driven Bevel Gear Shims for Backlash Adjustment

Thickness Part Number

0.15 mm (0.006 in.) 92180-1307

0.2 mm (0.008 in.) 92180-1308

0.5 mm (0.020 in.) 92180-1309

0.8 mm (0.031 in.) 92180-1310

1.0 mm (0.039 in.) 92180-1349

1.2 mm (0.047 in.) 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).

•Set up a dial gauge [A] against the output drive shaft

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 hous-

ing and into contact with driven gear. This may help to

hold it still. The difference between the highest and low-

est 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 sup-

ply stores for the purpose of checking differential gear

tooth patterns and contact. Use this for checking the

bevel gears.

•Turn the output driven shaft for 3 or 4 turns in the drive

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 chang-

ing 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 thick-

ness 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

•Visually check the bevel gears [A] for scoring, chipping,

or other damage.

Replace the bevel gears as a set if either gear is dam-

aged.

Cam Damper Inspection

•Visually inspect:

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

•Drain the final gear case oil (see Final Drive in the Periodic

Maintenance chapter).

•Remove:

Swingarm [A] (see Suspension chapter)

Propeller Shaft [B]

Propeller Shaft Installation

•Wipe the old grease off the front and rear end splines

[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

•Refer to the Final Drive in the Periodic Maintenance chap-

ter.

Propeller Shaft Inspection

•Remove the propeller shaft (see Propeller Shaft Re-

moval).

•Check that the universal joint [A] works smoothly without

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 pro-

peller 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

•Drain the final gear case oil (see Final Drive in the Periodic

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]

•Tap [A] the right end of the rear axle [B] and pull it out from

the left.

The left axle bearing comes off with the axle.

Rear Axle Installation

•Install the rear axle from the left side with the left bearing

installed, while aligning the splines.

•Apply grease:

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. Re-

moval may damage it.

•Check the ball bearing.

Since the ball bearing is made to extremely close toler-

ances, the wear must be judged by feel rather than mea-

surement.

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

•Visually inspect the axle for damage.

If the axle is damaged or bent, replace it.

•Set the rear axle in an alignment jig or on V blocks, and

place a dial gauge [A] against the middle point.

•Turn the axle slowly. The difference between the highest

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

•Park the vehicle so that it is level, both side-to-side and

front-to-rear.

•Remove the filler cap.

CAUTION

Be careful not to allow any dirt or foreign materials

to enter the gear case.

•Check the oil level. The oil level should come to the bot-

tom 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

•Refer to the Final Drive in the Periodic Maintenance chap-

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.

•Tighten the final gear case bolts following the tightening

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

•Visually check the pinion gear and ring gear for scoring,

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).

•Apply a non-permanent locking agent to the pinion gear

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

•Press the oil seals in the right and left covers to the spec-

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 con-

tact 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 Part Number

0.15 mm (0.006 in.) 92180-1320

0.2 mm (0.008 in.) 92180-1319

0.5 mm (0.020 in.) 92180-1321

0.8 mm (0.031 in.) 92180-1322

1.0 mm (0.039 in.) 92180-1345

1.2 mm (0.047 in.) 92180-1346

7. Ring Gear Shims for Backlash Adjustment

Thickness Part Number

0.15 mm (0.006 in.) 92180-1318

0.2 mm (0.008 in.) 92180-1316

0.5 mm (0.020 in.) 92180-1317

0.8 mm (0.031 in.) 92180-1315

1.0 mm (0.039 in.) 92180-1343

1.2 mm (0.047 in.) 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 As-

sembly).

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 disap-

pears. Then, change the ring gear shim to a thinner one.

•Temporarily, install the rear axle in the gear case and hold

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 thick-

ness 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.

•Assemble the final gear case (see Final Gear Case As-

sembly).

•Turn the pinion gear for one revolution in the drive and

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 nec-

essary.

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 re-

placed 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, re-

place 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 bot-

tomed.

•Install the pinion gear bearing holder nut [B] so that the

projection [C] faces outward.

•Apply a non-permanent locking agent to the pinion gear

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

•Visually check the bevel gears [A] for scoring, chipping,

or other damage.

Replace the bevel gears as a set if either gear is dam-

aged.

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 toler-

ances, the clearance cannot normally be measured.

CAUTION

Do not remove any bearings for inspection except

the right rear axle bearing.

•Turn each bearing in the case or hub back and forth [A]

while checking for plays, roughness, or binding.

If bearing play, roughness, or binding is found, replace

the bearing.

•Check the needle bearings [A] in the final gear case.

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

•Inspect the oil seals [A].

Replace any if the lips are misshapen, discolored (indicat-

ing that the rubber has deteriorated), hardened, or been

otherwise damaged.

BRAKES 12-1

Brakes

TABLE OF CONTENTS

Exploded View.................................... 12- 2

Specifications ..................................... 12- 6

Special Tool ........................................ 12- 7

Brake Fluid ......................................... 12- 8

Brake Fluid Recommendation....... 12- 8

Brake Fluid Level Inspection......... 12- 8

Brake Fluid Change ...................... 12- 8

Brake Line Air Bleeding ................ 12- 8

Master Cylinder .................................. 12- 9

Master Cylinder Removal.............. 12- 9

Master Cylinder Installation........... 12- 9

Master Cylinder Disassembly ....... 12- 9

Master Cylinder Assembly ............ 12-10

Master Cylinder Inspection (Visual

Inspection).................................. 12-10

Calipers .............................................. 12-11

Caliper Removal ........................... 12-11

Caliper Installation ........................ 12-11

Caliper Disassembly ..................... 12-12

Caliper Assembly .......................... 12-12

Piston and Cylinder Damage ........ 12-13

Caliper Holder Shaft Wear

Inspection................................... 12-13

Brake Pads ......................................... 12-14

Brake Pad Removal ...................... 12-14

Brake Pad Installation ................... 12-14

Brake Pad Wear Inspection .......... 12-14

Brake Discs ........................................ 12-15

Disc Cleaning................................ 12-15

Disc Removal................................ 12-15

Disc Installation............................. 12-15

Disc Wear ..................................... 12-15

Disc Runout .................................. 12-16

Brake Hoses ....................................... 12-17

Brake Hose Inspection.................. 12-17

Brake Hose Replacement............. 12-17

Rear Brake Lever, Pedal and Cables . 12-18

Brake Pedal Position Inspection ... 12-18

Brake Pedal Position Adjustment.. 12-18

Rear Brake Lever Free Play

Inspection................................... 12-18

Brake Pedal Free Play Inspection. 12-18

Rear Brake Lever and Pedal Free

Play Adjustment ......................... 12-18

Brake Pedal Removal ................... 12-18

Brake Pedal Installation ................ 12-19

Brake Cable Removal ................... 12-19

Brake Cable Installation ................ 12-20

Brake Cable Lubrication................ 12-20

Brake Pedal Shaft Removal.......... 12-20

Brake Pedal Shaft Installation....... 12-20

Internal Wet Brake.............................. 12-21

Internal Wet Brake Disassembly... 12-21

Internal Wet Brake Assembly........ 12-22

12-2 BRAKES

Exploded View

BRAKES 12-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Reservoir Cap Screws 1.5 0.15 13 in·lb

2Brake Lever Pivot Bolt 5.9 0.60 52 in·lb

3Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb

4Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb

5Brake Switch Mounting Bolt 1.2 0.12 10 in·lb

6Brake Hose Banjo Bolts 25 2.5 18

7Caliper Mounting Bolts 25 2.5 18

8Bleed Valves 7.9 0.80 69 in·lb

9Disc Mounting Bolts 37 3.8 27 L

B: Apply brake fluid.

L: Apply a non-permanent locking agent.

Si: Apply silicone grease.

12-4 BRAKES

Exploded View

BRAKES 12-5

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Parking Brake Lever Screw – – – L

2Gasket Screws – – – L

3Brake 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 DOT3orDOT4 –––

Front Disc Brake:

Pad lining thickness 4.0 mm (0.16 in.) 1mm(0.04in.)

Disc thickness 3.3 ~3.7 mm (0.130 ~ 0.146 in.) 3mm(0.12in.)

Disc runout TIR 0.2 mm (0.008 in.) or less 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 pre-

cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left

unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in

the brake. This lowers the brake fluid boiling point

and could cause the brake to be ineffective. It may

also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of time

to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong

wind is blowing.

6. Except for the disc pads and disc, use only disc brake

fluid, isopropyl alcohol, or ethyl alcohol for cleaning

brake parts. Do not use any other fluid for cleaning of

these parts. Gasoline, engine oil, or any other petro-

leum 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 rub-

ber 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 : DOT3orDOT4

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

•The master cylinder clamp must be installed with the "UP"

mark [A] upwards.

•Tighten the upper clamp bolt first, and then the lower

clamp bolt. There will be a gap at the lower part of the

clamp after tightening.

Torque - Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)

•Use a new flat washer on each side of the brake hose

fitting, and tighten the banjo bolt.

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•Bleed the brake line after master cylinder installation (see

Brakes in the Periodic Maintenance chapter).

•Check the brake for good braking power, no braking brag,

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 pis-

ton since removal will damage it.

12-10 BRAKES

Master Cylinder

Master Cylinder Assembly

•Before assembly, clean all parts including the master

cylinder with brake fluid or alcohol.

CAUTION

Except for the disc pads and disc, use only disc

brake fluid, isopropyl alcohol, or ethyl alcohol for

cleaning brake parts. Do not use any other fluid for

cleaning these parts. Gasoline, engine oil, or any

other petroleum distillate will cause deterioration of

the rubber parts. Oil spilled on any part will be diffi-

cult to wash off completely, and will eventually de-

teriorate the rubber used in the disc brake.

•Take care not to scratch the piston or the inner wall of the

cylinder.

•Apply brake fluid to the removed parts and to the inner

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

•Remove the front wheel (see Wheels/Tires chapter).

•Loosen the banjo bolt [A] at the brake hose lower end,

and tighten it loosely.

•Unscrew the caliper mounting bolts [B].

•Detach the caliper [C] 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 Disas-

sembly).

Caliper Installation

•Install the caliper and brake hose lower end.

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)

•Check the fluid level in the brake reservoir.

•Bleed the brake line (see Brakes in the Periodic Mainte-

nance chapter).

•Check the brake for good braking power, no brake drag,

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 com-

pressed 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

•Replace the fluid seal [A] with a new one.

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

•Apply brake fluid to the outside of the pistons [A], and

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 spe-

cial 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)

•Install the anti-rattle spring [A] in the caliper as shown.

•Install the pads (see Brake Pad Installation).

Piston and Cylinder Damage

•Visually inspect the pistons [A] and cylinder surfaces.

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 con-

stant drag on the disc will raise brake and brake fluid tem-

perature.

•Check to see that the caliper holder shafts are not badly

worn or stepped, and that the rubber friction boots 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

•Remove the front wheel (see Wheels/Tires chapter).

•Detach the caliper from the disc (see Caliper Removal).

•Draw out the clip [A], and remove the pad holder pin [B].

•Remove the pad [A] on the outside.

•Push the holder [B] towards the piston, and remove the

pad [C] on the piston side.

Brake Pad Installation

•Push the caliper piston in by hand as far as it will go.

•Be sure that the anti-rattle spring is in place.

•Install:

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

•The disc must be installed with the marked side [A] facing

toward the steering knuckle.

•Apply a non-permanent locking agent:

Disc Mounting Bolts

•Tighten:

Torque - Disc Mounting Bolts: 37 N·m (3.8 kgf·m, 27 ft·lb)

•After installing the discs, check the disc runout. Com-

pletely clean off any grease that has gotten on either side

of the disc with a high flash-point solvent. Do not use one

which will leave an oily residue.

Disc Wear

•Measure the thickness of each disc at the point [A] where

it has worn the most.

Replace the disc if it has worn past the service limit.

Disc Thickness

Standard: 3.3 ~3.7 mm (0.130 ~ 0.146 in.)

Service Limit: 3 mm (0.12 in.)

12-16 BRAKES

Brake Discs

Disc Runout

•Jack up the vehicle so that the wheels are off the ground.

•Remove the front wheels and turn the handlebar fully to

one side.

•Set up a dial gauge against the disc [A], and measure the

disc runout.

If the runout exceeds the service limit, replace the disc.

Disc Runout

Standard: TIR 0.2 mm (0.008 in.) or less

Service Limit: TIR 0.3 mm (0.012 in.)

BRAKES 12-17

Brake Hoses

Brake Hose Inspection

•Refer to the Brakes in the Periodic Maintenance chapter.

BrakeHoseReplacement

•Refer to the Brakes in the Periodic Maintenance chapter.

12-18 BRAKES

Rear Brake Lever, Pedal and Cables

Brake Pedal Position Inspection

•Check that the brake pedal [B] is in the correct position as

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

•Loosen the locknut [A], and turn the adjusting bolt [B] until

the brake pedal is correctly positioned.

•Tighten the locknut.

•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)

•Loosen the locknut and the adjusting bolt.

•Remove the brake switch spring [A].

•Loosen the brake pedal bolt [B].

•Remove:

Washers [C]

Brake Pedal [D]

BRAKES 12-19

Rear Brake Lever, Pedal and Cables

Brake Pedal Installation

•Apply grease to the tip of the brake pedal shaft.

•Install the brake pedal.

•Align the punch mark [A] on the brake pedal shaft with the

punch mark [B] on the brake pedal.

•Install the washers [A].

•Tighten:

Torque - Brake Pedal Bolt [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•Install the brake switch spring [C].

•Adjust the brake pedal position (see Brake Pedal Posi-

tion).

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 circlip [C] and pull the cables out of the cable

mount [D].

•Loosen the knurled locknut [B] at the rear brake lever and

screw in the adjuster [C].

•Line up the slots [A] in the brake lever, knurled locknut,

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

•Grease the brake cable front ends.

•Replace the cotter pin with a new one.

•Route the brake cables according to the Cable, Wire, and

Hose Routing section in Appendix chapter.

•Install the parts removed (see the appropriate chapter).

•Adjust the brake pedal and rear brake 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

•Apply grease to the tip of the brake pedal shaft [A].

•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

•Apply [A] MOBIL FLUID 424 or equivalent oil to the brake

camshaft and the inside of the collar.

•Install the brake cam lever inserting the camshaft in the

swingarm.

•Align the punch mark [A] on the brake cam lever with the

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......................................................................................................................... 13- 2

Specifications .......................................................................................................................... 13- 4

Special Tools ........................................................................................................................... 13- 5

Shock Absorbers ..................................................................................................................... 13- 6

Front Shock Absorber Inspection....................................................................................... 13- 6

Front Shock Absorber Preload Adjustment........................................................................ 13- 6

Front Shock Absorber Removal......................................................................................... 13- 6

Front Shock Absorber Installation...................................................................................... 13- 7

Rear Shock Absorber: .......................................................................................................... 13- 7

Compression Damping Adjustment ................................................................................... 13- 7

Rear Shock Absorber Removal ......................................................................................... 13- 8

Rear Shock Absorber Installation ...................................................................................... 13- 8

Rear Shock Absorber Preload Adjustment ........................................................................ 13- 8

Rear Shock Absorber Inspection ....................................................................................... 13- 9

Rear Shock Absorber Scrapping ....................................................................................... 13- 9

Suspension Arms .................................................................................................................... 13-10

Suspension Arm Removal ................................................................................................. 13-10

Suspension Arm Installation .............................................................................................. 13-10

Suspension Arm Disassembly ........................................................................................... 13-10

Suspension Arm Assembly ................................................................................................ 13-11

Swingarm................................................................................................................................. 13-12

Swingarm Removal............................................................................................................ 13-12

Swingarm Installation......................................................................................................... 13-12

Swingarm Disassembly...................................................................................................... 13-13

Swingarm Assembly .......................................................................................................... 13-14

Swingarm Bearing Inspection ............................................................................................ 13-15

Swingarm Bearing Lubrication ........................................................................................... 13-15

13-2 SUSPENSION

Exploded View

SUSPENSION 13-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Front Shock Absorber Mounting Nuts 42 4.3 31

2Rear Shock Absorber Mounting Nuts 62 6.3 46

3Suspension Arm Pivot Bolts 42 4.3 31

4Steering Knuckle Joint Nuts 29 3.0 21

5Swingarm Pivot Right Shaft 152 15.5 112 L

6Swingarm Pivot Left Shaft 20 2.0 14 L

7Swingarm 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 Service Limit

Front Shock Absorbers: (Usable Range)

Spring preload setting position No. 2 1~5

Rear Shock Absorber:

Spring preload adjustment

(Adjusting nut position from the center (Adjustable Range)

of the mounting hole upper) 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 (Adjust Range)

tuned fully clockwise) 14 clicks counter-clockwise 19 clicks

Gas pressure 980 kPa (10 kgf/cm², 142 psi) –––

SUSPENSION 13-5

Special Tools

Inside Circlip Pliers :

57001–143

Outside Circlip Pliers :

57001–144

Oil Seal & Bearing Remover :

57001–1058

Hook Wrench :

57001–1101

Bearing Driver Set :

57001–1129

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 neces-

sary.

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 ab-

sorber has 5 positions so that the spring can be adjusted

for different terrain and loading conditions. If the spring ac-

tion feels too soft or too stiff, adjust it in accordance with the

following table.

Spring Action

Position Spring

Force

Setting Load Terrain Speed

1Soft Light Smooth Low

2(STD)    

4¯ ¯ ¯ ¯ ¯

5Stronger Hard Heavy Rough High

•Turn the adjusting sleeve on shock absorber to the de-

sired position with the hook wrench [A].

Owner’s Tool - 92110–1129

Front Shock Absorber Removal

•Support the vehicle on a stand or a jack so that the rear

wheels are off the ground.

Special Tool - Jack: 57001–1238

•While holding the rear wheels, remove the lower and up-

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

•Apply plenty of grease to the inside of the bushing, sleeve

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

•Turn the compression damping adjuster [A] on the rear

shock absorber gas reservoir with a flat-bead screwdriver.

If the damping feels too soft or too stiff, adjust it in accor-

dance with the following table.

Seated position : adjuster turned fully clockwise [A].

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

•While holding the rear wheels, remove the lower and up-

per shock absorber mounting bolts [A], nuts, and wash-

ers.

•Remove the rear shock absorber [B].

Rear Shock Absorber Installation

•Apply plenty of grease to the inside of the needle bearing,

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

•Measure the spring free length.

•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

Spring

Position Force Setting Load Te rrai n Speed

94.2 mm Weak Soft Light Smooth Low

(3.71 in.)     



104.3 mm ¯ ¯ ¯ ¯ ¯

(4.11 in.) Stronger Hard Heavy Rough High

Rear Shock Absorber Inspection

•Check the upper pivot.

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 reser-

voir tank without first releasing the gas or it may

explode.

•Remove the shock absorber (see Rear Shock Absorber

Removal).

•Remove the valve cap [A] and release the nitrogen gas

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

•Install the following parts as shown.

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

•Support the vehicle on a stand or a jack so that the rear

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

•Apply molybdenum disulfide grease to the spline of the

output shaft [A].

•Fit the propeller shaft on the output shaft.

•Apply a non-permanent locking agent:

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 Remover [B]:

57001–1058

•Remove:

Oil Seal [A]

•Remove:

Collar [A]

Oil Seal [B]

Swingarm Assembly

•Apply grease:

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)

SUSPENSION 13-15

Swingarm

•Apply Amoco Rykon Premium Grease No.2 EP Green:

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

•Remove the final gear case (see Final Drive chapter).

•Move the swingarm up and down to check for abnormal

friction, and push and pull it back and forth to check for

bearing play.

If abnormal friction is felt, the bearings are damaged. Re-

place the oil seals and both left and right bearings.

•The play developed during use may indicate bearing dam-

age. In this case, remove the swingarm and inspect the

bearings. Replace both left and right bearings, if either of

the bearings is damaged.

Swingarm Bearing Lubrication

•Remove the swingarm.

•Using a high flash-point solvent, wash the bearings clean

of grease, and dry them.

•Inspect the bearings and oil seals for abrasion, color

change, or other damage.

•Apply grease to the outer races [A], and pack the tapered

roller bearings [B] with the same grease.

•Apply Amoco Rykon Premium Grease No. 2 EP (green)

to the inside of the oil seals.

•Install the swingarm (see Swingarm Installation).

STEERING 14-1

Steering

TABLE OF CONTENTS

Exploded View......................................................................................................................... 14- 2

Specifications .......................................................................................................................... 14- 4

Steering ................................................................................................................................... 14- 5

Steering Stem Removal ..................................................................................................... 14- 5

Steering Stem Installation .................................................................................................. 14- 6

Knuckle Removal ............................................................................................................... 14-7

Knuckle Installation ............................................................................................................ 14- 7

Tie-Rod Removal ............................................................................................................... 14-7

Tie-Rod Installation ............................................................................................................ 14- 7

Tie-Rod End Removal........................................................................................................ 14- 8

Tie-Rod End Installation..................................................................................................... 14- 8

Steering Maintenance.............................................................................................................. 14- 9

Steering Inspection ............................................................................................................ 14- 9

Steering Stem Straightness ............................................................................................... 14- 9

Steering Lubrication........................................................................................................... 14- 9

Steering Stem Clamp Inspection ....................................................................................... 14- 9

Steering Stem Bearing Inspection ..................................................................................... 14-10

Steering Knuckle Bearing Inspection ................................................................................. 14-10

Tie-Rod End and Steering Knuckle Joint Inspection.......................................................... 14-10

Handlebar................................................................................................................................ 14-11

Handlebar Removal ........................................................................................................... 14-11

Handlebar Installation ........................................................................................................ 14-11

14-2 STEERING

Exploded View

STEERING 14-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Handlebar Holder Bolts 29 3.0 22 S

2Tie-Rod Adjusting Locknuts 22 2.2 16

3Tie-Rod End Nuts 42 4.3 31

4Steering Stem Clamp Bolts 25 2.5 18

5Steering Stem Bearing Joint Bolts 21 2.1 15 L

6Steering Stem Bottom End Nut 40 4.1 30

7Suspension Arm Pivot Bolts 42 4.3 31

8Knuckle Joint Nuts 29 3.0 22

9Master 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.

14-4 STEERING

Specifications

Item Standard Service Limit

Tie-Rods:

Tie-rod length 387.4 ± 1.5 mm (15.3 ± 0.06 in.) –––

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)

•Pull the steering stem out of the frame.

•Remove:

Cotter Pin [A]

Steering Stem Bottom End Nut [B]

Collar [C]

Steering Stem Bearing [D]

14-6 STEERING

Steering

Steering Stem Installation

•Full grease up the seal grooves [A] in the steering stem

bearing [B].

•Install:

Collar

•Tighten:

Torque - Steering Stem Bottom End Nut: 40 N·m (4.1 kgf·m,

30 ft·lb)

•Bend both ends of the cotter pin [A] as shown.

Steering Stem Bottom End Nut [B]

•Apply a non-permanent locking agent:

Steering Stem Bearing Joint Bolts [A]

•Apply Amoco Rykon Premium Grease No.2 EP (Green):

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

•Inspect the spherical bearing [A].

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

•The right and left tie-rods are identical.

•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

•Remove the tie-rod (see Tie-Rod Removal).

•Holding the width across flats [A] on the tie-rod, loosen

the locknut [B] 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].

•Install the tie-rod ends so that width across flats on the

tie-rod face to the knuckle arm, the tie-rod has the correct

length [A], and both visible thread lengths [B] are approx-

imately 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

•Remove the steering stem (see Steering Stem Removal).

•Check the steering stem for straightness.

Use a straightedge along the stem.

If the steering stem is bent, replace the steering stem.

Steering Lubrication

•Lubricate the steering stem clamps.

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 sur-

face [C] of the clamp.

•Lubricate the steering stem bearing [A].

Remove the steering stem bearing.

Pack the grease seal lips with grease.

Steering Stem Clamp Inspection

•Inspect the steering stem clamps [A].

If roughness, excessive play, or seizure is found, replace

both clamps.

14-10 STEERING

Steering Maintenance

Steering Stem Bearing Inspection

•Inspect the spherical bearing [A].

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.

•Removethesteeringknuckle(seeSteeringKnuckleRe-

moval).

•Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

•Turn [A] the bearing back and forth while checking for

roughness or binding.

If roughness or binding is found, replace the bearing.

Tie-Rod End and Steering Knuckle Joint Inspection

•Inspect each spherical bearing [A].

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

•Install the handlebar so that the angle of the handlebar

matches the angle of the steering stem as shown.

[A]:Parallel

•Install the handlebar holder [A].

•Tighten the holder front bolts [B] first and then the rear

bolts [C].

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

•Install the left switch housing [C] on the handlebar [B] so

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]=2~3mm(0.08~0.12in.)

FRAME 15-1

Frame

TABLE OF CONTENTS

Exploded View......................................................................................................................... 15- 2

Seat ......................................................................................................................................... 15- 6

Seat Removal .................................................................................................................... 15- 6

Seat Installation ................................................................................................................. 15- 6

Fenders ................................................................................................................................... 15- 7

Front Fender Removal....................................................................................................... 15- 7

Front Fender Installation .................................................................................................... 15- 7

Rear Fender Removal........................................................................................................ 15- 8

Rear Fender Installation..................................................................................................... 15- 8

Covers ..................................................................................................................................... 15- 9

Side Inner Cover Removal................................................................................................. 15- 9

Side Inner Cover Installation.............................................................................................. 15- 9

Air Cleaner Cover Removal ............................................................................................... 15- 9

Air Cleaner Cover Installation ............................................................................................ 15- 9

Radiator Cover Removal.................................................................................................... 15-10

Guards..................................................................................................................................... 15-11

Front Guard Removal ........................................................................................................ 15-11

Front Guards Installation.................................................................................................... 15-11

Engine Bottom Guard Removal ......................................................................................... 15-11

Engine Bottom Guard Installation ...................................................................................... 15-11

Rear Bottom Guard Removal............................................................................................. 15-11

Rear Bottom Guard Installation.......................................................................................... 15-11

Foot Guard and Stay ............................................................................................................... 15-12

Foot Guard and Stay Removal .......................................................................................... 15-12

Foot Guard and Stay Installation ....................................................................................... 15-12

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

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Engine Mounting Bracket Bolts 52 5.3 38

2Engine Mounting Nut 62 6.3 46

3Footrest Mounting Bolts 44 4.5 33

AD: Apply adhesive agent.

15-6 FRAME

Seat

Seat Removal

•Push down the seat latch [A], and then remove the seat

[B] by pulling it up to the rear.

Seat Installation

•Slip the front seat hooks [A] into the button [B] on the air

cleaner cover and the brace [C] on the frame.

•Put the stoppers [D] into the holes [E] in the frame.

•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

•Remove the fuel tank cap.

•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

•Insert the tabs [A] of the cover into the recesses (both

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

•Install the front guard.

•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

•For left side, install the guard and tighten it.

•Install the footrest [A] and foot stay [B].

•Tighten the 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.................................... 16- 4

Specifications ..................................... 16-10

Special Tools ...................................... 16-12

Parts Location..................................... 16-13

Precautions......................................... 16-14

Electrical Wiring.................................. 16-16

Wiring Inspection .......................... 16-16

Battery ................................................ 16-17

Battery Removal ........................... 16-17

Battery Installation ........................ 16-17

Electrolyte Filling .......................... 16-17

Initial Charge ................................ 16-19

Precautions ................................... 16-19

Interchange ................................... 16-20

Charging Condition Inspection...... 16-21

Refreshing Charge ....................... 16-21

Charging System ................................ 16-23

Alternator Cover Removal............. 16-23

Alternator Cover Installation.......... 16-24

Alternator Rotor Removal ............ 16-25

Alternator Rotor Installation .......... 16-26

Alternator Stator Removal............. 16-26

Alternator Stator Installation.......... 16-26

Regulator/Rectifier Output Voltage

Inspection................................... 16-27

Alternator Inspection ..................... 16-28

Regulator/Rectifier Inspection....... 16-29

Ignition System ................................... 16-32

Spark Plug Removal ..................... 16-32

Spark Plug Installation .................. 16-33

Spark Plug Cleaning/Inspection.... 16-33

Spark Plug Gap Inspection ........... 16-33

Ignition Coil Removal .................... 16-33

Ignition Coil Installation ................. 16-34

Ignition Coil Inspection.................. 16-34

Ignition Coil Primary Peak Voltage

Inspection................................... 16-36

Crankshaft Sensor Removal ......... 16-36

Crankshaft Sensor Installation ...... 16-37

Crankshaft Sensor Inspection....... 16-37

Crankshaft Sensor Peak Voltage

Inspection................................... 16-38

Alternator Rotor Inspection ........... 16-38

Ignition Timing Test ....................... 16-39

Vehicle-down Sensor Outline........ 16-39

Vehicle-down Sensor Removal ..... 16-40

Vehicle-down Sensor Installation .. 16-40

Vehicle-down Sensor Inspection... 16-41

Electric Starter System ....................... 16-45

Starter Motor Removal.................. 16-45

Starter Motor Installation............... 16-45

Starter Motor Disassembly............ 16-46

Starter Motor Assembly ................ 16-47

Commutator Cleaning/Inspection.. 16-48

Armature Inspection...................... 16-49

Starter Motor Brush Length........... 16-50

Brush Assembly Inspection........... 16-50

Brush Plate and Terminal Bolt

Inspection................................... 16-50

Starter Relay Inspection................ 16-50

Starter Circuit Relay Inspection .... 16-51

Starter Motor Clutch Removal....... 16-52

Starter Motor Clutch Installation.... 16-53

Starter Motor Clutch Inspection .... 16-53

Torque Limiter Inspection.............. 16-54

Lighting System.................................. 16-55

Headlight Beam Vertical

Adjustment ................................. 16-55

Headlight Bulb Replacement ........ 16-55

Taillight Bulb Replacement............ 16-57

Radiator Fan System.......................... 16-60

Radiator Fan Circuit Inspection..... 16-60

Radiator Fan Motor Inspection...... 16-60

Fuel Pump/Fuel Reserve Switch ........ 16-61

Fuel Pump Inspection ................... 16-61

Fuel Reserve Switch Inspection

(1)............................................... 16-62

Fuel Reserve Switch Inspection

(2)............................................... 16-62

Indicator Unit ...................................... 16-64

Indicator Unit Removal.................. 16-64

Indicator Unit Installation............... 16-64

Indicator Unit Inspection ............... 16-64

Switches ............................................. 16-67

16-2 ELECTRICAL SYSTEM

Brake Light Switch Adjustment ..... 16-67

Radiator Fan Switch Inspection .... 16-67

Coolant Temperature Warning

Light Switch Inspection .............. 16-68

Switch Inspection .......................... 16-68

Fuses.................................................. 16-70

30 A Main Fuse Removal.............. 16-70

Radiator Fan Fuse Removal ......... 16-70

Main Fuse Inspection.................... 16-70

Radiator Fan Fuse Inspection....... 16-71

Wiring Diagram................................... 16-72

16-4 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-5

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Battery Cable Bolts 5.9 0.60 52 in·lb

2Starter Motor Mounting Bolts 8.8 0.90 78 in·lb

3Starter Motor Terminal Nut 4.9 0.50 43 in·lb

4Starter Motor Terminal Locknut 6.9 0.70 61 in·lb

5Starter Motor Bolts 4.9 0.50 43 in·lb

6Starter Motor Clutch Bolts 34 3.5 25 L

7Alternator Stator Bolts 13 1.3 113 in·lb

8Crankshaft Sensor Mounting Bolts 5.9 0.60 52 in·lb

9Alternator 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

16-6 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-7

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Spark Plugs 13 1.3 113 in·lb

2Ignition Coil Mounting Bolts 5.5 0.55 48 in·lb

3Igniter Mounting Bolts 2.3 0.23 20 in·lb

4Oil Pressure Switch 15 1.5 11 SS

5Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

6Neutral Position Switch 15 1.5 11

7Reverse Position Switch 15 1.5 11

8Fuel Pump Mounting Bolts 2.0 0.20 17 in·lb

9Regulator/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).

16-8 ELECTRICAL SYSTEM

Exploded View

ELECTRICAL SYSTEM 16-9

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1Radiator Fan Switch 18 1.8 13

2Coolant Temperature Warning Light Switch 6.9 0.70 61 in·lb SS

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

16-10 ELECTRICAL SYSTEM

Specifications

Item Standard Service Limit

Battery:

Type Sealed Battery –––

Capacity 12 V 12 Ah –––

Charging System:

Alternator type Three-phase AC –––

Charging voltage 14 ~15 V –––

(Regulator/rectifier output voltage)

Alternator output voltage 36 ~54 V 3 000 r/min (rpm) –––

Stator coil resistance 0.33 ~0.49 –––

Ignition System:

Spark plug:

Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in.) –––

Spark plug cap resistance 3.75 ~6.25 k –––

Ignition coil:

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 –––

Vehicle-down Sensor

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 –––

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.)

Fuel Pump:

Fuel pump pressure 17.7 ~ 22.6 kPa –––

(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 Standard Service Limit

Falling temperature From ON to OFF at 91 ~ 95 C–––

(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

Timing Light :

57001–1241

Compression Gauge Gasket :

57001–1314

Hand Tester :

57001–1394

Flywheel Puller Assembly :

57001–1405

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]

ReversePositionSwitch[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 ob-

serve 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 con-

nected 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. De-

fective wires and bad connections will affect electrical sys-

tem operation.

Measure coil and winding resistance when the part is cold

(at room temperature).

Color Codes:

BK Black G Green P Pink

BL Blue GY Gray PU Purple

BR Brown LB Light blue R Red

CH Chocolate LG Light green W White

DG Dark green O Orange Y Yellow

ELECTRICAL SYSTEM 16-15

Precautions

Electrical Connectors:

Female Connectors [A]

Male Connectors [B]

16-16 ELECTRICAL SYSTEM

Electrical Wiring

Wiring Inspection

•Visually inspect the wiring for signs of burning, fraying,

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. Re-

place the lead or the wiring harness [B] if necessary.

ELECTRICAL SYSTEM 16-17

Battery

Battery Removal

•Turn off the ignition switch.

•Remove the seat (see Frame chapter)

•Loosen the bolts [A] of the battery holder [B].

•Remove the battery with the holder and the case.

•Disconnect the battery negative (–) cable [C] first, and

then the positive (+) cable [D].

•Take out the battery [E].

Battery Installation

•Turn off the ignition switch.

•Put the battery with the case and the holder in place.

•Connect the positive cable first and then the negative ca-

ble.

•Put a light coat of grease on the terminals to prevent cor-

rosion.

•Tighten the battery holder bolts.

Electrolyte Filling

•Make sure that the model name [A] of the electrolyte con-

tainer matches the model name [B] of the battery. These

names must be the same.

Battery Model Name : KMX 14–BS

CAUTION

Be sure to use the electrolyte container with the

same model name as the battery since the elec-

trolyte volume and specific gravity vary with the

battery type. This is to prevent overfilling of the

electrolyte, shorting the battery life, and deteriora-

tion of the battery performance.

•Check to see that there is no peeling, tears or holes in the

seal sheet on the top of the battery.

•Place the battery on a level surface.

•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

•Take the electrolyte container out of the vinyl bag.

•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.

•Place the electrolyte container upside down aligning the

six seals with the six battery filler ports.

•Push the container down strongly enough to break the

seals. Now the electrolyte should start to flow into the

battery.

NOTE

Do not tilt the container as the electrolyte flow may be

interrupted.

•Make sure air bubbles [A] are coming up from all six filler

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 con-

tainer is completely emptied.

•Be certain that all the electrolyte has flowed out.

•Tap the bottom the same way as above if there is any

electrolyte left in the container.

•Now pull the container gently out of the battery.

•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

•Fit the seal caps [A] tightly into the filler ports until the seal

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 bat-

tery, never remove it, nor add any water or elec-

trolyte.

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

At low temperatures (lower than 0 C) 1.4 A x 2 ~3 hours

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 no-

ticeably if charged under conditions other than given above.

Never remove the seal caps during refresh charge.

If by chance an excessive amount of gas is generated due to overcharging, the safety valve

operates to keep the battery safe.

3) When you do not use the motorcycle for months

Give a refresh charge before you store the motorcycle and store it with the negative lead re-

moved. Give a refresh charge once a month during storage.

4) Battery life

If the battery will not start the engine even after several refresh charges, the battery has ex-

ceeded its useful life. Replace it. (Provided, however, the vehicle’s starting system has no prob-

lem.)

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 loos-

ened.

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 electri-

cal 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

•Remove the battery [A] (see Battery Removal).

•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

1.4Ax5~10 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 min-

utes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

•Determine battery condition after refreshing charge.

Determine the condition of the battery 30 minutes after

completion of the charge by measuring the terminal volt-

age according to the table below.

Criteria Judgement

12.6 V or higher Good

12.0 ~12.5 V or lower Charge insufficient ®Recharge

12.0 V or lower Unserviceable ®Replace

ELECTRICAL SYSTEM 16-23

Charging System

Alternator Cover Removal

•Drain the coolant (see Cooling System chapter).

•Remove:

Bolts [A] and Alternator Bolt Cover [B]

Water Pump Cover [C] and Impeller (see Cooling Sys-

tem 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

•Install and tighten the drive pulley holder [A] and the three

bolts [B].

Special Tool - Drive Pulley Holder: 57001–1520

[C] Arrow

•Holding the drive pulley with the drive pulley holder,

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.

•Place an oil pan under the engine left side.

•Remove:

Alternator and Crankshaft Sensor Lead Connectors (dis-

connect)

Alternator Cover Bolts [A]

Alternator Cover [B]

Clamp [C]

Alternator Cover Installation

•Be sure all of the old gasket has been removed from the

alternator cover and the left crankcase sealing surfaces.

•Check that the dowel pins [A] are in place, and fit a new

gasket on the crankcase.

•Check that the bearing [B] is in place.

•Fit the grommets [A] into the notch in the cover.

•Grease the alternator cover oil seal.

•Tighten

Torque - Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78

in·lb)

ELECTRICAL SYSTEM 16-25

Charging System

•Check that the O-ring [A] in the collar [B] is in good con-

dition.

•Apply grease to the O-ring.

•Install the collar on the alternator cover.

•Install 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

•Holding the flywheel puller, turn the rotor puller until the

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

•Clean [A] the inside of the rotor and the end of the crank-

shaft.

•Fit the rotor onto the crankshaft so that woodruff key [B]

fits in the groove [C] in the hub of the rotor.

•Install the torque limiter [A].

•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 Re-

moval)

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

•Remove the seat (see Frame chapter).

•Check the battery condition (see Battery section).

•Warm up the engine to obtain actual alternator operating

conditions.

•Check that the ignition switch is turned off, and connect a

hand tester to the battery terminals.

Special Tool - Hand Tester : 57001–1394

•Start the engine and note the voltage readings at various

engine speeds with the headlight turned on and then off.

The readings should show nearly battery voltage when

the engine speed is low, and as the engine speed in-

creases, the readings should also increase.

Regulator/Rectifier Output Voltage

Connections

Tester Range Te s t er ( + ) t o Test e r ( – ) t o Reading

25 V DC Battery (+) Battery (–) 14 ~15 V

•Turn off the ignition switch, and disconnect the hand

tester.

If the regulator/rectifier output voltage is between the val-

ues given in the table, the charging system is working nor-

mally.

If the output voltage is much higher than the values spec-

ified in the table, the regulator/rectifier is defective or the

regulator/rectifier leads are loose or open.

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 electromag-

netic field, or just by aging, will result in low output.

•To check the alternator output voltage, perform the follow-

ing 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

Test e r

Range Te s t e r ( + ) t o Tes ter ( – ) t o @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 al-

ternator is defective.

•Check the stator coil resistance as follows:

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

Connections

Test e r

Range Tes ter (+) t o Te s ter (–) to Reading

x1 One yellow lead 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, neces-

sitating 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

W/R-Y1, W/R-Y2, W/R-Y3

Test e r

connection 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 read-

ing 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 cur-

rent limiter to protect the regulator/rectifier from ex-

cessive current. Do not use an ammeter instead of

a test light.

•Check to be sure the rectifier circuit is correct before con-

tinuing.

Regulator Circuit Test-1st Step:

•Connect the test light and the 12 V battery to the regula-

tor/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 man-

ner 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 man-

ner 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/recti-

fier. 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 3. Regulator/Rectifier 5. Main Fuse 30 A

2. Alternator 4. Battery 6. Load

16-32 ELECTRICAL SYSTEM

Ignition System

WARNING

The ignition system produces extremely high volt-

age.

Do not touch the spark plug, ignition coil, or spark

plug lead while the engine is running, or you could

receive a severe electrical shock.

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)

•Fit the spark plug caps securely.

•Pull up the spark pug caps lightly to make sure of the

installation of the spark plug caps.

Spark Plug Cleaning/Inspection

•Refer to the Spark Plug Inspection in the Periodic Main-

tenance chapter.

Spark Plug Gap Inspection

•Refer to the Spark Plug Inspection in the Periodic Main-

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

•Connect the primary leads to the ignition coil terminals as

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

•Remove the ignition coil.

•Measure the arcing distance with a coil tester [A] to check

the condition of the ignition coil [B].

•Connect the ignition coil (with the spark plug cap left at-

tached at the end of the spark plug lead) to the tester in

the manner prescribed by the manufacturer and measure

the arcing distance.

Ignition Coil Arcing Distance

7mmormore

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 counterclock-

wise.

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

•Measure the primary winding resistance [A] as follows:

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 ter-

minal.

Set the tester to the x 1 k range.

Ignition Coil Winding Resistance

Primarywindings: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.

•Remove the spark plug cap (see Spark Plug Removal),

but do not remove the spark plug.

•Measure the primary peak voltage as follows.

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

•Repeat the test for the other ignition coil.

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)

•Fit the lead grommets into the notch on the alternator

cover.

Grommets [A] for Alternator Leads

Grommets [B] for Crankshaft Sensor Leads

Crankshaft Sensor Inspection

•Remove the rear fender (see Frame chapter).

•Disconnect the crankshaft sensor lead connector [A].

•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 crank-

shaft sensor.

16-38 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Peak Voltage Inspection

NOTE

Be sure the battery is fully charged.

•Remove the spark plug caps, but do not remove the spark

plugs.

•Disconnect:

Crankshaft Sensor Wire Connector [A]

•Set the hand tester [B] to the 10 V DC range.

•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 Adapter Hand Tester

Blue ¬Red ®(+)

Black/White ¬Black ®(–)

•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

•Check the timing projection [A] for damage such as chip-

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

•Remove the ignition timing inspection plug.

•Attach a timing light [A] and a tachometer in the manner

prescribed by the manufacturer.

Special Tool - Timing Light : 57001–1241

•Start the engine and aim the timing light at the timing mark

on the alternator rotor.

•Run the engine at the speeds specified and note the align-

ment of the timing marks.

[A] F or R mark

Ignition Timing

Engine speed r/min (rpm) Slot [B] aligned with:

Advanced mark [C] on alternator

rotor

1 100 and below

Advanced mark [D] on alternator

rotor

5 000 and above

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] Constant Voltage Circuit [E]

Ground Terminal [B] BK/Y Hall IC (Integrated Circuit) [F]

Output Terminal [C] Y/G Vehicle-down Sensor Circuit [G]

Power Source Terminal [D] BR 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

•Install the vehicle-down sensor [A] so that the sensor lead

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 situ-

ations, 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)

•Turn the ignition switch OFF.

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

•Turn the ignition switch OFF.

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 volt-

age with the connector joined.

Vehicle-down Sensor Power Output Voltage

Standard: 0.4 ~ 1.4 V

(with sensor arrow mark pointed up)

•Tilt the sensor 60 ~ 70 or more [H] right or left, and mea-

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

•When installing the starter motor, clean the starter mo-

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 hard-

ened, 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)

•Apply grease to the O-ring [D] in the joint duct [E].

•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]

•To remove the brush plate assembly [A], remove the ter-

minal nut [B].

ELECTRICAL SYSTEM 16-47

Electric Starter System

•Hold the brush spring [A] with needle nose pliers, and pull

the brush [B] off the holder.

Starter Motor Assembly

•Replace the O-rings.

•Install the brush plate assembly to the right end cover

so that the 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)

•Install the washers [A].

•Install the armature [B] between the brushes.

•Install the yoke [A] onto the right end cover [B] aligning

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].

•Align the mark [A] on the left end cover with the mark [B]

on the yoke.

•Tighten:

Torque - Starter Motor Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)

Commutator Cleaning/Inspection

•Smooth the commutator surface [A] if necessary with fine

emery cloth [B], and clean out the grooves.

ELECTRICAL SYSTEM 16-49

Electric Starter System

•Measure the diameter [A] of the commutator [B].

Replace the starter motor with a new one if the commu-

tator diameter is less than the service limit.

Commutator Diameter

Standard: 28 mm (1.10 in.)

Service Limit: 27 mm (1.06 in.)

Armature Inspection

•Using the x 1 range, measure the resistance between

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

•Using the x 1 range, measure the resistance as shown.

[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

•Using the highest range, measure the resistance as fol-

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

•Connect the hand tester [A] and a 12 V battery [B] to the

starter relay [C] as shown.

If the relay does not work as specified, the relay is defec-

tive. Replace the relay.

Testing Relay

Hand Tester Range: x 1 range

Criteria : When battery is connected Þ0

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 Cir-

cuit)

The starter circuit relays for the brake and neutral switch

circuits are identical.

•Connect the hand tester [A] and a 12 V battery [B] to the

starter circuit relay [C] as shown.

If the relay does not work as specified, the relay is defec-

tive. Replace the relay.

Testing Relay

Hand Tester Range: x 1

Criteria: When battery is connected Þ0

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 Relay

(Brake)

7. Ignition Switch

8. Starter Motor

9. Starter Relay

10. Main Fuse 30A

11. Battery

12. Starter Circuit Relay

(Neutral)

13. Neutral Switch

Starter Motor Clutch Removal

•Remove the alternator rotor (see Alternator Rotor Re-

moval).

•Hold the rotor with the flywheel holder and take out the

starter motor clutch bolts [A].

Special Tool - Flywheel Holder: 57001–1313

ELECTRICAL SYSTEM 16-53

Electric Starter System

•Take out the one-way clutch [A].

Starter Motor Clutch Installation

•Install the one-way clutch so that the flange [A] fits on the

recess[B]oftherace.

•Apply a non-permanent locking agent:

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)

•Fit the starter clutch gear into the starter motor clutch.

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. Re-

place 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)

•Remove the torque limiter [A] and visually inspect it.

If the limiter has wear, discoloration, or other damage,

replace it as a unit.

ELECTRICAL SYSTEM 16-55

Lighting System

Headlight Beam Vertical Adjustment

•Turn the adjusting screw [A] on each headlight rim in or

out to adjust the headlight vertically.

NOTE

On high beam, the brightest point should be slightly be-

low horizontal with the vehicle on its wheels and the

rider seated. Adjust both headlights to the same an-

gle.

Headlight 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

•Push the holder [A] and turn it counterclockwise.

•Remove:

Holder

Headlight Bulb [B]

•Insert the new bulb [A] by aligning the projection [B] with

the notch [C] in the headlight unit.

•Push the bulb holder [A] in, turn it clockwise, and release

it. It should lock in position.

•Fit the dust cover [A].

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]

•Remove the screws [A].

•Remove the taillight lens [B] from the taillight assembly.

16-58 ELECTRICAL SYSTEM

Lighting System

•Push the bulb [A] in, turn it counterclockwise, and pull it

out.

•Be sure the socket is clean.

•Insert the new bulb by aligning the pins [A] with the

grooves [B] in the walls of the socket.

•Push the bulb in, turn it clockwise, and release it. It should

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

•Disconnect the leads from the radiator fan switch [A].

•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

•Disconnect the connector [A] in the fan lead.

•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) Termi-

nal

•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. Re-

place 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 pres-

sure, 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)

•Fill the fuel tank with fuel.

•Close the fuel tank cap surely.

•Remove the fuel tank (see Fuel System chapter).

•Connect the test light [A] (12 V 3.4 W bulb a socket with

leads) and the 12 V battery [B] to the fuel 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 the test light (12 V 3.4 W bulb in a socket with

leads) and the 12 V battery to the fuel pump connector as

shown.

12 V Battery [A]

Test Light [B]

Fuel Pump Connector [C]

FuelReserveSwitch[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 han-

dlebar [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

•Refer to the Brake Light Switch Inspection in the Periodic

Maintenance chapter.

Radiator Fan Switch Inspection

•Remove:

Radiator Fan Switch (see Cooling System chapter)

•Suspend the fan 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 con-

tainer sides or bottom.

•Place the container over a source of heat and gradu-

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, re-

place 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 con-

tainer sides or bottom.

•Place the container over a source of heat and gradu-

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, re-

place 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

•Using the hand tester, check to see that only the con-

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

•Inspect the fuse element.

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

•Removethefuse(seeRadiatorFanFuseRemoval).

•Inspect the fuse element.

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.

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 ............................................................................................................ 17- 2

Cable, Wire, and Hose Routing ............................................................................................... 17- 6

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 mal-

adjusted

Pilot jet or air passage clogged

Air cleaner clogged, poorly sealed, or miss-

ing

Starter jet clogged

No spark; spark weak:

Spark plug dirty, broken, or 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

Valvespringbrokenorweak

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 con-

tact

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 mal-

adjusted

Pilot jet or air passage clogged

Starter plunger stuck open

Air cleaner clogged, poorly sealed, or miss-

ing

Fuel level too high or too low

Fuel tank air vent obstructed

Carburetor holder loose

Air cleaner duct loose

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened

down

No valve clearance

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

Valvespringbrokenorweak

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 con-

tact

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 miss-

ing

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

Valvespringbrokenorweak

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

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 in-

stalled (too loose)

Shifting too slowly:

Belt dirty or worn

Drive or driven pulley sheave dirty or worn

Drive pulley weight doesn’t move smoothly

Drive pulley movable sheave doesn’t move

smoothly

Drive pulley spring incorrect installed (too

tight)

Driven pulley movable sheave doesn’t

move smoothly

Gear Shifting Faulty:

Doesn’t go into gear:

Shiftshaftbentorseized

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

Valvespringbrokenorweak

Camshaft bearing worn

Rocker arm worn

Other noise:

Connecting rod small end clearance exces-

sive

Connecting rod big end clearance exces-

sive

Piston ring worn, broken, or stuck

Piston seizure, damage

Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head con-

nection

Crankshaft runout excessive

Engine mounts loose

Crankshaft bearing worn

Camshaft chain tensioner trouble

Camshaft chain, sprocket, guides worn

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 inade-

quate

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, elec-

trolyte level too low)

Battery leads making poor contact

Load excessive (e.g., bulb of excessive

wattage)

Ignition switch trouble

Regulator/rectifier trouble

Alternator trouble

Wiring faulty

Battery Overcharged:

Regulator/rectifier trouble

Battery trouble

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 Light

Switch

2. Reserve Tank

3. Reserve Tank Breather Hose

4. Cooling Hose

5. Clamp

6. Radiator Hose

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 Con-

nector

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 har-

ness.

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 Beginning Frame No.

2004 KSV700–A1 JKASV700AAB600001 or

JKASV6A1 4B500001

:This digit in the frame number changes from one machine to another.

Part No. 99924-1315-01 PrintedinJapan

Print Preview C 2004 Kawasaki KFX 700 V Force Service Manual

Kawasaki KFX700 V-Force 2003 Service Manual Kawasaki KFX700 V-Force 2003 Service Manual

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