Kawasaki KLR250 _ Motorcycle Service Manual SupplementThis quick reference guide will assist you in locating a desired topic or pro- cedure, “Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page. *Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required. ad Quick Reference Guide [General information 1 [FuelSystem [Cooling System [EngineTopEnd Engine Removal/Installation H [CrankshaftTransmission _8 Il [Wheels/Tires OO [FinalDrive [Brakes [Suspension 12 [Steering [Frame [Electrical System 15 [Appendix [Supplement — 1998 ~ 1999 Models 17 fl [Supplement - 2000 ~ 2005 Models 18 Il @| fon] || foo] |r} | | |~Kawasaki KLR250 Motorcycle Service Manual Supplement All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Divisior/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 are 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 fo make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication Al information contained in this publication is based on the latest product information available at the time f publication, lilustrations and photographs in this publication are intended for reference use only and may Not depict actual mode! component parts. © 1984 Kawasaki Heavy Industries. Ltd. 15th Edition (1): Jun. 13, 2007 (K)LIST OF ABBREVIATIONS ABDC Ac ATDC BBDC BDC BTDC ampere(s) tb poundis) after bottom dead center m meter(s) alternating current min minute(s) after top dead center N newton(s) before bottom dead center Pa pascal(s) bottom dead center Ps horsepower before top dead center psi poundis) per square irch degree(s) Celsius r revolution direct current rpm revolution(s) per minute farad{s) Toc top dead center degree(s) Fahrenheit TR total indicator reading | foot, feet v volt(s) ram(s) w watt(s) hours) 2 ohm(s) liter(s) WARNING CONTAINS ASBESTOS | | | Fatom sey [Trine This warning may apply to any of the following components or any assembly containing one or more of these components:— Brake Shows or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS ‘Operate if possible out of doors or in a well ventilated place. ‘Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high spoed tools are used, they should always be so equipped. ‘elf possible, dampen before cutting or drilling feDampen dust and place it in properly closed receptacle and dispose of it safely. Read OWNER’S MANUAL before operating.EMISSIONT 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 reo ulations of the United States Environmental Protection Agency and California Air Re- sources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board (on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system, 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle, The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmos phere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. ‘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.” “See. 203 (a) The following acts and the causing thereof are prohi (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motot vehicle or motor vehicle engine in compliance with : regulations under this ‘title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser. BREE: 8 (Continued on next page.)generally interpreted as follows. @ Nore © The phrase "remove or render inoperative any device or element of design” has been Fa 7. Tampering does not include the temporary removal or rendering inoperative of y devices or elements of design in order to perform maintenance. $5 2 Tampering could include: 3 2. Maladjustment of vehicle components such that the emission standards are Fa exceeded. b. Use of replacement parts or accessories which adversely affect the performance 3 or durability of the motorcycle. ¢. Addition of components or accessories that result in the vehicle exceeding the BS” Sancoas «Permanently removing, disconnecting, or rendering inoperative any component % or element of design of the emission control systems. § WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. SAS Sac ECR CCURRURERCOCEE RS {AAA ae TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED : Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle forthe purpose of noize control prior to its sale or delivery to the ultimate purchaser or while it is s in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. ‘*Replacement of the original exhaust system or muffler with a component not in com. pliance with Federal regulations. ‘Removal of the muffier(s) or any internal portion of the muffler(s). ‘Removal of the air box or air box cover. ‘Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. é Amon hse a presumed to consis tampering he act ited below: SUUENEME MAREForeword This KLR250 Service Manual Supplement is designed to be used in conjunction with the KLR600_ Motorcycle Service Manual (P/N 99924-1050-01). The maintenance and repair procedures described in this supplement are only those that are unique to the KLR250 motor- cycle. Most service operations for these models remain identical to those described in the base Service Manual. Complete and proper servicing of the KLR250 motorcycle therefore requires both this supplement and the base Service Manual. The base Service Manual and this Supplement are designed primarily for use by motorcycle mechanics in a properly equipped shop. However, they contain enough detail and, basic, information to make them useful to the operator who desires to perform his own basic maintenance and repair work. A basic know- ledge of mechanics, the proper use of tools, and work shop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the operator has insufficient experience or doubts his ability to do the work, the adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly famiiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the Use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled ‘maintenance be performed in accordance with this Service manual. Any owner maintenance or repair Procedure not performed in accordance with this ‘manual may void the warranty. To get the longest life out of your vehicle: © Follow the Periodic Maintenance Chart in the Service Manual © Be alert for problems and non-scheduled maintenance. © Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual, Genuine parts provided as Spare parts are listed in the Parts Catalog, ‘© Follow the procedures in this manual carefully Don't take shortcuts. © Remember to keep complete records of ‘maintenance and repair with dates ard 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 ofthe product's system and assists in locating their chapters. Each chapter in turn has its ‘own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the ignition coll section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. This warning symbol identifies special instruc- tions or procedures which, if not correctly followed, could result in personal injury, or loss of life. oThis caution symbol identifies special instruc- tions or procedures which, if not strictly served, could result in damage to or destruction of equipment. This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE ©This note symbol indicates points of particular interest for more efficient and convenient operation. ‘Indicates a procedural step or work to be done. Olndicates a procedural sub-step or how to do the work of the procedural step 't follows. It also precedes the text of a WARNING, CAUTION, or 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 follows. Indicates a conditional sub-step or what action to take based upon the results of the condi: tional step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing . : Doe tea 12 Model Identification....... ° General Specifications. Periodic Maintenance Chart.........++ z gaat sess ee TB1-2 GENERAL INFORMATION Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des- criptions have been included wherever necessary. Nevertheless, even a detailed account has limite- tions, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (~) lead from the battery before performing any disassembly operations on the motorcycle. This prevents: (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. {c) damage to electrical parts. (3) Tightening Sequence Generally, when installing 2 part with several bolts, nuts, or screws, they should all be started in their holes and tightened to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque ‘The torque values given in this Service Manual should always be adhered to, Either too little ‘or too much torque may lead to serious damage. Use a good quality, reliable torque wrench, (5) 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 removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) 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 Stoddard solvent (generic name). Always follow manufac: turer and container directions regarding the use of any solvent. (8) Gasket, O-ring Do not reuse a gasket or O-ring once it has been in service, The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (3) Liquid Gasket, Non-permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a nonpermanent locking agent commonly available in North ‘America is Loctite Lock’n Seal (Blue). (10) Press ‘A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing ‘When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole, (13) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature ‘grease on the lips to reduce rubber to metal friction. (14) Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them, When installing circlips and retaining rings, take care to compress or expand them only enougit to install them and no more. (15) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old ‘grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don’t use just any oil or grease. 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. This manual makes reference to molybdenum disulfide grease (MoS: ) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. (16) Electrical Wires Al the electrical wires are either single color or two color and, with only a few exceptions, must be connected to wires of the same color. On any of the two color wires there is a greater amount of one color and a lesser amount of a second color, so a two color wire is identified by tirst the primary color and then the secondary 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 to make red the main color. ted on the Wire [en Wire (cross-section) | Cole indi Red (17) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) 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 ¢ (19) Service Data Numbers of service data in this text have following meanings: “Standards”: Show dimensions or performanees 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.1-4 GENERAL INFORMATION Model Identification KL250-D2 Left Side View: U.S. Model KL250-D2 Right Side View: European ModelGeneral Specifications GENERAL INFORMATION 1-5 eam 1250-02, 03 k1250-04, 05 |_KL250-06 KL250.07~ Dimensions: Overall length 2.200 mm, © @® O 2,140 mm <_ —_ <_ Overall width 855 mm <_ <— <_ Overalt height | 1.210 mm <_ <_ <_ Wheelbase 1418 mm — <_ <_ Road dearance | 270 mm <_ <_ <_ Seat height 855 mm <_— <_ <— Dry weight 1,160 N (118 kg), © 1,150N a7 ie eSN ita oa Ee as Curb weight: Front | 600 N (61 kg), G3) 600 N (61.5 ka) <_ <_ << Rear | 720 N (73 kg). © G3 © 700 N (72 ka) <_ <_ <_ Fuol tank capacity | 11.0 L <_ <= < Performance: Climbing ability 32° <_ << <_— Braking cistance | 12.5 m from $0 km/h <_ <_ <_ ee | 2am — <_ <_ Engine: Type ‘A-sroke, DOHC, 4-valve, 1-eylinder <_ <_ <_ Cooling system | Liguid-cooled <_ << <_ Bore and stroke | 74.0x80 mn <_ <_ <_ Displacement | 249 mL. <_ <_ = Compression ratio | 11.0 <_ <_ <_ Maximum horee- | 20.6 KW (28 PS) @9000 r/min (rom), <- < _freokwiesps) power |@9000 r/min (rpm), @ 12.5 kW (17 PS) @7,000 r/min (rpm) |OE — JOEY — _ |wer12.5KW(17 PS) |@7800 r/min (rpm) (@ 1255 kW117 PS) @9,000 r/min DIN (rpm), DIN oe) — Maximum torque 23 Nem (2.3 kg-m, 16.5 ft-1b) @8,000 _— an }19.5 N-m (1.95 kg-m, r/min (rpm), |14ft-Ib) @7500 r/min o@ — |® 20.N-m (2.0 [rpm), \e>17.5 N-m kg-m, 14.5 ft-lb) (1.75 kg-m, 12.5 ft-lb) ore r/min 1@3500 r/min (rpm) © 19 N-m (1.9 kgm, 13.5 ft-1b) 4,000] [DIN rein (ror) GO 19.N-m (1.9 kom, 13.5 fb) 4,000 r/min (rpm) (DIN) CCarburetion system | Carburetor, Keihin CVK34 <_ <_ _ Starting system Primary kick _— -_ — fanition system | CDI <_ <_ <_ Timing advance | Electically advanced <_ <_ <_ 'gnition timing From 10° BTDC.@1,300 r/min (rpm) to | eas ae 36° BTDC @3,000 r/min (rpm) Spark plug NGK DPROEA.9 or ND X27EPR-U9 @OE@) NGK DPSEAS or <_ <_ Did NO X27EP-U9 (Continued on next page)1-6 GENERAL INFORMATION Items KL250-02, D3 K1250-04,05| _K1250.06__|_KL250-D7~ Valve timing? Inlet Open [41° BTDC <— |-@aretoc | ~ p@@ G1" s100 Clore |51° ABDC <— | +.@s2" aabe | ~, @@C) wo) 59° ABDC Duration |272° <— |= @ 268° + DOO) GO" Exhaust Open |70° BBDC <— | +.@s7°aave | ~, DOG)@o) 57" BBD Clore [30° ATOC <— |= @ 27°aTOC | +, QOG)@O 27" aTOE Duration |260° <— | +, @ 264° +“ DOGO a4 | Lubrication system | Foroed lubrieation (wet sump) _— —_ <_ | rade | SE or SF class — <_ <_ Viscosity |SAE 10W40, 1OWSO, 20040, 20w50 | <— <_ <_ Capacity [1.5.20 (Engine No. KL250DE013168 ~) on are ai Drive T Primary reduction system Type Gear <_ <_ <_ Reduction ratio |2,913 (67/23) Cal -_ <_ Ccutoh type Wet multi cise =_ <_ —_ Transmission: Type | peed, constant mesh, return shift <_ <_ <_ Gear ratios: 1st | 3.000 (20/10) <_ <_ <_ 2nd |2.000 (30/15) <_ — — ard |1.500 27/18) <_ <_ <_ ath |1.250 (25/20) <_ <_ — sth |1.050 (21/20) — — <_ 6th 0.904 (19/21) <_ — <_ Final drive system: Type | Chain drive <_ <_ <_ Reduction ratio |2:933 (44/18) <— |«@200 |-00@e azi1sy 2.800 (42/15) Overall drive ratio |7.731 @Top gear <—_|+ ©7379 +, BOO WO 7379 ‘Tubular, semi-double‘cradle <_ —_ <_ 285° <_ <_ <_ 117 mm <_ <_ — Front tre: Type [Dunlop K7508 — |-~e0no |-.coae TRAIL MAX Dutlop TRAIL MAX Size 3.0021 4PR <_ —_— <—_ Rear tire: Type Dunlop K750A/K150_ <— |-.@dunop | +.@OGD wa) TRAIL MAX Dunlop TRAIL MAK Size 4.60-17 4PR < <_ <— Front Suspension: Type | Telescopic fork (pneumatic) <_ <_ <_ Whee! travel|230 mm <_ <-_ <_ Rear Suspensi Type ‘wing arm (uni-trak) _ <_ <_ Whee! travel] 230 mm < <_ <_ Brake type:Front {Single dise _ <_ <_ Rear Drum’ — es a (Continued on next page)GENERAL INFORMATION 1-7 Items KL250-D2~ Electric Equipmen Battery 12V 4Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen), ED® 12 V 35/36.5 W (quartz-halogen) Tail/brake light 12V 5/21 W, ©@DO 12 v 8/27 W Alternator: Type ‘Single-phase AC Rated output 10.5 A @8,000 r/min (rpm), 14.V % : @Ga) NGK DPRBEA-9 or ND X27EPR-U9 Specifications subject to change without notice, and may not apply to every country. : Australian Model Australian Model ( ~'91) Canadian Model California Mode! : European Model Greek Model ‘Swiss Model South African Model U.S. Model1-8 GENERAL INFORMATION Periodic | Maintenance Chart “The goheduled maintenance must be Gone in accordance with this chart to keep the motoreyele in goad running condition. The initial maintenance is vitally important and must not be neglected. [Whichever *ODOMETER READING FREQUENCY [comes first J CLL OPERATION oy, S/S) 8/8) Fee Every Page| ae eas mae SEE fo | Throttle grip play - check eTelelelelele| 25 a ere ae POSS aS ae Fa a, eS eel met tet tte Sea ne oe) pe: |stats ee atti pet eps ee Toe San Te apt tes oe See ae a Bn oe = al eS oh ae : or aee a mae aon a a Se eer Brake play - check? ele Se rr tH oe = Se a Ta =o Fwheel being = ubneaia [a years z Speedometer gear = kbrcate ‘Byears. = Se Sherr ee ee a SO sates eS a Se aa So ae ee ms : +: For higher odometer readings, repeat at the frequency interval established here. * : Replace, add, adjust, clean, or torque if necessary. BM: Base Manual (KLR600) (CA): Calfomia Model (U): U.S.A. Mode! (C): Canadian Mode! mit item for D4 and after model (applicable for D2, D3 mode! also).FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View 222 Specifications .. rirdttesonieis once an oem 24 Special Tools pie 24 Throttle Grip and Cable. er Throttle Grip Play Inspection cee BS Throttle Cable Adjustment sees 25 Throttle Cable Lubrication +25 Throttle Cable Inspection +26 Choke Cable... ceteris sees 26 Choke Cable Free Play Inspection wi sas oi I | Choke Cable Adjustment ....-.- seen BB | Choke Cable Lubrication ea is aa Choke Cable Inspection 7 -26 Carburetor ...... ++ 2-7 Base Manual p. 2-4 Idle Inspection = Base Manual p. 2-4 Idle Adjustment “ ca Base Manual p. 2-4 Service Fuel Level inspection ...-.+.+. cose» Base Manual p. 2-4 Service Fuel Level Adjustment sss+++ Base Manual p. 2-5 Carburetor Disassembly, Assembly Notes Base Manual p. 2.6 Coolant fiter Cleaning i 27 Air Cleaner 27 Element Removal «-.--- ‘ ++: Base Manual p. 2-7 Element Installation ‘ 27 Inspection and Cleaning +++++++++++++ +++ Base Manual p. 2-7 Body Removal and Installation Note Base Manual p. 2.8 Fuel System Base Manual p. 2.8 Inspection s Base Manual p. 2-8 Cleaning ate Base Manual p. 2-8, Fue! Tank Cap inspection +++ Base Manual p. 2-8 Evaporative Emission Control System (California Model Only) Base Manual p. 2.9 Periodic inspection «..... Base Manual p. 2-10 Installation . Base Manual p. 2-10 Canister Inspection : Base Manual p. 2-10 Liquid/ Vapor Separator Inspection seeeeeeeesees Base Manual p. 2-10 Liquid/ Vapor Separator Test seseeteeeeeseseeses Base Manual p, 2-10 Fuel Tank Cap Inspection bites Base Manual p. 2-102-2 FUEL SYSTEM Exploded Views = a2-4 FUEL SYSTEM Throttle Grip Free Play ‘Standard: 2-3mm Choke Cable Free Play Stand: 2-3mm Carburetor Specifications K1L250-D2 — D6 Make Type CVK34 Main Jet 120, @ @us Main Air Jet $0 Jet Needle N31A, @ Gad N3IC Pilot Jet 35 Pilot Air Jet 145 Pilot Screw “2turns out, @ GD - @® 1% (06) Stater Jet 40 Fuel Level 1.5 mm (upper) — 0.5 mm (lower) from bottom edge of carburetor body Float Height___17. mm Ku260-07- Make Type CVK34 Mant 12, 1,0 118 Main Air Jet Jet Needle ior, © N31A, © GDN3ic Pilot Jet Piet Airjet 130, © [email protected] Plot Seow Tturmscut,© 20, @ - Starter Jot Fuel Level ; 5 mm (upper) — 0.5 mm (lower) from bottom edge of carburetor body Float Height 17 mm Bsn @ :Gilifornia Model West German Model Idle Speed Standard: 1,200 — 1,400 r/min (rpm) Special Too! Fuel Level Gauge: 67001-1017 — 57001-1239Throttle Grip and Cable Throttle Grip Play Inspection eCheck throttle grip free play. ‘If free play is not correct, adjust the throttle cable. ‘Throttle Grip Free Play 2-3mm A. Leoknut B. Adjuster © Accelerator Cahle D, Decelrator Cable E, Free Play +f the free play is correct, make the following test: ‘Start the engine, ‘eTurn the handlebar from side to side while idling the engine. ‘idle speed varies, the throttle cable may be poorly routed or it may be damaged ‘Correct any problem before operating the motorcycle. COpention with an impropmiy sud, isarecty routed, or damaged cable could result in an unsafe riding condition. Throttle Cable Adjustment Loosen the locknut, and screw both throttle cable adjusters in fully atthe upper end of the throttle cables $0 as to give the throttle grip plenty of play. ‘Turn out the decelerator cable adjuster until there is no clearance between the cable and adjuster when the throttle grip is completely closed ‘Turn out the accelerator cable adjuster until there is no clearance between the cable and adjuster when the ‘thyottle grip is completely closed ‘Turn in the decelerator cable adjuster until correct throttle grip play is obtained. Tighten both locknuts FUEL SYSTEM 2-5 NOTE If the throttle cables cannot be adjusted by using the cable adjusting nuts at the upper end of the throttle cables, use the cable adjusters at the lower ends of the throttie cables. Do not forget to securely tighten the adjuster mounting nuts. ‘A. Accelerator Cable C. Adjusters B. Decelerator Cable D. Lockauts Throttle Cable Lubrication Whenever the throttle cable is removed, and in accordance with the Periodic Maintenance Chart (see General Information chapter), perform the following. Apply a thin coating of grease to the throttle cable ower end. A. Apply grease. ‘Lubricate the throttle cable by seeping oll between the cable and cable housing26 FUEL SYSTEM Cable Lubrication Throttle Cable Inspection ‘With the throttlt cable disconnected at both ends, the cable should move freely within the cable housing Choke Cable Choke Cable Free Play Inspection eCheck that the choke lever returns properly and that the inner cable slides smoothly. ‘If there is any irregularity, check the choke cable as follows: ‘ePush the choke lever back all the way to its released position. ‘*Determine the amount of choke cable play at the choke cable adjusting nut. Pull out and push in the cable housing; the amount of cable travel is the amount of cable free play. A. Choke Lever B. Locknut C. Adjusting Nut D. Play +f free play is not correct, adjust the choke cable. Choke Cable Free Play 2-3mm Choke Cable Adjustment Loosen the locknut at the choke cable adjusting nut, and turn the adjusting nut until the cable has the proper amount of play. ‘Tighten the lockrut after adjustment. Choke Cable Lubrication Whenever the choke cable is removed, lubricate the choke cable as follows: ‘Lubricate the choke cable by seeping oil between the cable and cable housing, Cable Lubrication Choke Cable Inspection With the choke cable disconnected at the both ends, the cable should move freely within the cable housing.#If cable movement isnot free after lubricating (see Choke Cable Lubrication), if the cable is frayed, or if the housing is kinked, replace the cable, Carburetor Coolant Filter Cleanings Before winter season starts clean filter of carburetor system. ‘eDrain the coolant Remove the filter front the cooling hoses of carburetor system. ‘eBlow off dict and sediment on the filter with compressed air Air Cleaner Element installation ‘eRefer to p. 2-7 ofthe Base Manual nothing the following exception, Install the element assembly so that the wite netting Side faces forward and frame joint faces upward. 1. Element 3 2 Wire Netting Side 3, Frame Joint Frame FUEL SYSTEM 2-7 Evaporative Emission Control System (California Model Only) Refer to p. 2-10 of the Base Manual noting the following exception. Evaporative Emission Control System ‘gu Hs (niCOOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View a2 Specifications : 33 Coolant 7 sss Base Manual p. S-4 Coolant Deterioration - Base Manual p. 5-4 Coolant Level inspection - Base Manual p. 5-4 Coolant Changing sabcones ee ss: 8:4 Base Manual p. 5-4 Coolant Filling +++» eee ee Base Manual p. 5-5 Air Bleeding — era Base Manual p. 5:6 Visual Leak Inspection +.-+.+.2++++ Base Manual p. 5-6 Cooling System Pressure Testing v....0c..ce+..e+. esses Base Manual p. 5-6 Pliahip -:+-sessser one a cesses Bage Manual p. 5-6 Coolant Filter Cleaning - 34 Disassembly and Assembly Pricautions «+ Base Manual p. 5-7 Water Pump. a Base Manual p. 5:9 Water Pump Removal -.. siss+: 3-4 Base Manual p. 5-9 Water Pump Inspection ...-. | Base Manual p. 5-9 Water Pump Installation assess 3-4 Base Manual p. 5-10 Radiator, Radiator Fan -.-... sessses++ Base Manual p. 5:7 Radiator, Radiator Fan Removal Note Base Manual p. 5-7 Radiator Inspection cesceseeteeseeceierssreresees Base Manual p. 5-7 Radiator Cap Inspection ¢ . Base Manual p. 5-7 Radiator Hose, Reservoir Tank Hose Inspection Base Manual p 5-8 Thermostat... eee sees Base Manual p. 5:8 Installation Note »-+-+- Base Manual p. 5-8 Thermostat Inspection Base Manual p. 5-9 ‘Thermostat Fan Switch, Water Temperature Sensor Base Manual p. 5-8 Removal Noto Base Manual p. 5:8 Installation Note Base Manual p. 5-8 Inspection Base Manual pp. 14-22, 233-2 COOLING SYSTEM Late Model 1. Fan Switch 2. Water Temperature Sensor 3. Thermostat (air bleeder hole is on top). LG : Apply luquid gasket to the threads. G : Apply high temperature grease. TH : 3.9 Nem (0.40 kg-m, 35 in-ib) 72 : 7.4 Nem (0.75 kg-m, 65 in-Ib) 115 Nem (1.5 kgom, 11.0 ftb) .8 Nem (1.0 kg-m, 87 in-tb)COOLING SYSTEM 33 Cooling System Specifications Item Standard Coolant Provided when Shipped Type Permanent type antifreeze for aluminum engine and radiator Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point — 35°C (- 31°F) Total amount 1.5L Radiator Cap: Relief pressure 93 — 123 kPa (0.95 — 1.25 kg/cm? 14— 18 psi) Thermostat: Valve opening temperature 69.5 — 72.5°C (157.1 — 162.5°F) Valve full opening lift more than 3 mm @85°C (185° F)3-4 COOLING SYSTEM Coolant Coolant Changing Refer to p. lof the Base Manual noting the following exception. ‘@When the coolant is drained, remove the cooling fan switch from the bottom of the right hand radiator after removal of the drain plug Coolant Fiter Changing Refer to the chapter of carburetor in Fuel System for the cleaning procedures. Water Pump Water Pump Removal Refer to p. 5-9 of the Base Manual noting the following, expantion, (To remove the mechanical seal, insert a metal rod into the right engine cover from the inside, and tap evenly around the bottom of the seal ‘Mechanical Seal Removal » ® 1. Metal Rod 3. OilSeal 2 Tap 4. Mechanical Seal Water Pump Installation Refer to p. 5-10 ofthe Base Manual noting the following, expantion. ‘e\When installing the impeller, measure the dimension ‘Aaand select a shim according to the table below. Impeller Installation Cs 1. Dimension A 2. Shim Impeller Shim Selection Dimension A Shim No. Thickness More than Less tham 92025, 607mm — 670mm “1507 10.8 mm 671mm — 7.38mm “1508 0.3mm Engine No. KL2500009938 ~ Dimension A Shim No. Thickness Morethan Less tham 92025 557mm — 6.20mm “1506 1.4mm 621mm — 688mm 507° t0.8mmEngine Top End Table of Contents Exploded View Specifications... Special Tools coe Gylinder Head Cover 02-2. eee eee Cylinder Head Cover Installation Note. Camshaft Chain Tensioner. Chain Tensioner Removal Chain Tensioner Installation ; Replacement Chain Tensioner installation Camshafts, Camshaft Chain Camshaft Removal Notes Camshaft Installation Notes. . Camshafts Inspection Camshaft Chain Removal Camshaft Bearing Oil Clearance Inspection Rocker Arms, Rocker Shafts ‘Rocker Arms and Rocker Shaft Removal Rocker Arms and Rocker Shaft Installation Notes Rocker Arms and Racker Shaft Inspection Note KACR (Kawatald Automatic Compretsion Releste) Oil Pipe 2 (it Pe Installation Note Cylinder Head. Compression Measurement Cylinder Head Removal Cylinder Head Installation Nore Cylinder Head Disassembly Note Cylinder Head Warp. Valves Valve Clearance Inspection Valve Clearance Adjustment Voive Seat Inspection. Valve Seat Repair . ‘Measuring Valve-to-Guide Clearance (Wobble Method) Cylinder, Piston. Cylinder Removal Piston Removal Notes Piston, Cylinder Installation Note. Piston Ring End Gap Cylinder Inside Diameter Piston Diameter Boring, Honing Muffler ae ‘Muffler Installation Note ‘Muttier Cleaning (U.S. model) Saprk Arrester Cleaning (U.S. model). 42 4a 46 47 47 a7 47 48 48 ENGINE TOP END 4-1 Base Manual p. 37 Base Manual p. 3:7 Base Manual p. 36 Base Manual p.36 Base Manual p. 36 Base Manual p. 3:7 48 Base Manual p. 3-10 48 48 48 49 AG Baze Manual p. 3.10 Base Manual p. 3:11 ‘Base Manual p. 3:11 49 49 49 49 410 410 4.10 410 an an 41 4 an 441 412 412 412 443 413 Base Manual p. 3:17 Base Manual p. 3-18 Base Manual p. 3:18 Base Manual p. 319, Base Manual p. 316 Base Manual p. 3.18 Base Manual p. 3:17 Base Manual p.3:21 Base Manual p.3:21 Base Manual p. 3:21 Base Manual p.3-21 Base Manual p.3:21 Base Manual p.3-21ENGINE TOP END 43 EX Rocker Arm L_ = Apply non-permanent locking agent to the threads. LG = Apply liquid gasket to the threads, 1:45 Nem (4.6 kgm, 33 flb)4-4 ENGINE TOP END Engine Top End Specifications Item Standard Service Limit Cylinder Head, Valves: Valve clearance: Inlet 0.20 — 0.24 mm Exhaust 0.20 — 0.24 mm Cylinder head warp - | 0.05 mm. Valve head thickness: Inlet 0.5mm 0.25 mm Exhaust 1mm | 0.7mm Valve stem bend Less than 0.02 mm TIR 0.05 mm TIR. Valve stem diameter: Inlet 5.475 — 5.490 mm | 5.46 mm Exhaust 5.455 — 5.470 mm 5.44 mm Valve guide inside diameter: Inlet 5,500 — 5.512 mm | 5.58mm Exhaust 6,500 — 5.512 mm 5,58 mm Valve/vaive guide clearance (wobble method) Inlet 0.02 — 0.08 mm 0.24 mm Exhaust 0.06 — 0.12 mm 0.26 mm Valve seating surface: Outside diameter Inlet 28.3 — 28.5 mm --- Exhaust 24,0 — 24.2 mm : Width Inlet 0.5 — 1.0 mn ee Exhaust 0.5 —1.0mm --- Valve spring free length: Inner 36.3 mm 35mm Outer 39.2 mm 37.5 mm Valve seat cutting angle: __Inlet, Exhaust | 32°, 45°, 60° --- Valve Head Valve Stem Bend Valve stem iameter Valve head thickness XYENGINE TOP END 45 tem Standard Service Limit ‘Camshaft | Cam height Inet 35.532 ~ 35.648 mm (US)(CN)(EU : 89 and 35.43 mm earlier\(AS :'88 and eartier) 35.119 ~ 35.175 mm (EU : 90 and later) 35.01 mm (AS :'89 and tater) Exhaust | 35,649 ~ 35.765 mm (US)(CN)(EU : 89 and 35.85 mm eearier)(AS :'88 and earlier) 35.119 ~ 35.175 mm (EU : '90 and later) 38.01 mm (AS : 89 and later) Camshaft bearing ol clearance (0.045 ~ 0.073 mm 0.16 mm, Camshaft journal diametst 22.940 ~ 22.955 mm 22.81 mm Camshatt bearing inside diameter 23.000 - 23.013 mm 23.07 mm ‘Camshaft chain 20-link length 127.00 ~ 127.36 mm 1289 mm Rocker arm inside diameter 12.500 ~ 12.518 mm 12.55 mm Rocker shaft diameter 12.486 ~ 12.484 mm 12.44 mm Cylinder Compression (usable range) — 410 kPa ~ 785 kPa (4.9 ~ 8.0 kg/ome, 60 - 114 psi) Cylinder Block, Piston : Cylinder inside diameter 74.000 ~ 74.102 mm 74.19 mm Piston dameter 73.950 ~ 73.965 mm 73.61mm Pistonicylinder clearance: 0.038 ~ 0.062 mm - Piston ring/grove clearance: Top 0.03 ~ 0.07 mm 0.17 mm Second | 0.02 ~ 0.06 mm 0.1mm Picton ring grove width Top 1.02 ~ 1.0amm 1.2mm Second | 1.01 1.03mm 112mm oi 251 -2.53mm 26mm Piston ring thickness: Top 097 -0.99 mm 0.9mm Second | 0.97 - 0.9mm 0.9mm Piston ring end gap: Top 02 - 0.35 mm 7mm Second | 02 - 0.35 mm 0.7 mm ou 02-07 mm 1.0mm US: US.A model ‘CN: Canada model EU: European mode! AS : Australia model Cam Height Measurement Cam Height46 ENGINE TOP END Compression Gauge: 5701-221 Valve Guide Arbor: 57001-1021 Valve Guide Reamer: 57001-1079 Adapter: $7007-1183 Valve Spring Compressor: 5701-241 45° 0275 Seat Cutter: 57001-1114 45° — 632.0 Seat Cutter: 57001-1115 32° — 628.0 Outside Cutter: 57001-1119 32° — $30.0 Outside Cutter: 57001-1120 60° — $30.0 Inside Cutter: 7001-1123 9898 8 o Adapter: 57001-1019 Bar: §7001-1128 Cutter Holder 95:5 mm: 57001-1125 ~ & =ICamshaft Chain Tensioner Chain Tensioner Installation Refer to p. 36 of the Base Manual noting the following exception. feWhen the chain tensioner is installed; pay attention to the following items. ‘Remove the cap bolt and O-ing, ‘While compressing the push rod, turn it clockwise with a suitable screwdriver until it stops. ENGINE TOP END 4-7 ‘¢Remove the following parts before camshaft removal. Cylinder head cover Camshaft chain tensioner Camshaft caps Camshaft Installation Notes ‘Position the crankshaft-at TDC. Turn the crankshaft until the *T* mark is aligned with the sit in the inspection window. ‘A. Compress the rod B, Screwdriver Camshaft Removal Notes ‘Position the crankshaft at TDC of compression stroke. Camshaft Chain Timing (Lefthand View) Exhaust Camshaft, ‘A. Timing Mark slit B. Inspection Window (eWhen setting the camshaft chain timing, pay attention. 10 the following items ‘Pull the exhaust side of the chain taut before fitting to the chain to the exhaust camshaft sprocket, The exhaust side timing mark must be aligned with the cylinder head upper surface. The inlet side timing mark must be positioned upward about 3° from the cylinder head upper surface. he Inlet Camshaft48 ENGINE TOP END install the camshaft caps in the correct locations as Camshaft Bearing Oil Clearance Inspection shown in the figure. Refer to p. 3-10 of the Base Manual noting the following exception, Camshaft Bearing Oil Clearance Camshaft Cap Installation Standard Service Limit 0.045 — 0.073 mm + 0.16 mm Rocker Arms, Rocker Shafts Rocker Arms, and Rocker Shaft Removal ‘Remove the following parts before removing the rocker arm and rocker shaft. ‘Cylinder head cover (Camshafts ‘Rocker shaft plug (exhaust side) 1, Camshaft Cap (Exhaust, left) 2. Camshaft Cap (Exhaust, right) 3. Camshaft Cap (Inlet, left) 4, Camshaft Cap (Inlet right) 55, Mark: Must be faced forward A, Rocker Shaft B, Rocker Shaft Plug Rocker Arms and Rocker Shaft Installation Notes ‘eBlow the rocker arm oil passage clean with compressed air and apply oil to the racker arm bore before instal- Camshafts Inspection lation. ‘inspect the camshafts If they are badly worn, replace them, Replacement exhaust camshafts from stock have the KA.CR. and rocker arm, When the new exhaust camshaft. is installed, exchange the KAC.R. and rocker arm at the same time. ‘Camshaft Chain Removal ‘Remove the following parts before cimshaft chain removal Camshafts Magneto flywheel Balancer chain Camshaft chain guide AA. Rocker Arm 8, Oil Passage‘install the retainer spring on each rocker arm so that the spring is on the other side of the rocker arm from the camshaft sprackets, |A. Retainer Spring B. Rocker Arm ‘Apply engine oil'to the rocker shaft, and insert the shaft running it through the cylinder head, the rocker arms and springs. ‘Tighten the rocker shaft and rocker shaft plug to the specified torque (see Exploded Views). Rocker Arms and Rocker Shaft Inspection Note ‘inspect the rocker arms and rocker shafts. +f they are badly worn, replace them. The exhaust side rocker arm has an A to D mark. When changing the rocker arm with new one, select the rocker arm with same mark as former. NOTE Off the marks are not matched, it will affect the timing when the cam pushes down the rocker arm and therefore KACR will not operate properly. A Mark ENGINE TOP END 49 KACR (KAWASAKI Autom: Compression Release) KACR Inspection Refer to p. 3-10 of the Base Manual noting the excep: tion, +f the weight do not move smoothly, replace the KACR t. Cylinder Head Compression Measurement Refer to p. 3:17 of the Base Manual noting the following exception. Cylinder Compression. Usable Range: 410 — 785 kPa (4.2 — 8.0 kg/em*, 60 — 114 psi) Cylinder Head Removal Refer to p. 3-17 of the Base Manual noting the following exception. ‘eRemove the following parts before cylinder head removal ‘Radiator hose ‘Cylinder head bracket Cylinder head cover ‘Camshaft chain tensioner Camshafts Oit pipe (under the left side of the camshafts) ‘Exhaust pipe Carburetor Oil pipe (behind of the cylinder) Cylinder Head Installation Note ‘eWhen installing the carburetor holder, the projection faces to the right. A. Carburetor Holder B. Projection Faces Rightwards ‘*Torque the éylinder head bolts and nuts following the tightening sequence,410 ENGINE TOP END Cylinder Head Bolts, Nuts Tightening Sequence NOTE Torque them first to about 15 Nem (1.5 kgm, 11.0 feb) of torque and then torque them to the specified torque. Cylinder Head Disassembly Note Refer top. 3-18 of the Base Manual noting the following exception. ‘eRemove the cylinder head parts by using these special tools. '057001-241 : Valve spring compresser assembly .©57001-1019: Adapter (©5700-1021: Valve guide arbor (057001-1079: Valve guide reamer Valves Valve Clearance Inspection ‘Valve clearance must be checked when the engine is cold (room temperature). feRemove the following parts before valve clearance inspection. (Fuel tank *~ ‘Cylinder head bracket Radiator fan Cylinder head cover ‘Magneto cover upper and center plug ‘eUsing a wrench on the crankshaft rotation bolt, turn the crankshaft counterclockwise while watching the movement of the inlet valves (valves to the rear). ‘eWhen the valves have just finished opening and closing (moving downwards and returning upwards), turn the crankshaft in the same direction for about another turn until the “T mark on the magneto flywhee! is aligned with the slit in the inspection window in the ‘magneto cover. ‘A. Timing Mark c. stit B. Inspection Window feMeasure the clearance of cach valve by inserting 2 thickness gauge between the adjusting screw and the valve ster, Valve Clearance (when cold) Inlet, Exhaust : 0200.24 mm Valve Clearance Adjustment ‘+If the valve clearance is incorrect, loosen the locknut ‘and turn the adjusting screw until the correct clearance is obtained Tighten the locknutValve Seat Inspection Refer to p. 316 of the Base Manual noting the exception, \Valve Seating Surface Width Inlot, Exhaust; 0.5 ~ 1.0 mm Ive Seating Surface Outside Diameter Inlet : 283-285 mm Exhaust + 243-245 mm Valve Seat Repair Refer to p. 3-16 of the Base Manual noting the exception, Follow the manufacturer's instructions for the use of the valve seat cutter set Valve Sea Cutter Set Part Number: 67001-1110 Valve Cutters in Set Inlet Valve 45° — 932.0 87001-1115, 32° — 930.0 57001-1120 60° — 630.0 57001-1123 Exhaust Valve 45° — 9275 57001-1114 32° — 928.0 57001-1119 60° — 630.0 57001-1123 Holder and Bar = 965 57001-1125 57001-1128 Cylinder, Piston Cylinder Removal ‘Remove the following parts before cylinder removal Cylinder head cover Carburetor Camshafts Cylinder head Radiator hose (Cylinder side) ENGINE TOP END 4-11 Piston Removal Notes ‘*Wrap a clean clotr around the base of the piston to secure it in position for removal and so that no parts fall into the crankcase To remove the piston pin, use a piston pin puller (special too), if the pin is thet. A. Piston Pin Puller. 5701-910 B. Adapter Piston, Cylinder Installation Note CAUTION ©Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall f°Do not mix up the top and second ring. of Piston Rings Top ring 2nd ring412 ENGINE TOP END ‘Position each piston ring so that the opening in the top ring and oil ring steel rails are facing forwards, and the second ring and oll ring expander openings face the rear. The openings of the oil ring steel rails must be about 30 — 40° of angle from the opening of the top ring. Piston Ring Openings Viewed from Front Arrow 1. Top ring 2. Second ring 3. Steel ral, oil ring 4. Expander, oil ring ‘The arrow on the top of the piston must point toward the front. ‘install the cylinder and tighten the moutning bolts to the specified torque. Cylinder 1. Cylinder Mounting Bolts ‘eAfter cylinder installation, install the chain guide as shown, Chain Guide Piston Ring End Gap Refer to p. 3-21 of the Base Manual noting the exception, Piston Ring End Gap Standard Serive Limit Top, Second 02 -0.35mm 0.7 mm oil 02-07mm — 1.0mm Cylinder Inside Diameter Refer to p. 3-21 of the Base Manual noting the following exception, Cylinder inside Diameter Standard: 74,000 — 74.012 mm and less than 0.01 mm difference between any two meas- urements. Service Limit: 74.10 mm, or more than 0.05 mm difference between any two mest: ‘urements, Piston Diameter Refer to p, 3-21 of the Base Manual noting the following exception. Piston Diameter Standard Service Limit 73,950 ~ 73.965 mm 7381 mmMuffler Muffler Cleaning (U.S. model) WARNING J To avoid burns, wear gloves while cleaning the muffler Since the engine must be run during this procedure, the ‘muffler will become hot. ‘Remove the drain plugs from the muffler. A. Drain Plugs ‘ln an open area away from combustible materials, start the engine with the transmission in neutral ‘Raise and lower engine speed while tapping on the ‘muffler with a rubber mallet until carbon particles are purged from the muffler. WARNING J Do not run the engine in a closed area. Exhaust gases ‘contain carbon monoxide, a colorless, odorl fous gas. Breathing exhaust gas leads to carbon mon- ‘oxide poisoning, asphyxiation, and death. #Stop the engine. ‘Install the drain plugs in the muffle. Spark Arrester Cleaning (U.S. model) This motorcycle is equipped with a spark arrester approved for off-road use by the US, Forest Service. It ‘ust be properly maintained to ensure its efficiency. In Accordance with the Periodic Maintenance Chart, clean the spark arrester. {cauTion The spark arrester must be installed correctly and func: tioning properly to provide adequate fire protection. ENGINE TOP END 4.13 WARNING ‘To avoid burns, wear gloves while cleaning the spark arrester. ‘Remove the spark arrester mounting screw from the muffler, (Pull che spark ar ster out of the muffler A. Screw B. Spark Arrester ‘Scrape carbon deposits off the spark arrester and slide it back into the muffler. ‘install the mounting serew and tighten them securely Never run the engine with the spark arrester removed. Hot carbon particles may start a fire.Engine Right Side/Left Side Table of Contents Exploded ‘ 52 Kick Starter Idie Gear Removal and Specification scivecsswonpiinevts, BS Installation Notes 58 Special Tools .. 53 Water Pump 34 Base Manual p. 5-9 Right Engine Cover... 6... cece BA Water Pump Removal... 34 Base Manual p. 5-9 Right Engine Cover Removal 54 Water Purp Inspection. Base Manual p. 5-9 Right Engine Cover instalation Notes... 5-4 Water Purnp clutch Installation 34 Base Manual 0. 5-10 Clutch Lever Play Ol Filter... see ee. 6A Base Manual p.4-13 Inspection .........+.. Base Manvel p.4-8 it Filter Removal and Clutch Lever Play Adjustment 54 Installation Note... 64 Base Manual p.4-13 Clutch Release Lever Removal... .. 55 oll Pump... 65 (Clutch Release Lever installation Notes 55 Oil Purp Removal........- * 65 Clutch Removal... mates st< 16 41 Purp Clutch Installation Notes eee BB Installation Note... 65 Base Manual p.4-14 Friction Plate Wear, Damage O11 Pup Disassembly... - 65 Inspection .. 56 Base Manual p. 4-10 O11 Purp Assembly Note a 65 Friction and Steet Plate Warp Balancer Mechanism. 88 Inspection ....... 56 Base Manual p. 4:10 Front Right Side Balancer Removel .... 38 Clutch Housing Finger Front Right Side Balancer tnsallation...... 8 Inspection ‘ase Manual p. 4-10 Rear Balancer Removal a 88 Clutch Hub Spline Rear Balancer Installation Note 88 Inspection ............ Base Manual p. 4-11 Front Left Side Belancer, External Shift Mechanism Balencer Chain Removal. . 89 External Shift Mechanism Removal 57 Front Left Side Balancer, Balancer Chain Installation External Shift Mechanism (including Chain Timing Procedure) ..... 8-9 Installation Note 57 Balancer Sprocket Removal Note......... 840 External Shift Mechanism Inspection 87 Balancer Sprocket Installation Note Bt Primary Gear Flywheel Magneto dios: cats 1AM Primary Geor Removal i 587 Flywhee! Magento Primary Gear Installation Note . se 6B Removal ..... 1841 Kick Starter... 58 Flywheel Magneto Kick Starter Removal, eons (66 Installation sos 15H Kick Starter Magneto Cover Installation Note... 2... 18-42 Installation Note... ...s.seeseeees BB Magneto Stotor Installation Note... 1512 Kick Starter Disassembly and Left Engine Cover Removal............. 1842 Assembly Note..... peneree 8 Left Engine Cover Installation Note 15.135-2 ENGINE RIGHT SIDE/LEFT SIDE | Z i LL: Apply non-permanent locking agent to | ‘the threads. L (M : Apply molybdenum disulfide grease. 1: 59 Nem (6.0 kgm, 43 fib) 72: 9.8 Nem (1.0 kgm, 87 intb) 73: 12.Nem (1.2 kgm, 104 in-tb) ‘Ta: 39 Nem (4.0 kg-m, 29 fib)Engine Right Side Specifications ENGINE RIGHT SIDE/LEFT SIDE 5-3 gear backlash Item ‘Standard Service Limit Clutch: Clutch lever play 2—3mm --- Clutch spring free length 33.6 mm 323 mm Friction plate thickness 2.7 -2.9mm 2.5mm Friction and steel plate warp Less than 0.15 mm 0.3 mm Primary Reduction: Pri r/clutch hous imary gear/clutch housing 6 soatinn cies Special Too! Along with common hand tools, :he following more specialized tools are required for complete clutch servicing Gear Holder: 67001-1015 Outside Circlip Pliers: 570011446-4 ENGINE RIGHT SIDE/LEFT SIDE Right Engine Cover Right Engine Cover Removal ‘Drain the engine oi! ‘eRemove the following part before removing the right engine cover. oKick pedal ‘Lower end of the clutch cable Clutch release shaft >Brake pedal and cable Radiator hose (cover side) Oi filter Water pump impeller Right Engine Cover Installation Notes ‘eWhen installing the right engine cover, use a kick shaft cil seal guide (special tool) to avoid seal damage. ‘A. Kick Shaft Oil Seal B, Oil Seal Guide ‘eCheck that the O-ring is in good condition. Fit the oil filter O-ring in place, being careful not to twist or damage it. 8B, Oil Filter Hole A. Oxing Clutch Lever Play Adjustment @Loosen the knurled locknut at the clutch lever, tur the adjuster to obtain the proper amount of lever play and tighten the lockmut. Hf the upper cable adjuster has reached its limits, use the adjuster at the lower end of the clutch cable. ‘Loosen the knurled locknut at the clutch lever, and screw in the adjuster. ‘A. Dust Boot €. Clutch Cable B. Adjusting Nuts ‘Slide the lower cable adjuster to give the cable plenty of play, and readjust the lever play. ‘Turn the clutch release lever until it becomes hard to turn, At this time, check that the clutch release lever to clutch cable angle is 80 — 90°(Tighten the adjusting nut NOTE \Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play 10 prevent clutch disengagement. feAfter the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly, Clutch Release Lever Removal ‘Remove the following parts before removing the clutch ‘release lever. (Clutch cable upper end (from clutch lever) Clutch cable lower end (from release lever) Positioning bolt ‘Turn the release lever counterclockwise about 90°, and then pull out the release lever and shaft assembly. A. Release Lever B. Turn about 90° C. Positioning Bolt Clutch Release Lever Installation Notes ‘Release lever and shaft assembly installation is the reverse of removal. ‘Check the clearance between the release lever and the Tight engine cover, and install the positioning bolt. ENGINE RIGHT SIDE/LEFT SIDE 5-5 Clutch Removal ‘Remove the right engine cover before removing the clutch, ‘Remove the clutch spring bolts, washers, and springs; then take off the clutch spring plate, ‘*Remove the circlip with circlip pliers (special tool), and pull off the clutch hub, plates, and housirg, A. Circlip B. Circlip Pliers: $7001-144 . Clutch Hub Clutch Installation Notes ‘install the friction plates and steel plates, starting with a friction plate and alternating ther,56 ENGINE RIGHT SIDE/LEFT SIDE Clutch Washer Bush Clutch Housing Clutch Hub Friction Plate Steel Plate Spring Plate savsens The grooves on the friction plate surfaces are cut tangentially and radially; install the friction plates so that the grooves run toward the center in the direction cof clutch housing rotation (couterclockwise viewed from the engine right side). Friction Plate Installation \ oO @ 1. Oil Groove 2. Direction of Rotation Of new dry steel plates and friction plates are installed ‘apply engine oil to the surfaces of each plate to avoid ‘@Apply a molybdenum disulfide grease to the rod before clutch spring plate pusher installation, ‘Fit the spring plate into place, aligning the mark on the plate with the mark on the clutch hub. A. Spring Plate B. Arrow Mark Friction Plate Wear, Damage Inspection Refer to p. 4.10 of the Baro Manual noting the following exception. Friction Plate Thickness ‘Standard 27-29 mm Service Limit: 25mm Friction and Stee! Plate Warp Inspection Refer to p. 4-10 of the Base Manual noting the following exception, Friction and Steel Plate Warp ‘Standard Loss than 0.15 mm, Service Limit: 0.3mmExternal Shift Mechanism Removal ‘*Loosen the footpeg mounting nut and rotate the right hand footpeg downward. ‘eRemove the following parts before shift mechanism removal ‘Shift pedal Right engine cover Clutch housing ‘ePull out the shift shaft. ‘Remove the bolt and the gear positioning lever. External Shift Mechanism Installation Note ‘lf the gear positioning lever was removed, install it as shown below. A Operating Plate D. Spring B. Gear Positioning Lever _E. Stopper Bolt External Shift Mechanism Inspection ‘¢Examine the shift shaft for any damage. Check the shift shaft for bending or damage to the splines “if the shaft Is bent, straighten or replace it. If the splines are damaged, repalce the shaft. Check the return spring and arm spring for breaks or distortion ‘if the springs are damaged in any way, replace them, Check the shift mechanism arm for distortion. ‘if the shift mechanism arm is damaged in any way, replace the arm, ‘Check that the return spring pin is not loose. ‘if itis loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it to the specified torque (see Exploded Veiw) ENGINE RIGHT SIDE/LEFT SIDE 5-7 A. Shift Shaft D. Return Spring Pin 8. Return Shift E. Shift Mechanism Arm CC. Arm Spring ‘°F the shift shaft oll seal guide in the oll seal in the left crankcase half, and insert the shift shaft into the crankcase. A. Shift Shaft Oil Seal Guide B. Shift Shaft Oil Seal Primary Gear Primary Gear Removal @Remove the following parts before primary gear removal ight engine cover Oil Pump ‘eUsing the gear holder (special tool) to prevent the clutch and primary gear from rotating, loosen the primary gear nut. ‘eRemove the clutch housing and oil pump drive gear, then remove the primary gear5-8 ENGINE RIGHT SIDE/LEFT SIDE ‘A. Oil pump Driver Gea C. Gear Holder: 57001-1015 B. Primary Gear Primary Gear Installation Note ‘Replace the lockwasher with a new one, and tighten the primary gear nut to the specified torque. Kick Starter Kick Starter Removal ‘*Remove the Following parts before kick starter removal. Kick pedal ORight engine cover Kick spring lower end Spring guide Kick spring ‘eRemove the kick shaft assembly by twisting it to the left. Kick Starter Installation Note Refer to p. 4-11 of the Base Manual noting the following exception. ‘Put the thrust washer on the kick shaft end, and fit the kick shaft assembly to the right crankcase Kick Starter Disassembly and Assembly Note Refer to p. 4-12 of the Base Manual. Kickstarter 1. Girctip 2. Washer ® 3. Spring 4, Ratchet Gear ‘A 5. Cilip ° ® 6. Wane 7, Kiek Gear o 8 Kick Shaft Kick Starter Idie Gear Removal and Installation Notes feRemove the right engine cover and clutch housing before idle gear removal ‘eThere is a washer on either side of the idle gear,ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View - 62 Specifications ........ sean din riven OS Special Tools. ‘| 63 Engine OW cesnjnwsyaescsrsmeee < ++ 6-4 Base Manual p. 4-12 Oil Level Inspection cesses Base Manual p. 4-13 Oil Change. . . 6-4 Base Manual p. 4-12 Oil Pressure... 6-4 Base Manual p. 4-14 Oil Pressure Measurement 6-4 Base Manual p. 4-14 Oil Fitter... ceeeeeeetteeeesteseeceesss 64 Base Manual p. 4-13 Oil Filter Removal and installation Note 6-4 Base Manual p. 4-13 Oil Pump. vile + 6:5 Base Manual p. 4-14 Oil Pump Removal .. - 65 i! Pump Installation Note . . * + 6-5 Base Manual p. 4-14 Oil Pump Disassembly...... 2... 00.0000. 65 Oil Pump Assembly Note - 6562 ENGINE LUBRICATION SYSTEM 73 : 29N-m (2.3 kg-m, 16.5 ft-lb) Ta : 15 N-m (1.5 kg-m, 11.0 fb) TS : 4.9 Nem (0.5 kg-m, 43 in-tb)ENGINE LUBRICATION SYSTEM 6-3 Engine Lubrication System Specificati Item Standard Engine oil: Grade SE or SF class Viscosity SAE 10W40 Amount 1.2L (when filter is not changed) 1.5L (when filter is changed) Engine No. KL250DE013186 ~ : 1.7L (when filter is not changed) 2.0 L (when filter is changed) Level Between upper and lower level lines Gil pressure @4,000 r/min (rpm), oil temp. 90°C (194°F) More than 98 kPa (1.0 kg/em?, 14 psi) Special Tools ‘Along with common hand tools, the following, more specialized tools are required for complete engine lubrication system servicing (Ol Pressure Gauge: 5701-164 Oil Pressure Gauge Adapter: 57001-12786-4 ENGINE LUBRICATION SYSTEM Engine Oil Engine Oil Change Refer to p. 4-12 of the Base Manual noting the following exception. ‘*Remove the engine drain plug and oil passage plug, and let the oil drain completely 7] A, Drain Plug. B. Oil Passage Plug Engine Oil Grode £ SE or SF class Viscosity SAE 10W40, 10W5O, 20W40, or 20W50 Required Amount When filter is not changed : 1.2 L When filter is changed 1SL Engine No. KL250DE013186 ~ When filter is not changed When filter is changed we QOL Olt Pressure Measurement Refer to p. 414 of the Base Manual noting the following exception. install an oll pressure gauge with an adapter (special tools) at the oll passege. A. Oil Pressure Gauge: 5701-164 B. Adapter: 57001-1278 it Pressure ‘More than 98 kPa (1.0 kg/em?, 14 psi) @4,000 r/min (rpm), 90°C (194°F} oil temp. Oil Fitter il Filter Removal and Installation Note Refer to p. 4-13 of the Base Manual noting the following exception. ‘eWhen installing the oil filter, put the mounting pin into the filter so that the smaller diameter end is inward, A. Oil Filter B. Smaller End C. Mounting PinOi! Pump Removal Remove the following parts before oll pump removal Right engine cover Magneto cover center plug Primary gear nut Oi! pump drive gear ‘#Remove the oil pump screws(3), and remove the pump. il Pump Gear Gil Pump Cover Screw: removal is not required il Pump Screws Oil Pump Installation Note Refer to the p. 4-14 of the Base Manual noting the following exception, Before installing the oil pump, install the oil pump drive gear. Oil Pump Disassembly ‘Remove the oil pump. Remove the oil pump cover screw, and take off the pump cover. (Take out the inner and outer rotor. Take out the pin, and pull off the oil pump gear and shaft Oil Pump Assembly Note ‘*Before installing the oil pump, be sure the shaft and rotors turn freely ENGINE LUBRICATION SYSTEM 6-5ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal Installation Table of Contents Exploded View . Engine Removal, Installation. Engine Removal Engine Installation 72 73 73 737-2 ENGINE REMOVAL/INSTALLATION TH: 29 Nem (3.0 kg-m, 22 ftb) 12: 54 Nem (5.5 kg-m, 40 ftb) 3: 88 N-m (8.0 kg-m, 65 tttb)Engine Removal, Installation Engine Removal ‘Drain the engine oil, Drain the coolant, ‘eRemove the following parts, ‘Side covers: Seat ‘OFue! tank ignition coil Exhaust pipe Radiator sub tank Throttle cable ‘Choke cable Carburetor ‘Lower end of the clutch cable ‘Radiator hoses ‘Breather hose Brake pedal ‘Rear wheel ‘Drive chain and engine sprocket Skid plate ‘Disconnect the wiring connectors from the engine ‘Magneto lead ‘Neutral switch lead Pickup coil lead ‘Water temperature sensor lead Place a stand under the frame to raiso the rear wheel off the ground. ‘Remove the engine brackets. ‘Engine bracket ‘Engine mounting bolt ‘Swing arm pivot shaft Cylinder head bracket (Pull the swing arm backward. ‘®Remove the left side Footpeg, ‘Remove the engine to the left. A. Engine Bracket 1B. Engine Mounting Bolt D. Cylinder Head Bracket, . Swing Arm Pivot Shaft ENGINE REMOVAL/INSTALLATION 7-3 Engine Installation ‘Engine Installation is the reverse of removal ‘eTighten the engine mounting bolts to the specified torque. ‘°F ll the engine with the specified engine cil Fill the reservoir tank up to the FULL mark with coolant. ‘Adjust the following items Throttle cable Choke cable Drive chain Rear BrakeCRANKSHAFT/TRANSMISSION 8-1 Crankshaft/Transmission Table of Contents Exploded View . ‘Specifications Special Tools. Crankcase Splitting... Crankcase Splitting... Crankcase Assembly ‘Transmission . Transmission Removel. Transmission Installation Notes . ‘Transmission Maintanance. ....... Shift Drum, Shift Fork, Shift Rod, Gear Groove Inspection. Crankshaft... Crankshaft Removal . i Crankshaft Installation Notes . . Crankshaft Disassembly and Assembly Crankshaft Maintenance . Connecting Rod Big End Radial Clearance . Big End Seizure. . Connecting Rod Side Clearance. Crankshaft Runout . Crankshaft Alignment... Roller Bearing Wear, Damage . Balancer Mechanism... .. Front Right Side Balancer Removal Front Right Side Balancer Installation . .. Rear Balancer Removal... ++ Rear Balancer Installation Note. . .. Front Left Side Balancer, Balancer Chain Removal ......... Front Left Side Balancer, Balancer Chain Installation (including Chain Timing Procedure) . Balancer Sprocket Removal Note . . Balancer Sprocket installation Note . sevens BT 82 84 84 - 85 85 . 85 . 86 a6 «++ Base Manual p. 7-8 . Base Manual p. 7-8 Base Manual p. 7-8 Base Manual p. 7-9 ss ee++ Base Manual p. 7-9 - Base Manual p. 7-9 « Base Manual p. 7-9 ~ Base Manual p. 7-10 teveees Base Manual p, 7-10 Base Manual p. 7-10 - 89 89 Liga0 8-10CRANKSHAFT/TRANSMISSION 8-3 1. Shielded side faces out 71: 60.Nan (6.0 kom, 43 fb) 1M : Apply molybdenum disulfide grease. 72: 10.N-m (1.0 kgm, 7.0 flb) © : Apply engine oil transmission gears and 73:16 Na (1.5 kgm, 11 feo) shift forks. 74:25 Nan (2.5 kg-m, 18 feb) LG = Apply liquid gasket to the crankcase 75:23 Nan (225 ko-m, 165 ftb) face. T6: 10.N-m (1.2 kgm, 8.5 fib) LL = Apply non-permanent locking agent to 7: 40 Nem (4.0 kgm, 29 ft) the threads, TB: 4.9 Nem (0.5 kgm, 43 inh)8-4 CRANKSHAFT/TRANSMISSION Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod Bend 0.05/100 mm 0.2/100 mm Connecting rod twist --- 0.2/100 mm Connecting rod big end radial clearance 0.004 — 0,018 mm 0.10 mm D4 and after model: 0.008 — 0.020 mm 0.07 mm Connecting rod big end side clearance 0.25 — 0.35 mm 0.06 mm Crankshaft runout L: 0.025 mm 0.06 mm TIR R:0.04 mm 0.10 mm TIR Cold-fitting tolerance between ‘crankpin and flywheels 0.077 - 0.112 mm --- Transmission: Gear shift fork groove width 6.05 — 5.15 mm 5.3mm Shift fork ear thickness 49-5.0mm 48mm Shift fork guide pin diameter 5.9-—6.0mm 5.8mm Shift drum groove width 6.05 — 6.20 mm 6.3mm Special Tools Crankshaft Installing Jig: 57001-1174Crankcase Splitting ‘®Remove the Following parts after engine removal. ‘Cylinder head cover Camshaft chain tensioner Camshaft Cylinder head ‘Cylinder, piston Right engine cover Clutch ‘External shift mechanism Kick starter Water pump Oi pump oBalancer oF tywheel magneto ‘Remove the left crankcase half bolts ‘ePry at the points indicated in the figure to split the two crankcase halves apart, and them pull off the left crankcase half. A Pry Points Tap the ourput shaft end lightly with a mallet if necessary. Remove the collar at the output shaft from the left crankease hall. Crankcase Assembly eCrankcase assembly is the reverse of disassembly. Pay attension to the following. Apply high temperature grease to the lips of the new oil seals. ‘olnstall the output shaft oil seal and bearing into the left crankcase half as shown. CRANKSHAFT/TRANSMISSION 8-5 ‘Output Oi! Seal, Ball Bearing Installation 1. Crankease 2. Ball Bearing 3. Shield sides face out 4. Oil Seal ©Any oil seal that is removed is damaged and must be replaced with anew one. Clnstall the ball bearings and oil seals using a press and the bearing driver sot (special toot) ‘Apply liquid gasket co the mating surface of the left crankease half. When installing the transmission, insert the shift rods into the shift forks (see Transmission installation Notes). Shift Rod and Shift Fork og Rod (Drive Shafi) Fork (Drive Shaft) Rod (Output Shaft) Shift Fork (Output Shaft) aepe (et the balancer shafts correctly. Balancer Shaft rg o® ° 2 1, Front Balancer Shaft 2 Rear Balancer Shaft86 CRANKSHAFT/TRANSMISSION Transmission Removal *Remove the following parts from the inside of the ‘crankcase, Shift rods(2) Shift forks(3) Drive shaft and output shaft assemblies ‘Shift drum (if necessary} Drive Shaft, Output Shaft Ve 1. Circlip 9, Washer 18. Bushing 2. Needle Bearing 10. Sth Gear (D} 19. 3rd Gear (0) 3. Washer 11, Drive Shaft 20. Washer 4, 2nd Gear (D} 12, Output Shaft 21. 4th Gear (0) 5. Cirelip 13, 2nd Gear (0) 22. Sth Gear (0) 6. Splined Washer 14. Washer 23. Ist Gear (0) 1. Top Gear (D) 15. Cirelip 24. Collar 8. 3rd, 4th Gear (D) 16. Top Gear (0) 25. O-ringTransmission Installation Notes + ‘installation isthe reverse of removal. ‘Be careful of the following items. OApply a little engine oil 10 the transmission gears, needle bearings, and shaft journals. ‘Apply a little engine oll to the shift fork fingers, and fit each shift fork into its gear groove. ‘oApply a little engine oil to the shift rods, and insert the short shift rod, running it through the drive shaft shift fork. Insert the fong shift rod, running ic through the ‘output shaft forks, Shift Rod and Shift Fork sh ye 1. Shift Rod (Drive Shaft) 2 Shift Fork (Drive Shaft) 3. Shift Rod (Output Shatt) 4. Shift Fork (Output Shaft) Replace any circlips that were removed with new ones. olnsall the cirelip so that its opening coincides with one ‘of the splined grooved in the transmission shaft. ‘lnstall the splined washers so that their teeth do not ‘coincide with the ciclip openings. Circtip, Splined Washer Installation t — bin Mh \ \\ U SS \ 1. Splined Washer 2s 2. Tooth 3. Girelip 4, Groove 5. Shaft \ ‘When assembling the output shaft 3rd gear bushing to the shaft, align tho oil hole with the hole in the shaft, ‘Fit the O-ring to the groove at the left side of the ‘output shaft, and apply a little grease to the O-ring. When installing the output shaft collar to the shaft, apply a little grease to the inside of the collar and push the collar with hand, CRANKSHAFT/TRANSMISSION 8-7 Crankshaft Crankshaft Removal ‘Split the crankcase. ‘eRemove the transmission, ‘Remove the crankshaft from the right crankcase half with the press. Crankshaft Installation Notes ‘eFit the crankshaft assembly into the right crankcase using a crankshaft installing jig inserted between the flywheels opposite the connecting rod big end. ‘This special tool is easily adjustable to fit in any gap between the flywheels. Install the crankshaft as follows. Crankshaft Installing Jig: 57001-1174 Constantly check the alignment of the two crankcase halves, and the position ofthe transmission shafts, and shift drum. The front and rear of the crankcase must be pushed together evenly eCheck to see that the crankshaft, drive shaft, and output shaft all turn freely (in the neutral position) HIF the crankshaft will not wien, probably the crank shaft is aot centered; tp the appropriate end of the crankshaft with a mallet to reposition it. ‘Spinning the output shaft, shift the transmission through all the gears to make certain there is no binding and that all the gears shit properly.88 CRANKSHAFT/TRANSMISSION Crankshaft Disassembly and Assembly Crankshaft Maintenance Refer to p. 7-8 of the Base Manual noting the Refer to p. 79 of the Base Manual noting the following exception. following exception. ‘Crankshaft Assembly Pin Center Direction ©. ee! a View A 1. Sprocket Mark 4, Crank Pin 2 Camshaft Chain Sprocket 5. Oil Passage 3. Left Hand Main Bearing pen Rear Balancer Removal Balancer Mechanism ‘Split the crankcase. ‘Remove the rear balancer assembly, and then separate ie Front Right Side Balancer Removal ‘¢Remove the right engine cover before balancer removal, Rear Balancer Installation Note eRomove the circlip and washer, and the take the align the rear balancer weight punch mark with the balancer weight off the right end Of the balancer shaft. balencer shaft punch mark. Balancer weight — Symmetry on either side. 7 Balancer shaft — The longer serration side toward Front Right Side Balancer Installation the weight feThe balancer shaft and weight have punch marks. When installing the weight, align the marks on the shaft and weight. ‘A. Align the Marks . Balancer Shaft A. Balancer Weight . Balancer Shaft B. Balancer Weight 8. Align the Marks D. Longer Serration SideCRANKSHAFT/TRANSMISSION 8-9 Front Left Side Balancer, Front Left Side Balancer, Balancer Chain Removal Balancer Chain Installation Remove the following parts before balancer and (including Chain Timing Procedure) balancer chain removal ‘Postion the crankshaft at TOC. ‘OMagneto cover “Engage the rear balancer sprocket punch mark with the Flywheel magneto balancer chain single plated link. eft engine cover ORight engine cover ‘Remove the cirelip and washer from the front left side balancer sprocket. A Single Plated Link _C, Balancer Sprocket B. Punch Mark A.Cirelip . Balancer Chain Guide B. Washer ‘Align the rear balancer sprocket coupling punch mark with the balancer shaft punch mark. ‘°Pull the front balancer shaft toward the right until it is stopped by the right side of the crankcase. ‘A. Coupling Punch Mark B, Shaft Punch Mark ‘A. Balancer Shaft ‘*Remove the balancer chain guide, ‘eEngage the front balancer spracket punch mark with ‘*Remove the balancer sprockets with the balancer chain. ‘the balancer chain paired plated links.8-10 CRANKSHAFT/TRANSMISSION se ‘A. Sprocket Punch Mark _B. Paired Plated Links © Fit the punch marked tooth on the crankshaft sprocket into the single plate link. ‘A. Single Plated Link B, Punch Mark ‘install the rear chain guide and balancer chain guides as, shown. ‘Chain Guides 1, Balancer Chain Guide 2. Rear Chain Guide ‘Align the punch mark on the front balancer sprocket ‘coupling with the balancer shaft punch mark. ‘A. Coupling Punch Maris 8B Shaft Punch Mark ‘Push the front balancer shaft toward the inside, and insert the shaft into the front balancer sprocket coupling. ‘install the washers and circlips on the left end of the balancer shaft, Balancer Sprocket.Removal Note ‘¢Remove the spring and pin, then separate the sprocket and weight. A. Balancer Ws . Spring, B. Sprocket D.Pin Balancer Sprocket Installation Note ‘Align the sprocket punch mark with the sprocket coupling punch mark,CRANKSHAFT/TRANSMISSION 8-11 A. Sprocket Punch Mark 8. Coupling Punch Mark. Balancer Chain Timing 1 Shaft Mark 2 Coupling Mark 3. Sprocket Mark 0d® 4. Marking PlateWHEELS/TIRE 9-1 Wheels/Tires Table of Contents Exploded View ........... 92 Specifications ..... 6.666. 93 93 94 94 Front Wheel Installation ...... 94 Rear Wheel Removal... tere 94 Rear Wheel Installation... +. 6.-cveeecees OF Axle Inspection... Spokes and Rims. .... eee ‘Spoke Tighteness inspection.........+- Rim Runout Inspection... . ++» Base Manual p. 86 +++» Base Manual p. 86 +++, Base Manual p. 87 9-4 Base Manual p. 8-4 Mo ee ect cee test the Tire Air Pressure Measurement .... 94 Tire Wear Inspection........--..-..-+.++. 95 Base Manuai p. 8-5 Tire Removal and installation. .......++1.+. 95 Base Manual p. 8-4 Wheel Bearings .......- eee 9-5 Base Manual p. 8-7 Wheel Bearing Removal.......+ + « Base Manual p. 8:7 Wheel Bearing Installation Notes . Base Manual p. 8-7 Wheel Bearing Inspection ........ Base Manual p. 8-7 Bearing Lubrication. ... 6.2: 000000505 Base Manual p. 88 ‘Special Tools (Addition).9-2 WHEELS/TIRE 71: 2.0—3.9N-m (0.2—0.4kg-m, 17 = 35 in-tb) 72: 7AN-m (8.0kg-m, 58 fb) | — 73: 30N-m (8-1 kg-m, 22M) ¢ T4: 98N-m (10.0kg-m, 72tt-Ib) gs * «ae ) Ne JWHEELS/TIRE 9-3 Trem ‘Standard Service Limit Wheel Tire tread depth: Front. | 8.8mm 2mm Rear 105 mm 2mm Standard tire: Front | SUNLOPRY5OA, --- @ DUNLOP TRAIL MAX (08~) nee 4.00.17 4PR DUNLOP K750a/K 150 @ DUNLOP TRAIL MAX (06~) J Etiee Load Air Pressure (when cold) alas : 147 kPa Be (1.8 kg/om? , 21 psi} Us and 147 kPa coneden | Up to 956 N (97.5 kg, 215 Ib) a eeeeeaa: ear Model 956 —1,471N 172 kPa Tire air (97.5 — 160 kg, 215 — 331 Ib) (1.75 kg/em? , 26 psi) Pressure 147 kPa Front | —— ; Other then (1.5 kg/em® , 21 psi) US and 147 kPa Canadian Up to 1,471 N (150 ka, 331 1b) | (4.5 kg/om?, 21 psi) Rear eae 1,471 — 1,824 N 172 kPa (150 — 186 kg, 331 — 410 tb) (1.78 kg/ern®, 25 psi) Rim runout: Axial | ——— 2mm Radial | ~~~ 2mm Axle runout/100 mm: Less than 0.05 mm 0.2mm | Australian Model Special Tools Bearing Driver Set: 57001-1129 NY Useithe following tools in the set SS Bearing Driver Holder: 67001-1132 57001-1135 Bead Breaker Assembly : 57001-1072 57001-1136 87001-1143 Bearing Driver: 7001-114494 WHEELS/TIRE Front Wheel Removal @ Remove the speedometer cable lower end before front wheel removal. ©Do not lay the wheel on the ground with the disc facing down. This ean damage or warp the dise. Place blocks under the whool so that the dise does not touch ‘the ground. Front Wheel Installation ‘eWhen installing the front wheel, be careful of the following items. ‘olnstallation is the reverse of removal "NOTE install the speedometer gear housing so that it fits in the speedometer gear drive notches. Fit the speedometer gear housing stop to the fork leg stop, and check that the collar is on the right side of the hub. . Housing Stop . Fork Leg Stop 8, Speedometer Gear Housing Tighten the axle nut to the specified torque and install the new cotter pin. (eCheck the front brake, WARNING J Do not attempt to drive the motorcycle until a full brake lever it obtained by purmping the brake lever until the pads are against the disc. The brakes will not function on the first application of the lever if this is not done. lf the axle nut is not correctly tightened and the cotter pin is not installed, an unsafe riding condition may rosult. Rear Wheel Removal ‘eRemove o loosen the following parts before rear whee! removal ‘Coter pin Axle nut (loosen) ‘Drive chain (Fully foosen) ‘Axle nut and axle (remove) ‘ePull the drive chain toward the left, and remove the rear wheel Rear Wheel Installation ‘eWhen installing the rear wheel, be careful of the following itoms. ‘olnstallation is the reverse of removal oAdjust the drive chain after installation (see Drive ‘Chain Adjustment in Final Drive chapter}. Tighten the axle nut to the specified torque and install the new cotter pin. ‘Chock the rear brake. Cf the axle nut is not correctly tightened and the cotter ‘pin is not installed, an unsafe riding condition msy result, Axle Inspection ‘eTo measure axle runout, remove the axle, place it in V blocks that are 100 mm apart, and set a dial gauge on the axle at a point halfway between the blocks. Turn the axle to measure the runout, The amount of runout the amount of dial variation. #1f runout exceeds the service limit, straighten the axle for replace it. If the axle cannot be straightened t ‘within the service limit, or ifrunout exceeds the repair limit, ceplace the axte. Axle Runout/100 mm 02mm = 100 mim Tire Air Pressure Measurement Refer to p. 84 of the Base Manual noting the following exception. ‘eCheck the tire pressure when the tires are cold,Tire Air Pressure (when cold) WHEELS/TIRE 9-5 Load ‘Air Pressure ce 147 kPa US and (1.8 kg/em? , 21 psi) Canadian 147 kPa 4 Up to 956 N (97.5 kg, 215 Ib) fae tiienoi al Rear "956 — 1.471 N 172 kPa (97.5 — 180 ko, 215 — 331 Ib) (1.75 kglem?, 25 pail Front 147 KPa Other than (1.5 kg/em?,, 21psi) US and, 187 kPa 1471N Canadian Up t0 1471 N (150 K9, 33118) | C15 ka/om*, 21 pal neal Rear | 1,471 —1,824N 172 kPa (150 — 186 kg, 331 ~ 410 Ib) (1.76 ka/om?, 26 psi) Tire Wear Inspection Refer to p. &5 of the Base Manual noting the following exception, Tira Tread Dopth From Standard 8.8 mm 2mm Rear 105mm Service Limit 2mm Standard Tire Front Size 3.0021 4R Make, Type DUNLOP K750A ‘@DUNLOP TRAIL MAX (os~) Rear Size 4.60-17 4PR Make, Typo _ DUNLOP K7S0A/K150 (@ DUNLOP TRAIL MAX (os~) ® + Australian Model Tire Removal and Installation Refer ta p. &4 of the Base Manual noting the following exception, ‘@Check the tire rotation mark on the front and rear tires. NOTE The direction of the tire rotation is shown by an arrow ‘on the tire side wal. B. Wheel Rotation Wheel Bearings Wheel Bearing Installation Note Refersto p. 87 of the Base Manual noting the following exception. ‘Press each bearing into the hub with 2 bearing driver (special tool)96 WHEELS/TIRE Front 1. Bearing Driver Holder: $7001-1132 2. Bearing Driver Disc Side: $7001-1144 Speedometer Gear Side: 57001-1143, 3. Bearing Driver Disc Side: $7001-1136 Speedometer Gear Side: $7001-1135 Rear 57001-1132 1. Bearing Driver Holder 2. Bearing Driver: $7001-1143 3. Bearing Driver: 37001-1136 Special Tools (Addition) ‘The following special tools are newly available. Bearing Remover Shaft: 57001-1265 Bearing Remover Head: 57001-1267 % ‘©The bearing remover shaft and head [special tools) can bo used to remove the hub bearings. oe fe 3), fo 4, Bearing Remover Shaft: 57001-1265 2. Bearing Remover Head: 57001-1267FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View . . an Specifications . 103 ial Tools. 103 10-4 Base Manual p. 9-3 104 Base Manual p. 93 104 104 - Base Manual p, 9-4 « Base Manual p. 9-5 Drive Chain Slack Inspection. Drive Chain Slack Adjustment. Wheel Alignment Adjustment . Drive Chain Wear Inspection Drive Chain Lubrication Drive Chain Removal........ 10.4 Drive Chain Installation... . 105 Sprocket, Coupling........... 105 Engine Sprocket Removal...... 105 Engine Sprocket Installation + 105 Rear Sprocket, Coupling Removal. + 105 Sprocket Wear... 105 Sprocket Warp...... an 106 Coupling Bearing Removal .... 106 Coupling Bearing Installation . 106 Coupling Bearing Inspection and Lubrication... . - 106 Grease Seal Inspection and Lubrication....... 10-7 Damper Inspection ......0e. 60005 107G Apply grease. T1 :9.8 Nem (1.0 kg-m, 87 in-Ib) 72 :34 Nom (3.5 kg-m, 25 feb)Final Drive Specifications FINAL DRIVE 10-3 item Standard Service Limit 7 Drive Chain. Standard Chain: Make ENUMA CHAIN Type Endless EK520 L-O Link 104 links Chain Stack 0~5 mm (Space between chain and swing arm) Reference: 20 ~ 35 mm (midway between sprockets) 20 = link length 317.5 ~ 318.2 mm Sprockets Rear sprocket warp Less than 0.4 mm 0.5 mm J Use following tools in the set Bearing Driver Holder: 57001-1132 Bearing Driver: 57001-1136 Bearing Driver: 57001-114510-4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection Refer 10 p. 93 of the Base Manual noting the following exception. To measure the chain slack, pull up the lower run of the drive chain, ‘*The space between the chain and swing arm at the ‘owing arm protector mounting bolt is the chain slack. Chain Stack 1. Engine Sprocket 2 Space (Chain and Swing Arm) 3. Rear Sprocket 4, Protector Mounting Bolt rive Chain Slack ‘Standard: 0 ~ S mm Reference (vertical movemont midway between sprock- ts) Stender: 20-35 mm ‘AIF the drive chain is too tight or to0 loose, adjust itso that the chain slack will be within the standard value, Drive Chain Slack Adjustment ‘Remove the cotter pin, and loosen the rear axle nut, D. Rear Axle Nut A. Swing Arm Pin B Chain Adjuster Mark, Chain Adjuster C. Cotter ‘eRotate the chain adjuster at each end of the swing arm 10 obtain the specified chain slack. ‘eMake sure both adjusters are set to the same position for correct wheel alignment. ‘sCenter the brake panel assembly in the brake drum. This is done by tightening the axte lightly, spinning the wheel, and depressing the brake pedal forcefully. The partially tightened axle allows the brake panel assembly 10 center itself in the brake drum, NOTE This procedure can prevent a soft, or “spongy feeling” brake. ‘Tighten the axle nut to the specified torque. ‘Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. ‘insert 2 new cotter pin through the axle nut and axle, and spread its ends. ol th en ot sorety onda sh or ‘pin is not installed, an unsafe riding condition may result. ‘eCheck the rear brake. (see the Brakes section) Wheel Alignment Adjustment See drive chain adjustment. Drive Chain Removal ‘*Remove the following parts before drive chain removal ‘ORear wheel oF ootpeg Brake pedal Swing arm pivot shaft (Engine sprocket ‘Lift the front part of the swing arm, and take out the rive chain between the rear frame and swing arm. A. Rear Frame B. Swing Arm €. Drive ChainDrive Chain Instatlation ‘eWhen installing the drive chain, be caroful of the following items. ‘installation Is the reverse of removal ‘Adjust the drive chain after installation, Tighten the pivot shaft nut to the sp¢ ‘Adjust the rear brake after installation, Sprocket, Coupling Engine Sprocket Removal ‘Remove the engine sprocket cover. Unscrew the engine sprocket bolts while applying the tear brake, and take off the holding plate. A. Engine Sprocket B. Holding Plate C. Sprocket Bolts ‘eRemove the rear axle. ‘@Remove the engine sprocket with drive chain. ‘Remove the sprocket from the drive chai Engine Sprocket Installation ‘Engine the sprocket with the drive chain so that the shoulder faces inside. ‘install the sprocket onto the output shaft, and finger tighten the sprocket bolts, ‘install the rear axle, and adjust‘the chain slack, ‘Tighten the sprocket bolts to the specification, while applying the rear brake. ‘install the engine sprocket cover. Rear Sprocket, Coupling Removal Remove the rear wheel (see tear wheel removal in ‘Wheels/Tires chapter). FINAL DRIVE 10-5 Remove the coupiing from the wheel, Pull out the coupling collar from the left, and the ‘coupling sleeve fromthe right. ‘install the rubber damper and wheel coupling tempo- sarily on the rear hub to aid in rear sprocket removal Remove the rear sprocket nuts (6) to separate the rear sprocket from the wheel coupling. ‘*Remove the coupling from the rear wheel. Rear Sprocket, Coupling Installation ‘When installating the rear sprocket and coupling be careful of the following items. Olnstallation is the reverse of removal Replace the grease seal with a new one using suitable river. Press the seal in until the face ofthe seal is level with the end of the grease seal hole. Apply a little srease to the grease seal lip. lnstall the rear sprocket with the chamfered side facing ‘toward the hub, A. Rear Sprocket B. Chamfered Side ‘Tighten the rear sprocket nuts to the specified torque, then loosen them and tighten them to the specified torque again, Sprocket Wear Visually inspect the sprocket teeth, If they are worn 3s illustrated, replace the sprocket.10-6 FINAL DRIVE Sprocket Teeth ® fam © [A] Worn Tooth (Engine Sprocket) [B] Worn Tooth (Rear Sprocket) {C} Direction of Rotation NOTE © If a sprocket requires replacement, the chain is probably worn also. Upon replacing a sprocket, inspect the chain. ~* Sprocket Warp Elevate the rear wheel so that it will turn freely, and set 2 dial gauge against the rear sprocket near the teeth as shown. Rotate the rear wheel. The difference between the highest and lowest dial gauge readings is the amount of runout (warp). If the runout exceeds the service limit, replace the rear sprocket ‘A. Rear Sprocket B. Dial Gauge Rear Sprocket Warp Standard Under 0.4 mm Service Limit 0.5 mm Coupling Bearing Removal ‘Using a hook, pull out the grease seal and remove the tip. ‘Using bearing driver and driver holder (special tools) or some other suitable tool, remove the bearing by tapping from the whee side, Coupling Bearing Installation ‘When installing the coupling bearing be careful of the following items. ‘lnstalation is the reverse of removal Olnspect the bearing, and replace if necessary (see Coupling Bearing Inspection). Lubricate it, and then instal it using the wheel bearing driver and the bearing driver holder (special tools). 1. Bearing Driver Hodler: $7001-1132 2. Bearing Driver: $7001-1145 3. Bearing Driver: $7001-1136 Coupling Bearing Inspection and Lubrication ‘Since the coupling bearings are made to extremely close tolerances, the clearance cannot normally be measured. Wash the bearing with a high flash-point solvent, dry it (do not spin it while it is dry), and oil it, Spin it by hand to check its condition. If itis noisy, {does not spin smoothly, or has any cough spots, it must be replaced. If the same bearing is to be used again, re-wash it with a high flash-point solvent, dry it, and pack it with good quality bearing grease before instalation. Turn the bearing by hand a few times to make sure the grease is distributed uniformly inside the bearing, and wipe the old grease out of the bearing housing before installation. Grease the wheel bearings in accordance with the Periodic Maintenance Chart.Grease Seal Inspection and Lubrication IF the grease seals are examined without removing the seals themselves, look for discoloration (indicating the rubber has deteriorated), hardening, damage to the internal ribbing, or other damage. If the seal or internal "lpbing has hardened, the clearance between the seal and the axle sleeve will not be taken up, which will allow dirt and moisture to enter and reach the bearing. fin doubt 5 (0 its condition and whenever the seal i removed for sreasing the bearing, the seal should be replaced. The seals are generally damaged upon removal. Damper Inspection Remove the rear wheel coupling, and inspect the rubber damper. Replace the damper if it appears damaged or dete- ciorated, A, Rubber Damper FINAL DRIVE 10-7Brakes Table of Contents Exploded View. Specifications Special Tools ............. Front Brake Adjustment/Inspection ...... . Brake Lining Wear Inspection Brake Fivid Level Inspection . . Brake Fluid Change... . Broke Line Air Bleeding . Brake Fluid Recomendtion Front Brake Disassembly/Assembly .... 2... . Inspection and Adjustment after Installation Pad Removal Notes . Calfper Removal Notes... Caliper Installation Notes Calfper Disassembly Notes. Caliper Assembly Notes... ise installation Notes . Front Master Cylinder Installation . Front Master Cylinder Disassembly Notes Front Master Cylinder Assembly Notes ....... Rear Brake Adjustment/Inspection Pedal Position Adjustment . Pedel Play Adjustment Brake Lining Weer Inspection . Cam Lever Angie Adjustment . Rear Brake Disatsombly/Assombly Disassembly Notes. Assembly Notes Brake Maintonanes . Disc Wear... Dise Clesning . Disc Runout. . te Brake Drum Wear... vee. Rear Brake Camshaft Lubrication. 12 3 13 = Base Manual p, 10-4 Base Manual p. 10-4 + Base Manual p. 104 + Base Manual p. 10-4 = Base Manual p. 105 = Base Manual p. 105 Base Manual p. 10.6 + Base Manual p, 106 Base Manual p. 10.6 Base Manual p. 10-6 Base Manual p. 106 + Bese Manual p. 10-7 Base Manual p. 10.7 = Base Manual p. 10-7 Base Manual p. 10-7 Base Manual p. 10-8 Base Manuel p. 10.8 Base Manual p. 108 Base Manual p, 10.8 + Base Manual p. 108 Base Manual p. 10-9 Base Manual p. 10.9 Base Manual p. 109 Base Manual p. 10.9 Base Manual p. 10-11 Base Manual p. 10-10 11-4, Base Manual p. 10-11 4 4 14 4 BRAKE 11-111-2 BRAKE orrasans +: 25 Nem (2.5 kg-m, 18.0 ft-lb) + 8.8 Nem (0.90 kg-m, 78 intb) £25 Nem (2.5 kg-m, 18.0 ftb) 7.8 Nem (0.80 kg-m, 69 in-tb) + Apply non-permanent locking agent. + Apply PBC (Poly Buty! Cuprysil) grease. : Apply grease. 9.8 Nem (1.0 kg-m, 87 in-Ib)BRAKE 11-3 item ‘Standard Service Limit Brakes: Pad lining thickness 45mm 1mm Brake fluid grade DOTS or 4 === Brake pedal position 0-30 mm Brake pedal play 20 ~ 30 mm. Disc runout Less than 0.15 mm 0.3 mm Disc thickness 2.8~3.1 mm 2.5 mm Drum brake cam lever angle —_|80 ~ 90° === Drum inside diameter 120.00 ~ 120.14 mm 120.75 mm Brake shoes thickness ‘wear indicator within wear indicator beyond the USABLE RANGE: the USABLE RANGE11-4 BRAKE Rear Brake Disassembly/Assembly Assembly Note Refer to p. 10-10 of the Base Manual noting the following exception. The camshaft must be installed so that the triangular ‘mark on the cam surface points toward the center of Teor ‘olmproper cam installation will cause ineffective braking. ‘A. Brake Cam Shaft 8. Triangular Mark Brake Maintenance Disc Wear Measure the thickness of each disc at the point where it has worn the most. Replace the disc if it has ‘worn past the service limit. 1. Brake Dise 2, Measuring Points Disc Thickness Standard 28-3. mm Service Limit 25 mm Disc Cleaning Poor braking can be caused by oil on the disc. Oil on che disc must be cleaned off with an oil-ess cleaning fluid such as trichloroethylene or acetone. These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturers warnings. * Disc Runout Jack up the motorcycle so that the front wheel is off the ground, and turn the handlebar fully to one side Set up a dial gauge against the front disc as illustrated, land measure disc runout. Remove the jack, set the ‘motorcycle up on its center stand, and then measure the rear disc runout. If runout exceeds the service limit, replace the dis. 1, Brake Dise 2, Measuring Points Dise Runout Standard Uncier 0.1 mm. Service Limit 0.3mm. Brake Drum Wear ‘Measure the inside diameter of the brake drum with calipers to determine wear. Since uneven drum wear will decrease braking effectiveness, take measurement at 2 minimum of two places. If the drum is worn unevenly or if itis scored, turn the drum down on a brake drum lathe or replace the hub. If any diameter measurement exceeds the service limit, replace the hub.BRAKE 11-5 Brake Drum tnside Diameter Standard 120.00 - 120.14 mm Service Limit 120.75 mmSuspension Table of Contents Exploded eat = 122 Specifications .......... 123 Special Tools. ae 123 Front Fork ....... 124 Air Pressure Adjustment 124 Fork Oil Level... 124 Fork Oil Change 12-4 Front Fork Removal 12-4 Front Fork Installation . : 12-4 Front Fork Disassembly ....... 125 Front Fork Assembly . Inner Tube Inspection... Guide Bush Inspection .. . Guide Bush Replacement 125 Rear Shock Absorber . : 126 Damper Adjustment ........ sees 126 Spring Preload Adjustment . . 126 Rear Shock Absorber Removal . f Rear Shock Absorber Installation ....... SUSPENSION 12-1 Base Manual p. 11-8 Base Manual p. 11-9 Base Manual p. 11-9 Base Manual p. 11-9 - Base Manual p. 11-11 = Base Manual p. 11-11 » Base Manual p, 11-11 Base Manual p. 11-12 Base Manual p. 11-12 Base Manual p. 11-13 Base Manual p. 11-14122 SUSPENSION + Apply non-permanent locking agent. Apply molybdenum disulfide grease. + Apply liquid gasket. 2 12.Nem (1.2 kg-m, 104 inte) 29 Nem (3.0 kg-m, 22 fib) 14.5 Nem (0.15 kg-m, 13 in-1b) +: 21 Nem (2.0 kgem, 15.0 ft-lb) £88 Nem (9.0 kg-m, 65 ft-b) 99 Nem (4.0 kgm, 29 ft-b)SUSPENSION 12-3 ‘Suspension Specifications tem Standard Service Limit Front Fork: Oil type KAYABA G10 or SAE 10W20 --- Oll capacity 321 — 329 mL (approx. 270 mL at oil change) Oil level 190 22 mm (Fully Compressed, without spring) Air Pressure ‘On road: 0 kg/em? (atm.) Rough road: 0.2 ~ 0.3 ka/em? Fork spring free length 421.5 mm Rear Shock Absorbers: a : Spring preload adjustment | On road: 32mm Rough road: 37 — 42 mm ‘Special Tools Front Fork Cylinder Holder Handle: 6701-183, Front Fork Cylinder Holder Adapter: 57001-1057 a i Fork Outer Tube Weight: 57001-1218 Fork Oil Seal Driver: 57001-1219 = /)12-4 SUSPENSION Front Fork Air Pressure Adjustment ‘Raise the front wheel off the ground using a jack or suitable stand under the engine. NOTE Atmospheric air pressure is for riding on pavarnent, but ft should be increased for riding on rough rosdt. Front Fork Air Pressure ‘On Pavement Atmospheric Pressure ‘On Rough Roads 20 ~29 kPa (0.2 —03kg/em? 28 ~ 43 psi) Clnject air little by little so that air pressure does not rise rapidly. Air pressure exceeding 245 kPa (2.50 ka/em’ , 36 psi) may damage the oll seal. WARNING Be sure to adjust the air pressure within the usable range, Pressure too high or too low can produce a hazardous riding condition, Only air or nitrogen gas can be used. Never i oxygen or any Kind of explosive gas. Do not incinerate the front fork. Do not remove the springs and rely on compressed air ‘only. Correct springs must be used in this suspension tystem. Use without springs can lead to a condition causing accident and injury. Fork Oil Level Refer to p. 11-9 of the Base Manual noting the following exception, Fork Oil Lavel ‘Standard: 188 ~ 192 mm below the top end of he Inner tube. Fork Oi! Change Refer to p. 11:9 of the Base Manual noting the following exception. Front Fork Oil Viscosity KAYABA G10 or SAE 10W20 Amount per side When changing oil: After disassemble and completely dry: about 270 mL 321 ~ 329 mL. Front Fork Removal ‘eRemove the following parts before front fork removed, ‘Release the air at the fork. Cable clamps (Speedometer, brake hose) ‘Holder (Speedometer lower end) Caliper (from the fork leg) Front whoo! OF rk top plug (loosen f#eLoosen the upper and lower fork clamp bolts. A. Top Plug B, Upper Clamp Bolt . Lower Clamp Bolt ©. Rubber Boot ‘eWith a twisting motion, work the fork leg down and Front Fork Installation ‘eWhen installing the fork log, be careful of the following fork leg was disassembled, check the fork oil level. Tighten the lower and upper clamp bolts to the specified torque. Tighten the caliper mounting bolts to the specified torque: (Check the front ake after installation.Front Fork Disassembly See the Base Manual, noting the following. ‘Use the weight (special too!) to separate the from the outer tube. ‘Mount the weight (special tool) on the top of the outer tube, by fitting the step of the weight (special tool) to the top corner of the outer tube. ner tube Weight Mounting Fork Outer Tube Weight: 57001-1218 step = Corner Outer Tube ‘Holding the inner tube by hand in a vertical position, stroke the outer tube several times and pull it down, Front Fork Separation 1. Inner Tube 2. Fork Outer Tube Weight: 570011218 3. Outer Tube 4, Stroke SUSPENSION 125 NoTE ‘Frome Fork Oil Seal Driver: 67001-1091 can be used. Front Fork Assembly ‘*Fork assembly is the reverse of diassembly. Pay attention to the following items, ‘Check the top plug O-rings for damage. Replace them with new ones if damaged. Replace the oil seal with 2 new one. DOlnspect the guide bushes (see Guide Bush Inspection), and replace them with new ones if necessary. ‘onsert the cylinder unit into the inner tube, and put on the washers and the stop. insert the inner tube and cylinder into the outer tube. ‘Apply liquid gasket to both sides of the gasket, and apply a non-permanent locking agent to the Allen bolt. Tighten the Allen bolt to the specified torque, using the front fork cylinder holder handle and ‘holder adapter (special tools) to stop the cylinder from turning. ‘lnstall the guide bush by placing a used guide bush on top of it and them tapping the used guide bush with the driver (special tool) until it stops. The slit of the bush must faced toward the left or right side of the vehicle. Guide Bush Installation 1. Driver: $7001-1219 2. Used Guide Bush 4, New Guide Bush 5. Outer Tube 3. Slit 6. Tap Olnstall the oll seal with the driver (special tool) after washer installation, Olnstall the dust seal with the driver (special tool), then install the retainer.12-6 SUSPENSION If the drain screw was removed, check the gasket for damage. Replace a damaged gasket with a new one. Before installing the drain screw, apply 2 liquid gasket to the threads of the screw, and tighten the screw securely. ‘Pour in the type and amount of fork oil sp Specifications}, and adjust the oil evel. Tighten the top plug to the specified torque after fork installation, 4 (see Rear Shock Absorber Damper Adjustment Refer to p. 11-12 of the Base Manual noting the following exception. NOTE ©The damping force can be left soft for average riding. But it should be adjusted harder for rough roed riding, or riding with a passengor. If the damping feels too soft or too stiff, adjust it in accordance with the following table: Damper Adjuster Aajoster | Dameine | soxin Position | Force | Sewn Load | Road | Speed T Stronger | Soft | Light} Good] Low ! ett mm Hard [Heavy] Bad = Ee L ‘A. Swing Arm’ B. Dust Cover C. Damper Adjuster . Arrow Mark to Upward Spring Preload Adjustment ‘®Remove the rear frame. Loosen the focknut using the hook wrenches, and turn the adjusting nutas required. Turning the adjusting nut down makes the spring preload stronger. |A. Rear Shock Absorber B. Locknut C. Adjusting Nut Protoad Adjustmont 1. Adjusting Nut 2. Rear Shock Absorber 3, Adjusting Range Spring Preload Setting ‘Adjusting Nut Position: ‘On Pavement (On Rough Roads 32 mm 37 — 42 mmSTEERING 13-1 Steering Table of Contents Exploded View....... Special Tools. 13:2 133 Steering Inspection , . : c+se+, Base Manual p. 11-6 Steering Inspection . : cesses, Base Manual p. 11-6 ‘Steering Adjustment . i Base Manual p. 11-6 Steering Removal, Installation. Steering Stem Removal 13.4 Steering Stem Installation . vee 134 Steering Maintenance . . : - 135 Steering Stem Bearing Lubrication . 135 Bearing Wear, Damage...... 13-6 ‘Stem Cup (Grease Seal) Deterioration, Damage ... 136 Handlebar .. o +--+ Base Manual p. 12-413-2 STEERING Exploded Views ro MH: T2: Ts: v4: 15: 16: +: Apply grease, + Apply non-permanent locking agent io the threads. 23 N-m (2.9 kg-m, 16.5 -1b) 412N-m (1.2 kgem, 104 in-b) 23 Nem (2.8 kgem, 16.5 1b) 21 Nem (2.1 kg-m, 15.0 ft-ib) '39N-m (4.0 kg-m, 29 f-1b) 44.9 Nem (0.50 ka-m, 43 in-b)STEERING 133 Driver Press Shaft: 67001-1075 ‘Stem Bearing Remover: 7001-1107 [Pa ® ‘Storm Bearing Driver: 7001-137 Driver: 57001-1076 SS @ ‘Adapter: 57001-107413-4 STEERING ‘Steering Removal, Installation ‘Steering Stem Removal Remove the following parts before steering stem removal ‘oF uel tank Front wheel (Front fender Master cylinder clamp Handlebar Caliper mour Headlight cover Front fork feRemove the steering stem head nut and flat washer. ‘eRemove the lower mounting bolt at the meter bracket. ‘eRemove the connectors (4) and wiring leads from the meter bracket. ‘eRemove the stem head and meter brackot assembly. ‘eRemove the collar and lockwasher. ‘sHold the stem base toward the bottom, remove the stem locknut using the stem nut wrench. ‘®Remove the stem base, and then take off the stem cap and upper stem bearing. ig bolls Steering Stem \ \ 4 1. Stem Head Nut 7. Stem Cap (Grease Seal) 2. Flat Washer 8. Stem Bearing (Set) 3. Stem Head 9. Stem Bearing (Set) 4 Collar 10. Grease Seal 5. Lockwasher 11. Stem Base 6, Stem Locknut ‘*To remove the outer races pressed into the head pipe, install a stem bearing remover as shown below, and the hammer the stem bearing remover to drive the race out. ‘Outer Race Removal 1, Stem Bearing Remover: 57001-1107 ‘eRemove the lower inner race, which is pressed onto the steering stem, with a chisel NOTE Cf any steering stem bearing is damaged, itis recom- ‘mended that all the bearings and the steering stern should be replaced with nev ones. Steering Stem lastallation ‘Apply grease to the outer races, and then drive them into the head pipe using a beaieng driver and driver press shaft (special tool). Be sure to press them in until they stop at the step in the head pipe, Outer Race Installation 1. Driver Press Shaft 2. Driver: 3. Driver 57001-1075 57001-1106 57001-1076 ‘install the lower grease seal on the stem being careful of the installation direction (see Exploded Views). The lower grease seal has a bigger diamter than the stom cap, ‘*Apply grease to the steering stem bearing, and érive it ‘onto the steering stem using the bearing driver (special to‘A. Bearing Driver: 7001-137 B. Adapter: 57001-1074 ‘Lubricate the upper stem bearings with grease, ‘install the stem cap, and then install the stem focknut so that the notched side faces down. A. Notched Side 8. Stom Cap ‘install the lockwasher and collar. ‘@install the connectors (4), and route the wiring leads correctly. ‘install the meter bracket assombly, stem head, washer, and nut. Loosely install the nut at this time. ‘if a new steering bearing is installed, or if the removed bearing is reinstalled, seat the bearing according to the following Tighten the stem locknut to 39 Nem (4.0 ke-m, 29 fc} ‘Check that there is no play and that the steering stem tums smoothiy without rattling If the steering stem does not tum smoothly, the bearings may be damaged. Loosen the steering stem locknut a little until it turns lightly (oTurn the steering stem locknut lightly clackwise until it just becomes hard to turn. Do not overtighten, or the steering will be too tight. STEERING 13.5 NOTE Tightening the stem focknut t0 39 Nm (4.0 kgm, 29 felb) of torgua Is only to seat the bearing. After seating the bearing, loosen and handkighten the locknut. To torque the locknut with steering stem nut wrench (special tool), hook the wrench on the stem jocknut, and pull the wrench at the hole with 218 N (22.2 kg) force in the direction shown. 1, Stem Nut Wrench: $7001-1100 ‘Adjust the steering, ‘Reinstall the parts removed, ‘Route the cables and wiring harnesses correesty, The cables and haresses-must not hinder handlebar movement ‘eCheck and adjust the Following items Front brake cCiutch Throttle cables Rear view mirrors Headlight aim Steering Stern Bearing Lubrication ‘In accordance with the Periodic Maintenance Chart, ‘the steering stem bearings should be relubricated. ‘@Remove the steering stem, ‘Using 2 high flashpoint solvent, wash the upper and lower bearings in the cages, and wipe the upper and lower outer races (which are press-fited into the frame head pipe) clean of grease and dirt ‘*Visually check the outer races and the bearing rollers. ‘#Repiace the bearing assemblies if they show wear or damage. ‘ePack the upper and lower caged roller bearings with ‘grease, and apply 2 light coat of grease to the upper and lower outer races. ‘lnstall the steering stem, and adjust the steering.13-6 STEERING Bearing Wear, Daniage a high fash-point solvent, wash the upper and lower rollers in their cages, and wipe the upper and ower outer races (which are pressfitted into the frame head pipe) clean of grease and dirt. Visually check the outer races and the beating rollers. ‘Replace the bearing assemblies if the show damage. ‘Stem Cap (Grease Seal) Deterioration, Damage ‘inspect the stem cap on the upper bearing for any ‘signs of deterioration or damage. ‘#Replace the stem cap if necessary.FRAME 141 Frame Table of Contents 14.2 14-4 144 : 144 Sees 144 ‘Suggested Cable or Hose Routing .. [=|142 FRAME144 FRAME Rear Frame Removal ‘*Remove the following parts before rear frame removal. ‘Side Covers Seat Muffler Battery (Connector at the regulatorfrectifier (right side of the frame) (cConnector at the brake light switch (right side of the frame) ‘oBrake light switch spring (right side of the frame) Connector at the main harness (left side of the frame) ‘Rear frame mounting bolts, nuts ‘Remove the rear frame. Rear Frame Installation ‘Rear frame installation isthe reverse of removal ‘Suggested Cable or Hose Routing ‘For later installation convenience, note and record how land where cables, wires, and hoses are routed. They should not be allowed sharp bends, kinking, or wine Operation with improperly adjusted, incorrectly routed, o damaged cables could result in an unsafe iding condition ‘Clutch Cable Routing 1. Clutch Cable ‘A, Front Brake Hose . Breather Tube B, Throttle Cables A. Cable Guide D. Cable Guides B. Front Brake Cable E. Front Brake Hose ©. Cable Clamp. F. Hose Clump A. Throttle Cables