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Kawasaki KDX200/KDX220 service manual 1995-2006
This manual is comprised of a base manual for the Kawasaki KDX200, along with a
supplement manual to make it relevant for the KDX220. Kawasaki service manuals
sometimes utilize this build-on-earlier models method when two models are similar to
each other. Use the links below or the bookmarks to the left to get to the manual that
covers your model.
Kawasaki KDX200 base manual
Kawasaki KDX220 supplement manual
Kawasaki
KDX200
Motorcycle
Service Manual
© Kawasaki Heavy Industries. ltd. 1994
First Edition (1) : J ut 15, 1994 (M)
LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
"C
DC
F
"F
ampere(s)
Ib
after bottom dead center
m
alternating current
min
after top dead center
before bottom dead center
N
Pa
PS
psi
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
TOC
TIA
ft
foot. feet
V
9
h
L
gram(s)
hour(s)
liter(s)
W
bottom dead center
,
'pm
n
pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound{s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)
Read OWNER'S MANUAL before operating.
Quick Reference Guide
General Information
Fuel System
Cooling System
Engine Top End
Clutch
Engine Removal/Installation
CrankshaftlTransmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix
This quick reference guide w it! assist you in
locating a desired topic or procedure.
• Bood the pages back to match the black tab
of the desired chapter number with the black
tab on the edge at each table of contents
page.
• Refer to the sectional table of con toots for
the exact pages to locate the specific topic
required.
I1 1
I2 1
I3 1
I4 1
I5 I
I6 1
I7 1
I8 1
1
101
111
121
131
14.
151
9
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop
However, It contains enough detail and basic
Information to make It useful to the owner who
deSires to perlorm his own baSIC maintenance and
repair work_ A basic knowledge of mechanics, the
proper use of tools. and workshop procedures must
be understood in order to carry out maintenance and
repair satisfactorily. Whenever the owner has
insufficient expertence or doubts his ability to do the
work, all adjustments. maintenance. and repair
should be carried out only by qualified mechanics .
In order to periorm the work efficiently and to
avoid castly mistakes, read the text. thoroughly
familiarize yourself with the procedures before
starting work, and then do the work carefully in a
clean area. Whenever special tools or equipment are
specified, do not use makeshift tools or equipment.
Precision measurements can only be made if the
proper instruments are used, and the use of substi tute tools may adversely affect safe operation
We recommend that all repairs and scheduled
maintenance be performed in accordance with this
service manual.
To get the longest life out of your Motorcycle:
e Follow the Periodic Maintenance Chart in the
Service Manual.
e Be alert for problems and non -scheduled mamtenance.
.U se proper tools and genuine Kawasaki Motorcy cle parts. Special tools, gauges, and testers that
are necessary when servicing Kawasaki Motorcycles are introduced by the Special Tool Catalog or
Manual. Genuine parts provided as spare parts are
listed in the Parts Catalog .
.Follow the procedures in this manual carefully.
Don't take shortcuts.
e Remember to keep complete records of maintenance and repair with dates and any new parts
installed.
How to Use this Manual
In preparing this manual. we divided the product
Into ItS major systems. These systems became the
manual's chapters. All information for a particular
system from adjustment through disassembly and
inspection is located in a single chapter.
The Quick Reference Guide shows you all of the
product's system and assists in locating their
chapters. Each chapter in turn has its own comprehensive Table of Contents.
The Periodic Maintenance Chart is located in the
General Information chapter. The chart gives a time
schedule for required maintenance operations.
If you want spark plug information, for example,
go to the Periodic Maintenance Chart first. The chart
tells you how frequently to clean and gap the plug.
Next, 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
Spark Plug section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions I Always
follow safe operating and maintenance practices.
..WARNING
This warning symbol identifies special instructions or
procedures which. if not correctly followed. could
rasult In personal Injury. or loss of life.
CAlJT10N
This caution symbol identifies spaciel instructions or
procedures which. if not strictly observed, could result
in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distingUIsh different types of information.
NOTE
o
This note symbol indicates points of particular interest
(Of
more efficient and convenient operation.
• Indicates a procedural step or work to be done.
Otndicales a procedural sub-step or how to do the work
of the procedural step it follows. II also precedes the
text of a NOTE.
*lndicates a conditional step or what action to take based
on the results of the test or inspection in the procedural
step or sub-slep it follows.
In most chapters an exploded "jew 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 .........................................................................................................1· 2
Model Identification ....................................................................................................1 -4
General Specifications ................................................................................................ 1-5
Periodic Maintenance Chart .......................................................................................1- 7
Technical Information - KIPS (Kawasaki Integrated Power Valve System) ............ 1-8
Torque and Locking Agent .......................................................................................1 · "
Special Tools and Sealant ..................................................................................... ... 1·14
Cable, Wire, and Hose Routing ....................................................................... ,.... ,... 1 ·19
1-2 GENERAL INFORMATION
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate
unnecessary work. Photographs. diagrams, notes, cautions, warnings, and detaJled descriptions have been
included wherever necessary. Nevertheless, even a detailed account has limitations. a certain amount of basic
knowledge is also required for successful work.
Especially note the following ;
(1) Dirt
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Before removal and disassembly, clean the motorcycle , Any dirt entering the engme 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.
Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. But if this Service Manual
has installation or assembly procedures, follow them .
Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them an in their holes and
tighten them to a snug fit. Then tighten them evenly in a cross panern. 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 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.
Torque
When torque values are given in this Service Manual, use them. Either too linle or too much torque may
lead to serious damage. Use a good quality, reliable tOfque wrench.
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.
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.
High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly
available in North America is Stoddard solvent (generic name) . Always follow manufacturer and container
directions regard ing the use of any solvent.
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 maner and perfectly smooth to avoid oil or compression leaks.
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 non-permanent locking agent commonly available in North America is Loctite Lock'n Seal
(B lue).
Press
A part installed using a press or driver, such as a wheel bearing (hub bearing), should first be coated
with oil on its outer or inner circumference so that it will go into place smoothly.
Bait Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or
needle bearings that were removed with new ones, as removal generally damages bearing.
Install bearings with the marked side facing out applying pressure evenly with a suitable driver. Only
press on the race that forms the press fit with the base component to avoid damaging the bearings. This
prevents severe stress on the balls or needles and races, and prevent races and balls or needles 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
(13)
(14)
(15)
(16)
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. Before a shaft passes through a seal. apply a little high
temperature grease on the lips to reduce rubber to metal friction.
Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens and
deforms them. When installing circtips and retaining rings, take care to compress or expand them only
enough to install them and no more.
Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.
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 (MOS2 ) in the assembly of certain engine and chassis
parts. Always check manufacturer recommendations before using such special lubricants.
Electrical Wires
All 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 first 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.
Wire (cross-section)
Name of Wire Color
Red
Wire Strands
Yellow/Red
Yellow
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) Specifications
Specification terms are defined as follows:
"Standards show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated
performance, replace the damaged parts.
H
1-4 GENERAL INFORMATION
Model Identification
K0X200-H1 Left Side View
K0X200-H1 Right Side View
GENERAL INFORMATION 1-5
General Specifications
KDX200-H1
Items
Dimensions:
2120 mm
890 mm
1 230mm
1 435 mm
340mm
920 mm
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight:
Front
Rear
Fuel tank capacity
101 kg
53 kg
57 kg
11L
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing:
Inlet
2 -stroke, single cylinder, piston reed valve
Liquid- cooled
66 .0 x 58.0 mm
198 mL
7.9 : 1
Carburetor, KEIHIN PWK35
Primary kick
COl
Scavenging
Exhaust
Open
Close
Open
Close
Open
Close
Lubrication system (Gasoline: oil)
21 · [email protected] 000 r/min (rpm)
NGK BR8ES
Full open
60' BBDC
60' ABDC
78.8· BBDC (low speed) , 92.7" BBDC (high speed)
78.8· ABDC (low speed), 92.7" ABDC (high speed)
Petrol mix (32:1)
Drive Train:
Primary reduction system :
Type
Reduction ratio
Clutch type
Transmission:
Type
Gear ratios:
Gear
2.864 (63/ 22)
Wet, multi disc
6-speed, constant mesh, return shift
1st
2nd
3rd
4th
5th
6th
Final drive system :
Overall drive ratio
Transmission oil:
Type
Reduction ratio
Grade
Viscosity
Capacity
2.692
2.000
1.533
1.235
1.042
0.870
(35/ 13)
(28/14)
(23/15)
(21/17)
(25/ 24)
(20/ 23)
Chain drive
3.615 (47/13)
[email protected] gear
SE, SF, or SG class
SAE 10W- 30 or 10W-40
0.7 L
(Continued on next page.)
1-6 GENERAL INFORMATION
KDX200-Hl
Items
Frame:
Type
Sleering angle
Caster (rake angle)
Trail
Front tire:
Rear tire:
Tubular, semi -double cradle
45° to either side
26.5'
Size
Make/Type
Sile
Make/Type
Front suspension:
Type
Aear suspension:
Type
Wh~e l
travel
Wheel travel
Brake type:
Front and Rear
Effective disc diameter: Front
108 mm
80/100 - 2151 M
DUNLOP K490. Tube type
l00/ 100- 1859M
DUNLOP K695. Tube type
Telescopic fork
290mm
Swingarm (Uni -trak)
300mm
Single disc
220mm
Rear
190 mm
Type
Semi -sealed beam
Bulb
Bulb
12V30W
12Vl0W
Type
Single-phase AC
Electrical Equipment:
Headlight
Taillight
Magneto
Rated output
Specifications are subject to change without notice. and may not apply to every country.
GENERAL I NFORMATION 1 -7
Periodic M aintenance Chart
The maintenance must be done in accordance with this chart to keep the motorcycle in good running
condition.
FREOUENCY
km (mi)
Traveled Distance
100
(60)
500
(300)
1000
(600)
1500
(900)
2000
(1200)
Clutch ad US!
Clutch plates-check'
Thronle cable check'
clean, gap'
Spam plug
Air cleaner element clean
Air deaner element
replace
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
a
Carburetor - inspect/ad USI'
a
a
a
a
-
OPERATION
ENGINE
If damaged
a
•a
•a
••
•
Transmission oil - chanQe
clean/check'
Piston and piston rin
Cylinder head, cylinder and el{haust valves
Muffler clean
Small end bearing
check'
replace
Exhaust pipe O-ring
Engine sprocket check'
Coolanl change
Radiator hoses, connections check'
Spark arrester
clean
inspect'
a
Every 2 years
a
a
a
Every 4000 km (2500 mi)
CHASSIS
Brake ad'ustment - check '
a
Brake pad wear - check'
Brake fluid level - check "
Brake fluid-chan e
Brake masler linder cu and dust seal - r8 lace
Brake cali
iSlon seal and dust seal
I.",
Brake hose
Spoke ti htness and rim runou t check'
D rive Chain - ad'ust
D rive chain
lubricate
Drive chain wear check'
Chain slipper and guide
replace
Front fork
inspect/clean
Front fort<. oil - change
Steering play - check'
Steering stem beaflng - grease
Rear sprocket check"
Wheel bearing ' check '
Swingarm and Uni-trak linkage pivots . grease
Swingarm and Uni-trak linkage pivots check'
Rear shock oil
replace
ENGINE and CHASSIS
Fuel system clean
Fuel hose-replace
Nuts. bolts, fasteners check'
General lubrication
lubricate
,
•••
•••
''''''
a
•
•
••
a
a
a
Ev
2 years
Eve
2
Eve 2
Ev 4
a
a
.ffi
"ffi
.'ffi
••
•
•
•
•
•
Every 300 km (200 mi)
Before and after each day of operation
a
a
If damaged
a
a
a
Every )'98r
a
a
•
a
a
•
•a
••
a
a
Every year
•
•a
I
a
a
I
Every 4 years
I
I
a
( "): Replace, add, adjust. clean, or torque if necessary.
{ . ):Service more frequently when operated in m ud, dust or o ther harsh riding condi tion.
a
a
I
I
•
•
•a
•
•
•
•
•••
••
•
a
a
•
1-8 GENERAL INFORMATION
Technical Information - KIPS (Kawasaki Integrated Power Valve System)
KIPS changes exhaust port dImenSIons so that the exhaust system characteristics match engine speed, KIPS helps the
engine to breathe in fresh mixture and breathe out exhaust gas mora effectively, Improving horsepower and fuel economy
over a wide range of engine speed.
The unfavorable power characteristiCs of the conventional two -stroke engine are remedied with more low-end torque
and more lop-end power.
As a result, the bike is faster and easier to ride.
Mechanism
The exhaust valve advancer [A] IS driven by the primary gear LB] on the crankshah. As It SPinS. centrifugal force acting
on the weights in the advancer moves them outward against the weight holder [C] . When the engine speed rises to a
predetermined point. the thrust force caused bV centrifugal force 00 the weights overcomes the spring force and moves the
weight holder [C] . Weight holder mOlion is transmitted as follows: weight holder [Cl -+ advancer lever [0] -+ advancer
shaft [EJ -+ advancer shaft lever [Fl -+ main shaft [G] -+ main valves [H] and sub-valves [I] .
Since the motion is transferred by a face gear of the advancer shalt lever, the KIPS mechanism IS compact. This allows
the muffler to be installed closer to the motorcycle's centerline, narrowing the engine width, and making the bike easier to
ride.
Mechanism
-+ : Valves open.
Exhaust Valve Advancer
at Mid to High Engine Speed
Exhaust Valve Advancer
at Low Engine Speed
Advancer lever Pin fi ts in.
Weight
!
Out
In
A.
B.
C.
D.
Exhaust Valve Advancer
Primary Gear
Weight Holder
Advancer Lever
E.
F.
G.
H.
Advancer Shaft
Advancer Shaft Lever
Main Shalt
Main Valves
In
I.
J.
Sub-valves
Resonator
GENERAL INFORMATION 1-9
Operation at low Engine Speed
At lower engine speeds. the KIPS valves are positioned so Ihallhe sub-valves [A] are closed, t he resonator [8] IS open,
and the mam valves [C] afe down .
Exhaust port area IS reduced and exhaust timing IS relatively conservative [D). These conditions help t he engine to
breathe in fresh gas smoothly because the exhaust gas [E] is charged at the proper speed and time to produce a useful
exhaust vacuum pulse.
Some of the exhaust gas lIows Into the resonator The resonator generates a delayed pressure wave (Fjlhat suppresses
the escape of fresh gas, lowenng fuel consumption
Under these conditions, the exhaust system tuning Improves bottom -end power, idling, and fuel economy.
Operation at Low Engine Speed
•
A
Main El(haust Port
Cylinder
Sub ·el(haust Ports
Closed Sub-el(haust Ports
(Slide Valve)
@
©
(Flap Valve)
Main El(haust
Opening
MaIn El(haust Port
A.
B.
Sub-valves
Resonator Open
C. Main Valves Down
D. Conservative El(haust Timing
E.
F.
El(haust Gas
Delayed Pressure Wave
1-10 GENERAL INFORMATION
Operation at Mid to High Engine Speed
When engine speed increases over 6000 rpm, the exhaust valve advancer opens the sub-valves [A], pulls the main valves
[C1 up, and closes the resonator [8J .
Exhaust port area IS increased and the exhaust port timing is advanced [OJ . The exhaust gas [ E] escapes quickly
enhancing top-end power.
Under these conditions, the exhaust system characteristics improve top-end POW8f.
Operation at Mid to High Engine Speed
•
A
Cylinder
Main Exhaust Port
Opened Sub-exhaust Ports
(Slide Valve)
@
t
C
~pVaIVe)
Full -opened Exhaust Port
A.
Sub -valves
B. Resonator Closed
C. Main Valves Up
D. Advanced Exhaust Timing
E.
Exhaust Gas
GENERAL INFORMATION 1-11
Torque and l ocking Agent
The following tables list the tightening torque for the
major fasteners requiring use of a non -permanent locking
agent or liquid gasket.
letters used in the ~ Remarks " column mean:
CR : Cross lighten.
The table below, relating tightening torque to thread
d iameter, lists the baSIC torque for the bolts and nuts. Use
thiS table for only the bolts and nuts which do not require
a specific torque value. All of the values are for use with
dry solvent -cleaned threads.
Basle Torque for Genera l Fasteners
L
Apply a non -permanent locking agent to Ihe
t hreads.
lG : Apply liquid gasket to the threads.
lh
Threads dia.
(mm )
Left-hand threads.
M
o
S
Apply molybdenum disulfide grease.
Apply an oil to the threads and seating surface.
; Tighten the fasteners following the specified
sequence.
S5
Apply silicone sealant .
St : Stake Ihe fasteners to prevenlloosening.
R : Replacement pans
kg-m
N-m
5
6
8
10
12
1.
16
18
20
Fastener
Fuel System :
Ca rburetor Holder Bolts
Fuel Tap Plate Screws
Reed Valve Screws
Air Cleaner Housing Bolts
Rear Frame Pipe Bolts
Cooling System :
Cooling Hose Clamp Screws
Reserve Tan k BollS
Coolant Air Bleeder Bolt
Coolant Drain Plug (Water Pump)
Water Temperature Warning Lig ht Switch
Water Pump Impeller Nut
Water Pump Elba Bolts
Water Pump Cover Bolts
Engine Top End :
Spark Plug
Water Hose Clamp Screws
Cylinder Head Nuts
Cylinder Nuts
Engine Mounting Nuts
Eng ine M ounting Bracket Bolts
Reso nator Bolts
Advancer Shaft Lever Cover Bolts
M ain Va lve Cover Bolts
M ain Shaft Nut
Advancer Shaft Lever Nut
Main Valve Holder Bolts
M ain Valve Lever Bolt
Valve Rod Plugs
Va lve Lockbolt
M uffler Bolts
Carburetor Holder Bolts
Torque
ft -Ib
0.35 - 0.50 30 - 43 in-Ib
0.60 - 0.80 52 - 69 in -Ib
1.4-1.9
10.0 - 13.5
19.0-25
2.6 - 3.5
4.5 - 6.2
33 - 45
7.4 _ 10.0
73 - 98
54 - 72
115-155 11.5 ... 16.0 83 . . . 115
165-225 17.0 - 23.0 125_165
165-240
225 - 325
23 - 33
3.4
5.9
14
25
44
_
4.9
7.8
19
34
61
Torq u e
Rem ar ks
N- m
kg- m
ft -Ib
9.8
0.8
1.0
1.0
0.08
0.10
87 in-Ib
7 in-Ib
9 in -Ib
-
-
-
25
2.6
19.0
1.5
0.15
13in-lb
-
-
-
98
22
7.8
9.8
8.8
9.8
1.0
2.2
0.80
87 in -lb
27
1.5
25
25
2.8
0.15
2.5
2.5
1.0
0.90
1.0
44
4.5
29
5.9
5.9
5.9
8.8
8.3
5.9
3.9
18
7.8
3.0
0.60
0.60
0.60
0.90
0.85
0 .60
0 .40
l
l
16.0
69
87
78
87
in -Ib
in-Ib
in-Ib
in - Ib
20
13in -Ib
18.0
18.0
33
22
52
52
52
78
74
52
35
in-Ib
in-Ib
in-Jb
in- Ib
in- Ib
in- Ib
in- Ib
1.8
13.0
0.80
69 in-Ib
-
-
-
9.8
1.0
87 in-Ib
CR
CR
10mm
8mm
lh
l
1-12 GENERAL INFORMATION
Fastener
Clutch:
Transmission Drain Plug
Right Engine Cover Bolts
Clutch Cover Bolts
Kick Pedal Nut
Kick Lever Plug Screw
Brake Pedal Bolt
Kick Ratchet Guide Bolts
Exhaust Valve Advancer Lever Bolts
Shift Shaft Return Spring Pin
Gear Set Lever Bolt
Clutch Spring Bolts
Clutch Hub Nut
Primary Gear Nut
Magneto Cover Bolts
Advancer Shaft Lever Nut
Engine Removal / Installation:
Swingarm Pivot Nut
Engine Mounting Nuts
Engine Mounting Bracket Bolts
CrankshaftfTransmission:
Transmission Drain Plug
Primary Gear Nut
Crankcase Bolts
Drive Shaft Bearing Bolts
Shift Shaft Return Spring Pin (Bolt)
Shift Drum Bearing Holder Bolts
Shift Drum Cam Bolt
WheelsITires:
Front Axle Clamp Nuts
Front Axle
Rear Axle Nut
Spoke Nipples
Final Drive:
Rear Sprocket Nuts
Rear Axle Nut
Brakes:
Caliper Bleed Valves
Brake Hose Banjo Bolts
Brake lever Play Adjuster locknut
Brake lever Pivot Bolt
Brake lever Pivot Bolt locknut
Front Brake Reservoir Cap Screws
Front Master Cylinder Clamp Bolts
Caliper Mounting Bolts (Front, Rear)
Torque
Remarks
N-m
kg~m
ft-Ib
20
8.8
8.8
49
9.8
9.8
3.9
22
9.8
8.8
88
78
9.8
8.3
2.0
0.90
0.90
5.0
1.0
1.0
0.40
2.2
1.0
0.90
9.0
8.0
1.0
0.85
14.5
78 in -tb
78 in - tb
88
44
29
9.0
4.5
3.0
65
33
22
20
78
9.8
8.3
22
9.8
23
2.0
8.0
1.0
0.85
2.2
1.0
2.3
14.5
58
9.8
88
98
1.5-2.1
1.0
9.0
10.0
0.15 - 0.21
72
, 3 - 18 in -Ib
29
98
3.0
10.0
72
7.8
25
5.9
5.9
5.9
1.5
8.8
25
0.80
2.5
0.60
0.60
0.60
0.15
0.90
2.5
36
L
-
5t
87 in - tb
87 in - tb
35 in -tb
L
16.0
L
87 in - tb
78 in -tb
65
58
87 tn -tb
74 in-Ib
87 in - tb
74 in - tb
16.0
87 in - Ib
Lh
L
L
16.5
87 in- Ib
65
5
5
22
69 in -Ib
18.0
52 in - Ib
52 in - Ib
52 in -Ib
13 in -Ib
78 in - Ib
18.0
5
GENERAL INFORMATION 1 -13
To rqu e
Fast ener
Brake Pad Bolt Plugs (Front)
Brake Pad Bolts
Front Brake Disc Bolts
Rear Brake Disc Bolts
Rear Master Cylinder Mounting Screws
Rear Master Cylinder Push Rod Locknut
Brake Pedal Bolt
Suspension:
Front Fork Air Screws
Fron t Fork Clamp Bolts (Upper)
Front Fork Clamp Bolts (Lower)
Front Fork Top Plugs
Fron t Fork Cylinder Valve Assembly
Piston Rod Nuts
Front Axle Clamp Nuts
Rear Shock Absorber Bolts
Swi ngarm Pivot Nut
Remarks
N-m
kg· m
ft -Ib
15
18
23
23
8.3
18
98
0.15
18
2.3
2.3
0.85
1.8
1.0
13in-lb
1.3
20
25
29
71
15
9.8
39
88
0.13
2.0
2.5
3.0
7.2
1.5
1.0
4.0
9.0
11 in-Ib
88
83
9.0
8.5
65
61
13.0
16.5
16.5
L
L
74 in-Ib
13.0
87 in- Ib
14.5
18.0
22
52
11.0
87 in-Ib
L
S
29
65
Uni·trak
Rocker Arm Nut
Tie-rod Nuts
Stee ring:
Steering Stem Head Nut
Steering Stem Nut
Handlebar Clamp Bolts
Front Fork Clamp Bolts (Upper)
Front Fork. Clamp Bolts ( l ower)
Frame;
Side Stand Bracket Bolts
Side Stand Nut
Rear Frame Pipe Bolts
Electrical System ;
Spark Plug
Magneto Flywheel Nu l
Magneto Stator Screws
Magneto Cover Bolts
Taillight Mounting Nuts
44
4.5
33
Hand -tight
or 3.9
Hand -tight
or 0.40
Hand- tight
or 35 in-Ib
25
20
25
2.5
2.0
2.5
18.0
14.5
18.0
59
25
25
6.0
2.5
2.6
43
18.0
19.0
27
64
2.9
9.8
5.9
2.8
6.5
0.30
1.0
0.60
20
47
26 in-Ib
87 in-Ib
52 in-lb
S
L
1-14 GENERAL INFORMATION
Special Tools and Sealant
Spark Plug Wrench, Hex 21: 57001 -1 10
InSide Circlip Pliers: 57001 - 143
/
Piston Ring PliafS: 57001-11 5
Outside Circlip Pliers: 57001 -144
Fuel l evel Gauge, Ml B x 1 .0: 57001 -122
Bearing Puller: 57001 -158
Bearing Puller Adapter. 57001 -'36
Compression Gauge" 57001-221
Steering Stem Bearing Driver: 57001- 137
Flywheel Puller. 57001 -252
GENERAL INFORMATION 1 -15
Steering Stem Bearing Driver Adapter- 57001 -1074
Piston Pin Puller Assembly: 57001 · 910
"oo
Hand Tester: 57001 -983
Head Pipe Outer Race Press Shaft: 57001 -1 075
Oil Seal & Bearing Remover: 57001 - ' 058
Head Pipe Outer Race Driver: 57001 -1077
Rim Protector: 57001 -1063
Crankcase Splitting Tool Assembly: 57001 -1098
Bead Breaker Assemblv: 57001 -1072
Steering Stem Nut Wrench: 57001-1100
1-16 GENERAL INFORMATION
Hook Wrench: 57001 ~ 1101
Crankshaft J ig: 57001 - , , 74
Head Pipe Outer Race Driver: 57001 -1106
Fork. Outer Tube Weight: 57001 -1218
Head Pipe Outer Race Remover: 57001 -1107
front fork Oil Seal Driver: 57001 -1219
Bearing Driver Set: 57001 -'129
Jack: 57001 -1238
Compression Gauge Adapter, M14 x 1.25: 57001 ·1159
Fork Cylinder Holder. 57001 -1245
GENERAL INFORMATION 1-17
Bearing Remover Shaft: 57001 -1265
Bearing Remover Head, $20 x ¢In· 57001 -1293
Bearing Remover Head, 411 0 x $12: 57001 -1266
Fork Piston Rod Puller, Ml0 x , .0: 57001-1298
Bearing Remover Head, $15 x q>17" 57001-1267
Flywheel Holder: 57001 -1313
Fork Spring Holder. 57001 ·1286
Pressure Cable Luber: kS6019 -021
Fork Oil Level Gauge: 57001 -1290
Kawasaki Bond (Silicone Sealant): 56019-120
1 -18 GENERAL INFORMATION
Kawasaki Bond ( Liquid Gasket - Silver): 92104 -002
GENERAL INFORMATION 1 -19
Cable. Wire. and Hose Routing
1. Throttle Cable
2. Clutch Cable
3. Brake Hose: Be sure to run the hose
inside the headlight cover.
4. Run the throttle cable in front of
the fuel tap
5 . Clamps
6. Abou t 45·
7. Front Fork Upper Bracket
8. Trip Meter Cable
9. Abou t 30'
2
4
o
®
7
Run the throttle cable
outside the main harness.
Bend the clamp end.
2
/~ 5
8
1-20 GENERAL INFORMATION
Run the throttle cable outside the main harness.
Fasten the damp
and the left radiator.
1. Main Harness
2. Aun the main harness between
the downtuba and the right radiator.
3. Main Harness Position Mark
4. Ignition Coil
5. COl Unit
6. Regulator
7. Clamps
8. Run the main harness over the frame.
9. Bands
10. Thronle Cable
GENERAL INFORMATION 1 - 21
,.
2.
3.
4.
5.
6.
7.
8.
9.
Front Master Cylinder
Clamps
left Front Fork.
Front Brake Hose
Front Caliper
Rear Master Cylinder
Holders
Rear Brake Hose
Rear Caliper
, O. Carburetor
"
Front
0
Air Vent Hoses
12. Over Flow Hose
"
Front
Front
1 -22 GENERAL INFORMATION
Run the reserve lank hose
Inside the radiator hose.
Fro nt
p"",,",,~
Fro nt
Aun [7] as shown. --:>=~::::~
Fro nt
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11 .
Left Radiator
Ignition Coil
"
Engine Bracket
Spark Plug
Reserve Tank
Reserve Tank Hose
Reserve Tank Vent Hose
Right Radiator
Radiator Hose
Advancer Shaft Lever Cover
Engine Guard
Magneto Lead
Carburetor Holder
Air Cleaner Housing
Band ( M ain Harness and [ 16])
Crankcase Breather Hose
12.
13.
14.
15.
16.
17. Run the hose in front of
the cross pipe.
1 B. Carburetor
@
Front
¢
0"
FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded View .......................................................................................................... .. 2-2
Specifications ..............................................................................................................2-4
Throttle Grip and Cable ...............................................................................................2-5
Free Play Inspection ...............................................................................................2-5
Free Play Adjustment ..............................................................................................2-5
Installation ...............................................................................................................2-6
Cable Lubrication ............................................. ....................................................... 2 -6
Cable Inspection .....................................................................................................2-6
Carburetor ........................................................................................ ............................ 2-7
Idle Speed Inspection .............................................................................................2-7
Idle Speed Adjustment ...........................................................................................2-7
Service Fuel Level Inspection ................................................................................. 2-7
Service Fuel Level Adjustment ...............................................................................2-8
Removal ........................................................................................................... .... .2-9
Installation ............................................................................................................... 2-9
Fuel Inspection .....................................................................................................2-10
Disassembly ..........................................................................................................2-10
Assembly ............................................................................................................... 2-11
Carburetor Cleaning ..............................................................................................2-12
Carburetor Inspection ..........................
....................................................2- 12
Air Cleaner .................................................................................................................2 -14
Housing Removal .................................................................................................2-14
Housing Installation ..................................................................... ......................... 2-14
Element Removal ..................................................................................................2 -14
Element Installation ..............................................................................................2-14
Element Cleaning and Inspection ........................................................................ 2-14
Fuel Tank ...........................................................................
............................ 2- 16
Removal ............................................................................................................... 2-16
Installation .............................................................................................................2-16
Fuel Tap Removal .................................................................................................2-16
Fuel Tap Installation .............................................................................................2-16
Fuel Tap Inspection ..............................................................................................2·17
Fuel Tank and Tap Cleaning ................................................................................2-17
Reed Valve .............................................................................................................. .. 2-' 8
Removal ................... .... ......................................................................................... 2- 18
Installation .............................................................................................................2-18
Inspection .............................................................................................................2-18
2 -2 FU EL SYSTEM
Exploded View
CL
~
~
~
o
I
Ii
e
o
1
3.
4.
5.
Throttle Cable
Reed Valve
Choke Knob
Jet Needle
Pilot Air Screw
Main Jet
8..
Throttle Stop
2.
6.
7
J
Pilot et
Screw
A Ply grease.
G:
P
CL: Apply
ca ble lubricant.
87
Tl : 1.0 Nm (D.l0 k9~m 9 in.
in . lb)
lb)
T2: 9.8 Nm (1.0 kg . ,
I
FUEL SYSTEM 2-3
AO: Apply high-quality- Ioam -alr -filter oil.
G: Apply grease.
Tl : 0.8 Nm (0 .08 kg-m, 7 in - Ib)
-0
AO
2-4 FUEL SYSTEM
Specifications
Item
Standard
Throttle grip free play
Carburetor:
Make, type
2 - 3mm
KEIHIN , PWK35
Slowest smooth idle speed
Idle speed
1 % ± Y.
2 mm above the float bowl mating surface
16 ± 2 mm
Air screw (turns out)
o-
Service fuel level
Float height
Main jet
Main air jet
# 160
#200 (unremovable)
N426- 24COO
R11 74K 2AFKG
Needle jet
Jet needle mark
3rd groove from the top
Jet needle clip position
Pilot jet (slow jet)
Starter jet
Throttle valve cutaway
Air Cleaner Element Oil
Reed Valve
#48
#78
#5
High -quality -form -air fitter oil
0.2 mm (service limit)
Reed warp
Throttle Valve [A)
Jet Needle [8]
Needle Jet (C]
Slow Jet [ 0]
Pilot Air Jet [E]
Air Screw [F]
Special Tools -
Cutaway [G]
Float Valve (H]
Float Arm (I]
Main Jet [J]
Drain Plug (K]
Pressure cable Luber: K5601~21
Fuel Level Gauge, M18 x 1.0: 57001-122
c
o
FUEl SYSTEM 2 - 5
Throttle Grip and Cab le
If the throttle grip has excessive free play due to cable stretch or
misadjustment, there w ill be a delay in thronle response. Also, the
throttle valve may not open fully at full throttle. On the other hand, if the
throttle grip has no play, the thronle will be hard to control, and the idle
speed will be erratic. Check the thronle grip play periodically in accord ~
ance wit h the Periodic Maintenance Chart. and adjust the play if
necessary.
The throllie cable routing is shown in the Cable, Wire, and Hose
Aou ting section in the General Information chapter.
Free Play Inspection
• Check the throttle grip 'ree play (A] by lightly turning the throttle grip
back and forth.
* 11 t he free play is improper, adjust the throttle cable.
Throttle Grip Free Play
Standard:
2 - 3 mm
Free Play Adjustment
• l oosen t he locknut [A] .
• Turn the adjuster [8] until the proper amount of t hrottle g rip free play
is obtained .
• Tighten the locknut.
* If the t hrottle grip free play cannot be adjusted with the adjuster at the
upper end of the throttle cable, use the cable adjuster at the carburetor.
o Pull t he boot off the carburetor top. loosen t he locknut [A). After
making free play adjustment at the lower cable adjuster [B], tigh ten
t he locknut and install the boot.
.Turn the handlebar from side to side while id ling the engine. If the idle
speed varies, the thrOllle cable may be poorly routed or it may be
d amaged.
Operation with an Improperly adjusted, Incorrectly rouled,
cable could resuilin an unsafe riding condition.
2-6 FUEL SYSTEM
Installation
elnstall the thronle cable in accordance w ith the Cable, Wire and Hose
Routing section in the GenerallnformBtion chapter.
• Ahar installation, adjust the cable properly.
Operation with an Incorrectly routed or Improperly adjusted cable
could result in an unsafe riding condilion.
Cable Lubrication
Whenever the cable is removed, and in accordance with Ihe Periodic
Maintenance Chart (see General Information chapter) , do Ihe following .
• Applya thin coating of grease [AJ to the cable upper end .
• Lubricate the cable with a penetrating rust inhibitor.
OThe cable may be lubricated by using a pressure cable luber [AJ with
an aerosol cable lubricant [8] .
Special Tool - Preuure Cable Lubrer. K5601g..()12 [ 8]
Cable Inspection
.With the throttle cable disconnected al both ends, the cable should
move freely [A] within the cable housing.
If the cable movement is not tree after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.
*
FUEL SYSTEM 2-7
Carburetor
Since the carburetor regulates and mixes the fuel and air gOing to the
engine, there are two general types of carburetor trouble: too rich a
mixture (too much fuel), and too lean a mixture (too little fuel) . Such
trouble can be caused by dirt, wear, maladlustment, or Improper fuel level
In the floa t chamber. A dirty or damaged air cleaner can also alter t he fu el
to Sir ratiO.
Idle Speed Inspection
• Start the engine and warm It up thoroughly_
. Wlth the engine Idling, turn the handlebar to both Sides.
* If handlebar movement changes the idle speed, the throttle cable may
be Improperly adjusted or incorrectly routed, or it may be damaged.
Be sure to correct any of these condit ions before riding (see Cable,
Wire and Hose Routing secl lon In the General Information chapter) .
Operation with an
damaged cable could resun In an unsafe riding condition .
• Check the Idle speed
* AdJust it as needed
Idle Speed A djustment
. First turn in the air screw (A) until it seats lightly, and back it out 1 %
turns .
• Start the engine and warm it up thoroug hly.
• Turn the throttle stop screw [B] to obtain desired id le speed (the
slowest smooth idle speed) . If no idle is preferred, tum out t he screw
until the engine stops.
• Open and close the throttle a few times to make sure that the id le
speed is as desired. Read/ust if necessary.
Service Fuel Leve/ lnspection
~·.. WARNING
Gasoline is extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure the
area Is well venlllatecl and tree from any source of Ilame or sparts;
this Includes any appliance with 8 pilot light.
Tum the fuel tap to the OFF poSition.
Remove the fuel tank .
Remove the carburetor, Bnd hold it in true vertical posit ion on a stand.
Put the fuel tank on a bench, and connect the fuellBp to the carburetor
using a suitable hose.
• Remove the drain plug from the bottom of the float bowl, and screw
a fuel level gauge [A) into the plug hole.
.
•
•
•
Special Tool - Fuel Level Gauge, M18 x 1.0: 57001 ·122
• Hold t he gauge vertically against the side of the carburetor body so
thai the middle line [B) of the gauge is several millimeters higher than
the float bowl mating surface [C] .
• Turn t he fuel tap to the ON position to feed fuel to the carburetor.
• Walt until t he fuel level in t he gauge settles .
• Keeping t he gauge vertical, slowly lower the gauge until t he middle
line IS even wit h the float bowl mating surface.
B
2 -8 FUEL SYSTEM
NOTE
o Do
nor lower the middle line below the float bowl mating surface.
/{ the gauge is lowered and then raised again, the fuel level measure
shows somewhat higher than the actual fuel level. If the gauge is
lowered too far, dump the fuel out of it into a suitable container and
start the procedure over again .
• Read the fuel level ( 0] in the gauge and compare it to the specification.
Service Fuel level
o - 2 mm above the Iloat bowl mating surface
* If the fuel level is incorrect, adjust the floal height.
*If the fuel level is correct tum the fuel tap to the OFF position and
remove the fuel level gauge .
• Install the drain plug on the bonom of the float bow.
Service Fuel Level Adjustment
.i .WARNING
Gasoline 18 extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure the
area Is well venillated and free from any source of flame or aparta;
this Includes any appliance with a pilot light
• Remove t he carburetor, and drain the fuel into a suitable container.
• Remove t he float bowl.
eDrive out the pivot pin [AJ and remove the floats [BJ .
e Bend the tang (C] on t he float arm very slightly to change the float
height. Increasing the fJoat height towers the fuel level and decreasing
the float height raises the fuel level.
• Install the float
• Measure t he float height tilting the carburetor so that the tang on the
float just touches the needle rod in the float valve.
Float Height
Standard:
16
± 2 mm
Float Bowl Mating Surface [A]
Needle Rod [8]
Float [C]
Float Height [0]
Float Valve [E]
NOTE
o The needle rod must not come out during float height measurement.
• Assemble t he carburetor, and recheck the fuel level.
If t he fuel level cannot be adjusted by this method, t he float or the float
valve is d amaged.
*
FUEL SYSTEM 2-9
Removal
AWARNING
Gasoline Is extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure the
area Is well ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.
. Turn the fu el tap to the OFF position and pull the fuel hose off the tap.
e Loosen the clamps (A. B]. and remove the carburetor from the end of
the air cleaner ducl, and then puli it ou t of the carburetor holder.
• Dram the fuel from the float bowl by removing the drain plug. After
draining. Install the drain plug securely .
• Unscrew t he carburetor cap [ A], and pull Qut the throttle valve
assembly [ B] .
CAUTION
II the throttle valve Is not removed Irom the c able, wrap It In a clean
cloth to avoid damage.
. After removing the carburetor, push a clean, iint · free towel into the
carburetor holder and the air cieaner duct to keep dirt or ot her foreign
material fro m entering .
~
0
I
Ii
" dirt or dusl is allowed to pass through into the carburetor, the
throttle may become sluck, possibly causing an accident
CAUTION
" dirt gets through Inlo the engine, excessive engine wear and
possibly engine damage will occur.
Installation
.Be carefu l not to bend or otherwise dam age t he Jet needle. Check to
see that the throttle valve [A J goes all the way down into the
carburetor body, and slides sm oothly.
e•
I
~
~
~
~
.When installing th e carbu retor into the carburetor holder. align the
proj ection [AJ of th e carburetor w it h the g roove ( B] on the holder.
2-10 FUEL SYSTEM
.Route the air vent and overflow hoses properly (see Cable, Wi fe and
Hose Routing section in the General Information chapter) .
CAUTION
Always keep the hoses free from obstruction, and m ake sure they do
nol gel pinched by the chain or shock absorber.
e After installing the carburetor, do the following.
OTum the fuel tap to the ON position. and check on the fuel leakage
from the carburetor.
OAdjust the fol/owing items if necessary:
Throttle Cable
Idle Speed
Fuel Inspection
':"WARNING
Gasoline Is extremely flammable and can be explosive under certain
conditions. Always stop th e engine and do not smoke. Make sure the
area Is well ventilated and free from any source of flame or sparil:s;
this Includes any appliance with a pilot light.
. Turn the fuel tap to the OFF position .
• Place a suitable container beneath the carburetor.
• Remove t he drain plug [A] from the bottom of the float bowl and
check fo r water o r din in the fuel.
If any water or din comes out, clean the carburetor, fuel tap and fuel
tank (see Fuel Tank) .
• Install the drain plug on the Iloat bowl, and tighten it securely.
*
Disassembly
• Remove the carburetor .
• Unscrew the carburetor cap .
• Remove the throttle valve assembly (AJ , spring [B], and collar [C)
from the throttle cable lower end .
• Disassemble the throttle valve assembly; connector [A] , jet needle
with circlip [ B} and throttle valve [C).
FUEL SYSTEM 2-11
. Remove the choke knob (starter plunger assembly) [A] from the
carburetor
• Remove the following parts from the carburetor body.
Throttle Stop Screw and Spring [AJ
Air Screw and Spring [8]
Float Bowl (C]
Slow Jet (D)
Main Jet [E]
Pin [F]
Float [G]
Flost Valve Needle [H]
Assembly
. Clean the disassembly parts before assembling (see Carburetor
Cleaning) .
CAl/TlON
Do not overUghten the Jets.
They could be damaged requiring
replacement
• Replace the float bowl O-ring with a new one .
• Turn in the air screw {A] fully but not lightly, and then back it out the
specified turns.
Carburetor Cleaning
i~WARNING
Clean the carburetor In a well-venlflaled area, and take car. thaI
thar. Ie no apart or Ilame anywhere near the wol1tlng ar•• ; this
Include. any appliance with a pilot light Because of the danger of
highly Ilammable liquids, do not use gasoline or low lIash-polnl
I.OIIIent to clean the carburetor.
• Disassemble th e carburetor.
2-12 FUEL SYSTEM
CAUTION
Do not use compressed air on an assembled carburetor, or the lloal
may be deformed by the pressure.
Remove as many rubber or plasllc parts Irom the carburetor 8S
po•• lble before cleaning the carburetor with 8 cleaning 80lullon.
This will prevent damage or deterioration of the parts.
The carburetor body has plastic parts that can not be removed.
Do not use a strong carburetor cleaning solution which could attack
the plasUc parts; Instead, use a mild high flash-point cleaning
lIOiution safe for plastic parts.
Do not use wire or any other hard Instrument 10 clean carburetor
parts, especially lets, as they may be damaged.
• Immerse all the metal parts in a carburetor cleaning solulion _
.Rinse the parts in water.
eAlter the parts are cleaned, dry them with compressed air.
eBlow out the fuel passages with compressed air.
• Assemble the carburetor, and install it on the motorcycle.
Carburetor Inspection
nWARNING
Gasoline Is extremely flammable and can be explosive under certain
condlUons. Always alop the angina and do not smoka. Make aure the
ara. Is well·ventllated and fru from any source of Ilame or sparks;
thla Includes any appllanca with a pilot light
• Remove the carburetor.
• Before disassembling the carburetor, check the fuel level (see Fuel
Level Inspection).
the fuel level is incorrect. inspect the rest of the carburetor before
correcting it
• Pull the throttle cable and check that the throttle valve moves smoothly
and returns by spring force.
If the throttle valve does not move smoothly. replace the carburetor.
• Disassemble the carburetor (see Carburetor Disassembly in this
chapter) .
*If
*
• Clean the carburetor.
• Check the plastic tip [A] of the float valve needle for wear [ 8].
should be smooth without any grooves. scratches. or tears [C] .
If the plastic tip is damaged. replace the valve needle.
• Push the rod [0] in the valve needle.' then release it.
*If the rod does not spring out. replace the valve needle.
*
It
FUEL SYSTEM 2-13
. Check the slow let for any damage.
*[f the slow jet is damaged. replace it with a new one.
• Inspect the outside of the
Infante
valve for scratches and abnormal
wear.
* If il is badly scratched or worn, replace Ihe thronle valve.
• Inspect the insIde of the carburetor body for these same faults .
* If the inside of the body is badly scratched or worn, replace the entIre
carburetor.
• Check the jet needle for wear.
* A worn Jel needle should be replaced .
• Clean the fuel and air passages with a high flash · POint solvent and
compressed air.
2-14 FUEL SYSTEM
Air Cleaner
Housing Removal
. loosen the air deaner duct clamp.
• Remove:
S ide Covers
Seat
Air Cleaner Intake Cap
Rear Fender
Rear Flap
Rear Frame Pipe [Al
• Remove the air cleaner housing
Housing Installation
.Torque the fear frame pipe bolts.
Torque - Rear Frame Mounllng Pipe: 25 N-m (2.6 kg·m, 19.0 tt-Ib)
Non-permanent LociI:lng Agent - Air Cleaner Housing Bolls
Element Removal
eRemove:
Seat
Air Cleaner Intake Gap
• Remove the seat
• Remove the wing bolt [B] and take out the element assembly [A].
.Stuff a piece of clean, lint-free towel into the carburetor to keep any
dirt out of the carburetor.
• Wipe out the inside of the air cleaner housing with a clean damp towel.
Element Installation
.When installing the element assembly, coat the lip [Al of the element
with a thick layer of all purpose grease to assure a complete seal
against the air cleaner element base. Also, coat the base where the lip
of the element fits .
• Take out the towel from the carburetor securely.
Element Cleaning and Inspection
NOTE
Oln dusty areas, the e/emtmt should be cleaned more frequently than
recommtmded interval.
OAfter riding through rain or on muddy tracks, the element should be
cleaned immediately.
Olf there is a break in the element material or any other damage to the
element. replace the element with a new one.
FUEL SYSTEM 2-15
AWARNING
Clean the element In a well-ventilated area, and take care thai there
are no sparks or flame anywhere near the working areai this Includes
any appliance with a pitot light.
Because 01 the danger of highly flammable liquids, do nol use
gasoline or a low flash-point solvent to clean Ihe element.
• Remove the air cleaner element assembly, and separate the element
[AJ from the holder (8 ).
.Clean the element in a bath of high flash -point solvent using a soft
bristle brush. Squeeze it dry in a clean towel. Do not wring the
element or blow it dry; the element can be damaged .
• Check ali the parts of the element for visible damage.
*[f any part of the element is damaged, replace it.
.After cleaning, saturate the element with a high-quality-foam-air-filter
oil, squeeze out the excess, then wrap it in a clean rag and squeeze it
as dry as possible. Be careful not to tear the sponge filter .
• Assemble the element.
• Install the element assembly.
2· 16 FUEL SYSTEM
Fuel Tank
Remo val
~.WARNING
Gasoline Is extremely Itammable and can be explosive under certain
conditions. Always stop the engine and do nol smoke. M ake sure the
area Is well ventilated and free from any source 01 flam a or sparks;
this Include! any appliance with . pilot light.
• Remove:
Side CovetS
Seat
Shrouds
. Tum the fuel tap to the OFF position.
•
•
•
•
•
Pull the fuel hose off the fuel tap .
Remove the fuel tank mounting bolts [AJ .
Take off the band [B] .
Remove the fuel tank.
Drain t he fuel tank.
Installation
. Check the rubber dampers [AJ on the frame and fuel tank.
* If the dampers are damaged or deteriorated, replace them.
• Be sure the fuel hose is clamped 10 the fuel tap to prevent leaks.
Fuel Tap Removal
• Remove the fuel tank and drain it (see Fuel Tank Removal) .
• Remove the mounting bolts (AJ and take out the fuel tap [B).
Fuel Tap Insta/latJ"on
. Se sure the O-ring is in good condition to prevent leaks.
• Be sure to clamp the fuel hose to the tap to prevent leaks.
FUEL SYSTEM 2 -17
Fuel Tap Inspection
• Remove the fuel tap .
• Check the fuel tap filter screens [A] for any breaks or deterioration.
*If the fuel tap screens have any break or deterioration, they may allow
dirt to rBach the carburetor, causing poor running. Replace the fuel
tap.
* 1' the fuel tap leaks, or allows fuel to flow when it is at the OFF
position. replace the damaged O-rings [B] .
Fuel Tank and Tap Cleaning
AWARNING
Clean the tank In a well-ventilated area, and take care th at there Is
no spart s or Ilame anywhere near the wortd ng area. Because of the
danger of highly flammable liquids, do not use gasoline or low
Ilash-point solvent to ciean the lank.
• Remove the fuel tank and drain it.
. Pour some high flash-point solvent into the fuel tank and shake the
tank to remove dirt and fuel deposits.
• Pour the solvent out of t he tank.
• Remove the fuel tap from the tank by taking out the bolts .
• Clean the fuel tap fil ter screen in a high flash-point solvent .
• Pour a high flash -point solvent through the tap in all lever positions.
• Dry the tank and tap wi th compressed air.
• Install t he tap in the tank .
• Install the fuel tank.
2 -18 FUEl SYSTEM
Reed Valve
Removal
• Remove the carburetor.
• Remove the holder bolts, and take off the carburetor holder.
• Take t he reed valve [A] oul of the cvlinder [8].
Installation
• Face the tab [A] of t he reed valve to the lel1.
e Torqu e t he carburetor holder bolts [A).
Torque - Carburetor Holder Bolta: 9.8 N·m (1 .0 kg-m, 87 In-Ib)
Inspection
. Inspect the reeds (A] for cracks, folds. or other visible damage.
* If there is any doubt as to the condit ion of a reed, replace the reed with
a new one.
* If a reed becomes wavy, replace the reed with a new one even if its
warp is less than the selVice limit
. Measure the clearance between the reed and holder [B] , and check
the reed warp as shown.
*11 anyone of the clearance measurements exceeds the service limit,
replace the reed part with 8 new one.
Reed Warp
Service LImit
0.2 mm
COOLING SYSTEM 3-1
Cooling System
Table of Contents
Exploded View ................ ..................................................... ............. .. .. ...................... 3 -2
Specifications .................. .. ............................................................................. ....... ......3-3
Coolant ....................................................................................................................... .3-4
Coolant Level Inspection ........................................................................................3 -4
Coolant Deterioration Inspection: ...................................................................... .... 3-4
Coolant Change ...................................................................................................... 3 -5
Coolant Draining: ........................................................................................ .......3-5
Coolant Filling: ...................................................................................................3-5
Cooling System Pressure Testing ...........................................................................3-7
Cooling System Flushing .......................................................................................3-8
Water Pump .................................................................................................................3 -9
Cover Removal ........................................................................................................ 3-9
Cover Installation .............. ............................................................................ .. ..... ... 3- 9
Impeller Removal .................................................................................................... 3-9
Impeller Installation ................... ..................... ....................................... ......... ....... ..3-9
Impeller Inspection .................................................................................................3-9
Shaft Removal ................ ........................ ................................................. .............. 3- 10
Shaft Installat ion ............. ........... .......... .. .......................... .... .. ............................ ... 3 -' 0
Water Pump Inspection ....................................................... .......... .. .................... 3- 10
Mechanical Seal Replacement ...................................... ... ...... .. ........... .. ............... 3 - 10
Mechanica l Seal Inspection ... .......... .. .. ............. ...... .. ....... ....................................3- 11
Radiator .......................... .............................................................. .... .. .......... ............. 3- 12
Removal ................................................................................................................ 3- ' 2
Installation ................................................................................................... ..........3- 12
Inspection ............................................................................................................. 3-12
Cap Inspection ........ ................................................. ................................ ........... ..3- 13
Filler Neck Inspection ............................................................................... ....... .... .3- 13
Cooling Hoses, Breather Hose Installation ..........................................................3-14
CQoling Hoses, Breather Hose Inspection ........................................................... 3- 14
3-2
Ex I CO OLiNG SYSTEM
poded View
1.
2.
3.
4.
~
Reserve Tank
oM,echaniCa! Seal
II Seal
Ball Bearing
Air Breeder Boll
Apply a non
M : Apply mol -permanent locki
T1 : 9.8 N -m (Vbdenum disulfide n9 agent.
T2' 22 N
1.0 kg -m 87 .
grease.
T .
-m ( 22 k
•
In- Ib)
9
/ : 1.5 N-m (O.15 ;m. 16.0h -lb)
4. 8.8 N -m (0.90 g -m, 13 tn- tb)
kg - rn, 78 tn - tb)
COOLING SYSTEM 3-3
Specifications
Item
Standard
Coolant provided when shipping:
Type
Permanent type of antifreeze
(soh water and ethylene glycol plus corrosion and
Color
Mixed ratio
rust inhibitor chemicals for aluminum engines
and radiators)
Green
Soft water 50%, Coolant 50%
Total amount ·
- 35"C ( - 31 "F)
1.1 L (reserve tank full level including radiator and engine)
Cap relief pressure
93 - 123 kPa
Freezing point
Radiator:
(0.95 - 1.25 kg/em', 14 - 18 psi)
Special Too/ - Bearing Driver Set 57001-1129
Bearing Remover Shaft: 57001·1265
Bearing Remover Head, ((:110 x ¢ll2: 57001-1266
3-4 COOLING SYSTEM
Coolant
Check the coolant level each day before riding the motorcycle, and
replenish coolant if the level is low. Change the coolant in accordance
with the Periodic Maintenance Chart (see the General Information
chapter).
~·.. WARNING
To avoid burna, do not remoye the radiator cap or try to Inspect the
coolant level or change the coolant when the engine Is stili hot. Wall
until II cool. down.
Coolant Leve/lnspection
NOTE
o Check the/evel when the engine is cold (room 01 ambient temperature) .
• Check the coolant level in the reserve tank fAJ with the motorcycle
held perpendicularly.
*If the coolant level is lower than the LOW mark [el, remove the cap
[0] and add coolant to the FULL mark (8).
CAUTlON
For refililng, add the specified mlxtur. of coolant and soft water.
Adding water alone dilutes the coolant and degradea I.. anlk:orroaion properties_
The diluted coolant can attack the aluminum engine parts. In an
emergency,
waler can be added. But the diluled coolant must
be returned to the correct mixture rallo within a few daYI.
It coolant mUlt be added often or the reserve lank hal run comp~lely
dry; ther. II probably leakage In the cooling ayltem. Check the
Iyatem for leakl.
.on
Recommended Coolant
Permanent type of anlltreeze (aoft water and ethylene glycol plus
corrosion and rust Inhibitor chemicals lor aluminum engines and
radiators)
Coolant mixture ratio when shipping:
Soft waler
Coolant
Freeglng point - 35·C (-31"f)
Coolant lotal amount 1.1L
SO"'.,
30.,..
Coolant Deterioration Inspection:
.Visually inspect the old coolant in the reserve tank.
*If whitish couon-like wafts are obseNed, aluminum parts in the
*
cooling system are corroded. If the coolant is brown, iron or steel parts
are rusting. In either case, flush the cooling system.
If the coolant gives off an abnormal smell, check for a cooling system
leak. It may be caused by exhaust gas leaking into the cooling system.
COOLING SYSTEM 3-5
Coolant Change
The coolant should be changed periodically to ensure long engine life.
Coolant Draining:
AWAANING
Coolant on Ilres will make them slippery and can cause an accident
and Injury. Immediately wash away any coolant that spills on the
Irame, engine or other painted parts. Since coolant Is harmful to th e
human body, do nol use for drinking .
• Remove the right shroud .
• Remove the radiator cap [AJ.
NOTE
ORemove the radiator cap in (wo steps. First turn the cap counterclockwise to the first slop and wait (here for a few seconds. Then
push down and tum it further in the same direction and remove the
cap .
• Place a container under t he coolant drain plug and drain t he coolant
from the rad iator and engine by removing the drain plug on t he right
engine cover. Immediately w ash out any coolant that spills on t he
frame, t he engine, or the wheel.
Water Pump Cover (AJ '
Drain Plug [BJ
• Unscrew the bolts [AJ and remove t he reserve tank [8] wit h hoses left
installed .
• Unscrew the cap [C] and po ur the coolan t into a container.
• Inspect the old coolant for visual evidence of corrosion and abnormal
sm ell (see Coolant Deterioration) .
• Install th e reserve tank.
Non·permanent Lod:lng Agent - Reserve Tank Bolts
Coolant Filling:
CAUTION
Use coolant containing corrosion Inhibitors made specifically for
aluminum engines and radiators In accordance with the Instruction
of the manufacturer's. Soft or distilled water must be used with the
antifreeze (see below lor antifreeze) In the cooling system. If hard
water Is used In the system, It causes scale accumulation in the water
passages, and considerably reduces the efficiency of the cooling
system.
3-6 COOLING SYSTEM
Recommended Coolant
Permanent type of antifreeze (80ft water and ethylene glycol plus
corrosion and rust inhibitor chemicals lor aluminum engines and
radiators)
Coolant Mixture rallo when shipping:
Soft water 50%, coolant 50-;.
Freezing point: - 35·C ( - 31 "F)
Coolant lotal amount 1.1 L
NOTE
OChoose
8
suitable mixture ratio by ,e/effing to the coo/ant
m8nufacturels directions .
• Replace the gasket with 8 new one.
e lnstall the d rain plug.
Torque - Coolant Drain Plug: 22 N-m (2.2 kg-m, 16.0 tt.lb)
eFill the rad iator up to the bottom of the rad iator filler neck [A] wi th
coolant.
NOTE
O Pour in the coo/ant slowly so that the air in the engine and (adiator
can Bscape.
• Check the cooling system for leaks .
• Sleed the air from the cooling system as follows.
O Loosen the air bleeder bolt [A) on the cylinder head until the coolant
begins to flow out the air bleeder bolt hole (that is, until all the
remaining air has been forced out) .
o Tighten the air bleeder bolt.
Torque - Air Bleeder Bolt 9.8 N.m 11 .0 kg.m, 87 In-Ib)
COOLING SYSTEM 3 -7
o Stan the engine with the radiator cap removed and run it until no more
air bubbles [AJ can be seen in the coolanl.
O lap Ihe radiator hoses to force any air bubbles caught inside
OStop the engine and add coolant up 10 the radiator filler neck .
• Install the radiator cap .
• Fill the reserve lank up to the FULL mark with coolant and install the
"P
CAUTlON
00 not add more coolant above the FULL mark .
• Install the right shroud.
Cooling System Pressure Testing
CAUTlON
During pressure tesllng, do not exceed the pressure for which the
system Is designed to work. The maximum pressure Is 123 kPa (1.25
kg/em', 18 psi).
• Remove the right shroud .
• Remove the radiator cap, and install a cooling system pressure tester
[AJ and adapter [8] on the radiator filler neck.
NOTE
o Wet
the adapter cap sealing surfaces with water or coolant to
prevent pressure leaks.
• Build up pressure in the system carefully until the pressure reaches 123
kPa (1.25 kg/em', 18 psi) .
• Watch t he gauge for at least 6 seconds.
If the pressure holds steady, the cooling system is all right .
*
• Remove the pressure tester, replenish the coolant, and install the
radiator cap and the right shroud.
* If the pressure drops and no external source is found, check for internal
leaks. Droplets in the transmission oil indicate internal leakage. Check
the water pump mechanical seal and oil seal. If a droplet is found in
the spark plug. check the cylinder head gasket for leaks.
• Install the right shroud.
A
3-8 COOLING SYSTEM
Cooling System Flushing
Over a period of time, the cooling system accumulates rust, scale, and
lime in the water Jacket and radialor. When this accumulation is
suspected or observed, flush the cooling system. If thIs accumulation IS
nOI removed, it will clog up the water passages and considerably reduce
the efficiency of the cooling system.
• Drain the cooling system .
• Fill the cooling system with fresh water mixed with a flushing
compound.
CAUTlON
Avoid the use of a flushing compound which Is harmful to the
aluminum engine and radiator. Carefully follow the Instructions
supplied by the manufacturer 01 the cleaning product
.Warm up the engine, and run It at normal operating temperature for
about ten minUies.
e SloP the engine, and drain the cooling system aher the coolant cools
down.
eFili the system with fresh water.
• Warm up the engine and drain the system after t he coolant cools
down.
• Repeat the previous two steps once more.
• Fill the system with a permanent type coolant, and bleed the air from
the system.
COOLING SYSTEM 3 - 9
W ater Pump
Cover Removal
. Drain the coolant (see Coolant Draining) .
• Loosen the cooling hose clamps, and disconnect the cooling hoses
on the water pump cover.
• Remove the cover bolts [B], and remove the water pump cover [AJ.
Cover Installation
• Replace the pump cover gasket with a new one.
• Torque the water pump cover bolts.
Torque - Water Pump Cover Bolts: 9,8 N-m (1.0 kg -rn, 81 In-Ib)
. Fill the cooling system (see Coolant Filling).
• Bleed the air from the cooling system.
Impeller Removal
. Drain the coolant (see Coolant Draining).
• Remove the water pump cover with the cooling hoses attached .
• Remove the impeller nut [B], and take out the impeller [A] and O-ring.
Impeller Installation
. Install the new O-ring [B] in the impeller [AJ,
. Torque the impeller nut.
Torque - Impeller Nut 9.8 N-m (1 .0 kg-m t 87 in-Ib)
Impeller Inspection
. Visually check the impeller [AJ.
* If the surface is corroded, or if the blades [BJ are damaged, replace the
impeller.
3-10 COOLING SYSTEM
Shaft Removal
• Remove:
Impeller
Right Engine Cover (see Clutch chapter)
. Pull out the water pump shaft [A) from the inSide of the right engine
cever.
Shaft Installation
eTo prevent the oil seal lips from peeling, apply molybdenum disulfide
grease to the water pump shaft and insert it into the oil seal from the
inside of the right engine cover.
CAIlllON
Be sure to apply molybdenum disulfide grease to the water pump
shaft when installing. "II is Installed dry, the seal may wear
excessively.
Water Pump Inspection
Any lime the system slowly loses water, inspect for leaks .
• Check the drainage outlet passage [A) at the bottom of the water
pump body for coolant leakage.
* If the mechanical seal is damaged, the coolant leaks through the seal,
*
and drains through the passages. Replace the mechanical seal, ball
bearing and oil seal (see Mechanical Seal Replacement) .
If there are no apparent leaks, pressure test the system.
Mechanical Seal Replacement
• Remove:
Water Pump Impeller (see Impeller Removal)
Right Engine Cover (see Clutch chapter)
• Pull out the water pump shaft from the inside of the right engine cover.
• Take the bearing [A] out of the right engine cover, using bearing
remover.
8
A
Special Tool - 8earlng Remover Shaft: 57001 ·1265 [ 8]
8earlng Remover Head, Q)10 x Q)12: 57001·1266 [e )
• Press out the mechanical seal [A] and oil seat [8] from the inside of
the right engine cover w ith the bearing driver set [C).
Special Tool - 8earlng Driver Set: 57001·1129
o Use the bearing driver which has a smaller diameter than the oil seal.
A
COOLING SYSTEM 3-11
o Be sure to replace the mechanical seal, oil seal, and ball bearing with
new parts becuase these parts will be damaged by removal.
. Apply plenty 01 high temperature grease to the oil seal lips .
• Apply oil to the outer circumference of the oil seal.
• Press the oil seal [A] into the hole from the inside of the right engine
cover with the bearing driver set so that the spring side of the seal lips
is toward the inside of Ihe cover.
Special Tool - Bearing Driver Set: 57001-1129
• Press the oil seal in until the seal end is even with the step [B) of the
hole as shown.
o Use the bearing driver which has a larger diameter than the oil seal.
CAlJTJON
Do not block the coolanl drainage outlet passage wIth the 011 seal by
pressing illoo tar inlo the cover .
• Press in the ball bearing [C] with the seal side facing the oil seal until
it bottoms out.
• Press the mechanical seal [A] into the hole With the bearing driver set
( B] until its flange touches the step [C].
A
B
CAlJTJON
Never tap on the mechanical seal, use a press only.
8e careful not to damage the sealing surface of the mechanical seal.
o
• Instal! the water pump shaft from the inside of the right engine cover.
c
.Clea~
the sliding surface of a new mechanical seal with a high-flash
point solvent, and apply a little coolant to the sliding surface to give
the mechanical seal initial lubrication .
• Apply coolant [C] to the surface of the rubber seal and sealing seat
(A], and press the rubber seal [6] and seating seat into the impeller
by hand until the seat bottoms out.
Mechanical Seal Inspection
.Visually inspect the mechanical seal.
*If anyone of the parts is damaged, replace the mechanical seal as a
unit.
Impeller Sealing Seat Surface [AJ
Rubber Seal [8]
Mechanical Seal Diaphragm [e]
3 -12 COOLING SYSTEM
Radiator
Removal
• Remove:
Shrouds
Louver
Fuel Tank
• Drain the coolant (see Coolan t Change) .
• loosen the hose clamps, and pull off the cooling and breather hoses .
• Remove the mounting bolts [Al , and take out the radiator ( 8 ).
Installation
. Route the cooling and breather hoses according to the Cable, Wire,
and Hose Roul ing section in the General Information chapter.
Torque - Cooling Hose Clamp Screws: 1.5 N·m (0.15 kg-m, 13 in·lb)
O Position the hose clamp screws [Al downward between the radiators
to prevent the screws from touching t he fuel tank.
O The clamp screw [Alan t he hose between the cylinder head and the
left rad iator must face forward to prevent the screw from touching the
fuel tank.
A
Fron t
Inspection
. Check the radiator core.
*1 1 there are obstructions to air flow, remove them.
* If the corru gated (Al fi ns ate deformed, carefully straighten them w ith
t he thin blade of a screwdriver.
CAUTlON
Do not tear the radiator tubes while straightening the fins.
*If the air passages of the rad iator core are blocked more than 20% by
unremovable o bstru ctions or irreparably deformed fins, replace the
rad iator with a new one.
CAIJTION
When cleaning the radiator with steam cle aner, be careful of the
following to avoid damage to the fins.
Keep the steam gun over 0.5 m (20 In.) away from the radiator .
Blow steam perpendicularly to the radi ator core.
Never blow steam at an angle against the fins but straight through
them In the direction of natural air flow.
Never shake the steam gun at a right angle against the fins, be sure
to move" at a level with the fins.
< angle >
< perpendicula r >
good
ove r 0. 5 m
COOLING SYSTEM 3 -1 3
Cap Inspection
. Check the condition 01 the valve spring [A], and the top valve seal
c
[8] and bottom valve seal [C] of the radiator cap_
* If anyone of them shows visible damage. replace Ihe cap.
A
e Wel the top and bottom valve seals with water or coolant to prevent
pressure leaks.
• Install the cap [AJ on a cooling system pressure tester [8].
e Watching the pressure gauge, slowly pump Ihe pressure tes ter to build
up the pessure.
The gauge pointer must remain within the relief
pressure range in the table below at least 6 seconds. Continue 10
pump the tester until the relief valve opens, indicated by the gauge
pointer flicks downward. The relief valve must open Within the
specified range.
Radiator Cap Relief Prnsure
Standard:
93 - 123 kPa (0.95 _ 1.25
6 seconds
k g/cm ~,
14 - 18 psi) lor
* If the cap cannnot hold the specified pressure, or if it holds too much
pressure, replace it with a new one.
Fl1Ier Neck Inspection
. Check the radiator filler neck for signs of damage.
• Check the condition of the top and bonom sealing seats [A] in the
filler neck. They must be smooth and clean for the radiator cap to
function properly.
3 -14 COOLING SYSTEM
Cooling Hoses, Breather Hose Installation
. Install the cooling hoses [AJ , breather hose [8] and
being careful to follow bending directions.
kinking, flattening, or twisting .
• Tighten the hose clamps securely.
alf
vent hose
[el
Avoid sharp bending.
Torque - Cooling Hose Clamp Screws: 1.5 N·m (O.15 kg-m, 13In.lb)
Cooling Hoses, Breather Hose Inspection
.In accordance with the Periodic Maintenance Chart, visually inspect
the hoses for signs of deterioration. Squeeze the hose. A hose should
not be hard and brittle, nor should it be soft or swollen .
• Replace any damaged hose.
I
ENGINE TOP END 4 -1
Engine Top End
Table of Contents
Exploded View ....................................... .................................................................4-2
Specifications ,...........................................................................................................4-4
Cylinder Head ....................................................... ,.................................................. .4-5
Cylinder Compression Measurement .................................................................. ..4-5
Removal ..................................................................................................................4-5
Installation ... ................
................................................................................4-6
Warp Inspection ..................................................................
............................ 4-6
Cylinder, Piston .......................................................................................................4-7
Cylinder Removal... ............. ............ .... .............. .......
.. .......................4-7
Cylinder Installation ................................................................................................4-7
Piston Removal ....................................................................................................4-8
Piston Installation ......................................................... ,......................................... 4-8
Cyl inder Wear Inspection .......................................................................................4 -9
Piston Diameter Measu rement ............................................................................ ,4 -' a
Piston/Cylinder Clearance ....................................................................................4-10
Piston Ring, Piston Ring Groove Inspection ...................................................... .4-, a
Piston Ring End Gap Inspection ..........................................................................4- 11
Exhaust Valve ( KIPS) ...............................................................................................4 - 12
Removal......
................
............. , ......................................... 4-12
Installation....
.................................
........................................................4-12
Muffler ( Expansion Chamber, Silencer) ..................................................................4- 14
Spark Arrester Cleaning ........................................................................................4 -14
Removal ................ ..............................................................................................4-14
Installation ....................... ,............................... ,................................. ...................4- 15
•
~
ENGIN E TOP END 4 -3
L
CA: Cross lighten.
G: Apply grease.
l: Apply a non-permanent locking agent.
l h: l eft-hand Threads
M:
EO:
1.
2.
3.
4.
Apply molybdenum disulfid e grease.
Apply 2-stroke engine oil.
Main Shaft
Main Valve (Slide Valve)
Main Valve (Flap Valve)
Main Valve Holder
5.
Main Valve Lever
6.
7.
8.
Valve Lockbolt
HRN marked side faces upwards.
Arrow points to t he front.
9.
Advancer Shaft lever
T1 :
T2:
T3:
T4:
T5:
T6:
T7:
T8:
T9:
9.B N-m (1.0 kg -m. 87 in-Ib)
27 N-m (2.8 kg-m, 20 ft-Ib)
25 N-m (2.5kg-m, lB.Oft-lb)
5.9 N-m (0.60 kg-m. 52 in-Ib)
8.8 N-m (0.90 kg-m, 78 in -Ib)
8.3 N-m (0.85 kg-m, 74 in -Ib)
3.9 N-m (0.40 kg-rn, 35 in-/b)
18 N-m (l .Bkg-m, 13.0ft- lb)
7.8 N-m (o.ao kg-m. 69 in-Ib)
4-4 ENGINE TOP END
Specifications
Ite m
Service limit
Standard
Cylinder Head :
Cylinder com pression
---
(usable range)
655 - 1 040 kPa
(6.7 - 10.6 kg/ em ', 95 _ 151 psi )
---
Cylinder head warp
Cy linder . Piston :
Cylinder inside diameter
Piston diameter
Pisto n/ cyli nder clearance
Piston ring / groove clearance:
Top
Second
0.05 mm
66.026 - 66.04 1
mm
." '.
65.942 _ 65.957 mm
0 .079 - 0 .089 mm
- -- (keystone)
0.025 _ 0.065 mm
,,-
0
"
66 ,1 mm
'.J"I65.80 mm
.9 - - d
--0. 16 mm
Piston ring groove width:
Top
Second
--- (keystone)
1.215 - 1.235mm
--1.31 mm
Piston ring thickness:
Top
1.17 - 1.19mm
Second
1.17 - 1.19mm
Top
Second
0 .15 - 0.35 mm
0.15 - 0.35 mm
1 .1
1 .1
mm
mm
Piston ring end gap:
KIPS Valve
KIPS valve opening
about 6 000
rIm (rpm)
engine speed
Special Tools -
Piston Ring Pliers: 57001 -115
Compression Gauge: 57001 -221
Piston Pin Puller Assembly: 57001 -910
Compression Gauge Adapter I M14 x 1.25: 57001 -1159
O.65 mm
0.65 mm
---
ENGINE TOP END 4-5
Cylinder Head
Cylinder Compression Measurement
eStart the engine.
• Thoroughly warm up the engine so that the engine oil between the
piston and cylinder wall Will help seal compression as it does during
normal rUnning .
• Stop the engine.
eTurn the fuel tap lever to the OFF position .
• Remove:
Seat
Shrouds
• Move back the fuel lank with the hose installed.
e Remove the spark plug, and screw a compression gauge firmly into the
spark plug hole.
Special Tools -
Compression Gauge: 5700'-221 [A j
Compression Gauge Adapter, M14 x 1.25:
57001·1159 [ Bj
.With the throttle fully open, turn the engine over sharply with the
klckstarter several times until the compression gauge stops rising; the
compression is the highest reading obtainable.
Cylinder Compression
Usable Range: 655 _ 1040 kPa (6.7 _ 10.6 kg/em ' , 95 _ 151 psi)
*11 cylinder compression is higher than the usable range, check the
following:
Carbon build-up on the piston head and cylinder head - clean off
any carbon on the piston head and cylinder head.
Cylinder head gasket, cylinder base gasket - use only the proper
gaskets for the cylinder head and base. The use of gasket of the
incorrect thickness wllf change the compression.
*11 cylinder compression is lower than the usable range, check the
following:
Piston/ cylinder clearance, piston seizure.
Gas leakage around the cylinder head - replace the damaged
gasket and check the cylinder head for warping.
Piston ring, piston ring groove.
Gas leakage from the crank chamber - check the crankshaft oil
seals
Removal
.Orain the coolant (see Coolant Change in the Cooling System
Chapter) .
• Remove:
Side Covers
Seat
Shrouds
Fuel Tank
Radiators
Cooling Hose
Spark Plug [Aj
Engine Mounting Brackets [B]
.Remove the cylinder head nuts [Cj , and take off the cylinder head
[D] and gasket.
4-6 ENGINE TOP END
Installation
• Replace the head gasket with a new one.
eScrape out any carbon and clean the head with a high flash - point
solvent.
• Check a crust of minerals and rust in th e head water Jackel. and remove
them if necessary.
eTighten the cylinder head nuts in a criss-cross pattern.
Torque - Cylinder Head Nuts: 25 N·m (2.5 kg·m, 18 ft·lb)
O The clamp screw [A] on the hose between the cylinder head and the
left radiator must face forward to prevent the screw from louching the
fuel tank.
Torque - Cooling Hose Clamp Screw: 1.5 N-m (0.15 kg-m, 13 In-lb)
e Totque the engine mounting bracket bolts.
Torque - Engine Mounting Nuts ($10 mm): 44 Nom (4.5 kg.m. 33 tt-Ibl
Engine Mounting Bracket Botts (418 mm):
29 N-m (3.0 kg-m, 22 tt-Ib)
.Tighten the spark plug.
Torque - Spa"" Plug: 27 N-m (2.8 kg-m, 20 ft-fb)
Warp Inspection
. laya straightedge [A] across th e lower surface of t he head at several
different points. and measure warp by inserting a thickness gauge [8]
between the stra ightedge and the head.
II warp exceeds the service limit, repair the mating surface. Replace the
cylinder head if the mating surface is badly damaged .
*
Cylinder Head Warp
Servk:e Limit
0.05 mm
ENGINE TOP END 4-7
Cylinder. Piston
Cylinder Removal
. Remove:
Expansion Chamber
Carburetor
Cylinder Head
Cooling Hose
• Remove the advancer shaft lever cover [Al on the cylinder.
• Remove the shaft lever nut [Al and take off the shah lever [8).
CAUTION
The shaft lever nul has left·hand threads. Turn the nul clockwise lor
loosening .
• Free the magneto leads from the clamp on the cylinder.
• Remove the cylinder nuts .
• lift off the cylinder [Al, and remove the cylinder base gasket. If
necessary, tap lightly around the base of the cylinder wi th a plastic
mallet [8], taking care not to damage the cy linder.
Cylinder Installation
• Scrape any carbon out of the exhaust ports.
• Check lor a crust of minerals and rust in the cylinder water jacket, and
remove them as needed.
• Replace the cylinder base gasket with a new one.
*11 a new piston and or new cylinder are instaned. apply a thin coat of
molybdenum disulfide grease on the new piston and cylinder bore.
• Apply 2-stroke engine oil to the piston surface, piston rings and
cylinder bore.
• Check to see that the pin in each piston ring g roove is between the
ends of the piston ring. and fit the base of the cylinder over each ring,
pressing in on opposite sides of the ring as necessary. Be certain that
the rings do not slip out of position .
• Torque the cylinder nuts in a criss-cross panern.
Torque - Cylinder Nuts: 25 N-m (2.5 kg-m, 18 fl-Ib)
4-8 ENGINE TOP END
.Apply grease 10 the teeth of the main shaft pinion [Al and Ihe face
gear [Bl
.Install the advancer shaft lever [C] , fitting the pin [ D] into the lever.
• Check that the small hole of Ihe lever aligns (El with the notched tooth
of the main shaft pinion .
• Tighten the advancer shaft lever nut (left -hand threads) [F ].
Torque - Advancer Shaft Lever Nut (Lett-hand Threads): 8.3 N-m (0.85
kg-m, 74 In-Ib)
Piston Removal
• Remove the cylinder.
• Stuff a dean cloth into the crankcase opening around the connecting
rod so that no parts will fall into the crankcase.
• Remove one of the piston pin snap rings with needle nose pliers.
eRemove the piston bV pushing the piston pin out the side from which
the snap ring was removed.
Special Tool - Piston Pin Puller Assembly: 57001·910 [A]
Adapter [B)
• Remove the piston rings.
Special Tool - Piston Ring Pliers: 57001·115
* If the special tool is not available, carefully spread [A] the ring opening
with your thumbs and then push up [8] on the opposite side of the
ring to remove it.
Piston Installation
.Stuff a clean cloth into the crankcase opening around the connecting
rod so that no parts will fali into the crankcase .
• Scrape off any carbon of the piston, then lightly polish the piston with
fine emery cloth.
• Clean carbon and dirt out of the piston ring groove using a suitable
tool.
CAUTlON
carbon particles can be very abrasive to piston rings. Oon't allow
such particles to lall onto the cyllndar walls .
w
• Install the piston rings so that the ...
marked side faces upward .
• If installing the piston ring by hand, first fit one end [A] of the piston
ring against the pin in the ring groove, spread [8] the ring opening
with the other thumb and then slip [C] the ring into the groove.
ENGINE TOP ENO 4-9
• Install the ring so that the pin [A) in the piston ring groove is between
Ihe ends of Ihe piston ring.
A
. Apply 2-stroke engine oil to the connecting rod needle bearing and the
piston pin .
• Install the piston so that the arrow [A] on the top of the piston points
toward the front.
. When installing the piston pin snap ring (8], compress it only enough
to install it and no more.
A
•
CAUTION
Do not reuse snap rings, as removal weakens and deforms them.
They could fall out and score the cylinder wall .
• Fit a new piston pin snap ring into the side of the piston so that the
ring opening [A] does not coincide with the notch [8] in the edge of
the piston pin hole.
•
Cvlinder Wear Inspection
NOTE
o Measure (he cylinder inside diameter when the cylinder is cold
(room or ambient temperature) .
• Inspect the inside of the cylinder for scratches and abnormal wear.
* If the cylinder is damaged or badly worn, replace it with a new one.
• Since there is a difference in cylinder wear in different directions, take
a side-Io-side and a front-to -back measurement shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service
limit, the cylinder must be replaced with a new one since the
ELECTRO FUSION cylinder cannot be bored or honed.
*
Cylinder Inside Diameter
Standard:
66.026 ,... 66.041 mm, and less than
0.01 mm difference between any
two measuremenls.
Service Limit
66.1 mm, or more than 0.05 mm
difference between any two
measurements.
16mm [A]
o
4-10 ENGINE TOP END
Piston Diameter Measurement
. Measure the outside diameter of the piston 16 mm [A] up from the
bottom of the piston at a right angle to the direction of the piston pin.
* t, the m easurement is under t he service limit, replace the piston .
PIston DIameter
Standard:
65.942 - 65.957 mm
Service Limit.:
65.8 mm
/u
Piston/Cylinder Clearance
The piston -Ie -cylinder clearance is measured whenever a piston or
cylinder is replaced with a new one. The standard piston-Io-cylinder
clearance must be adhered to whenever the cylinder is replaced.
If only a piston is replaced, the clearance may exceed the standard
slightly. But it must not be less than the minimum in order to avoid
piston seizure.
The most accurate way to find t he piston clearance is by making
separate piston and cylinder diameter measurements and then compu ting t he difference between the two values. Measure the piston diameter
as just described, and measure the cylinder diameter at t he very bonom
of t he cylinder.
Piston /Cylinder Clearance
Standard:
0.079 - 0.089 m m
NOTE
o Whenever the piston or cylinder has been replaced with a new one,
the motorcycle must be broken in the same as with a new machine.
Piston Ring. Piston Ring Groove Inspection
. Visually inspect the piston rings and the piston ring grooves.
* If the ri ngs are worn unevenly or damaged, they must be replaced.
* If t he piston ring grooves are worn unevenly or damaged, the pis ton
must be replaced and fitted with new rings .
• Check for uneven groove wear by inspecting t he ring seat ing .
*The rings should f it perfectly parallel to the groove surfaces. If not, the
piston must be replaced .
• With the pis ton ring in its groove, make several m easurements with a
thickness gauge [A] to determine piston ring/groove clearance.
* " t he clearance exceeds t he service limit, measure the thickness of the
piston ring.
* If the ring has worn down to less than the service limit replace t he ring;
if the groove width exceeds the service limit, replace the piston.
Piston Ring/ Groove Clearance
Standard
- - - (keystone)
To.
Second
0.025 - 0.065 mm
Piston Ring Thickness
Standard
To.
Second
1.17 - 1.19 mm
1.17 - 1.19 mm
Piston Ring Groove Width
Standard
- - - (keystone)
To.
1.215 - 1.235 mm
s.c.nd
Service Limit:
0.16 mm
Serv ice Limit:
1.1 mm
1.1 mm
Sel"llce Limit:
1.31 mm
a
..If
/
j0
ENGINE TOP END 4-11
Piston Ring End Gap Inspection
• Place the piston ring [A) inside the cylinder [8]. uSing the
locate the ring squarely in place .
• Set It close to the top 01 the cylinder, where cylinder wear is
• Measure the gap [C] between the ends of the ring with a
gauge.
If the gap is wider than the service limit the ring is overworn
be replaced.
*
piston to
low.
thickness
'A
rc
and must
::---
Piston Ring End Gap
TOP
Standard:
Service Limit:
Second
Standard:
Service Limit
0.15 - 0.35 mm
(!l
0.15 _ 0.35 mm
0.65 mm
~
/00
0.65 mm
~,

d
1=
4-12 ENGINE TOP ENO
Exhaust V alve (KIPS)
Removal
• Remove:
Cylinder
Main Valve Cover
Resonator
. Remove the main valve holder bolt [A ], the main shaft nut [ 8], the
valve rod plugs [C] , and the main valve holder bolts [el
• Remove the left pinion on the main shaft and pun out the main shaft .
• Remove the main valve [A] and the left and right sub-valves [ 8].
. Pull out the exhaust valve rods.
Installation
e Scrape out any carbon and clean the valves with a high flash -point
solvent.
. Check th e following parts for signs of damage:
M ain Valves and O - ring
Sub -valves
Exhaust Valve Rods
Gaskets
* If necessary, replace them wit h new ones.
• Apply 2-stroke engine oil [A] to the following:
Sub-valve Journals
Exhaust Valve Pinions
Valve Rod Journals
Valve Rod Rack
. Apply high temperature grease ( 8 ]10 O-ring on the right valve rod.
CAIJT10N
Do not mix up the sub-valves and the exhaust valve rods on the right
and left.
The left sub-valve has s groove [Al and the right exhaust valve rod
has an O-ring (8 ] 1M IdenfHlcallon.
Loft
Right
ENGINE TOP END 4-13
e Align [AJ the notched teeth on the sub-valve [ 8J with the groove on
the exhaust valve rod [C] ,
A
c
. Align (A] each punch mark on the main shaft pinions [8] with each
groove on the 9Khaust valve rods [C] ,
.Tighten:
Torque - Main Valve Lever Bolt: 3.9 N-m (0.40 kg-m, 35 In.lb) [ A]
Main Shaft Nut 8.8 N..m (0.90 kg-m, 78 In-Ib) [8 ]
Valve Rod Plugs: 18 N-m (1.8 kg-m, 13.0 tt-Ib) [el
Valve Lockbolt: 7.8 N-m (0.80 kg-m, 69 In-Ib) [0 ]
• Install the resonator.
Torque - Resonalor Bolls: 5.9 N-m (0.60 kg-m, 52 In-Ib)
• Install the cylinder.
•
<>
•
~
4-14 ENGINE TOP END
Muffle ... (Expansion Chamber. Silencer)
This motorcycle is equipped with a spark arrester approved for
off-road use by the U.S. Forest Service. It must be maintained to ensure
its efficiency. In accordance with the Periodic Maintenance Chart, clean
the spark arresler.
Spark Arrester Cleaning
AWARNING
To avoid bums, wear gloves while cleaning the sparil arresler. Since
the engine must be run durIng this procedure, the muftler will
become hal
• Remove the drain plug [A) on the silencer .
• In an open area away from combustible materials, start the engine With
the transmission in neutral.
• Raise and lower engine speed while tapping on the silencer with a
rubber mallet until carbon particles are purged from the silencer.
~lWARNING
Do nol run the engine In a closed area. Exhaust gases contain
carbon monoxide; a colorless, odor leu, poisonous gas. Breathing
exhaust gas leads to carbon monoxide poisoning, asphyxiation, and
death.
Neve, run the engine with the speril arreater removed. Hot carbon
particles may start a fl,e .
• Stop the engine.
• Install the drain plug.
CAIITlON
The drain plug must be Installed correctly and functioning property
to provide adequate tire protection.
Removal
• Remove the tight side cover.
• Remove the mounting bolts [A] and pull the silencer [B) off toward
the rear.
• Remove the eKhaust pipe holding springs [A].
ENGINE TOP END 4 -15
• Remove the muffler damper mounting nut [A] and bolt [B]. and pull
off the expansion chamber [C] toward the Iront.
• Remove the exhaust gasket.
Installation
• Scrape any carbon out of the expansion chamber.
• Check the exhaust O-rings for signs of damage.
* If necessary, replace them with new ones.
e Apply molybdenum disulfide grease to the O-rings.
Non-permanent Locking Agent - Muftler Bolts
CLUTCH 5-1
Clutch
Table of Contents
Exploded View ...........................................................................................................5-2
Specifications .............................................................................................................5-4
Clutch Cable ................................................................................................................5-5
Clutch Lever Free Play Check ...............................................................................5-5
Clutch lever Free Play Adjustment ........................................................................5-5
Clutch Release Lever Angle Inspection, Adjustment .............................................5-6
Removal ..................................................................................................................5-6
Installation ......................... ,............................................ ,........................................5-7
Lubrication and Inspection ....................................................................................5- 7
Clutch Cover ................................................................................................................5-8
Removal .................................................................................................
. ........ 5-8
Installation ...................................................................... ,.......................................5-8
Right Engine Cover ............................................................................................... ,..... 5-9
Removal ................................................................................ ,..... ,........................... 5-9
Installation ... ,............................ ,..... ,.. ,........... ,......................................................... 5-9
Disassembly ....................................................................................................... ,5-10
Assembly.......
........................................... .......................................5-11
Exhaust Advancer Assembly ..............................................................................5-11
Clutch ................................................................
..........................................5-12
Removal ...............................................................................................................5-12
Installation ...................................................................................... ,...................... 5-1 3
Friction and Steel Plates Wear Inspection ...........................................................5-14
Friction and Steel Plate Warp Inspection .............................................................5-14
Spring Free Length Measurement ........................................................................5-14
Friction Plate/Clutch Housing Finger Damage ...................................................5-14
Clutch Hub Spline Inspection ..............................................................................5-15
External Shih Mechanism .................................................. ,...................................... 5- 16
Removal ...............................................................................
. ......... ,., ....... 5-16
Installation ............................................................................................................5-16
Inspection ......................................... .................................. ,................................. 5-16
Primary Gear ...................................................
.. ................................ 5-17
Removal ......................................... ,....................................................................5-17
Installation ..... ,... ,................ ,.............. ,........... ,... ,............................................. ...... 5-1 7
Kickstarter ........ ,.............................. ,................ ,.........................................................5-18
Removal ........................................................ ,.......................................................5-18
Assembly ............................................................................................................5-18
Kick Idle Gear Removal .......................................................................................5-19
Kick Idle Gear Installation ....................................................................................5-19
5- 2 CLUTCH
Exploded V ,ew
"
CL: Appt
G:
A y cable lubricant
l'
pply grease.
. Apply
a non -permanent I k"
Lh:
left
M'
- Itand Threads
oc '"g agent.
Apply the
molybden
.
51.: Stake
sc
um disulfide
grease
TO' A
raw.
.
. pply transmission 0 ..
"
1
2.
Kick Idle Ge.
K"Ick Gear
'
3.
Ratchet
4.
Exhaust Valve Ad
Advancer Shaft Lvancer
evo< lever
5.
CLUTCH 5 -3
a ~
o ol)~
00
§I~
~
e
~~
~
~
~
~
~
T3
T7.,
T1 : 20 N-m (2.0 kg-m. 14.5 ft -Ib)
T2: 88 N-m (9.0 kg -m, 65 ft -Ib)
T3: 8-8 N-m (0.90 kg -rn, 78 in -Ib)
T4: 22 N-m (2.2 kg -m, 16.0 ft -Ib)
TS: 78 N-m (8.0 kg -m. 58 ft -Ib)
T6: 64 N-m (6.5 kg -m, 47 ft -Ib)
T7: 9.8 N-m (1,0 kg -m. 87 in -Ib)
T8: 3.9 N-m (DAD kg -m, 35 in -Ib)
TS: 49 N-m (5.0 kg -m. 36 ft -Ib)
T10: 8.3 N-m (0.85 kg -rn, 74 in-Ib)
,
5-4 CLUTCH
Specifications
Standard
Item
Service limit
Clutch Cable:
Lever free play (at lever end)
10 - 20mm
- - -
Clutch :
Friction plate thickness:
Friction plate warp
Steel plate warp
Clutch spring free length :
Special Tools -
Outside ClrcUp Pliers: 57001·144
Flywheel Holder: 57001-1313
Pre.sure Cable Luber: kS&019-021
2.92 - 3.08 mm
0.2 mm or more less
0 .2 rnm or less
38.7 mm
2.73 mm
O.3mm
O.3mm
37 .2 rnm
CLUTCH 5-5
Clutch Cable
Due to friction plate wear and clutch cable stretch over a long period
of use, the clutch must be adjusted in accordance with the Periodic
Maintenance Chan.
To avoid II serious burn, never touch the hot englna or a.pansJon
chamber during clutch adjustment.
Clutch Lever Free Play Check
.
•
•
•
Slide the dust cover out of place.
Check that the clu tch cable upper end is fully seated in the adjuster.
Check that the locknut on the clutch cover is securely tightened .
Check the lever play [ 8] allhe lever end [A] .
lever End Free Play
10 - 20 mm
Standard:
* If the play is 100 large. the clutch may not release fully. If the play is
too small, the clutch may nol engage fully, In either case, adjust it.
Clutch Lever Free Play Adjustment
. Slide the dust cover out of place.
NOTE
OBe sure that the outer cable end at the clutch lever is fully seattJd in
the adjuster at the clutch lever. or it could slip into the place later.
creating enough cable play to prevent clutch disengagement.
• loosen the knurled locknut [AJ .
• Turn the adjuster [8] so that the clutch lever will have 10 - 20 mm
of play.
• Tighten the knurled locknut.
If the adjuster at the clutch lever has reached its limit, use the adjusting
nut in the middle of the cable .
*
• SIide the dust cover out of place .
• loosen the locknut [A] in the middle of the clutch cable, and tum the
adjusting nut [8) so that clutch lever has 10 - 20 mm of play.
• After the adjustment is made, tighten the locknut, and stan the engine
and check Ihat the clutch does not slip and that it releases properly.
5-6 CLUTCH
Clutch Release Lever Angle Inspection. Adjustment
II the clutch slips or the action at the lever feels heavy despite proper
clutch lever free play adjustment, inspect and adjust the clutch release
lever angle.
• Loosen the knurled locknut. and turn the adjuster to give the cable
plenty of plav. Tum the clutch release lever [ A] until it becomes hard to tum. This is
the point where the clutch is Just slattmg to release. At this time, check
that the clutch release lever to clutch cable angle is the specified
amount.
Clutch Relea se Lever Angle
Standard:
80' - 90' [8 ]
*
If it is not. adjust the clutch lever angle as follows.
O Check if the clutch release angle is more than 90' , or tess than SO' .
o Remove the clutch cover (see Clutch Cover Removal) .
*11 the release lever angle is more than 90", add the one shim [AJ
between the clutch pusher holder bearing [B) and the clutch pusher
[el .
* If the lever angle is less than SO', take off the one shim.
NOTE
o There must be 8t most two shims placed on the pusher.
If more than
two shims 8re needed for adjustment, check the clutch plates.
Removal
. Slide the dust cover out of place.
• loosen the locknut in the middle of the cable, and turn the adjusting
nut to give the cable plenty of play.
• Remove the handguard .
• loosen the knurled locknut [AJ at the clutch lever, and screw in the
adjuster (8) .
• Une up the slots [eJ in the clutch lever, knurled locknut, and adjuster.
and then free the cable from the clutch lever.
• Loosen the locknut at the cable lower end, then pull the outer cable
forward to slip the inner cable out of the slot in the stay.
• Free the clutch inner cable tip from the clu tch release lever.
• Pull the clutch cable out of the frame.
CLUTCH 5-7
Installation
. Run the clutch cable according to the Cable, Wire, and Hose Routing
section in the General Information chapter.
• AdJust the clutch cable (see Free Play Adjustment).
Lubrication and Inspection
. Lubricate the clutch cable uSing the pressure cable luber (special tool:
K56019 · 021) [A] with an aerosol cable lubricant [8] in accordance
with the PeriodiC Maintenance Chart.
• With the cable disconnected at both ends, the cable should move
freely within the cable housing (see General Lubrication in the
Appendix chapter).
5 -8 CLUTCH
Clutch Cover
Removal
. Free the clutch cable lower end [A] (see Right EngIne Cover
Removal).
e orain the transmission oil (see Transmission Oil Change in the
Crankshaft/ Transmission chapter) .
e Remova the clutch cover bolts ( 8 ), and take off the clutch cover I e ].
Installation
• Check that the dowel pins arB in place and fit a new gasket on the right
engine cover.
• Install the clutch cover with the clutch release lever turned toward the
rear .
• Engage the clu tch release shaft with the clu tch spring plate pusher by
turning the clu tch release lever toward the front (A] .
NOTE
o With the shah pulled a little out of the cover, tum the lever until it
becomes hard to tum.
o The fe/ease
fever should have about 6 mm (8) clearance between
the fever and the cover.
e Tighten the clutch cover bolts securely.
Torque - Clutch Cover bolts: 8.8 N.m (0.90 kg-m, 78In-lb)
. Install the clutch cable lower end and adjust the clutch lever free play
(see Clutch l ever Free Play Adjus tment) .
• Fill the engine with the transmission oil (see CrankshafttTransmission
chapter) .
CLUTCH 5-9
Right Engine Cover
Removal
e Remove:
TransmiSSion Oil (drain)
Coolant (drain)
Expansion Chamber (see Engine Top End chap ter)
Cooling Hose Lower End
Kick Pedal
Brake Pedal (see Brakes chapter)
Water Pump Cover
e Free the clutch cable lower end as follows.
O Loosen the knurled locknut at the clutch lever and screw in the
adjuster.
O Loosen the locknut In the middle of the cable, and turn the adjusting
nut to give the cable plenty of play.
e Slide the dust cover at the clutch cable lower end out of place.
o Loosen locknut [A] at the clutch cover.
e Free the clutch tnner cable tiP [8] from the clutch release lever.
e Remove the advancer shaft lever cover from the right side of the
cylinder.
eRemove the shaft lever nut [A] and take aH the shaft lever [8]
CAUTION
The shalt lever nut has lelt-hand threads. Tum the nul clocitwlae tor
loosening.
• Turn the clutch release lever toward the rear to free the release shaft
from the clutch spring plate pusher.
e Remove the right engine cover bolts (8) and take off the right engine
cover [ A] and gasket.
Installation
e lnstall:
Dowel Pins
New Right Engine Cover Gasket
e lnstall the right engine cover halfway and install the kick pedal.
eTap the right engine COV9r lightly while pushing down the kick pedal
tAl by hand a little at a time in order to mesh the advancer gears. And
then. tum the water pump impeller [8J a little al a time in order to mesh
the waler pump gears.
-
5-10 CLUTCH
. Install the right engine cover with the clutch release lever turned
toward the rear.
. Engage the clutch release shaft with the clutch spring plate pusher by
turning the clutch release lever toward the front [A).
NOTE
o With
the shaft pulled
a little out of the cover.
turn the lever until it
becomes hard to turn.
o The release lever should have about 6 mm [8 ] clearance between
the lever and the cover.
• Tighten the right engine cover bolts securely.
Torque - Right Engine Cover Bolts: 8.8 N·m (0.90 kg-m, 78In.lb)
. Apply grease to the tooth of the main shaft pinion [A] and the face
gear ( B] .
• Install the advancer shaft lever Ie], fitting the pin [D) into the lever.
• Check that the small hole of the lever aligns (E] with the notched tooth
of the main shaft pinion .
• Tighten the advancer shaft lever nut (left -hand threads) [F) .
OTum the advancer shaft lever nut counterclockwise for tightening .
Torque - Advancer Shaft lever Nut (Left-hand Threads): 8.3 N·m (0.85
kg-m, 74 In- Ib)
Non-permanent loc:tlng Agent - Kick Pedal Nut
Torque - Kick Pedal Nut: 49 N-m (5.0 kg-m, 36 ft·lb)
e Grease the brake pedal shaft and install the brake pedal.
Torque - Brake Pedal Bolt: 9.8 N-m (1 .0 kg-m, 87 In·lbl
e Adjust the clu tch lever free play (see Clutch Lever Free Play Adjust ment) .
• Fi1I:
Transmission Oil (see Crankshaft/Transmission chapter)
Coolant (see Cooling System chapter)
Disassembly
. Remove the right engine cover.
• Turn the advancer lever shaft (AJ and remove the exhaust valve
advancer [ B] .
• Remove the advancer lever bolts (C] . and take off the advancer lever.
CLUTCH 5-11
• Remove Ihe plug screw [AJ and take out the positioning pin [8].
.Pull the lever shaft [C] OUI of the right engine cover
.Pull off the water pump shaft (see Water pump Shaft Removal in the
Cooling System chapter).
CAUTION
Do not remove the clutch release lever and shaft assembly unless It
Is absolutely necessary. II removed, 011 seal replacement may be
required.
Assembly
* If the clutch release shaft has been removed, replace the oil seal with
a new one, apply high temperature grease to the oil seal lips. and apply
transmission oil to the release shaft.
• Apply high temperature grease to the oil seal lips before inserting the
advancer lever shaft.
eApply molybdenum disulfide grease to the surface of the lever shaft.
and insert the lever shaft into the right engine cover.
eTorque the advancer lever bolts [A).
Torque - Advancer Lever Bolts: 3.9 N--m (0.40 kg-m, 35 In-Ib)
.Fit the advancer lever pin [8] into the groove [C] on the exhaust
advancer [D), and install the exhaust valve advancer in the right
engine cover while turning the lever shaft.
elnsert the positioning pin into the plug screw hole and tighten the plug
screw securely.
Exhaust Advancer Assembly
• The exhaust advancer consists of the following parts.
e Check the exhaust advancer parts for damage.
Any damaged pans should be replaced with new ones .
• When assembling, apply molybdenum disulfide grease to the rod, the
needle bearings, and the outside and inside of the holder.
*
1.
2.
3.
4.
5.
Pins
Rod
Guide
O-ring
Steel Balls
6. Holder
7. Needle Beating
8. Spacer
9. Collar
10. Collar
11. Spring
12. Gear
•
5-12 CLUTCH
Clutc h
Removal
• Remove the clutch cover (see Clutch Cover Removal) ,
. Remove the clutch pusher [Al, shim [B], and clutch pusher holder
[el from the clutch spring holder.
• Remove the magneto cover.
elnstall the flywheel holder [A] on the magneto flywheel and loosen the
clutch hub nut [8],
NOTE
o Use the flywheel holder to prevent the clutch (rom turning.
Special Tool - Flywheel Holder: 57001-1313 [A]
e Remove the clutch assemblv. sleeve fA], and thrust washer (BJ.
• Remove the clutch spring bolts, springs, and clutch spring holder
[AJ, and clutch hub.
• Remove:
Spring Seat and Coned Disc Spring fA]
Friction Plates [8]
Steel Plates
CLUTCH 5-13
Installation
. Install:
Thrust Washer [AJ
Sleeve [8]
Clutch Housing [C]
Thrust Washer [D]
. Apply molybdenum disulfide grease to Ihe outside of the sleeve .
• Apply transmission oil to the inside of Ihe clutch housing gear and
kickstaner driien gear.
• Install the friction plates and steel plates, starting with a friction plate
and alternating them.
CAUTION
Do nol install dry steel plates and friction plates; apply transmission
01110 Ihe sur1aces of each plate to avoid clutch plale seizure.
e lnstallthe coned disc spring [AJ and the spring seal [B] as shown.
A
8
NOTE
OFirst. install the six friction places fitting the tangs of plates in the
grooves [AJ in the clutch housing. And then. install the last one
fitting the tangs in the grooves [8] in the housing
• Install the spring washer [A] and the clutch hub nut [B] as shown_
®
fL.).......-
5-14 CLUTCH
. Tighten:
Torque - Clutch Spring Bolts: 8.8 N-m (0.90 kg-m, 78 In.lb)
Clutch Hub Nul: 88 N-m (9.0 kg-m, 65 ft-Ib)
eApply molybdenum disulfide grease to the rubbing portion of the
clutch pusher,
Friction and Steel Plates Wear Inspection
. Visually inspect the friction and steel plates to see if they show any
signs of seizure, or uneven wear.
* If any plates show signs of damage, replace the Iriction plates and steel
plates as a set.
• Measure the thickness 01 the friction plates [AJ with vernier calipers.
* If they have worn past Ihe service limit, replace them wIth new ones.
A
Friction Plate Thickness
Standard:
2.92 _ 3.08 mm
Servk;e Limit:
2.70 mm
Friction and Steel Plate Warp Inspection
. Place each friction plate or steel plate [AJ on a surface plate, and
measure the gap between t he surface plate [C] and each friction plate
or steel plate with a thickness gauge [8]. The gap is the amount of
frict ion or steel plate warp.
* If any plate is warped over the service limit, replace it with a new one
Frlcllon and Steel Plates Warp
Standard:
0.2 mm or leu
Service limit 0.3 mm
Spring Free Length Measurement
e Since the spring [AJ becomes shorter as it weakens, check its free
length to determ ine its condition.
* If any of the springs is shorter than the service limit, it must be replaced.
Clutch Spring Free length
Standard:
Service Limit
38.7 mm
37.2 mm
Friction Plate/Clutch Housing Finger Damage
e Visually inspect the clutch housing fingers (A] where the friction plate
tangs hit them.
*If they are badly worn or if thare are groove cuts where the tangs hit.
replace the housing.
e Also, replace the friction plates if their tangs [8] are damaged.
A
CLUTCH 5-15
Clutch Hub Spline Inspection
. Visually inspect where the teeth on the steel plates wear against the
splines rA] of the clutch hub.
* If there are notches worn into Ihe splines, replace the clutch hub. Also,
replace the clutch plates if their tooth are damaged.
5-16 CLUTCH
External Shift Mechanism
Removal
.Remove;
Shih Pedal
Magneto Cover
Right Engine Cover
Clutch Housing
Idle Gear
•
•
•
•
Pull out the external shift mechanism [A J.
Remove the return spring [C}
Remove the bolt and take off the gear sel lever { B] .
Check that the return spring pin [D ] is not loose.
Installation
eBefore installing the shift shaft, apply high temperature grease to the
oil seal lips .
• Torque the gear set lever bolt.
Torque - Gear Set lever Bolt: 9.8 N·m (1 .0 kg-m, 87In-lb)
.lnstaU the arm spring [A] as shown .
Clutch
A
Side
~
Inspection
• Check the shift shaft [ A] for bending and the serrations for damage.
* If the shaft is bent. straighten or replace it.
If the S8fTations are
damaged, replace the external shift mechanism .
• Check the return spring [ 8] and arm spring [C] for cracks or distortion.
If the springs are damaged in any way, replace them.
eCheclc. the shift mechanism arm CO} for distortion.
*
*If
the shift mechanism arm is damaged in any way, replace the external
shift mechanism .
• Check that the shift shaft return spring pin [Al is not loose.
*If it is loose, unscrew it, apply a non- permanent locking agent to the
threads, 8f1d torque it.
Torque - Shift Shaft Return Spring Pin: 22 N-m (2.2 kg-m, 16.0 ft·lbl
.Check the gear set lever and its spring for cracks or distortion.
* If the lever or spring is damaged in any way, replace them.
A
CLU T CH 5 -17
Primary Gear
Removal
•
•
•
•
Remove the right engine cover (see Right Engine Cover Removal) .
Remove the magneto cover.
Remove the clutch (see Clutch Removal) .
Remove the primary gear nut (A) , the wa ter pump drive gear [8) , and
the primary gear [C] .
NOTE
o Use the flywheel holder to prevent the crankshaft (rom turning.
Special Tool - Flywheel Holder: 57001 -131 3
Installation
• Fit the woodruff key [ A) in the crankshaft groove and install the
primary gear [8) .
• Fit the pin [C) in the crankshaft .
• Install the water pump drive gear [ D) so that chamfered side [E] faces
outward .
• Torque the primary gear nut.
Torque - Primary Gear Nut: 78 N-m (8.0 kg-m, 58 ft-Ib)
NOTE
O Use the flywheel holder to prevent the crankshaft (rom turning.
Special Tool - Flywhee l Holde r: 57001 -1313
5-18 CLUTCH
Kickstarter
Removal
• Remove:
Right Engine Cover
Clutch Housing
• Remove the kick spring [AJ with pliers.
• Remove the kickstarter assembly (B).
• Remove the bolt [A]. and take off the ralchet guide [8].
Assembly
OThe kickstarter assembly consists of the following parts.
• Check the kickstarter assembly pans for damage. Any damaged parts
should be replaced with new ones.
1. Washer
5. Kick Gear
2. Circlip
3. Spring
4. Ratchet
6. Kick Shaft
7. Kick Spring
8.Spring Guide
CAlITlON
When aHambling the ratchet [8] onto the kick shaft [Al, align the
punch mark [el on the ratchet with the punch mark [e) on the kick
shalt.
.Apply molybdenum disulfide grease to the inside of the kick gear and
the ratchet teeth.
• Replace the circlips that were removed with new ones.
Special Tool - Outside Clrcllp Pliers: 57001-144
CLUTCH 5-19
Kick Idle Gear Removal
e Remove Ihe right engine cover and the clu tch housing (see Right
Engine Cover Removal and Clutch Removal) .
• Remove the circtip [8] and pull off the idle gear [A].
Special Tool - Outside Clrclip Pliers: 57001·144
Kick Idle Gear Installation
. Apply molybdenum disulfide grease to the inside of the idle gear.
• Replace the circ!ip that was removed with a new one.
SpecIal Tool - Outside Clrcllp Pliers: 57001 ·144
.Install the idle gear as shown
Idle Gear [A]
Washers ( BJ
Cirdip [C]
ENGINE REMOVAL/ INSTALLATION 6 -1
Engine Removal/Installation
Table of Contents
Exploded View ....... ,...................... ,,, ...........................................................................6· 2
Specifications .............................................................................................................. 6-3
Engine Removal ......................................................................................................6-3
Engine Installation .................................................................................................. 6-4
6-2 ENGINE REMOVAL/ INSTALLATION
Exploded View
T1 : 88 N,m (9.0 kg -m, 65 ft -Ib)
T2: 44 N-m (4.5 kg -m, 33 ft -Ib)
T3: 29 N -m (3.0 kg -m. 22 ft -Ib)
T3
"
ENGINE REMOVAL/ INSTALLATION 6 - 3
Specifications
Special Tool - Jack: 57001·1238
Engine Removal/ Installation
Engine Removal
. Draln the coolant (see Cooling System chapter) .
• Draln the transmission 011 (see Crankshaft/TransmisSion chapter) .
• Remove:
Side Covers
Seat
Fuel Tank
Expansion Chamber
Carburetor
Radiators
Clutch Cable lower End
Cylinder Head Brackets
Engine Sprocket Cover
Engine Sprocket
Drive Chain
Shift Pedal
Magneto lead Connectors
Brake Pedal
Spark Plug l ead
• Place the jack under the frame to lift the rear wheel off the gro und.
Special Tool - JadI:: 57001 ·1238
. Squeeze the brake lever slowly and hold it with a band (A].
CAlJT10N
Be sure to hold the front brake when removing the engine, or the
motorcycle may lalt over. The engine or the motorcyc~ could be
damaged.
Be sure to hold the fronl brake when removing the eogln., or the
motorcycle may lalt over. "could cause an accident and Injury.
6·4 ENGINE REMOVAL/ INSTALLATION
i,.WARNING
The swlngarm pivot shaft also serves as the engine mountlnb boll.
reke precautlonllo insure the frame is well supported, and thai the
motorcycle will not lall over when the pivot shaft Is removed .
• Pull out the 5wingarm pivot shah [AJ .
• Remove th engine brackets [8] and the engine mounting bolts [C] .
• Twist the engine clockwise and remove the engine from the vehicle's
right side.
Eng;ne Installation
eTlghten the following fasteners in the order lisled.
Torque - Swlngarm Pivot Nut: 88 N·m (9.0 kg-m, 65 ft-Ib)
10 mm Engine Mountrng Bolts and Nuts:
44 N-m (4.5 kg-m, 33 ft-Ib)
8 mm Engine Mounting Bolts and Nuts:
29 N-m (3.0 kg-m, 22 tt. lb)
. Install:
Engine Sprocket
• Run the cables, hoses, and leads according to the Cable, Wire, and
Hose Routing section in the General Information chapter.
elnstall the parts removed (see the appropriate chapters).
eAdjust:
Throttle Cable (see Fuel System chapter)
Clutch (see Clutch chapter)
Drive Chain (see Final Drive chapter)
e Fill the engine with transmission oil (see CrankshaftfTransmission
chapter) .
e Fill the engine with coolant and bleed the air from the cooling system
(see Cooling System chapter) .
eAdjust the throttle cable.
e Adjust the throttle stop screw.
e Check the brake effectiveness.
~ .. WARNING
Do not attempt to ride ttle motorcycle until a tull brake taver or pedal
.. obtained by pumping ttle brake lever or pedal until ttle pads are
agalmt ttle disc. The brake wilt not tuncUon on ttle nrst application
of the taver or pedal" ttl. Is not done.
CRANKSHAFT/ TRANSMISSION 7-1
Crankshaft/Transmission
Table of Contents
Exploded View ..........................................................................................................7· 2
Specifications .............................................................................................................7·4
Transmission Oil ............................................................................................ .. ............7-5
level Inspection ......................................................................................................7-5
Change .................................................................................................................. 7-5
Crankcase ..................................................................................................................7-7
Splitting ...................................................................................................................7-7
Assembly .................................................................................................................7-7
Crankshaft, Connecting Rod ....................................................................................7 -10
Removal ................................................................................................................7-10
Installation .............................................................................................................7-10
Disassembly ..........................................................................................................7-10
Assembly ...............................................................................................................7-10
Crankshaft Bearing Check ....................................................................................7 -11
Connecting Rod Big End Radial Clearanc6 ......................................................... 7-11
Connecting Rod Big End Seizure ........................................................................7- 11
Connecting Rod Big End Side Clearance ............................................................ 7-11
Crankshaft Runout ................................ ................................................................7-12
Crankshaft Alignment ...........................................................................................7-12
Transmission .............................................................................................................7-13
Shaft Removal .......................................................................................................7- 13
Shaft Installation ...................................................................................................7-13
Shaft Disassembly ................................................................................................7-13
Shaft Assembly ..................................................................................................... 7-13
Shift Drum and Fork Installation .......................................................................... 7 -14
Shift Fork Bending .................................................................................... ............7-14
Shift Fork/ Gear Groove Wear ...............................................................................7 -14
Shift Fork Guide Pin/ Shift Drum Groove Wear ................................................... 7- 15
Gear Dog, Gear Dog Hole. and Dog Recess Damage ........................................7 -15
Ball Bearing Wear .................................................................................................7-15
7-2 CRANKSHAFT / TRANSMISSION
Exploded View
EO: Apply 2 -st roke engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
lG: Apply liquid gasket
(Kawasaki Bond: 92104 ·002).
M : Apply molybdenum disulfide grease.
TO: Apply transmission oil.
R:
Replacement Parts
LO
L
T5
T1 :
T2:
T3:
T4;
TS:
T6:
20 N -m (2.0 kg -m, 14.5 ft -Ib)
9 .8 N-m (l .a kg-m, 87 in - Ib)
23 N -m (2.3 kg -m, 16.5 ft -Ib)
8.3 N-m (0.85 kg-m, 74 in -Ib)
22 N·m (2.2 kg-m, 16.0 ft-Ib)
78 N -m (8.0 kg -m, 58 ft -Ib)
CRANKSHAFT/ TRANSMISSION 7 -3
7-4 CRANKSHAFT/TRANSMISSION
Specifications
Standard
Item
Transmission Oil:
Grade
Viscosity
Capacity
SE, SF, or SG class
SAE10W·30 or 10W-40
0.65 L (when changing oil)
0.7 L (when engine is completely dry)
Between upper and lower level line
level
Crankshaft, Connecting Rod:
Connecting rod big end radial clearance:
Connecting rod big end side c learance:
Crankshaft runout
0.026 - 0.043 mm
0.40 - 0.50 mm
Service Limit
----- - - - -
-- 0.10 mm
TIR 0.03 mm or less
0.70 mm
TIR 0.08 mm
0.077 - 0.097 mm
---
Cold fitting tolerance between
crankpin and crankweb
Transmission:
Shift fork ear thickness:
Gear shift fork groove width:
Shift fork guide pin diameter
Shift drum groove width
Special 'Tools -
3.9 - 4.0 mm
4.05 - 4.15 mm
5.975 - 5.994 mm
6.05 - 6.20 mm
Bearing Puller Adapter: 57001·136
Outside Clrclip Pliers: 57001·144
Bearing Puller: 57001·158
Crankcase Splitting Tool Assembly: 57001·1098
Bearing Driver Set: 57001·1129
Crankshaft Jig: 57001-1174
Sealant - Kawasaki Bond (Liquid Gasket - Sliver): 92104-002
3.8mm
4.3mm
5.9mm
6.3mm
CRANKSHAFT/ TRANSMISSION 7 - 5
Transmission Oil
In order lor the transmission and clutch to function properly, always
maintain the transmiSSion oil at the proper level and change the oil
periodically.
AWARNING
Motorcycle operation with Insufficient, deteriorated, or contaminated
transmission 011 will accelerate wear and may result In transmission
seizure, accident, and Injury.
Level Inspection
• Situate the motorcycle so that it is perpendicular 10 the ground.
*11 the motorcycle has Just been used. wait several minutes until the oil
settles.
* 11 the oil has just been changed, start the engine and run it for three
minutes at idle speed. This fi lls the transmission with oil. Stop the
engine, then wait several minutes until the oil settles.
NOTE
OBe sure to idle the engine for correct oil level measurement.
• Check that the oil level comes up between the upper level [A) and
lower level [8] through the oil level gauge (C] on the clutch cover.
*11 the oil level is too high, remove the excess oil using a syringe or some
other suitable device.
* 11 the oil level is too low, add the correct amount of oil through the oil
filler opening. Use the same type and make of oillhat is already in the
engine.
NOTE
Olf the transmission oil type and make are unknown, use any brand
of the specified oil to top off the level in preference to running the
engine with the oil level low. Then at your earliest convenience,
change the oil completely.
Change
. Warm up the engine thoroughly so that the oil will pick up any
sediment and drain easily. Then stop the engine.
• Place an oil pan beneath the engine.
• Remove the transmission drain plug [AJ on the bottom of the engine,
and let the oil drain completely.
NOTE
OHold the motorcycle upright so that the oil may drain completely.
• Check the gasket al the drain plug for damage.
*• After
Replace the gasket with a new one if it is damaged .
the oil has completely drained out, install the drain plug with the
gasket, and torque it.
Torqu e - Transmission Drain Plug: 20 N-m (2.0 kg-m, 14.5 ft·lb)
. Fill the engine with a good quality motor oil specified.
CAllTlON
Measure the oil amount correclly according to the table and pour In
the oil.
7-6 CRANKSHAFT /TRANSMISSION
Transmission 011
Grade:
Viscosity:
Amount:
SE, SF, or SG etas.
SAE 10W-30 or 10W-40
0.65 L (when changing 011)
0.7 L (when engine Is completely dry)
.Check the oiliellel.
CRANKSHAFT/ TRANSMISSION 7-7
Crankcase
Splitting
• Remove the engine (see Engine Removal/Installation chapter) .
• Set the engine on a clean surface while parts are being removed .
• Remove:
Magneto Cover
Output Shaft Sleeve and O-ring
Right Engine Cover
Clutch
Primary Gear
Kickstarter Assembly
Kickstarter Idle Gear
Shift Drum Cam Bolt
Gear Set Lever
Magneto Flywheel and Stator
Cylinder Head
Cylinder
Piston
. Remove the crankcase bolts [A] .
• Install the crankcase splitting tool [A] and bearing puller adapter [ 8 ]
into the left side of the crankcase. Be certain to screw the tool in all
the way.
Special Tool - Crankcase Splitting Tool Assembly: 57001-1098 [AJ
Bearing Puller Adapter: 57001 -136 [B]
. Tighten the center bolt on the crankcase splitting tool to split the
crankcase halves.
• Once the crankcase is split, remove the crankcase splitting tool, and lift
off the left crankcase half .
• Pull out the shift rods [C]
. Disengage the shift fork guide pins from the shift drum grooves.
• Take out the shift drum [0] .
• Remove the shift forks [E] from the transmission gears .
• Take out the drive shaft [A] and output shaft [8] together with their
gears meshed.
• Remove the crankshaft from the right crankcase half using a press.
Assembly
. Chip off the old gasket from the mating surfaces of the crankcase
halves, and clean off the crankcase with a high flash-point solvent.
After cleaning, apply transmission oil to the transmission gears, shift
drum, shift forks and so on.
• Be sure to replace any oil seal removed with a new one. Press in the
new oil seal using a press and suitable tools so that the seal surface is
flush with the surface of the crankcase.
• Apply high tempera ture grease to the oil seal lips.
• Press in the ball bearings using the bearing driver sel until the bearing
bottoms out.
7-8 CRANKSHAFT / TRANSMISSION
Special Tool - Bearing Drtvef Set: 57001·1129
CAl1TION
Do not remove the bearings and the oil seals unless it is necessary.
Removal may damage them .
• Tighten the drive shaft bearing bolts.
Torque - Drive Shaft Bearing Bolts: 8.3 N-m (0.85 kg-m, 74 in·lb)
elf the crankshaft bearings stay on the crankshaft when splitting the
crankcase. remove the bearings from the crankshaft and install the new
bearings in the crankcase, and then assemble the crankcase (see
Crankshaft Removal and Installation) .
• Turn the crankshaft to BOC, and install the crankshaft jig [A] between
the flywheels opposite the connec ting rod big end to protect flywheel
alignment as shown.
o Instail the jig between the crankshaft flywheels before pressing the
crankshaft into the right crankcase half.
Special Tool - CrarbhaftJIg: 57001·1174 (A]
.Check to see that the crankcase knock pins are in place on the right
crankcase half. If any of them has been removed, replace it with a new
ona
.Apply liquid gasket to the mating surface of the left crankcase half.
Sealant -
Kawasaki Bond (Liquid Gaskel - Sltver): 92104-002
.Using a suitable tool on the left crankcase to press [A] around the hole
for the crankshaft. fit the crankcase halves together with a press on the
tool.
NOTE
o Constantly check the alignment of the two crankcase halves, and the
position of the transmission shafts, and shift drum. The front end
rear of the crankcase must be pushed together evenly.
.-
CRANKSHAFT/TRANSMISSION 7 - 9
. Remove the crankshaft jig (special tool) from the crankshaft flywheels .
• Tighten the crankcase bolts starting with the ones around Ihe
crankshaft, and then the farther ones.
o Tighlen Ihe crankcase bolt [A] and the clamp [8 ] for the carburetor
hoses as shown.
Torque - Crankcase Bolts: 9.8 N-m ( 1.0 kg-m. 87 In-Ib)
• Check to see that the crankshaft drive shaft. and output shaft all tum
freely (in the neutral position) .
* If the crankshaft will not tum. probably the crankshaft IS not centered:
tap the end of the right crankshaft with a mallei to reposit ion it.
. Spinning the output shatt, shift the transmission through all the gears
to make cenaln that there is no binding and that all the gears shift
properly.
• Inslall the parts removed in the reverse order of removal. and refer to
the appropria te chapters.
• Replace the O· rings on the output shaft with new ones.
7-10 CRANKSHAFT/ TRANSMISSION
Crankshaft. Connecting Rod
Removal
. Split the crankcase (see Crankcase Splitting).
e Remove the transmission shahs (see Transmission Shah Removal) .
• Using a press, remove the crankshaft from the right crankcase.
O lf t he bearings stay on the crankshaft, which is the most common
when splitting Ihe crankcase, remove the beanng from the crankshaft
with a bearing puller [AJ and adapter [ 8 J.
• Discard the bearings removed.
Special Tool - Bearing Puller: 57001·158 [A1
Bearing Puller Ad apter: 57001·136 [ 8 ]
Installation
. W hen installing t he crankshaft bearings, apply 2 -stroke oil to the outer
sides of the bearings, and then press them into the crankcase using the
bearing driver [AJ until the bearing bottoms against the step.
Special Tool - Bearing Driver Set 57001 ·11 29 [AJ
Crankshah Bearing (B)
Oil Seal (C]
• Insert the crankshahjig tA] between the crankshah flywheels opposite
t he connect ing rod big end to protect flywheel alignment as shown,
and press t he crankshah into the right crankcase.
O W hen pressing, position t he jig in the crankcase opening so the jig
does not hit the crankcase.
Special Tool - Crankshaft Jig: 57001 ·1174 [A]
. Apply 2 · s1roke oil to the connecting rod big end bearing.
Disassembly
Since assembly of the crankshah demands exacting tolerances, the
disassembly of the crankshaft can only be done by a shop having the
necessary tools and equipment.
. If it should be necessary to disassemble the crankshaft, use a press to
remove the crankpin.
Assembly
Since the assembly of the crankshah demands exacting tolerances,
the assembly of the crankshaft can only be done by a shop having the
necessary tools and equipment.
. Assemble the crankshah according to the standard tolerances in the
Specifications.
Connecting rod big end radial clearance
Cold-fitting tolerance between crankpin and flywheels
Side clearance between t he connecting rod big end and one of
flyw heels
Crankshaft runout .
CRANKSHAFT/ TRANSMISSION 7-11
Crankshaft Bearing Check
Since the ball bearings are made to extremely close tolerances, the
wear must be Judged by feel rather than measurement
• Remove the follOWing .
Piston (see Engine Top End chapter)
Primary Gear (see Clutch chapter)
.Turn the crankshaft, uSing the connecting rod
*11 the bearings are noisy, do nOI spin smoothly, or have any rough
spots, replace them.
Connecting Rod Big End Radial Clearance
e Sellhe crankshaft on V blocks {Al. and place a dial gauge ( BJ against
the connecting rod big end [e).
• Push the connecting rod first towards the gauge and thon in the
OPPosite direction . The difference between the two gauge readings is
the radial clearance.
If the radial clearance exceeds the service limit, the crankshaft should
be either replaced or disassembled and the crankpin, needle bearing,
and connecting rod big end examined for wear.
*
Connecting Rod Big End Radial Clearance
Standard:
0.02fi - 0.G43 mm
Service limit:
0.10 mm
Connecting Rod Big End Seizure
* In the case of serious seizure with damaged flywheels, the crankshaft
must be replaced.
* In case of less serious damage, disassemble the crankshaft and replace
the crankpin, needle bearing, side washers, and connecting rod.
~
Connecting Rod Big End Side Clearance
• Measure the side clearance [AJ of the connecting rod with a thickness
*
gauge.
If the clearance exceeds the service limit replace the crankshaft.
Connecting Rod Big End Side Clearance
Standard:
Service limit
0.40 - 0.50 mm
0.70 mm
,
-I
[}J
?5.
6.
-r
-
7 -12 CRANKSHAFT /TRANSMISSION
Crankshaft Runout
points indicated.
.Turn t he crankshaft slowly [ B]. The maximum difference in gauge
readings is the crankshaft runout.
*11 the runout at either point exceeds the service limit. align the
flywheels so that the runout falls within the service limit.
Crankshaft Runoul
Standard:
TIR 0.03 mm or less
Service Limit: TIR 0.08 mm
~©
Ion'v-
Crankshaft Alignment
*If the runout at either point exceeds the service limit. align the
flywheels so that the runout faUs within the service limit.
e ln the case of horizontal misalignment. which is the most common,
strike the projecting rim of the flywheel with a plastic, soft lead, or
brass hammer as indicated in the figure .
• Recheck the runout with a dial gauge, repeating the process until the
runout falls within the service limit.
o Vertical misalignment is corrected either by driving a wedge in
between the flywheels or by squeezing the flywheel rims in a vise,
depending on the nature of the misalignment. In the cases of both
horizontal and vertical misalignment, correct the horizontal misalignment first.
Don" hemme' ".lIywh••••
I-
=~
*If flywheel misalignment cannot be corrected by the above method,
replace the crankpin or th e crankshaft itself.
D
(.)
~ - I-©
6
'-'
'--
8 mm [C]
I
h
G:
. Set the crankshaft on V blocks, and place a dial gauge [AJ against the
~
JD
CRANKSHAFT/ TRANSMISSION 7-1 3
Transm ission
Shah Removal
. Split the crankcase (see Crankcase Splitting) .
• Pull out the shift rods (A1, and disengage the shift fork guide pins from
the shift drum grooves.
• Remove the shift drum [8].
• Remove the shift forks [C] from the transmission gears.
• Take out the drive shaft [ 0] and output shaft [E] together, with their
gears meshed.
Shah Installation
• Hold the drive shaft [A] and output shaft [B] together, with their gears
meshed, and fit them into the right crankcase half.
• Install the shift forks and shift drum (see Shift Drum and Fork Instal ~
lation) .
Shah Disassembly
• Remove the circlips and disassemble the transmiSSion shaft.
Special Tool - Outside Clrcilp Pliers: 57001·144
Shaft Assembly
. Apply transmission oil liberally to the transmission shaft, gears and
bearings.
• Replace any circiips [A] that were removed with new ones.
Special Tool - Outside Clrcilp Pliers: 57001-144
o The drive shaft gears can be identified by size; the smallest diameter
gear is 1Sl gear, and the largest is 6th gear. Be sure that all parts are
pul back in the correct sequence, and facing the proper direction, and
that all circlips and the washer are properly in place.
1st Gear [A ]
6th Gear (B]
3rd/ 4th Gears [ Cl
5th Gear [ D)
2nd Gear [E)
OThe output shaft gears can be identified by size; the largest diameter
gear is 1st gear, and the smallest is 6th gear. Be sure that ali parts are
put back in the correct sequence and facing the proper direction, and
that ali clrciips are properly in place.
O Apply molybdenum disulfide grease to the Inside diameter of the 4th
gear [0].
2nd Gear [A]
4th Gear [0]
5th Gear [8]
6th Gear [ El
3rd Gear [C]
1st Gear [F)
• Check that each gear spins or slides freely on the transmission shaft
without binding after assembly.
7-14 CRANKSHAFT/T RAN S M ISSION
Shfft Drum and Fork Installation
. Applva non-pem1anGflllocking agent to the threads of the shIh drum
bearing holder bolts [AJ and tighten them to the specified torque.
Torque - Shift Drum Bearing Holder Botts: 9.8 N-m (1.0 kg-m, 87In-lb)
. Apply transmission oil liberally to the transmission gears, bearings,
shah joumals, and shift fork ears.
• Fit the shih forks into the gear grooves .
• Apply a small amount of transmission oil to the shih rods, and install
the rods.
NOT E
0 8e careful not to confuse the shift forks, and the shift rods
Driva shah 3rd and 4th gear shift fork [AJ:
Fingers are shoner than those of the other two shift forks.
Ou tput shaft 5th gear shift fork [8] :
Guide pin goes to right side of the fingers.
Output shaft 6th gear shift fork [C] :
Guide pin goes to left side of the fingers.
Shaner Shift Rod [0]
Longer Shift Rod [E]
• Fit each shift fork into the groove of the proper gear so that the shift
fork guide pin is in the proper groove on the shift drum.
Shift Fork Bending
. Visually inspect the shift forks, and replace any fork that is bent. A bent
fork could cause difficulty in shifting, or allow the transmission to jump
out of gear when under power.
90' [A]
Shift Fork/Gear Groove Wear
• Measure the thickness of the shift fork ears [A] , and measure the width
[8] of the gear grooves.
*11 the thickness of a shift fork ear is less than the service limit, the shift
fork must be replaced.
Shift Fol1t Ear Thickness
Standa rd:
Serv ice Limit:
3.9 - 4.0 mm
3.8 mm
*11 the gear groove is worn over the service limit. the gear must be
replaced.
Front
o
o
CRANKSHAFT/ TRANSMISSION 7-15
Gear Groove Width
Standard:
4.05 _ 4.15 mm
Service Umlt:
4.3 mm
Shift Fork Guide Pin/Shift Drum Groove Wear
. Measure the diameter of each shilt fork guide pin [A] , and measure the
width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service limit. the fork
must be replaced
*
Shift Fork Guide Pin Dlameler
Standard:
Service limit
5.975 - 5.994 mm
5.9 mm
* If any shift drum groove is worn over the service limit, the drum must
be replaced.
Shift Drum Groove Width
Standard:
6.05 - 6.20 mm
Service Limit
6.3 mm
Gear Dog, Gear Dog Hole, and Dog Recess Damage
. Visually inspect the gear dogs [A], gear dog holes [B], and recesses
tel·
* Replace any damaged gears or gears with excessively worn dogs or
dog holes or dog recesses.
Bal/Bearing Wear
• Check the ball bearings [AJ in the crankcase.
O Since the ball bearings are made to extremelv close tolerances, the
wear must be Judged bv feel rather than measurement. Clean each
bearing in a high flash -point solvent, dry it (do not spin the bearing
while Lt is dry) , and oil it with transmission oil.
.Turn (AJ each bearing in the crankcase back and forth [AJ while
checking for plav, roughness, or binding. If bearing plav, roughness,
or binding is found, replace the bearing.
WHEELS / TIRES 8 -1
Wheels/Tires
Table of Contents
Exploded View ................................. ,', ... "." ... ,', ..... ,............ ,', ....... " .......... ,',." ... ,"",.,,8-2
Specifications .............................................................................................................8-3
Wheels (Rims) ............................................................................................................8-4
Front Wheel Removal .............................................................................................8-4
Front Wheel Installation ..........................................................................................8-4
Rear Wheel Removal ..............................................................................................8-5
Rear Wheel Installation .............. ...........................................................................8-6
Inspection ................................................................................................................ 8-6
Spoke Inspection ....................................................................................................8- 7
Rim Inspection ........................................................................................................8- 7
Axle Inspection .......................................................................................................8-7
Tires ............................................................................................................................8-8
Air Pressure Inspection/Adjustment .......................................................................8-8
Inspection ............................................................................................................. ... 8-8
Removal ..................................................................................................................8-9
Installation ............................................................................................................... 8-9
Hub Bearings (Wheel Bearings) ..............................................................................8-10
Removal ................................................................................................................8-10
Installation ........................................................................... ..................................8·' a
Inspection ............................................................................................................. 8· 11
Trip Meter Gear Housing ....................................................................... ................... 8-12
Gear Housing Disassembly ..................................................................................8-12
Gear Housing Assembly ...................................................................................... 8-12
Gear Housing Lubrication ....................................................................................8-12
8-2 WHEElS / TIRES
Exploded View
.~
G:
5:
WL:
T1:
T2:
T3:
T4:
Apply grease.
Follow the specific tightening
sequence.
Apply soap and water solution or
rubber lubricant.
88 N -m (9.0 kg~m, 65 h-Ib)
9.8 N-m (1.0 kg-m. 87 in-Ib)
98 N-m (10.0 kg-m, 72 ft -Ib)
1.5 _ 2.1 N -m (0.15 _0.21 kg-m,
13 - 18 in-Ib)
WHEElS/TIRES 8-3
Specifications
Item
Standard
Service limit
Wheels :
Rim (unout:
TIR 0.5 mm or less
TIR 0.8 mm or less
TIR 0.10 mm or less
Axial
Radial
Axle runout/l 00 mm
TIR 2 mm
TIR 2 mm
TIR 0 .2 mm
Tires :
Tire air pressure:
Standard tires:
80 kPa (0 .8 kg /em', 11 psi) _ 100 k Pa (1 .0 kg / em', 14 psi)
(to suit track conditions and rider preference)
Front:
Rear:
Make, type
Du nlop, K490 Tube type
Size
801100 -21 51 M
Make, type
Dunlop, K695 Tube type
Size
1001100-18 59M
SpecIal Tool - Jack: 57001·1238
a.ad Breaker Assembly: 57001·1072
Rim Protector: 57001·1063
Inside Clrcllp Pile,..: 57001 ·143
Se.rlng Remover Shaft: 57001 ·1265
Bearing Remover Head, $ 15 Jt /1)17: 57001 ·1267
aearlng Remover Head, CP20 x 4122: 57001 -1293
aearlng OrNer Set 57001-1129
8-4 WHEELS/ TIRES
Wheels (Rims)
Front Wheel Removal
eUsing the Jack [A] under the frame, raise the front wheel off the
ground.
Special Tool - Jack: 57001 ·1238 [A]
• Remove the meter cable lower end [C] .
• loosen the right axle clamp nuts [ 8 J. remove the axle [A]. and pull
out the wheel.
.Take off the collar and the gear housing from each side of the front
hub.
Do not lay the wheel on the ground with the disc facing down. This
can damage or warp the disc. Place blocks under the wheel 80 the
disc does not touch the ground.
• Insert a wood wedge between the disc brake pads. This prevents them
from being moved oul of their proper position, should the brake lever
be squeezed accidentally.
Front Whee/Installation
.Install the gear housing so that its projections [Al fit in the gear drive
notches [Bj.
eFit the fork leg stop [A] into the gear housing .stops [ 8].
WHEELS / T I RES 8-5
. Torq ue the axle [AJ.
Torque - Fronl Axle: 88 N·m (9.0 kg-m, 65 tt-Ib)
OThe arrOw mark (8) on the axle clamps must pOint upward .
• Tighten the upper clamp nuts [el first, and t hen tighten the lower
clamp nuts [D].
Torque - Front Axle Clamp Nuts: 9.8 N-m (1.0 kg-m, 87 in-Ib)
• Check the front brake for good braking power and no brake drag.
AWARNING
00 not attempt to drive the motorcyc le until 8 fu ll brake lever ,.
obtained by pumping the brake lever until th e pads are against the
disc. The brake will not function on the first application of the lever
it this is nol done.
Rear Wheel Removal
. Use the jack [AJ under the frame so that the rear wheel is off the
ground.
Special Tool - J ack: 57001-1238
e Remove the clip [AJ from the master link using pliers, and free t he d rive
chain from the rear sprocket.
• Remove the cotter pin [A) .
• Rem ove the axle nut [8J.
. Pull o ut the axle [C], and remove the chain adjuster, brake holder, and
rea r w heel.
. Take off the collar and cap from each side of the rear hub.
CAI.ITlON
Do not lay the wheel on th e ground with th e disc facing down. This
can damage or warp the disc. Place blocks under the wheel $0 the
disc does not touch the ground.
8-6 WHEELS/ TIRES
Rear Whee/Installation
*If the rear caliper has been removed, fit the brake holder [8 ] onto the
swingarm stop [AJ .
• Apply high-temperature grease to the grease seals.
•
•
•
•
Fit the projection [A] on the cap to the groove ( 8] on the collar.
'nstall the collars on the leh and right side of the hub .
Install the rear wheel.
Insert the axle from the left side of the wheel.
.Install the drive chain and the master link clip (A] so that the closed
end of the wU" points in the direction of the chain rotation [8] .
• Check the drive chain slack (see Drive Chain Slack Inspection in the
Final Drive chapter) .
• Torque the axle nut and caliper mounting bolts.
Tcwque - Rear Axle Nut: 98 H-m (10 kg-m, 72 tt-Ib)
Rear Caliper Mounting Bob: 25 N..m (2.5 kg-m, 18 ft-Ib)
• Install the new cotter pin.
• Check the rear brake for good braking power and no brake drag.
, .. WARNING
Do nol attempl 10 drive the molorcycle unlll a full brake pedal Is
obtained by pumping the brake pedal unlll the pads ar. agalnsl the
d*. The brake will not function on the IIrst application of the pedal
"this It not done.
Inspection
• Place the jack [A] under the frame so that the front/rear wheel is off
the ground.
Special Tool - Jack: 57001·1238
.Spin the wheellightty, and check for roughness or binding.
* If roughness or binding is found, replace the hub bearings.
• Visually inspect the front and rear axles for damage.
It the axle is damaged or bent, replace it.
*
WHEELS / TIRES 8-7
Spoke Inspection
• Check that all the spokes are tightened evenly.
* If spoke tigh tness is uneven or loose, torque the spoke nipples evenly.
Torque - Spoke Nipples: 1.5 _ 2.1 N·m (0,15 - 0.21 kg-m, 13 _ 18In_lb)
• Check the rim ru nou t.
J.,WARNING
" any spoke breaks, it should be replaced Immediately. A missing
spoke places an additional load on the other spokes, which will
eventually cause other spokes to break.
Rim Inspection
• Place the Jack under the frame so t hat the front/ rear wheel is raised off
the ground.
Special Tool - Jack: 57001-1238
• Inspect the rim for small cracks, dents, bending. or warping.
* If there is any damage to t he rim, it must be replaced.
e Set a dial gauge against the side of the rim, and rotate the rim to
measure the axial funout (A]. The difference between the highest and
lowest dial readings is the amount of runout.
• Set a dial gauge against the outer circumference of the rim. and rotate
the rim to measure radial runout [8]. The difference between the
highest and lowest dial read ings is the amount of runout.
If rim runout exceeds the service limit. check the hub bearings first.
Replace them if they are damaged. If the problem is not d ue to the
bearings. correct the rim warp (runout). A certain amount of rim warp
can be corrected by recentering the rim. loosen some spokes and
tighten others within the standard torque to change the position of
d ifferent parts of the rim. If the rim is badly bent. however. it must be
replaced.
*
Rim Runout (with tire installed)
Standard
Service limit
Axial
under 0.5 mm
2mm
Rad ial
under 0.8 mm
2mm
Axle Inspection
• Place the axle in V blocks that are 100 mm [AJ apart. and set a dial
gauge [ BJ on the axle at a point halfway between the blocks. Turn
[C) the axle to measure the runout. The difference between the
highest and lowest dial read ings is the amount of (unout.
* if runou t exceeds the service limit, replace the axle.
Axle RunouUl00 mm
Standard:
Service Limit:
TlR 0.10 mm or less
TIR 0.2 mm
8-8 WHEELS / TIRES
Tires
Air Pressure Inspection/Adjustment
. Using a tire air pressure gauge [A}, measure the tire press ure w hen the
tires are cold.
* Adjust the tire air p ressure to
SUit track conditions and rider preference,
but do not stray too far from the recommended pressure.
Track Condition
Tire Pressure
o When the track is wet muddy, sandy
or slippery, reduce the ure pressure to
increase the lire tread surface on th e
ground.
o When the track is pebbly or hard,
increase the l ire pressure to prevent
damage Of punctures, though the tires
80 kPa (0.8
kg/cm 1 , 11 psi)
1
j
l00kPa (1.0
kg/cm 2, 14 psi)
will skid more easily_
Inspection
As the t ire tread [A] wears down, the tire becomes more susceptible
to punct ure and failure .
• Remove an y imbedded stones or other foreign particles from the tread .
• Visually inspect the tire for cracks and cuts, replacing the tire in case
of bad damage. Swelling or high spots indicate internal damage.
requiring tire replacement.
To ensure safe handling and stability, use only th e recommended
standard tires lor replacement, Jnllated to the standard pressure.
NOTE
o Check the wheel when the tire is replaced with a new one.
Standard TIre
Fn>nt
Size
801100.21 51M
Make
Type
DUNLOP
Siz.
1oo/100.1859M
Make
Type
DUNLOP
K490, Tube type
RNr:
K695, Tube type
WHEELS/TIRES 8-9
Removal
B
CAUTlON
j
00 not lay the wheel on the ground with the disc facing down. This
can damage or warp the disc. Place blocks under the wheel so that
the disc does nollouch the ground.
• Remove the wheel from the motorcycle (see Wheels) .
eTo maintain wheel balance, mark [A] the valve stem position on the
tire with chalk so that the tire can be reinstalled in the same position .
• Take oUllhe valve core [ 8 ] to let out the air.
A
O When handling the rim, be careful not to damage the rim flanges .
• Remove the bead protector nut [ A].
eLubricate the tire beads and rim flanges on both sides with a soap and
water solution or rubber lubricant. This helps the tire beads slip off the
rim flanges.
CAUTlON
Never lubricate with minerai 011 (engine 011) or gasoline because they
will deteriorate of the tire.
• Break the beads away from both sides of the rim with the bead breaker
[AJ.
Special Tool - Bead Breaker Assembly: 5700'·'072 [ A]
..
.Pry the tire off the rim with the tire iron of the bead breaker [8]
protecting the rim with rim protectors [A].
Special Tool - Rim Protector: 57001·1063 [AJ
Tire Iron of the Bead
Breaker Assembly: 57001·1072 [B]
Installation
• Position the tire on the rim so that the valve (A] is at the tire balance
mark [8] (the chalk mark made during removal or the yellow paint
mark on a new tire) .
• Tighten the bead protector nut.
.Check and adjust the air pressure after installing.
A
-
(
8 -10 WHEELS / TIRES
Hub Bearings (Wheel Bearings)
Removal
• Remove the wheel, and take out the following:
Trip Meter Gear Drive (front hub)
CoUar(s) (A]
Grease Seal [B]
Circlip [C)
Special Tool - Inside Clrcllp Pliers: 57001 -143
eTake the bearings [A) out of t he hub, using bearing remover.
A
CAUTION
Do not lay the wheel on the ground with the disc facing down. this
can damage or warp the disc. Place blocks under the wheel 80 that
the disc: does not touch the ground.
Special Tool - ae.rlng Remover Shaft: 57001-1265 [8 ]
ee.rlng Remover Head, 4115
57001 -1267
[el -
If:
((117:
Front
B•• rlng Remover Head, CIl20 x 4122:
5700'·1293 (C] - Rear
Installation
• Before installing the wheel bearings, blow any dirt or foreign particles
out of the hub with compressed air to prevent contamination of the
bearings.
• Replace th e bearings with new ones.
• Press in t he following bearings until they bottom out
l eft Bearing ( Front Hub) [AJ
Right Bearing ( Rear Hub) (AJ
Speclll Tool - a.aring Driver Set 57001·1129 [8 ]
NOTE
OlnslBlI the bearings so that the marked side. or sealed side [C] faces
out
• Install:
New Circlip
Distance Co llar
Right Bearing (Front Hub)
l eft Bearing ( Rear Hub)
Special Tool - IMide Clrcllp Pile,..: 57001 -143
WHEELS / TIRES 8-11
• Replace the 011 seals with new ones.
O Apply high temperature grease to the grease seal tips.
• Press In the grease seal [AJ so that the seal surface IS flush [8] with
the end of the hole
Special Tool - Bearing Oriver Set 5700' ·11 29 [C]
InspeCI;on
Since the hub bearings afe made to extremely dose tolerances, the
clearance cannot normally be measured.
CAUTlON
00 not remove any bearings for Inspection. "any bearings are
removed, they will need to be replaced with new onel .
• Turn each bearing in the hub back and forth [AJ while checking for
plav. (OU9! , or binding. If bearing play, roughness. or binding is
found, tep
the bearing.
• Examine taring seal [BJ for damage or leakage.
* If the seal is damaged or is leaking, replace the bearing.
T
I
8 -12 WHEELS / TIRES
Trip Meter Gear Housing
Gear Housing Disassembly
• Remove:
Circlip (AJ
Washer ( 8 )
Gear
(el
Gear Housing Assembly
• Clean and grease the gear housing [El, gear, and pinion [ D]
Gear Housing Lubrication
. Clean and grease the gear housing [AJ.
FINAL DRIVE 9 -1
Final Drive
Table of Contents
Exploded View ............................................................................................................9-2
Specifications .............. ............................................................................................. ,.. 9-3
Drive Chain ................................................................................................................. 9 -4
Slack Inspection ...................................................................................................... 9 -4
Slack Adjustment .................................................................................................... 9·4
Wear Inspection ......................................................................................................9· 5
Lubrication ..............................................................................................................9-5
Removal ..................................................................................................................9-5
Installation ...............................................................................................................9-6
Sprockets .................................................................................................................... 9 -7
Engine Sprocket Removal ......................................................................................9-7
Engine Sprocket Installation ...................................................................................9 -7
Rear Sprocket Removal .........................................................................................9 -7
Rear Sprocket Installation .......................................................................................9 -7
Wear Inspection .............................................................................. ..... ... ..... ...........9 -7
Warp Inspection ....................................................................................................9-8
9-2 FINAL DRIVE
Exploded V·lew
~~
1. Ap
Face t he tooth number
HO.
T1 :' 98
heavy oil.
marking outwards.
T2-. 29 N-m
m (30
(10.0 kg -m, 72 ft- Ib)
. kg-m. 22 ft-Ib)
FINAL DRIVE 9-3
Specifications
Standard
Item
Service Limit
Drive Chain;
Standard chain
Make
DAIDD
Type
Link
Joint Endless, DID520DS 5
- - - -
-
Cha in slack
108 links
55 - 65mm
20-link length
317.5 - 318.2 mm
323mm
TIR 0 .4 mm or less
TIR O.Smm
Too tight: less than 55 mm
Too loose: more than 70mm
Sprockets:
Rear sprocket w arp
Special Tool - Outside Circlip Pliers: 57001-144
Jack: 57001-1238
9-4 FINAL DRIVE
Drive Chain
Slack Inspection
. Support the motorcycle on its side stand .
• Check to see thaI the notches [AJ of the adjusters fB] on both sides
afe in the same relative position.
If they are not, adjust t he chain slack and align them.
*
Misalignment of the wheel will result In abnormal wear and may
result In an unsafe riding condition.
NOTE
o Clean the drive chain if it is dirty, and lubricate it if it appears dry.
• Rotate the rear wheel to find the position where Ihe chain is lightest.
.Measure the space (chain slack) [AJ between Ihe chain and the
5wingarm at the rear of the chain slipper as shown.
* If the drive chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
Too Tight:
Too loose:
55 -65mm
Less than 55 mm
More than 70 mm
Slack Adjustment
• Remove the cotter pin [Al and loosen the axle nut (B).
.Rotate the chain adjuster [C] at each end of the swingarm to obtain
the specified chain slack.
• Check to see that the notches [0] on both sides are in the same
relative position.
Misalignment of the wheel will result In abnormal wear and may
resu" In an unsafe riding condition .
• Tighten the axle nut.
Torque
~
Rear Axle Nut: 98 N·m (10.0 kg-m, 72 ft·lb)
.Rotate the wheel. measure the chain slack again at the tightest
position, and readjust if necessary .
• Install a new caner pin through the axle nut and axle, and spread its
ends.
" the axte nut Is not securely tightened, or the cotter pin
installed, unsafe riding condition may result.
. Check the rear brake (see Brakes chapter).
NOTE
o In wet and muddy condiuons. mud sticks to the chain and sprockets
resulting in an ovedy ught chain and the chain may break. To
prevent this, adjust the chain to 60 - 70 mm of slack. whenever
necessary.
~;
FINAL DRIVE 9-5
Wear Inspection
• Rotate the rear wheel to inspect the d rive chain for damaged rollers,
and loose pins and links.
• If there is any irregularity. replace t he drive chain .
* l ubrlcale Ihe drive chain
ji lt
appears dry .
• Stretch Ihe chain taut by hang ing a 10 kg (22Ib) weight [Al on the
chain .
• M easure the lenglh (Bl of 20 links on the straight part [el o f t he chain
Irom the pin cenler of the 1 51 pin to the pin cen ter of the 21 SI pin wit h
a tape measure [ D]. Since the chain may wear unevenly, take
measurements al several places.
If any m easurements exceed the service lim it. replace the chain. Also.
replace the front and rear sprocke ts when the drive chain is replaced.
*
Chain 20-Link Length
Standard:
317.5 - 318.2 mm
Service Limit:
323 mm
~®~
1st
AWARNING
If the drive chain wear exceeds the service limit, replace the chain
or an unsafe riding condition may result. A chain that breaks or
jumps off the sprockets could snag on the engine sprocket or loci!: the
rear wheel, severely damaging the motorcycle and causing It to go
out 01 control.
Standard Chain
Make:
OAIOO
Type:
DID 52005 5
Link:
108 Links
Lubrication
e ll the chain appears especially dirty, it shou ld be cleaned before
lu bricat ion wit h a high flash- point solvent.
. Apply oil to the sides of the rollers so that o il w ill penetrate to the rollers
and bushings .
• Wipe off any excess oil.
Removal
• Remove t he engine sprocket cover.
• Remove t he dip [Al from t he master link using pliers, and free the drive
chain from the rear sprocket.
eRemove t he drive c hain from the chassis.
21st
9-6 FINAL DRIVE
Installation
• Fit the drive chain back onto the sprockels with the ends at the rear
sprocket.
• 'nstall the master link from the frame side.
• 'nstall the clip [AJ so that the closed end of the
u U ~ points in the
direction of chain rotation (8).
.Adjust the drive chain slack (see Drive Chain Slack Adjustm ent) .
• Check the rear brake effectiveness.
~'~WARNING
Do not anempl to ride the motorcycle until 8 full brake pedal I.
obtained by pumping the brake pedal until the pads are agalns!: the
disc. The brake will nol function on the Ilrat appllcaUon of the pedal
"this Is not done.
FINAL DRIVE 9-7
Sprockets
Engine Sprocket Removal
.Remove the engine sprocket cover.
• Remove the circlip [AJ, and pull off the engine sprocket (8].
Special Toot - Outside Cirellp Pliers: 57001-144
Engine Sprocket Installation
• Replace the circlip with a new one.
Special Tool - Outside Clrcllp Pliers: 57001-144
Rear Sprocket Removal
.Remove the rear wheel (see Rear Wheel Removal in WheelsfTires
chapter).
CAUTlON
Do not lay the wheelan the ground with the disc facing down. this
ean damage or warp the disc. Place blocll:s under the wheel so that
the disc does nollouch the ground.
• Unscrew the rear sprocket bolts [8], and remove the rear sprocket
[AI·
Rear Sprocket Installation
• Install the rear sprocket so that the marked side [AJ faces out.
.Tighten the rear sprocket nuts.
Torque - Rear Sprocket Nuts: 29 N-m (3.0 kg-m, 22 ft·lb)
Wear Inspection
.Visually inspect the front and rear sprocket teeth for wear and damage.
* If they are worn as illuslrated or damaged, replace th sprocket.
®
Worn Tooth (Engine Sprocket) [AJ
Worn Tooth (Rear Sprocket) [8]
Direction of Rotation [C]
}
,
"-
---
../
..
.
'---.-'
•
©
··
9-8 FINAL DRIVE
Warp Inspection
• Using the jack. raise the rear wheel off the ground
Special Tool - Jack: 57001 ·1238
e Set a dial gauge (AJ against the rear sprocket [B] near the teeth as
shown and rotate {C) the rear wheel. The difference between the
highest and lowest dial gauge readings is the amount of runout
(warp).
If the (unout e)(ceeds the service limit, replace the rear sprocket.
*
Rear Sprocket Warp
Slandard:
TIR 0.4 mm or less
Service Limit: TIR 0.5 mm
BRAKES 10-1
Brakes
Table of Contents
Exploded View ............. ,', .......................... ,.. ,......... 10-2
Specifications ......................................................... 10-4
Brake Lever, Brake Pedal
.................... ",.. ..... 10-5
Lever Play Adjustment .,..
............................10·5
Pedal Position Adjustment
................... 10-5
Pedal Removal ......................... ,......................... 10-5
Pedal Installation ................................................ 1 0-6
Brake Fluid ..............................................................10-7
Brake Fluid Recommendat ion ............................10-7
Level Inspection ................................................ 10-8
Change ................................................................10-8
Bleeding the Brake Line .....................................10-9
Caliper ..................................................................10-11
Front Caliper RemovaL ....................................10- 11
Fron t Caliper Installation ..................................10-11
Rear Caliper Removal .......................................10-11
Rear Caliper Installation ...................................10-1 2
Disassembly........... .............................. ........ 10-12
Assembly .....................................................10-13
Brake Pads ............................................................10-14
Front Brake Pad Removal ............................... 10 -14
Front Brake Pad Installation .............. .
..... 10-14
Rear Brake Pad Removal ................................10-14
Rear Brake Pad Installation ............................. 10- 15
Inspection ........................................................1 0-'5
Master Cylinder ..................................................... 10-16
Front Master Cylinder Removal .......................10-16
Front M aster Cylinder Installation ...................10-' 6
Rear Master Cylinder Removal .......................10-' 6
Rear Master Cylinder Installation ..................... 10-' 7
Front Master Cylinder Disassembly ................. 10-17
Rear Master Cylinder Disassembly .................. 10-17
Assembly .........................................................10- 18
Inspection (Visual Inspection) ....................... 10-18
8rake Disc ...........................................................10-19
Installation ..................................................... 10-1 9
Inspection ... .....................
................... 10-1 9
8rake Hose .............. .........................................10-20
Removal/ Installation ........................................10-20
Inspection ........................................................10-20
10-2 BRAKES
Exploded View
B: Apply brake oil.
G: Apply grease.
l : Applva non -permanent locking agent.
A: Replacement Pans
$: Follow the specific tightening sequence.
Si: Apply silicone grease (ex. PBC grease).
BRAKES 10- 3
o
T1 :
T2:
T3:
T4:
T5:
T6:
TI:
T8:
T9:
5.9 N-m (0.60 kg -m, 52 in- Ib)
1.5N -m(O.15kg· m, 13in-lb)
8.B N -m (0.90 kg -m, 78 in -Ib)
8.3 N·m (0.85 kg-m, 74 in -Ib)
18N -m(1 .8kg .m, 13.0ft -lb)
9.B N-m (1.0 kg-m, 87 in-Ib)
25 N-m (2.5 kg -m, 18.0 ft -Jb)
7.B N-m (0.80 kg . m, 69 in -Ib)
23 N-m (2.3 kg -rn, 16.5 tt-Ib)
10-4 BRAKES
Specifications
Standard
Item
Brake Adjustment:
Lever play
Pedal free play
Pedal position
Brake Fluid :
Recommended disc brake fluid:
Type
Brand
Service Limit
Adjustable (to suit rider)
Non -adjustable
about 0 mm below top of footpeg
-----
D.O.T.3 or 0 .0 T 4
[D.O.T.3J
---
Atlas Extra Heavy Duty
Sheil Super Heavy Duty
Texaco Super Heavy Duty
Wagner Lockheed Heavy Duty
Castrol Girling -Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid
---
---
---------
-----
[D.0.T.4J
Castrol Girting- Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid
Check Shock Premium Heavy Duty
Brake Pads:
Lining thickness:
Front
Rear
3.8mm
4.7 mm
--------1 mm
1 mm
Brake Disc:
Thickness:
Front
Rear
Runout
Special Tools -
2.85 - 3 .15 mm
4.35 - 4.65 mm
TI R 0.2 mm or less
Inside Clrcllp Pile,..: 57001-143
Jack: 57001-1238
2.5mm
3.8mm
TIR 0 .3 mm
BRAKES 10-5
Brake Lever. Brake Pedal
Lever Play Adjustment
. Adjust the front brake jever [A ] to suit you .
• loosen the adjuster locknut [ B] and turn the adjuster (C] to either
side .
• After adjustment, tighten the locknut.
Torque - Brake Le ver Play Adjuster Locknut 5.9 N·m (0.60 kg..m, 52
In-Ib)
Pedal Position Adjustment
. Check that the brake pedal [A] position is in the correct position.
Pedal Position
Standard:
About 0 mm below top ollootpeg [ S)
NOTE
o Usually it is not necessary to adjust the pedal position.
but always
adjust it when the master cylinder push rod nut is loosened.
• loosen the push rod locknut [A] .
• Tum the push rod wIth the hex head (B) to achieve correct pedal
position .
• Tighten the locknut.
Torque - Push Rod Locknut: 18 N-m (1 .8 kg-m, 13.0 tt·lb)
Pedal Removal
• Remove:
Coner Pin [A]
Joint Pin [ 8 ]
Return Spring lower End
• Remove the mounting bolt (A] and take oH the brake pedal [ BJ.
10-6 BRAKES
Pedal Installation
. Apply high temperature grease to the brake pedal shaft. and Install the
pedal onlo the shah.
Torque - Brake Pedal Mounting Boll: 9.8 N-m (1.0 kg-m, 87In.lb)
• Hook the return spring lower end on the pedal.
.Install the joint pin and a new cotler pin .
• Check the brake pedal position and pedal effectiveness.
~'~WARNING
Do not aHempt 10 ride the motorcycle until 8 full brake pedal is
obtained by pumping the brake pedal until the pads are agaln.t the
disc. The brake will not function on the liral application of th e pedal
If thllis not done.
BRAKES 10- 7
Brake Fluid
i",WARNING
When wor1dng with th e disc brake, observe the precaullons listed
below.
1. Never reuse old brake fl uid.
2. Do not use fluid from a container that has been left unsealed
or that has been open for a long time.
3. Do nOI mix two types and brands of fluid for use in the brake.
This lowers the brake fluid boiling point and could cause the
brake to be ineffectMI. It may also cause the rubber brake pans
to deteriorate.
4 Don't leave the reseNOlr cap off for any length of time to avoid
moisture contamination of the fl uid.
5. Don't change the fluid in the rain or when a sHang Wind is
blowing.
6. Except for the disc pads and disc, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do
not use any other flUid for cleaning these parts. Gasoline,
engine oil, or any other petroleum distillate will cause deteri oration of the rubber parts. Oil spilled on any part will be
difficult to wash off completely and will eventually deteriorate
the rubber used in the disc brake.
7. When handling the disc pads or disc, be carefullhat no disc
brake fluid or any oil gets on them. Clean off any fluid or oil
that inadvertently gets on the pads or disc With a high
flash -point solvent. Do not use one which will leave an oily
residue. Replace the pads with new ones if they cannot be
cleaned satisfactorily.
8. Brake fluid qUickly ruins painted surfaces; any spilled flUId
should be completely washed away immediately.
9. If any of the brake tine fin ings or the bleed valve is opened at
any time, the AIR MUST BE BLED FROM TtiE BRAKE.
Brake Fluid Recommendation
Recommended fluids are given in the table below. If none of the
recommended fluids are available, use extra heavy-duty brake fluid only
from a container marted D.O.T.3 or 4.
NOTE
Oe rake fluid of D.O. T.4 ;s installed in the brake system when shipped.
Recommended Disc Brake Fluid
Type:
0 .0 .T.3 or 0.0.T,4
Brand: [ 0 .0 .T.3]
Alias Extra Heavy Duty
Shell Super Heavy Duty
Texaco Super Heavy Duty
Wagner Lockheed Heavy Duty
Caslrol Glrllng-Unlversal
Castrol GT (LMA)
castrol Disc Brake Fluid
[ 0 .0 .T.4]
Castrol Girting - Universal
Castrol GT (LMA)
Caslrol Disc Brake Fluid
Checlt Shock Premium Heavy Duty
10-8 BRAKES
Leve/lnspection
In accordance wit h Ihe Periodic Maintenance Chart, inspect the brake
fluid level in the front and rear brake fluid reservoirs .
• Check that the brake fluid level in the front brake reservoir [A] is more
than half full.
NOTE
o Hold the reservoir horizonlal when checking brake fluid level.
• Check t he brake fluid level in the rear brake reservoir fA] is between
the upper [8] and lower [C] level lines.
If the fluid level is lower than t he tower level line, fi ll the reservoir to th e
upper level line of t he reservoir.
*
i .. WARNING
Change the brake fluid In the brake line completely If the brake lIuld
must be refilled but the type and brand of the brake fluid thai already
Is In the reservoir are unidentified. After changing th e fluid , use only
the same type and brand of fluid thereafter. Mixing dlHerent types
and brand of brake fluid lowers the brake fluid bolilng point and could
cause the brake to be IneHectlve. It may also cause the rubber brake
parts to deteriorate.
Change
In accordance with the Periodic Maintenance Chart, change the brake
fluid . T he brake flu id should also be changed if it becomes contaminated
with d irt or water. Furthermore, th e brake flu id should be changed to
bleed the air Quickly and completely whenever the brake line parts are
removed.
NOTE
o The
procedure to change the front brake fluid is as follows.
Changing the rear brake fluid is the same as for the front brake.
•
•
•
•
l evel the brake fluid reservoir.
Remove t he reservoir cap.
Rem ove the rubber cap on the bleed valve fA] .
A tt ach a clear plastic hose [8] to the bleed valve on t he caliper, and
run th e other end of the hose into a container.
BRAKES 10-9
. Change the brake fluid as follows:
ORepeal lhls operation until fresh brake fluid comes out from the plastic
hose or the color of the fluid changes.
1. Open the bleed valve [AJ.
2. Apply the brake lever and hold It [B].
3 Close the bleed valve [C).
4. Release the brake lever [0].
a Fill the reservoir with fresh specified brake fluid
NOTE
o The lIuid level must be checked often during the changing operation
and fap/en/shed with (resh brake fluid. "the fluid in the reservoir
funs almost out any time during the changing operation. the brakes
will need to be bled since air will have entered the brake line.
• Remove the clear plastic hose.
• Tighten the bleed valves, and install the rubber caps.
Torque - Caliper Bleed Valve: 7.8 N-m (0.80 kg·m, 69 in-lb)
Reservoir Cap Screws: 1.5 N-m (0.15 kg.m, 13In.lb)
. After changing the fluid, check the brake for good braking power, no
brake drag, and no fluid leakage.
necessary, bleed the air from the lines.
*If
Bleeding the Brake Line
The brake fluid has a very low compression coeHicient so that almost
aU the movement of the brake lever or pedal is transmitted directly to the
caliper for braking action. Air, however, is easily compressed. When air
enters the brake lines, brake lever or pedal movement will be partially
used in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power
... WARNING
Be sure 10 bleed the air from the brake whenever brake lever or
pedal action feels soft or spongy, atter the brake fluid Is changed, or
whenever a brake line fining has been loosened lor any reason.
NOTE
o The procedure to bleed the front brake line is as follows.
~
B
Bleeding
the re8r brake line is the seme 8S for the front breke
(v
• Remove the reservoir cap, and check that there is plenty of fluid in the
reservoir .
• With the reservoir cap oH, slowly pump the brake lever several times
until no air bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir .
• Attach a clear plastic hose to the bleed valve on the caliper, and run the
other end of the hose into a container.
• Bleed the brake line and the caliper as follows:
o Repeat thiS operation until no more air can be seen coming out into
the plastic hose.
1. Pump the brake lever until it becomes hard, and apply the brake
lever and hold it [A).
2. QUickly open and close the bleed valve [81 while holding the
brake lever applied.
3. Release the brake lever [C).
-.,
-,,"
-~
'-
<5
'Co
0
'-----nff--J
10-10 BRAKES
NOTE
o The fluid level must be checked often during the bleeding operation
and replenished with fresh brake fluid 8$ necessary. If the fluid
In
the reservoir runs almost out any lime during bleeding operation, the
operation must be done ovef again from the beginning
since air will
have entered the line.
C Tap the brake hose lightly from the caliper to the reservoir fOf easier
bleeding .
• Remove the clear plastic hose.
• Tighten the bleed valves, and install the rubber caps.
Torque - Caliper Bleed Valve: 7.8 N-m (0.80 kg-m, 69In-lb)
. Check the fluid level.
TOf'que - Reservoir Cap Screws: 1.5 N-m (0.15 kg.m, 13 In.lb)
. After the bleeding is done, check the brake for good braking power,
no brake drag, and no fluid leakage.
BRAKES 10- 11
Caliper
Front Caliper Removal
. Orain the brake fl uid (see Brake Fluid Change) .
• Loosen the banjO bolt [A) at the brake hose lower end, and tighten it
looselv
. Loosen the brake pad bolts ( E) before caliper removal if the caliper is
to be d isassembled.
NOTE
e lf the caliper is to be disassembled after removal and compressed air
is not available. remove the pistons before brake hose removal (see
Disassembly) .
• Unscrew Ihe mounting bolts [B]. and detach the caliper [e] from the
disc .
• Unscrew the banjo bolt and remove the brake hose from the caliper.
CAlITlON
Immediately wash away any brake Iluid thai is spilled.
Front Caliper Installation
• Tighten the brake pad bolts if they were removed.
Torque - Brake Pad Bolts: 18 N-m (1 .8 kg-m, 13.0 fe-Ib)
Brake Pad Bolt PIU9B: 1.5 N-m (0.15 kg-m, 13 m-tb)
• Install the caliper, and the brake hose lower end.
e Replace the washers on each side of Ihe hose fitting With new ones.
Torque - Caliper Mounllng Bolts: 25 N-m (2.5 kg-m, 18.0 fe·lb)
Brake Hose BanJo Bolt: 25 N-m (2.5 kg-m, 18.0 b·tb)
. Check the fl uid level in the master cylinder reservo ir and bleed the
brake line (see Bleeding the Brake Line) .
• Check the brake lever for good braking power, no brake drag, and no
fl uid leakage.
i,WARNING
00 nol attempt to drive the motorcycle unlit a full brake lever Is
obtained by pumping the brake lever unlil the pads al'1l agalnal the
disc. The brakes will nol function on the first appllcatkm 01 the lever
" ttl. Is nol done.
Rear Calip er Removal
• Remove the rear caliper cover [A J.
• Orain the brake fluid (see Brake Fluid Change) .
• Loosen the banjo bolt [ 8) at the brake hose lower end, and tig hten it
loosely.
NOTE
CIf the caliper is to be disassembled after removed and compressed
air is not available, remove the pisto n before brake hose removal (see
Dis8ssembly).
10-12 BRAKES
• Remove the rear wheel (see Wheels/Tires chapter).
eRemove the banjo bolt and the caliper mounting bolts (e ].
.Take off the caliper [0] from the sWlngarm tEl·
Rear Caliper Installation
• Install the rear wheel (see Wheels/Tires chapter) .
• Ad/ust the drive chain slack (see Final Drive chapter) .
• Tighten the caliper bolts.
Torque - Caliper Bolls: 2S N..m (2.5 kg-m, 18.0 H·lb)
• Connect the brake hose to the caliper pulting a new flat w asher on
each side of the brake hose filt ing .
• Tighten the banjo bolt.
Torque - 8anjo Bott: 25 N-m (2.5 kg-m, 18.0 ft·lbl
. Check the fluid level in the master cylinder (reservoir) and bleed the
brake line (see Bleeding the Brake) .
• Check the brake for good braking power, no brake drag, and no fluid
leakage.
i.,WARNING
00 not attempt to rkte the motorcycle until a full brake pedal Is
obtained by pumping the brake pedal until the pads are against the
disc. The brakes will not function on the Ilrstappllcallon of the pedal
" this ta not done.
Disassembly
•
•
•
•
Remove the front/rear caliper (see Caliper Removal) .
Remove the pads and spring (see Pad Removal) .
Insert a wooden board 5 mm thick inside the caliper opening .
lightly apply compressed air fA] to the hose joint opening until the
piston(s) hit the wooden board (8) .
o Remove the board and pull out the piston{s) bV hand .
.. ~WARNING
To avoid serious Injury, never place your fingers or palm Inside the
caliper opening. "you apply compressed air Into the caliper, tha
pl,lon(s) may crush your hand or lingers.
• Remov. the dust seals(s) and fluid seal(s) .
• Remove the caliper holder, shah rubber friction boot and dust cover.
• Remove the bleed valve and rubber cap.
NOTE
Olf the caliper is to be disassembled aher removal and compressed air
is not available, remove the piston(s) using the following four steps
before disconnecting the brake hose from the caliper.
8
BRAKES 10-13
a Prepare a container for brake flUid, and perform the work above.
o Remove the front/rear caliper wi th the banjo boll tightened lightly (see
Caliper Removal).
o Remove the pads and spring (see Pad Removal).
Dlnsert a wooden board 5 mm thick inside the caliper opening.
O Pump the brake lever or pedal to remove the caliper piston(s).
Assembly
.Clean the caliper parts excepllhe pads.
CAUTION
For cleaning the parts, use only disc brake fluid, Isopropyl alcohol,
or ethyl alcohol.
.Tighten the bleed valve.
Torque - Caliper Bleed Valve: 7.8 N-m (0.80 kg-m, 69ln·lbl
• Replace the flUid seals which are removed with new ones.
aApply brake fluid to the fluid seals [Al, and install them into the
cylinders by hand .
• Replace the dust seals [BJ with new ones if they are damaged.
QApply brake fluid to the dust seals, and install them into the cylinders
by hand .
• Apply brake fluid to the outside of the piston(s) [C], and push them
into each cylinder by hand .
• Replace the shaft rubber friction boot [A] and dust covet [B) if they
are damaged .
• Apply a thin coat of silicone or PBC grease to the caliper holder shafts
[C] and holder holes [0] (PBC is a special high temperature,
water-resistant grease) .
• Install the anti-rattle spring [A) in the caliper as shown .
• Install the pads (see Pads Installation) .
• Wash away any spilled brake fluid on the caliper.
10-14 BRAKES
Brake Pads
Front Brake Pad Removal
• Remo.... e the brake pad bolt plugs.
e Loosen the brake pad bolts [AJ,
e Remove the caliper bolts [ B],
• Detach the caliper from the disc.
• Pull out the pad bolts.
e Take the piston side pad out of the caliper holder.
• Push the caliper holder toward the piston, and then remove the other
pad from the caliper holder shaft.
Front Brake Pad Installation
• Push th e caliper pistons in by hand as far as t hey will go .
• 'nstall t he anti- ranle spring in place .
• 'nslaU t he piston side pad first, and then the other pad,
.Tig hten:
Torque - Brake Pad Bolts: 18 N-m (1 .8 kg-tn, 13.0 n.lbl
Brake Pad Bolt Plugt: 1.5 N-m (0.15 kg-m, 131n-lb)
.. WARNING
Do not attempt 10 ride the motorcycle until a fu ll brake lever ,.
obtained by pumping the brake le..,er until the pads are agalnl t th e
disc. The brake will nol function on tha 111111 applicatIon li thia II nol
done.
Rear Brake Pad Removal
•
•
•
•
•
•
•
Remove the rear caliper cover.
Loosen the pad bolts [AJ .
U nscrew the caliper mounting bolts.
Remove the rear wheel (see Wheels/Tires chapter).
Detach the caliper from the disc.
Remove the pad bolts.
Push the caliper holder toward the piston, and then remove the pad
[ 8) from t he caliper ho lder shafts.
BRAKES 10-15
Rear Brake Pad Installation
. Push the caliper piston in by hand as far as it will go .
• Install the anti- ranle spring in place.
• Install the piston side pad first, and then the other pad .
• Tighten the brake pad bolts.
Torque - Brake Pad Bolts: 18 N·m (1 .8 kg·m, 13.0 ft-Ib)
e lnstall the caliper (see Caliper Installation) .
e lnstall the rear wheel (see W heels/Tires chapter).
~"WARNING
Do nol attempt to drive the motorcycle until a tull brake pedal Is
obtained by pumping the brake pedal until the pads are agalnsl the
disc. The brake will not function on the first application of the pedal
It this is nol done.
Inspection
• Check the lining thickness and condit ion of t he pads in each caliper.
* If either pad is damaged, replace both pads in the caliper as a set.
* If the lining thickness [A] of either pad is less than the service limit
[B], replace bot h pads in the caliper as a set.
Lining Thickness
Standard:
Service Limit
Front
3,8mm
1mm
Rear
4.7 mm
1 mm
10-16 BRAKES
Master Cyl inder
CAlITlON
Brake tluld qulcldy ruins painted or plastic suriaces; any spilled lIuld
ahould be completely washed away Immediately.
Front Master Cylinder Removal
• Remove the banjo boll to disconnect the upper brake hose from the
master cylinder (see Brake Hose Removal/Installation).
e When removing the brake hose, temporarily secure the end of the brake
hose to some high place to keep fluid loss to a minimum .
• Unscrew the clamp bolts [AJ, and take off the master cylinder as an
assembly with the reservoir and brake lever.
Front Master Cylinder Installation
. The master cylinder clamp must be installed with the arrow mark (AJ
upward.
Onghten the upper clamp bolt (8] first. and then the lower clamp bott
[C]. There will be a gap at the lower part of the damp after tightening.
TOf'qUe - Masler Cylinder Clamp Bolli: 8.8 N~ (0.90 kg.m, 78 In-Ibl
• Replace the washers on each side of the hose fining with new ones.
• Tighten the brake hose banjo boll
Torque - Brake Hose Banjo Bolt 2.5 N~ (2.5 kg~, 18.0 It.lbl
• Bleed the brake line (see Bleeding the Brake Line) .
• Check the brake for good braking power, no brake drag, and no fluid
leakage.
Rea! Master Cylinder Removal
• Remove the reservoir guard and the reservoir mounting bolt.
• Remow the coner pin [AJ and the joint pin [B] .
• Unscrew the brake hose banjo bolt [C] (see Brake Hose
Removal/Installation) .
OWhen removing the brake hose. temporarily secure the end of the brake
hose to some high place to keep fluid loss to a minimum .
• Unscrew the master cylinder mounting screws [0]. and remove the
master cylinder [ E] with the reservoir.
• Remove the reservoir cap, and pour the brake fluid into a container.
• Remove the reservoir and its hose from the master cylinder.
BRAKES 10-17
Rear Master Cylinder Installation
e Tighten the feaf master cylinder mounting screws securelv_
Torque - Rear Master Cylinder Mounting Screws: 8.3 N-m (0.85 kg-m,
74 ln. lbj
• Replace the cotter pin with a new one.
• Replace the washers on each side of the hose fitting with new ones.
e Torque the following:
Torque - Brake Hose Banjo Bolt: 25 N-m (2.5 kg-m, 18.0 ft.-lb)
• Bleed the brake line (see Bleeding the Brake line) .
• Check t he brake for good braking power, no brake drag, and no fluid
leakage.
• Check t he brake pedal posi tion.
Front Master Cylinder Disassembly
• Remove the front master cylind er.
• Remove the reservoir cap and d iaphrag m, and pour the brake fl u id into
a container.
• Unscrew the locknut [A] and pivot bolt [8] . and remove the brake
lever [C] .
• Push the dust cover [0] out of place, and remove the clrelip [El.
Special Tool - Inside CirellI' Pliers: 57001-143
• Remove the washer [F], and pull out the piston assemblv [ G).
Do not remove the primary and secondary cups (H] from the piston
since removal will damage them.
Rear Master Cylinder Disassembly
• Remove the rear master cvlinder.
• Slide the dust cover (A] on the push rod [8) out of place, and remo .....
the cirelip [C] .
SjMCial Tool - Inside CirellI' Pliers: 57001 -143
• Pull out the push rod with the piston stop [D).
.Take off the piston assemblv [ E] and return spring [F] .
CAI1TION
Do not remove the primary and secondary cups [G] from the piston
since removal will damaga them.
eRemove the circlip [ H], and take off the connector [I] and O-ring
[J J.
10-18 BRAKES
Assembly
eBefore assembly, clean all parts including the master cylinder with
brake fluid or alcohol .
• Apply brake fluid to the removed parts and to the inner wall of the
cylinder,
CAlITlON
Except lor the disc pads and disc, un only disc brakeltukl, Isopropyl
alcohol, or ethyl alcohol lor cleaning brake parts. Do not use any
other fluid lor cleaning these parts. Gasoline, engine 011, or any other
petroleum distillate will cause deterioration of the rubber parts. 011
spilled on any part will be dlHlcutt to wash oft completely, and will
eventually deteriOf'ale the rubber used in the disc brake .
• Apply silicone grease.
Silicone Grease Brake lever Pivot Bolt
Brake lever Pivot Contact
Plllh Rod Contact (Rear)
OUst Cover
.Take care not to scratch the piston or the inner wall of the cylinder.
• Tighten the brake lever pivot bolt and locknut securely.
Torque - Brake Lever Pivot Bolt and locknut 5.9 N-m (0.60 kg-m, 52
In-Ib)
Inspection (Visual Inspection)
• Disassemble the front and rear master cylinders .
• Check that there are no scratches. rust or pitting on the inner wall of
each master cylinder [A] and on the outside of each piston [BJ .
* If a master cylinder or piston shows any damage. replace them .
• Inspect the primary [C] and secondary [0] cups.
*If a cup is worn, damaged, sohened (rotted). or swollen, the piston
assembly should be replaced to renew the cups.
*If fluid leakage is noted at the brake 18ler. the piston assembly should
be replaced to renew the cup.
• Check the dust covers (E] for damage.
* If they are damaged, replace them .
• Check that the relief [ F] and supply [G) ports are not plugged.
*If the small relief port becomes plugged, the brake pads will drag on
.
the disc. Blow the ports clean with compressed air.
• Check the piston return spring [HJ for any damage.
* If the spring is damaged, replace it.
G
•
BRAKES 10-19
Brake Disc
Installation
• Install t he brake disc as shown so that the marked side [AJ faces ou t .
Non-permanent LockIng Agent - Braka DIsc Bolts
Torque - Brake DIsc Bolts: 23 N-m (2.3 kg-m, 16.5 tt-tb)
Front Disc [BJ
Rear Disc [C]
Inspection
. Visu ally inspect t he d isc.
*If it is scratched or damaged, replace the disc.
• Measure the thickness of each disc at the point [Al where it has worn
the most.
Replace the disc if it has worn past the selVice limit.
*
Thickness
Standard:
Service Limit
Front
2.85 _ 3.15 mm
2.5mm
Rear
4.35 - 4.65 mm
3.8mm
• Place t he jack under the motorcycle so that the front/rear wheel is off
the ground.
Special Tool - Jack: 57001 -1238
. Set up a d ial gauge (Al against the disc
as illustrated.
o For the front d isc, turn the handlebar fully to one side.
• Measure the disc runout while rotating (Bl the wheel slowly.
* If t he runou! exceeds the service limit, replace the disc.
Runout
Standard:
Service LImit:
TIR 0.2 mm or leas
TIR 0.3 mm
10- 20 BRAKES
Brake Hose
Removal/Installation
CAUTlON
Brake lIuld quickly ruins painled or plaslic surfaces; any spilled fluid
should be completely washed away Immediately .
• When removing the brake hose, take care not to spin the brake fluid
on the painted or plastic parts.
• When removing the brake hose, temporarilv secure the end of the brake
hose to some high place to keep fluid loss to a minimum.
e There are washers on each side of the brake hose fitting. Replace them
with new ones when installing .
• When installing the hoses, avoid sharp bending, kinking, flattening or
twisting, and route the hoses according to the Cable, Wire and Hose
Routing section in the General Information chapter.
eTorque the banjo bolts at Ihe hose fittings.
Torque - Brake Hose 8 anJo Bolts: 25 N-m (2.5 kg-m, 18.0 tt-Ib)
. Bleed the brake line aher installing the brake hose (see Bleeding the
Brake Line).
Inspection
eThe high pressure inside the brake line can cause fluid to leak or the
hose to burst if the line is not properly maintained. Bend and twist the
rubber hose while examining it.
Replace.it if any crack or bulge is noticed.
*
SUSPENSION 11-1
Suspension
Table of Contents
Exploded View ........................................................11 -2
Specifications .................... ...........
.................. 11 ~ 4
Front Fork ...... .......... ...........
..................... 11 -5
Air Pressure Adjustment. ....
............... 11 - 5
Compression Damping Adjustment .................. 11 -5
Fork Oil Level Adjustment .. ..... .... ....... .. ... .......... , , -5
Fork Oil Change ...... .................
............... 11 ~ 8
Fork Spring Replacement............
... .11 -9
Removal ........................................................... .. 11 -9
Installation ......... ," ', .,", ... " ........... ....................... 11 -9
Disassembly ....................... .......................... 11 -10
Assembly ...
.. .. ... .... 11 -11
Inner Tube Inspection ... .................................. 11 -12
Spring Inspection ......... . .. .. .... .... .................. 11 -12
.....................11 -13
Rear Shock Absorber .........
Rebound Damping Adjustment .. .. ................... 11 -13
Compression Damping Adjustment. .... ... ......... 1' -13
Spring Adjustment ............................. .............. 11 -13
Removal ................. .. .......................................11 -15
Installation ............. .... .. .. ................................. 11-15
Spring Replacement ........................................ 11-16
Disassembly (Oil Change) ..............................11-16
Assembly ( Oil Filling) .... .. ..............................11-18
Spring Inspection
.. .. ......... .... 11 - 20
Scrapping .
.... ... ............. _......................11- 20
Swingarm .. ...........................................................11 -21
Removal ......................................
....... 11- 21
Installation ........................................ ... ............. , 1 -21
Swingarm Bearing Removal ...... ........ .. ............ " -21
Swingarm Bearing Installation .... ..................... 1' - 22
Swingarm Pivot Che<:k .................................... 11 - 22
Swingarm Bearing, Sleeve Inspection ............. 11 ~ 22
Tie-Rod, Rocker Arm ........................................ .. .. 11 -23
Tie-Rod Removal ..................... ........................ 11 -23
Tie-Rod Installalion .......................................... 1' -23
Rocker Arm Removal. .. .. ............
.. .. .... .11-23
Rocker Arm Installation ...... .......... ........ ......... 11 -24
Rocker ArmfTie-Rod Bearing Removal ........... 1' -24
Rocker ArmfTie-Rod Bearing Installation ....... 11 - 24
Un;-Trak link Pivot Check ............... ......... ..... 11 -24
Rocker Arm/Tie-Rod Bearing Inspection ........ 1 1 -24
Rocker Arm/Tie- Rod Sleeve Inspection .. ........ " -24
" -2 SUSPENSION
Exploded View
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0
~
~
0
e
~
T.
~
o-®
~
0
0
®®
@
®@
U
9
~
~
•~
,' ,
g
U
g
8
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0
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FO:Apply fork oil.
L: Apply a non-permanent locking agent.
M : Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specific tightening sequence.
T1: 1.3 N-m (0.13 kg-m, 11 in-lb)
T2: 29 N-m (3.0 kg-m. 22 h -Ib)
T3: 1SN-m(1.5kg-rn,11.0ft-lb)
T4:
T5:
T6:
TI:
20 N-m (2.0 kg-m, 14.5 ft -Ib)
25 N-m (2.5 kg -m, 18.0 ft -Ib)
9.8 N-m (1.0 kg-m, 87 in-Ib)
71 N-m (7.2 kg -m, 52 fI -lb)
SUSPENSION 11-3
1.
M:
Needle Bearings: Face the
manufacturer's marks out.
Apply molybdenum disulfide grease.
T1 : 88 N-m (9.0 kg -m, 65 h -Ib)
T2: 83 N -m (8.5 kg -m, 61 fl-Ib)
T3: 39 N-m (4.0 kg -m, 29 fl -Ib)
11-4 SUSPENSION
Specifications
Item
Standard
Front Fork (per one unit):
Fork. inner tube diameter
0>43 mm
Air pressure
Compression damper setting:
Atmospheric pressure (non-adjustable)
Standard
Usable range
10th click from the first click of the fully clockwise
position
1
_~
21 ± 3
KAYABA 01 (SAE SW)
623 ± 4 mL (completely dry)
apprax. 530 mL (when changing oil)
Fully compressed, without fork spring,
below from inner tube top 87 ± 2 mm
(Usable range: 85 - 100 mm)
457.5 mm (Service limit: 448 mm)
Fork oil viscosity
Fork oil capacity
Fork oil level
Fork spring free length
Rear Shock Absorber:
Rebound damper set:
Standard
Usable range
Standard
Compression damper set
Usable range
Spring setting:
Standard position
Nut adjusting range
Standard spring preload
Preload change per turn of the nut
Gas pressure
Oil type
Oil capacity
Shock spring free length
14th click from the first click of the fully clockwise
position
1 .... .-.21 ±3 clicks
16th click tram the first click of the fully clockwise
position
1 ..... -+ 23±3 clicks
11 6.5 mm between upper mounting hole center and
lower end of adjusting nut
103 - 125mm
Bl0 N (B2.5 kg, lB2 Ib)
74 N (7.5 kg, 16.5 Ib)
980 kPa (10 kg/cm l , 142 psi, Non-adjustable)
KYB K2·C (SAE5W or Bel-Ray SE2 #40)
291 mL
255 mm (Service limit: 250 mm)
Optional Fork Spring and Fork Oil
Parts No .•
Spring Constant
N/mm (kg/mm)
44026-1574
44026-1570 (STD)
44026·1575
44026-1576
6.6
6.9
7.1
7.3
(0.68)
(0.70)
(0.72)
(0.74)
Fork Oil Level (mm)
Fork Oil Capacity (mL)
Standard
Usable Range
Standard
Usable Range
88
87
93
9'
B6 - 101
B5 - 100
90 -105
B9 - 103
622
623
6'7
6'9
624 _ 609
625-610
620 - 605
62' - 607
C): The parts numbers are subject to change. Refer to the Parts Catalog to make sure their numbers.
Special Tools -
Jeck: 57001·1238
Fort.: 011 level Gauge: 57001-1290
Fort.: Piston Rod Puller, Ml0)( 1.0: 57001-1298
Fork Spring Holder: 57001·1286
Fort.: Cylinder Hoider: 57001·1245
Fort.: Outer Tube Weli!ht: 57001·1218
Front Fort.: 011 Seal Driver: 57001-1219
Hook Wrench: 57001·1101
011 Seal & Bearing Remover: 57001·1058
Bearing Driver Set: 57001 ·1129
SUSPENS ION 11 -5
Front Fo rk
Air Pressure Adjustment
The standard air pressure m the fork legs is atmospheric pressure. The
air pressure in the fork legs increases as the fork heats up, so the fork
action will get stiffer as the vehicle operation progresses.
• Place the jack under the frame so that the front wheel is off the ground.
Special Tool - Jack: 57001-1238
• Remove the screws (Al at the top of the front fork top plugs to let the
air pressu re equalize. Then install them.
Torque - Front Fork Air Screws: 1.3 N-m (0.13 kg-m, 11In·lb)
Compression Damping Adjustment
• Clean the bottom of the fork tubes.
• Remove the caps on t he bottom of the fork tubes .
• To adjust compression damping, turn the adjuster [Al on t he front fork
cylinder valve wi th the blade of a screwdriver until you feel a dick .
• Adjust the compression damping to suit your preference under special
conditions.
II both adJusters are nol adJusted equally, handling may be Impaired
and a hazardous condilion may re sult.
O The standard adjuster setting for an average-build rider 68 kg (150 Ib)
is the 10th click back from the 1 st click of the fully clockwise position.
. Put the caps into the bottom of the fork tubes.
*If the damper setting feels too soft or too stiff, adjust it in accordance
with the tables.
HardBf
(clockwise)
STO
I
1
Compression Damping AdJustment
1<1
Adjuster
Posit ion
Damping
Force
Setting
Terrain
Speed
21 ±3
Weak
Soft
Good
Low
1
1
1
1
I
I
I
I
1
Strong
Hard
Bad
1
I
High
Fork Oil Level Adjustment
• Place the jack or a stand under the engme so that the front wheel is
off the ground .
Specia l Tool - J ack: 57001 -1238
i~WARNING
Lift th e front wheel off the ground before unscrewing both fork lop
plugs, or the Iront fork tubes may compress all the way, dropping the
molorcycle off the stand.
• Remove the fron t fender.
• Loosen the upper fork clamp bolts and remove the fork top plugs.
Softer
(counterclockwise)
1
2
3
4
I
10 ....
I
Seated position
Adju5tBf turned fully clockwise
11 -6 SUSPENSION
. Slowly compress the front fork fully by pushing up the outer tubes
using a jack or block under the front wheel.
. Push down the fork spring [A] and insert the fork spring holder
[el
under the piston rod nut [8).
O One person should push down the fork spring, while another person
pulls up the top plug and inserts th e fork spring holder under the piston
rod nu t.
Special Tool - Fork Spring Holde r: 57001 -1286
o Use wrenches on the rod nut and the top plug to loosen the piston rod
nut.
• Remove:
Top Plug [A] and O-ring [8]
Fork Spring [C]
Spacer Guide [ D)
Spacer [El
Spring Seat
• Remove the other fork spring in the same manner.
• M easure the oil level, using the fork oille...el gauge CA).
Special Tool - Fort 011 Lev.1Ga uge: 57001-1290
Q Sel the gauge stopper (B] so that Its lower side shows the oil level
distance specified [C} .
o Insert the gauge tube into the inn9l' tube [ 0 ] and position th e stopper
across the top of the inn9l' tube [ E} .
A
NOTE
o The gauge tube should be in
the middle of the inn", tube, or the
correct oil level will not be measufed.
O Pull the handle slowly 10 draw out the excess oil until no more oil
comes up t he tube.
*If no oil is drawn out, there is not enough oil in the fork. Pour in some
more oil, then d raw out the excess.
Front Fot1t 011 l e vel (Fully compressed w ithout fork spring)
Standard:
87 ± 2 mm
Uu bkt Range: as - 100 mm
Fof1l 011 Viscolity
KAYABA01 or SAESW
E
SUSPENSION 11-7
. Screw the piston rod puller [8] onto the piston rod [AJ.
Specia l Tool - Forl!. Piston Rod Pulle r, Ml 0 x 1.0: 57001-1298
. Pull the piston rod up above the inner tube top.
• Tighten the rod nut finger . tight .
• Install:
Fork Spring [A]
Spring Seal [8 )
Spacer (C]
Spacer Guide [D]
o Either end of the fork spring may be up.
• Push down the fork spring [ A] and insen the fork spring holder
under the piston rod nut [ B].
[el
Special Tool - Fork Spring Holder: 57001-1286
o
• Remove the fork piston rod puller (special tool) .
• Check the O-ring [ 8 ] on the top plug [ A] and replace it with a new
one if damaged .
• Screw the top plug onto the piston rod .
• Holding the top plug with a wrench, tighten the piston rod nul against
the top plug.
Torqu e - Piston Rod Nut: 15 N·m (1.5 kg-m, 11 .0 ft-Ib)
. Pull out the fork spring holder (special (001) and screw the top plug
into the inner tube.
• Tighten the top plug.
Torque - Fori!; Top Plug: 29 N-m (3.0 kg-m , 22 ft-Ib)
. Adjust the oil level in the other fork leg .
• Install the parts removed.
Torque - Upper Fori!; Clamp Bolts: 20 N-m (2.0 kg-m, 14.5 ft-Ib)
11-8 SUSPENSION
Fork Oil Change
The oil should be changed in accordance w ith the Periodic Maintenance Chart.
• loosen the fork top plug .
• Remove the front fork (see Front Fork Removal ).
o
• Remove the boots.
• Hold the inner tube vertically in a vise.
• Unscrew the top plug out of Ihe inner tube.
e Slowly compress the front fork fully .
• Push down the fork spring (AJ and insen the fork spring holder [ 8 ]
under the piston rod nut [C] as shown.
Special Tool - Fork Spring Holder: 57001 -1286
O One person should push down the fo rk spring, while another person
inserts the fork spring holder.
. Use wrenches [Al on the rod nul and the top plug [B] lo loosen Ihe
piston rod nut [C] .
• Remove:
)
Top Plug
Fork Spring Holder (special 1001) [0]
Spacer Guide [El
Spacer [F]
Fork Spring Seal [ G)
Fork Spring [ HJ
H
.Pour out the fork oil with the fork upside down .
o Using the piston rod puller [A], move the piston rod [8] up and down
at least ten times to expel the oil from the fork.
Special Tool - Fort Piston Rod Puller, M10 x 1.0: 57001·1 298
. Pull the piston rod up above the inner tube top.
• Tighten t he rod nut (A] finger-tight.
• Hold the fork tube upright, press the inner tube and the piston rod all
t he way down.
A
NOTE
0 00 not install the fork spring yet.
• Fill the front fo rk with t he specified oil.
Fort 011 Vlacostty:
KAYABA 01 or SAE5W
Fort 011 Capacity (when changing oil):
Approx. 530 mL
. Using t he piston rod puller (A]. purge the air from the fork oil by gently
moving the piston rod (8] up and down five times.
Special Tool - Fork Piston Rod Puller, M10 x 1.0: 5700' -1298
. Wait for about five minutes so that any suspended air bubbles can
surface .
• Measure the oil level. using the fork oil level gauge (see Oil Level
Adjustment) .
• lnstaUthe parts removed (see Oil Level Adjustment) .
A
E
SUSPENSION 11-9
Fork Spring Replacement
In addition to the standard sprmg, heavy and light springs are
available. If the standard spring is improper for your purpose, select a
proper one according to the rider's weight or course conditions.
o Harder springs make the fork stiffer, and rebound act ion quicker.
o Softer springs make the fork softer. and rebound action slower.
• Raise the front wheel off the ground .
• Remove the top plugs and replace the fork springs with the optional
fork springs.
• AdJust the all leve!, referring 10 the Optional Fork Spring and Fork Oil
of the Specifications section and Oil level Adjustment in this chapter.
Removal
* If the fork leg is to be disassemble, loosen the lork top plug beforehand. To loosen the fork lOp plug, loosen the fork upper clamp bolts,
• Remove:
Front Wheel (see Wheels/Tires chapter)
. Loosen the upper and lower fork clamp bolts [A] .
• With a twisting motion, work the fork leg [A] down and OUI.
Installation
• Install the fork tube so that the top of the fork inner tube [A] is aligned
with the upper surface of the steering stem head [8] .
... . Run the cables, wires, and hoses as shown in the Cable, Wire, and
Hose Routing section of the General Information chapter.
• Install the front wheel (see Wheels/Tires chapter).
Torque - Upper Fot1l: Clamp Bolta: 20 N-m (2.0 kg-m, 14.5 ft·lb)
Lower Fori( Clamp Bolts: 25 N-m (2.5 kg-m, 18.0 tt-lb)
Top Plug: 29 N-m (3.0 kg-m, 22 ft-lb)
Brake Caliper Bolta: 25 N-m (2.5 kg-m, 18.0 ft-Ib)
. Check the front brake after installation.
~·.. WARNING
Do not aHempt to ride the motorcycle until a full brake lever Is
obtained by pumping the brake lever unlilthe pads are against the
disc. The brake will not function on the first appllcaUon of the lever
If this Is not done.
A
B
11-10 SUSPENSION
Disassembly
.Remove Ihe fron t fork (see Front Fork Removal) .
eorain Ihe fork oil (see Fork Oil Change) .
O The following parts are removed during draining the fork oil.
Top Plug
Spacer Guide
Spacer
Fork Spring Seat
Fork Spring
Piston Rod Nut
• Hold the front fork horizontally in a vise [ A] .
e Stop the cylinder unit [B] from turning by uSing Ihe lork cylinder
holder [e] .
• Unscrew the cylinder valve assembly [0], using a wrench [E ] .
Special Tool - Fork Cylinder Holder: 57001 ·1245
.Take the piston rod and cylinder unit out of Ihe inner tube.
D
~JiW
~.5:T
e Separate the inner tube from the outer tube as follows:
o Remove the dust seal [A] from the outer tube.
o Remove the retaining ring [B) from the ouler tube.
@[email protected]
O--®
~
-
o Use the fork outer tube weight [A] to separate the outer tube [BJ from
the inner tube [C]. Holding the inner tube by hand, pull the outer tube
several t imes to pull out the inner tube.
~ c~
~u
Special Tool - Fort Outer Tube Weight 57001·1218
O Take OUI the cylinder base OUI of the outer tube.
®--
,}
• Remove the guide bushes [AJ , washer (8), and oil seal [eJ from the
inner tube.
~
A
~
D
u
J
-'' ' '1

l-
I-<,
•
Sl
SUSPENSION " -,,
Assembly
• Replace the follow ing parts with new ones after remova l.
Dust Seal (A)
Re taining Ring [ 8 ]
Oil Seal [C)
Inner Guide Bush [ 0 ]
OUler Guide Bush [ E]
Cylinder Valve Assembly Gasket [ F]
~8 [email protected]
.Put the piston rod into the cylinder unit.
.Put the cylin der unit [ A] into the innenube [ 8] and install t he cylinder
base [CJ onto the bottom end of the cylinder unit protruding from the
inner tu be.
O lnsla!! the cylinder base with the ta pered end [0 ] up.
el nsta l1 the inner tube, cylinder unit, and cylinder base as a set into the
outer tube.
• Install the new guide bush [A] with a used guide bush [elan it by
tapping the used guide bush wi th t he fork oil seal driver ( 0 ] until it
o
stops.
o rhe split [ B] of the bush should face toward the side of the vehicle.
Special Tool - Front Fork 011 Seat Driver: 57001-1219
A
<==>
Front and Rear
. Apply molybdenum disulfide grease on the oil seal lips and install the
washer and the oil seal [A] inlO Ihe oUler tube.
Special Tool - Front Fork 011 Seal Driver: 5700'-' 219 [ 8 ]
. lnSl all:
Retaining Ring
Dust Seal
. Apply a non - permanent locking agent to the threa ds of the cylinder
valve assembly and screw the cylinder valve assembly into the bottom
of the outer l ube.
• Hold t he inner cylinder with t he fork cylinder holder fA] and tighten
the cylinder valve assembly (6].
Special Tool - Fork Cylinder Holder: 57001-1245
Non-permanent Locking Agent - Threads of Cylinder Valve Assembly
Torque - Cylinder Valve Assembly: 71 N-m (7.2 kg-m, 52 ft-lb)
• Pour in the specified type of oil and install the parts removed (see Fork
Oil Change) .
A
11-12 SUSPENSION
Fortt 011 Viscosity: KAYABA 01 Of' SAE5W
FOf1I: 011 Capacity (completely dry): 623
± 4 mL
Inner Tube Inspection
. Visually inspect the inner tube [AJ and repair any damage,
. Nick or rust damage can sometimes be repaired by using a wet -stone
to remove sharp edges or raised areas which cause seat damage.
*If the damage is not repairable, replace the inner tube. Since damage
10 the inner tube damages the oil seal, replace the oil seal whenever the
inner lube is repaired or replaced .
• Temporarily assemble the inner and outer tubes, and pump them back
and forth manually to check for smooth operation.
CAiJT10N
" the Inner tube Is badly benl or crease, replace It Excessive
bMM:Ilng, followed by aubsequenlstralghtenlng, can weaken the Inner
.....
Spring Inspection
.Since the fork spring [AJ becomes shorter as it weakens, check its free
length (B] to determine its condition.
*If the spring of either fork leg is shorter than the service limit. it must
be replaced. If the length of the replacement spring and that of the
remaining spring vary greatly, the remaining spring should also be
replaced in order to keep the fork legs balanced for motorcycle stability.
Fort Spring Free Length
Standard:
457.5 mm
Servke Limit
448 mm
A
SUSPENSION 11 -13
Rear Shock Absorber
Rebound Damping Adjustment
. Turn the rebound damping adjuster [A] the desired number of clicks.
o The standard adjuster setting for an average-build rider 68 kg (150 !b)
is the 14th click back from Ihe 1st click of Ihe fully clockwise position.
* If the damper setting feels to soft or too stiff. adJusl il in accordance
w ith the tables.
Harder
-<<---"':>~
Softer
(clockwise)
(counterclockwise)
Rebound Damping Adjustment
21
STO
Adjuster
Position
Damping
Force
Setting
Terrain
Spoed
21 ±3
Weak
Soft
Good
Low
1
!
1
!
1
!
1
!
1
!
B,d
High
Strong
1
Hard
!
I
14
I
t
±3
-I
Seated position
Adjuster turned full y clockwise
Compression Damping A djustment
. Turn the compression damping adjusler [A] on the gas reservoir until
you feel a click.
O The standard adjuster setting for an average-build rider 68 kg (150 lb)
is Ihe 16th elk:« back from the lSI click of the fully clockwise position.
* If the damper setting feels too soft or too stiff. adjust it in accordance
with the tables.
E
Harder
(clockwise)
::;.
Softer
(counterclockwise)
Compression Damping Adjustment
STO
Adjuster
Position
Damping
Force
Setting
Terrain
Speed
2
3
23±3
Weak
Soft
Good
Low
I
I
1
!
1
!
1
!
1
!
1
!
1
Strong
Hard
B,d
High
Spring Adjustment
• Remove:
Side Covers
Seat
. Using Ihe jack under the frame, raise the rear wheel off the ground.
Special Tool - J ack: 57001 -1238
• loosen the clamp screw of the air cleaner duct.
• Remove:
Rear Frame Pipe [A]
Air Cleaner Housing [ B]
Rear Fender [C]
,.
j
heated
4
position
Adjuster turned fully clockwise
I
23 ± 3
11-14 SUSPENSION
. Using two hook w renches [el, loosen the locknut (BJ and turn the
adjusting nut rA] as required.
Special Tool - Hook Wrench: 57001 ·1101
OTurning the adjusting nut [A] downward makes the spring action
harder and upward soher.
• Measure t he adjust ing nut position shown and adjust t he spring.
Spring Senlng
Standard adjusting nUl position [ 8 ] : 116.5 mm (4.6 In)
NUl adjusting range : 103 _ 125 mm (4.05 _ 5.0 In)
Standard spring preload : 810 N (82.5 kg, 182 Ib)
Preload change per tum of the nut : 74 N (7.5 kg, 16.5 Ib)
NOTE
OAdjusting nut position and nut adjusting range applies to the
optional springs.
• Tighten the locknut [C] securely .
• After adjustment, m ove the spring up and down to make sure Ihal lhe
spring is seated.
*If the spring action feels too soft or 100 stiH, adjust it in accordance
wi th the table below.
Spring Adlustment
Adjuster
Position
Spring
Foree
Sening
Terrain
Speed
103mm
Weak
Soh
Good
Low
r
r
Strong
Hard
r
!
125 mm
!
!
r
!
B.d
• Install the parts removed.
Non-permanent locking Agent· Air Cleaner Housing Bolts
Torque - Rear Frame Pipe Botts: 25 N-m (2.6 kg-m, 19.0 ft-Ib)
r
!
High
SUSPENSION 11-15
Removal
. Using the Jack (special tool) , raise t he rear w heel olf the ground,
Special Tool - Jack: 57001·1238
e Squeeze the brake lever slowlV and hold it wit h a band [AJ .
CAUTION
Be sure to hold the fronl brake when removing the shock absorber,
or the motorcycle may fall over. The motorcycle could be damaged.
Jlt.WARN1NG
Be sure to hold the Irani brake when removing the shod: absorber,
or the motorcycle may tall oller. II could cause an accident and
injury.
e Remove:
Side Covers
Seat
Rear Frame Pipe
Rear Fender
Air Cleaner Housing
• Remove:
Front Bolt [AJ or Tie- rod [9]
Lower Shock Absorber Bolt
• Suppon the rocker arm to slide out the bolts .
• Remove the upper shock absorber boll [AJ and take out t he shock
absorber [8] toward the ground.
Installation
. Pack t he shock absorber needle bearing wit h molybdenum disulfide
grease.
• Install the rear shock absorber so t hat t he reservoir laces right.
Torque - Tie-rod Nut: 83 N-m (8.5 kg-m, 61 tt-Ib)
Rear Shock Absorber Bolts: 39 N-m (4.0 kg-m, 29 "-fb)
Rear Frame Pipe Bolts: 25 N-m (2.6 kg-m, 19.0 It-fb)
Non·permanent Locking Agent· Air Cleaner Housing Bolts
11-16 SUS PENSION
Spring Replacement
In addition to the standard spring, heavy and light springs are
available. If the standard spring is improper for your purpose, select a
proper one according to the rider's weight or course conditions .
• Remove the rear shock absorber (see Rear Shock Absorber Removal) .
• Clean the threads of the upper of the rear shock absorber.
• Hold the lower end of the rear shock absorber with a vise .
• Using the hook wrenches [C], loosen the locknut [B] and turn the
adjusting nut [A] all the way up.
Special Tool - Hook Wrench: 57001-1101 [Cj
• Remove the fear shock absorber from the vise.
• Slide down the rubber bumper [A] .
• Remove the spring guide [B) from the shock absorber and lift oH the
spring (C] .
A
.'nstall the optional spring with the smaller end fA] facing downward .
• Installthe spring guide .
• Adjust the spring preload (see Spring Adjustment) .
• Installthe rear shock. absorber (see Rear Shock Absorber Installation).
Disassembly (Oil Change)
The oil should be changed in the rear shock absorber in accordance
with the Periodic Maintenance Chart. The frequency for best perform ance must be based upon riding conditions and rider ability.
• Remove the rear shock absorber from the frame (see Rear Shock
Absorber Removal) .
• Remove the shock absorber spring (see Spring Replacement) .
• Point the valve away from you. Slowly release nitrogen gas pressure
from the gas reservoir [A] by pushing down the valve core (B} with a
screwdriver.
i"WARNING
Be aure to point the reservoir valve away from you when releasing
nitrogen gas pressure. An 011 mist Is often released with the nitrogen.
Always release nitrogen gas pressure before disassembling the rear
shod!: absorber 10 prevenl explosive separation of parts.
SUSPENSION 11-17
. AdJust the gas reservOir damping adjuster to the softest position .
• Remove the air bleeder bolt [AJ and pump the rear shock to drain the
oil OUI of the rear shock body.
e pry [AI at the gaps [BJ in the stop
[CJ with suitable tools to free the
stop from the rear shock body [OJ .
e Slide the stop up the top of the push rod then lightly tap around the
seal with a suitable rod and mallet, and push the seal assembly 10mm
(0.4 in) down .
• Remove the circlip [AJ.
• lightly move the push rod back and forth, and pull OUI the push rod
assembly.
• Pour the remaining oil out of the rear shock body.
• Using a suitable tool (collar or nut) [AJ and a press, push the reservoir
cap [8] in 10 mm (0.4 in) .
e Remove the circlip [C] from the gas reservoir .
• Install a stool tire valve cap [AJ on the gas reservoir valve and pull the
gas reservoir cap (B] out of the gas reservoir using pliers.
OThe bladder [BJ comes out with the gas reservoir cap.
11-18 SUSPENSION
Assembly (Oi/ Filling)
. 'nslall the air bleeder bolt.
o Check the O-ring on the air bleeder bolt. and replace It il necessary.
• Pour KYB K2.c (SAE5W or Bel.Ray SE2 #40) oil into the gas reservOir
half full : about BOmm [AJ from the gas reservo ir upper end.
Oil Capacity (Iotal amount): 291 mL
.Check that the bladder [AJ on the gas reservoir cap is not partially
collapsed.
If it is, push down the valve cora with a screwdriver.
.Check the bladder for signs of damage or cracks.
*11 necessary. replace it with 8 new one.
*
CAUTlON
Do not use a damaged or partially collapsed bladder, because It may
burst, gently redUCing rur shocK performance .
• Apply grease to the lip [8] of the bladder.
• Push the bladder and gas reservoir cap into the gas reservoir slowly
until it just clears the circlip groove. Wipe out any spilled oil.
CAUTlON
Ensure that no air remains In the system.
• Check the circlip for weakening, deformity and flaws.
*If necessary, replace it with a new one.
.... WARNING
" weakened, deformed or flawed clrcrrp Is used, the gas reservoir
cap may not hoki when Injecting the nitrogen gas. This would allow
011 and Intemal parts to explode out of the reservoir .
• Fit the circlip fA] in the groove in the gas reservoir (B] .
J®
SUSPENSION 11-19
. Pull up the gas reservoir cap [A] against the circlip. The end [8] of
the gas reservoir cap must ahgn [C] with the end of the gas reservoir
[0].
AWARNING
If the end 01 the gas reservoir cap doesn't align with the end of the
gas reservoir, the clrcllp Is nol correctly lUted in the groove In the gas
reservoir or Is deformed. In this case, the 011 and Inlernal parts could
explode out 01 the reservoir when InJecllng the nitrogen gas or while
riding the motorcycle.
• Pour the fest of KYB K2-C (SAE5W or Bel·Ray SE2 #40) oil into the rear
shock body.
OThe oil level should be aboulS2mm [AJ from the shock body lower
end [6J .
elnsert the piston [A] end of the push rod assembly into the rear shock
body slowly_
.00 not insert the seal assembly [8] yet. Pump the push rod until all
the air is forced out of the rear shock body [e].
epush the seal assembly [A] into the rear shock body until it just clears
the circlip groove.
• Check the circiip.
* If it is deformed or damaged, replace it with a new one .
• Fit the circlip [8] into the groove in the rear shock body [C).
~·.WARNING
H the clrcllp Is nol a certain IfIln the groove In the reer.mx:k body,
the push rod assembly may come oul of the shock absorber when
InJecilng the nitrogen gas or riding the motorcycle.
A
.Pull up the push rod assembly [D] against thecirclip [8] .
• Force the stop [E] into the rear shock body by lightly tapping around
the edge of the stop wit h a mallet.
• Hold the lower end of the push rod assembly in a vise.
• Pump the rear shock up and down several times. and then leave it in
the fully extended position for about three minutes.
11-20 SUSPENSION
• Remove the air bleeder bolt (A) from the upper part of the rear shock
body.
* If oil comes out of the air bleeder bolt hole, let it overflow until it stops.
* If oil does nOI come out of the air bleeder bolt hole, add t he specified
oil inlO the air bleeder bolt hole unlil it overflows (that is, unlil all the
remaining air is forced out) .
. 'nstall the air bleeder bolt securely.
.Fu lly extend the push rod assembly.
e lnJect the nitrogen gas to a pressure of 50 kPa (0.5 kg/em ' , 7 psi)
through the valve on the gas reservoir .
• Check the rear shock body and gas reservoir for oil and gas leaks
*'1 there are no leaks, inject the nitrogen gas up to the 980 kPa (10
kg/em', 142 psi) pressure. Check and adjust the gas pressure when
the gas reservoir is cold (room temperature) .
~
.~
~/
Pressurize the gas reservoir with nitrogen gas only. Do not ule air
or other geses, since they may cause premature wear, rUlt, lire
hazard, or substandard performance.
High pressure gas Is dangerous. Have a qualified mechank: perlorm
this procedure .
• Install the spring and spring guide.
o Both damping adjusters must be on the same side.
Spring Inspection
Since a spring becomes shorter as it weakens. check its free length
[AJ to determine its condition.
*If the spring is shorter than the seNice limit it must be replaced.
Rear Shock Absorber Spring Free Length
Standard:
255 mm
Service Limit 250 mm
Scrapping
• Remove the rear shock absorber (see this chapter).
• Point the reservoir valve away from you and slowly release the nitrogen
gas pressure from the gas re5eNoir [AJ by pushing down the valve
core [8] with a screwdriver.
".WARNING
The high pressure gas Is dangerous. Do nOI point the valve toward
your lace or body.
00 not Incinerate a shock absorber without first removing the valve
or It may explode.
~
~
~.
J",WARNING
Compression Damping Adjuster [A]
Rebound Damping Adluster [B]
.Adjust the following.
Spring Force
Compression Damping Adjuster
Rebound Damping Adjuster
• Install the rear shock absorber.
~
Front
:0
A
SUSPENSION 11-21
Swingarm
Removal
• Place the jack under the frame so that the rear wheel is off the ground.
Special Tool - Jacll;: 57001 ·1238
. Squeeze the brake lever slowly and hold it wit h a band (Al
CAlITlQN
Be sure to hold the Iront brake when removing the awingarm or the
motorcycle may tali ovar. The motorcycle could be damaged.
Be sure to hold the front brake when removing the awlngarm, or the
motorcycle may tall over. It could cause an accident and injury.
• Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires
chapter) .
• Remove the brake hose holders and the mud flap _
• Remove the tie- rod rear mounting bolt [A] .
CAIJ1lON
When pulling out the mounting bolta, Iitt the rear end of the awlngarm
slightly. Forcing or tapping on 8 bott could damage the bolt, sleeve
and bearing.
• Remove the swingarm Pivot nut and pull QuI t he swingarm pivot shatt
(B] . and remove the swingarm [C] .
• Separate the chain guide and chain slipper from the swingarm.
Installation
. Apply plenty of molybdenum disulfide grease to the inside of the
needle bearings and the outside of the sleeves .
• Torque the following:
Torque - Swlngarm Pivot Nut: 88 N-m (9.0 kg-m, 6S ft·lb)
TIe-rod Nut: 83 N-m (8.5 kg.m, 61 ft-Ib)
. Install:
Rear Wheel (see Wheels/Tires chapter)
Drive Chain (see Final Drive chapter)
. Check the brake atter installation.
i"WARNING
Do not aUempt to ride the motorcycle until a full brake pedal Is
obtained by pumping the brake pedal untll the pad. are against the
disc. The brake will not function on the first application of the pedal
If this i9 not done.
Swingarm Bearing Removal
• Remove the swingarm (see t his chapter).
• Remove the grease seals.
• Remove the needle bearings [A], using the oil seal & bearing remover
[aJ.
Special Tool - Oil Seal & Bearing Remover: 57001 ·1058
• Replace the bearings and sleeves with new ones.
11-22 SUSPENSION
Swingarm Bearing Installation
. Apply plenty of molybdenum disulfide grease to new needle bearings
and sleeve.
• Be sure to install the needle bearings so Ihallhe manufacturer's marks
are faced out. This prevents bearing damage .
• Position the bearings [A] as shown, using a suitable beaflng driver in
the bearing driver set.
Special Tool - Bearing Driver Set: 57001·1129
A
Swingarm Pivot Check
. Check the pivot of the swingarm and uni-trak link (tie-rod and rocker
arm) for wear periodically, or whenever excessive play is suspected .
• Raise the rear wheel off the ground .
• Move the swingarm [A] up and down to check for abnormal friction,
and push and pull it to check for bearing play.
A small amount of play on the pivot is normal and no corrective action
is needed. However, if excessive play is felt, check the swingarm and
uni-trak link bearings for wear and replace them jf necessary.
*
,,·.WARNING
InstaliaNon of new bearlng(s) In the Iwlngarm and unl-trak link may
cause too stiff rear suspension. Test ride the motorcycle slowly and
prudenlly unlll the suspension becomes normal.
Swingarm Bearing, Sleeve Inspection
. The rollers in a needle bearing normally wear very little, and wear is
difficult 10 measure. Instead of measuring, inspect the bearing in the
swingarm for abrasion, color change, or other damage.
*U there is any doubt as to the condition of any of the needle bearings
or sleeves, replace all the sleeves, and needle bearings as a set.
SUSPENSION 11-23
Tie-Rod, Rocker Arm
Tie-Rod Removal
e Using the Jack under the frame, raise the rear wheel off the ground,
Special Tool - Jack: 57001 -1238
. Squeeze the brake lever slowly and hold it with a band .
• Remove the tie-rod front bolt [ AJ .
CAUTION
When pulling out the mounting bolts, 11ft the rocker arm sl~hlly.
Forcing or tapping on a bolt couid damage the bolt, steeYe and
bearing .
• Remove the tle-rocl rear bolt [ 8 ], and then take out the tie- rods [C] .
Tie- Rod Installation
. Apply plenty of molybdenum disulfide grease to the inside of the
needle bearings, the outside of the sleeves, and grease seals.
• Torque the tie-rocl front and rear nuts.
Torque - TIe-rod Nuts: 83 N-m (8.5 kg-m, 61 ft-Ib)
Rocker Arm Removal
e Using the Jack under the frame. raise the rear wheel off the ground.
Special Tool - Jack: 57001 -1238
e Squeeze the brake lever slowly and hold it with a band .
• loosen the swingarm pivot nut.
CAUTION
Loosen the swlngarm pivot nut for easy remoyal 01 the redter arm
bolt. Forcing or tapping on a bolt could damaD&: the bolt, sleeve, and
bearings.
• Remove the tie-rod front mounting bolt [AJ .
CAUTION
When pulling out the mounting bolts, 11ft the rocker arm slightly.
Forcing or tapping on • bolt could damage the bolt, sleeve and
bearing.
• Remove the feaf shock absorber lower bolt [8J .
• Remove the rocker arm pivot bolt [C] .
eRemove the rocker arm [ DJ.
11 - 24 SUSPENSION
Rocker Arm Installation
. AppiV plenty of molvbdenum disulfide grease to the InSide of the
rocker arm hole, the outside of the sleeve, and the needle bearing .
• Torque the following:
Torque - Rocker Arm Nut 88 N-m (9.0 kg-m , 651t-lb)
Re ar Shock Absorber Bolt
39 N-m (4.0 kg-m, 29 It-Ib)
T~rod
Nut 83 N-m (8.5 k(J-m, 61 It-Ib).
Swlngarm Pivot Nut 88 N-m (9.0 kg..m, 65 It-Ib)
Rocker Arm/ Tie- Rod Bearing Removal
. Remove the rocker arm for rocker arm bearing removal (see this
chapter) .
• Remove the swingarm for tie- rod bearing removal (see this chapter) .
• Remove the g rease seals [A] .
• Remove the needle bearings [B] using a suitable bearing driver in the
bearing driver set.
Special Tool - Bearing Driver Set 57001·11 29
• Replace the bearings and sleeves (C] with new ones.
Rocker Arm/ Tie- Rod Bearing Installation
. Apply plenty of molybdenum disulfide grease to the inside of new
needle bearings and the outside of the sleeves.
• Be sure to install the needle bearings so that the manufacturals marks
are faced out. This prevents bearing damage.
o Position the bearings [Al as shown, using a suitable bearing driver in
the bearing driver set (special tool) .
Special Tool - Bearing Driver Set: 57001-1129
Un;- Trak Link Pivot Check
. Check the pivot of the swingann and uni-trak link (tie-rod and rocker
ann) for wear periodically, or whenever excessive play is suspected
(see Swingann Pivot Check).
A small amount of play on the pivot is nonnal and no corrective action
is needed. However, if excessive play is felt. check the 5wingann, and
uni- trak link bearings lor wear, and replace them if necessary (see this
chapter) .
*
Rocker Arm/ Tie-Rod Bearing Inspection
. The rollers in a needle bearing nonnally wear very little, and wear is
difficult to measure. Instead of measuring, inspect the bearing installed
for abrasion, color change, or other damage.
If there is any doubt as to the condition of any of the needle bearings,
replace aU the sleeves, and needle bearings as a set.
*
Rocker Arm/Tie-Rod Sleeve Inspect;on
* If there is visible damage, replace the sleeves and all the needle
bearings as a set.
5mm
STEERING 12-1
Steering
Table of Contents
Exploded View ......................................................................................................... 12-2
Specifications ...........................................................................................................12-3
Steering .................................................................................................................... 12-4
Inspection .............................................................................................................12· 4
Adjustment .......................................................................................................... ..12-4
Stem, Stem Bearing Remova1. ..............................................................................12· 5
Stem, Stem Bearing Installation ...........................................................................12-6
Steenng Maintenance .. ............. .......................... ............ ......... ......... ...... ............. .... .12-8
Stem Bearing Lubrication ............................................ ......................................... 12-8
Stem Bearing Wear, Damage ...............................................................................12-8
Stem Warp ............................................................................................................12-8
12- 2 STEERING
Exploded View
T1
~D . Arrow points to the front.
Apply adhesive.
G'
S;
T1 :
T2:
-_
T3
T
4:
Apply grease.
Follow the spec'!'
25 N -m (2.5 k9~~ t~g8hotening sequence.
44 N
• . ft -Ib)
· m (4.5 kg-m. 33 ft-Ib)
20N .m(20k
. ' g -m, 14.5 ft -Ib)
Hand tight or 3.9 N - m (0.40 kg -m. 35 in -Ib)
STEERING 12-3
Specifications
Special Tools -
Sleering Slem Bearing Driver: 57001-137
Sleering Slem Bearing Driver Adapter: 57001-1074
Head Pipe Quter Race Press Shaft: 57001-1075
Head Pipe Outer Race Driver: 57001-1106
Head Pipe Quter Race Driver: S700l-l0n
Steering Stem Nul Wrench: 57001-1100
Head Pipe OUter Race Remonr: 57001-1107
Jack: 57001-1238
12-4 STEERING
Steering
Inspection
• Using the jack, raise the front whee! off the ground.
Special Tool
~
Jack: 57001-1238
.With the front wheel pointing straight ahead, alternately nudge each
end of the handlebar. The front wheel should sWing fully left and right
from the force of gravity until the fork hits the stop.
If the steering binds or catches before the SlOp, check the rouling of
the cables, wire, and hoses.
If the steering feels tight, adjust or lubricate the steering .
• Fee! for steering looseness by pUShing and pulling Ihe forks rAJ .
If you feel looseness, adjust Ihe steering.
*
*
*
Adjustment
• Remove:
Side Covers
Seat
• Move back the fuel tank with the hoses installed.
• Remove the handlebar.
• Loosen all the front fork lower clamp bolts [AI and the steering stem
head nut (8] .
• Tum the steering stem nut (A) with a suitable wrench [8] , or tap
lightly and turn the steering stem nut [A] with the blade of a
screwdriver to obtain the proper adjustment.
*If the steering is too tight, loosen the stem nut a fraction of a turn.
If the steering. is too loose, tighten the nut a fraction of a turn.
*
NOTE
o Turn the steering stem nut 1/Blum at a time maximum.
Torque - Sleering Slem Nut: 3.9 N-m (0.40 kg-m, 35In-lb) (lor relerence
~~)
.Tighten the following:
Torque - Steering Slem Head Nut: 44 N-m (4.5 kg-m, 33 ft-Ib)
Front Fork lower Clamp Bolm: 25 N-m (2.5 kg-m, 18.0 ft-Ib)
~.
STEERING 12-5
. Mount the handlebar clamps [A] so that the arrow marks [8] on the
clamp pOlms to the front (C] .
• Install the longer clamp bolts [D] on the right side clamp.
• Tighten the handlebar clamp bolts.
Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kg-m, 18.0 ft-Ib)
OTighten the front clamp bolts first. and Ihen the rear. If the handlebar
clamp is correctlv installed, there will be no gap [6] at the front [A]
and a gap
[CJ
at the rea r after tightening.
Stem, Stem Bearing Removal
• Remove:
Headlight and Meter Unit
Master Cylinder Clamp
Front Fender
Handlebar
Front Wheel
Front Fork
• Remove the steering stem head nut and washer.
• Remove the steering stem head .
• Pushing up on the stem base [A]. remove the steering stem nut [B],
with the steering stem nut wrench [D). then remove the steering stem
[C] and stem base.
Special Tool - Steering Stem Nut Wrench: 57001-1100 [0]
. Take off the upper stem bearing inner race (tapered roller bearing)
[Al·
1
12-6 STEERING
• Remove the outer races pressed into the head pIpe, using the head
pipe outer race remover [A], and hammer the head pipe outer race
remover to drive it out.
Special Tool - Head Pipe Outer Race Remover: 57001-1107 (A]
NOTE
Off either steering stem bearing is damaged, it is recommended that
both the upper and lower bearing (including outer races) should be
replaced with new ones,
.Remove the lower stem bearing inner race (tapered roller bearing)
[AJ with its grease seal from the stem using a chisel.
Stem, Stem Bearing Installation
• Replace the bearing outer race with new ones .
• Apply grease to the outer races. and drive them into the head pipe at
the same time using the head pipe outer race press shaft [Al and the
drivers [8] [C).
Special Tool - Head Pipe Outer Race Press Shaft: 57001-1075 (Al
Head Pipe Outer Race Driver: 57001 -1106 [ 8 ]
Head Pipe Outer Race Driver: 57001-1017 (e]
• Replace the lower inner races with new ones.
• Apply grease to the lower inner race, and drive it onto Ihe stem using
the steering stem bearing driver (Al and adapter (8] .
Speclal Tool - Steering Stem Bearing Driver: 57001-137 [Al
Steering Stem Bearing Driver Adapter: 57001-1074 CBl
. Apply grease 10 the upper inner race, and install it in the head pipe.
• rnstall the stem through the head pipe and upper bearing, install the
stem cap and hand-tighten the steering stem nut while pushing up on
the stem base.
• The following fou r steps should be periormed after steering bearing
replacement. This procedure settles the bearings in place.
O Tighten the stem nul to 39 N-m (4.0 kg - m. 29 ft - Ib) of torque. (To
tighten the steering stem nut to the specified torqu e, hook the wrench
[AJ on the stem nut, and pull the wrench at the hole by 218 N (22.2
kg, 49 Ib) force in the direction shown.)
Special Tool - Steering Stem Nue Wrench: 57001-1100 (Al
180 mm [ 81
Force (C]
B
,,'
©
STEERING 12-7
O Aga;n back out the stem nut a fracllon 01 turn until it turn s lightiV.
O To adjust the steering. turn the stem nut lightly clockwise until it Just
becomes hard to tum. Do not overtighten, or the steering will be too
tlghl.
Torque - Sleering Stem Nul: 3.9 N-m (0.40 kg-m, 35 in-Ib) (lor relerence
only)
. Install the stem head and washer, and lighten the stem head nut.
Torque - Sleering Stem Head Nut: 44 N-m (4.5 kg-m, 33 tt-Ib)
. Inslall the front fork (see Suspension chapter) _
. lnstall the pans removed (see the appropriate chapter) .
Do not Impede the handlebar turnIng by roullng the cable., wires and
hoses Improperly (lee Generallnlonnallon chapter) .
• Check and adjust:
Steering
Front Brake
Clutch Cable
Thronle Cable
Headlight
12-8 STEERING
Steering Maintena nce
Stem Bearing Lubrication
• Remove the sleering stem (see Slem, Stem Bearmg Removal) .
• Using a high flash - point solvent, wash the upper and lower tapered
rollers in the cages, wipe the upper and lower outer races, which are
press-fitted into the frame head pipe, and clean of grease and dirt.
e Visually check the outer races and the rollers.
--
* Replace the bearing assemblies if they shows wear or damage.
• Pack the upper and lower tapered roller bearings [A] in the cages with
grease, and apply a light coat of grease to the upper and loweI" outer
races.
e Tum the bearing around by hand a few limes to make sure the grease
is distributed uniformly inside the bearing .
J!j- . •
~
• Install the steering stem, and adjust the steering (see Stem, Stem
Bearing Inslallation, Steering Adjustment).
Stem B earing Wear. Damage
. Using a high flash -point solvent, wash the upper and lower tapered
rollers in the cages, wipe the upper and lower outer races, which are
press-fitted into the frame head pipe, and clean of grease and dirt.
• Visually check the outer race and the rollers.
* Aeplace the bearing assembly if it shows damage.
Stem Warp
. Whenever the steeling stem [AJ is removed, or if the steering cannot
be adjusted for smooth action, check the steering stem for straightness.
*11 the steering stem is bent. replace the steering stem.
A
FRAME 13-1
Frame
Table of Contents
Exploded View ..........................................................................................................13·2
Seat ...................... ......................................................................................................13-4
Removal ................................................................................................................13-4
13-2 FRAME
Exploded View
>--<i'l>--- T5
FRAME 13-3
" "
0: Applvoil.
T1 : 59 N-m (G.O kg-m, 43 ft - Ib)
~;; ~5 N-m (2.5 kg-m. 18.0 fHb )
5 N-m (2.6 kg-m, 19.0 ft-Ib)
13-4 FRAME
Seat
Removal
• Remove the seat boils [AJ on both sides.
• Pull off the seat [8} backward
ELECTRICAL SYSTEM 14-1
Electrical System
Table of Contents
Exploded View ....
..........................................................................................14 -2
Parts Location ...........................................................................................................14-4
KDX200- H1 Wiring Diagram ....................................................................................14-5
Specifications .................................................................... . ", .. "' ................................ , 4-6
Precautions ............... '" .............................................................................................. 14 ·7
Electrical Wiring ........................................................................................................14·8
Inspection ............................................................................................................14-8
Flywheel M agneto ....................................................................................................14-9
Removal .................... ............................................. ............................................... 14-9
Installation ........................................................................................................... 14 -9
Inspection ...........................................................................................................14· 10
Ignition System .................................................................................................... 14-11
Ignition Timing Ad justment. ......................................................... ...................... 14-11
Ignition Coil Removal .........................................................................................14- 11
Ignition Coil Arcing Distance Inspection ...........................................................14-12
Ignition Coil Resistance Inspection ................................................................... 14-12
Spark Plug Cleaning and Inspection .................................................................14-12
Spark Plug Gap Inspection ......
.................
............................... 14-13
Exciter Coil Inspection ........................................................................................14-13
COl Unit Remova l .............................................................................. ................ 14-14
COl Unit Inspection ...........................................................................................14-14
Lighting System .....................................................................................................14-16
Headlig ht Vertica l Adjustment. ...........................................................................14-16
Headlight Bulb Replacement ............................................................................. '4-16
Headlig ht Unit Insta llation .................................................................................14- ' 6
Taillight Bu lb Replacement ................................................................................14- 17
Regulator Removal .............................................................................................14- 17
Regulator Inspection .......................................................................................... 14-17
Lig hting Coil Inspection ..................................................................................14-18
Trip Meter ................................................................................................................14-19
Removal......
.........................................................................14-19
Installation ...........................................................................................................14-19
Meter Mounting Inspection ...............................................................................14-19
14-2 ELECTRICAL SYSTEM
Exploded View
1.
2.
3.
l:
Ignition Coil
COl Unit
Regulator
Apply a non -permanent locking agent.
SS' Apply silicone sealant
Tl T2:
T3:
T4'
2
(Kawasaki Bond' 56019-120)
27 N-m (2.8 kg -m, 20 h -Ib)
64 N-m (6.5 kg -rn, 47 ft Ib)
9.8 N-m (1.0 kg -m, 87 in-Ib)
2.9 N-m (0.30 kg . m. 26 in-Ib)
ELECTRICAL SYSTEM 14-3
1.
2,
Engine
light' Stop Button
3
T ' mg Switch
np Meter
T1 .'
5.9 N-m (0.60 kg -m, 52 in -Ib)
14-4 ELECTRICAL SYSTEM
Parts location
1. Ignition Coil
2. C Ol U nit
3. Stator
4. Magneto
5. Regulator
6. lighting Switch
KDX200-H1 Wiring Diagram
Engine Stoo Button
ON
--.L
A
I
0':1'
0
BK~W
BL
WR
BK
CD I Un It
I
0"
0
soar, Plug
~
BK
~-BK/W
BK
Headlight
12V30W
~ TI'"'' oo ""-----r---~
-----+---c:>C}---II~
BK/Y
-R~~~~~=:--~<r---i-r--------y~~
R
!
EnQlne 5too Button
Color" BK BK[I
ON
OFF
~
<D
~
'" ----
)
m
rm
C')
~
""
Regulator
Lighting Switch
Color R
Y
«:
ON
OF F I
1
Ta II1I ght
12VIOW
""
<D
0
Magneto
::K:D
'" ----
'"
Lighting Switch
I
Color Code
BK
BL
BR
R
W
Y
Black
Blue
Brown
Red
lh i t e
Ye II ow
(98051-144 7e)
::c
C')
l>
r-
fJl
-<
fJl
~
m
~
..
"",
U1
14-6 ELECTRICAL SYSTEM
Specifications
Standard
Item
Ignition System :
Ignition coil:
6 mm or more
3 needle arcing distance
0.16 _ 0.24 0 (. 1 0)
5.0 - 7.6 kO ( . 1 kO )
Primary winding resistance
Secondary winding resistance
Spark plug :
Spark plug gap
Spark plug cap resistance
0 .7 - 0 .8 mm
3.75 - 6.25 kO (. 1 kO)
Magneto
Type
Exciter coil resistance
COl unit resistance
Single plase AC
W/ R- BK : 250 - 3700 (. 1000)
in the text
lighting System:
Magneto type
Single phase AC
Lighting coil resistance
Y-BK: 1.6 _ 2.4 0 (.10)
Regulator
Special Tools -
Type
AC Regulator
Resistance
in the text
Hand Tester: 57001·983
Flywheel Hokler: 57001 ·1313
FlywhHI Puller: 57001·252
Spark PIt)Q Wrench, Hex 21: 57001·110
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
ELECTRICAL SYSTEM 14-7
Precautions
There are a number of Important precautions that are musts when
servicing electrical systems. learn and observe all the rules below.
O The electrical parts should never be struck sharply, as with a hammer,
or allowed to fall on a hard surface. Such a shock to the parts can
damage them.
OTo prevent damage to electrical pans. do not disconnect any other
electrical connections when the engme is runn ing.
O Troubles may involve one or in some cases ali Items. Never replace a
defective part without determining what CAUSED the failure. If the
failure was caused by some other item or items, they tOO must be
repaired or replaced, or the new replacement will soon fail again.
O Make sure all connectors in the circuit are clean and light, and e)(amine
wires for signs of burning, frayi ng. etc.
Poor wires and bad
connections will aHect alectrical system operation.
O Measure coil and winding resistance when the part is cold (at room
temperature).
o Color Codes:
P
Pink
BK Black
G Green
GY Gray
PU Purple
BL Blue
BR Brown
LB Light blue
R Red
CH Chocolate
LG Light green
W White
Orange
Y
Yellow
DG Dark green
o
o Electrical Connectors
Female Connectors [AJ
Male Connectors [81
v
14-8 ELECTRICAL SYSTEM
Electrical Wiring
Inspection
. Visually inspect the wiring for signs of burning, fraying, etc_
*If any wiring is poor, replace the damaged wiring .
• Pu ll each connector [AJ apan and InSpect it for corrosion, dirt, and
damage.
*11 the connector is corroded or dirty, clean II carefullv If it is damaged.
replace it .
• Check the wiring for continuity,
o Use the wiring d iagram to find the ends of the lead which is suspected
of being a problem.
OConnecl the hand tester between the ends of the leads.
SpecIal Tool - Hand Tester: 57001·983
OSe! the hand tester to the
*
JC
10 range, and read the tester.
If the tester does not read 0 n, the lead
or the wiring harness [8] if necessary.
IS
defective, Replace the lead
elECTRICAL SYSTEM 14- 9
Flywheel Magneto
Removal
• Remove:
Side Covers
Seat
Magneto Cover
. Holding the flywheel steady with the flywheel holder f A) , remove the
flywheel nut (B) .
Special Tool - Flywheel Holder: 57001 ·1313
• Remove the flywheel holder.
• Screw the flywheel puller [A) into the flywheel by turning II counter·
clockwise (Ieft · hand threads) .
• Screw in the pulier center bolt while tapping the head of the boll and
remove the flywheel.
Special Tool - Flywheel Puller: 57001 ·252
CAIJT10N
Nevar strike the grab bar or the flywheel Itself. Striking the bar can
bend Il If the lIywheel 'S struck, the magnets may lose their
magnetism .
• Unscrew t he mounting screws [A] , and remove the stator [B] and the
wiring grommet [C] .
• Disconnectlhe stator lead connectors.
Installation
. Using an oil · less cleaning fluid such as trichloroethylene or aceton,
clean o ff any oil or dirt that may be on the crankshaft taper (AJ or in
the hole [ B) in the flywheel. Dry t hem with a clean cloth.
~'~WARNING
These cieanlng fluids are usually highly lIammabe and harmful If
br.athed lor prolonged periods.
Be aure 10 heed the fluid
manufacturer's warnings .
• Apply Silicone sealant to the stator wiring grommet. set the grommet
fAJ securely in the notch in the left crankcase half, and rou te the wires
[ 8] accord ing to the Cable, Wire and Hose Rout ing section in the
General Information chapter.
14-12 ELECTRICAL SYSTEM
Ignition Coil Arcing Distance Inspection
O The most accurate test for determining the condition of th e ignition coil
is made bV measuring arcing distance using a suitable commerciallv
available coil tester for the 3-needle method.
• Remove the ignition coil.
• Connect the ignition coil [A ] (with the spark plug cap left Installed on
the spark plug lead) to the lester [B], and measure the arcing distance.
I
®~
,
110
* If the distance reading is less than the specified value, the ignition coil
@10'
c....:::.....
or spark plug cap is defective.
Ignition Coli Arcing Distance
Standard:
8 mm or more
fl0+ e
R-
Le
0
e Ta determine which part is defective, measure the arcing distance
again with the spark plug cap removed from the ignition cOil lead.
Remove the cap by turning it counterclockwise.
If the arcing distance is subnormal as before, the trouble is with the
ignition coil itself. If the arcing distance is now normal, the trouble is
with the spark plug cap.
®
/
}JJ
«5Ui
OK
*
Ignition Cot! Resistance Inspection
*If the coil tester is not available, the coil can be checked for a broken
or badly shorted winding with the hand tester. However, the hand
tester cannot detect layer shorts and shorts resulting from insulation
breakdown under high voltage.
Special Tool - Ha nd Tester. 51001 -983
• Remove the ignition coil [A] .
• Measure the primary winding resistance [B).
o Set the meter to the x 1 0 range, and read the tester.
• Measure the secondary winding resistance [C].
o Remove the spark plug cap by turning it counterclockwise.
o Set the tester to the x 1 kO range, and read the tester.
* If the tester does not read as specified, replace the coil.
If the tester reads as specified, the ignition coil windings are probably
good. However, if the ignition system still does not perform as it
should aher all other components have been checked, test replace the
coil with one known to be good.
*
Ignition Coli Wind ing Resistance
Primary windings!
0.16 - 0.24 0 (x 1 0)
Seconda ry windinGS!
5.0 _ 7.611:0 ()( 1 kO)
• Check the spark plug lead for visible damage.
* If the spark plug lead is damaged. replace the coil.
Spark Plug Cleaning and Inspection
• Remove the spark plug, and visually inspect it.
• Clean the spark p,lug, preferably in 8 sandblasting device, and then
clean off any abrasive particles. The plug may also be cleaned using
a high flash -point solvent and a wire brush or other suitable tool.
*If the center electroda [A] or side alectrode [ 8) ara corroded or
damaged, or if the inSUlator [C] is cracked, replace the plug. Use the
standard spark plug.
[SJ
IT]
?®?
©~
I~ "'-'~ ~
~
~
ElECTRICAL SYSTEM 14-13
Spark Plug Gap Inspection
e Measure the gap [ D] with a wire -type thickness gauge.
*If the gap is incorrect, carefully bend the side electrode [ 8 ] wit h a
suitable tool to obtain the correct gap.
Spark Plug Gap
Standard:
0.7 _ 0.8 mm
Exciter Coi/lnspection
• Remove the right side cover.
• Disconnect the magneto connector.
. Connect the hand tester as shown in the table.
Exciter Coli Winding Resistance
Connections:
Reading:
WIR·B K
250 - 370 0 (x 100 0)
* If there is more resistance than the specified value, the coil has an open
lead and must be replaced. Much less than this resistance means the
coil is shorted, and must be replaced .
• Using the highest resistance range of the hand tester. measure the
resistance between t he exciter coil lead terminals and chassis ground.
Any hand tes ter reading less than infinity ( 00 ) indicates a short.
necessitating replacement of the stator.
*
Ignition Circuit
n
"dHfL&J
~
~
2
'--------W/R
1
1. Exciter Coil
2. Magneto
3. COl Unit
_
O---BK/W~l?
T <v
BK - - - 0
o
:;:
0
4. Connector
5. Ignition Coil
6. Spark Plug
7. Engine Stop Button
®
14-14 ELECTRICAL SYSTEM
CD! Unit Removal
• Remove:
Side Covers
Sea •
• Disconnect the COl lead connector [AJ .
• Unscrew the mounting bolts [B], and remove the COl unit [C} ,
CD! Unit Inspection
e Remove the COl unit.
. Set the hand tester to the x1kO range, connect the tester to the
terminals in the COl unit lead, and check the internal resistance
following the table.
Special Tool - Hand Teater: 57001·983
*If the readings do not correspond to the lable, replace the COl unit.
CAIITlON
Use onty the Kawasaki Hand Tester for lhts tesl A multkneter other
than the Kawasaki Hanel Tnter may show different ,eadlngs.
Do not us•• megger Of'. meter with. large capacity battery, or the
COl unit will be damaged.
COl Unit Resistance
Tester Positive (+) Lead Connections
( -)-
Lead Color
BK/W
BK
W/A
BK/Y
BK
BK/W
-
0
BK
3.0 - 3.9
'"-
'"
W/ A
0
BK/Y
'"
'"
'"-
BK
Unit
Infinity
xlkO
kO
-
9.2 - 14.5
'"
2.8 - 3.7
9.0 - 14.5
2.9 - 3.9
0
2.9 - 3.9
(-)": Tesler Negative (-) lead Connections
'"Range
2.9 - 3.9
'"
0
'"
2.8 - 3.7
-
ELECTRICAL SYSTEM 14-15
COl Unit Troubleshooting:
(D CDI unit ()( pickup coil damaged
Beginning
® Even if the preceding checks show good, it may be
defective in some manner not readily detectable with
the hand tester.
Inspect COl unit
and pickup coil.
Do above
inspections prove
that COl unit and
pickup coil are
good?
No
Replace damaged
part.
2
Does engine still
operate poorly?
No
Replace
CO l unit
Replace part
which is not replaced
above step.
No
No
Replace pickup
coil.
No
Does engine still
operate poorly?
Trouble may be caused
by other ignition system
parts or engine itself.
End
14-16 ELECTRICAL SYSTEM
lighting System
Headlight Vertical Adjustment
oThe headlight beam is adjustable vertically only.
OTurning the adjusting screw counterclockwise makes the headlight
beam point downward.
Headlight [Al
Adjusting Screw [8]
NOT E
o On
high beam, the brightest point should be slightly below
horizontal with the motorcycle on its wheels and the rider seated.
Adjust the headlight to the proper angle (lccording (0 foelll
regulations.
Headlight Bulb Replacement
• Remove the headlight cover bolts [Al and take off the headlight cover
[8J .
• Slide back the dust cover and remove the bulb socket [AJ from the
headlight unit.
• Replace the bulb [6] with a new one.
• Check the headlight aim after installation.
Headlight Unit Installation
. Install the headlight unit [A] so that the #TOp# mark [B] on the lens
points up.
ELECTRICAL SYSTEM 14-17
Taillight Bulb Replacement
e Take Qut the screws [AJ in the taillight lens.
• Puillhe !ens off.
• Push the bulb in [AJ,lurn it counterclockwise [8], and pull it out.
e Se sure the socket is clean .
• Insert the new bulb by aligning the pins [A] with the grooves in the
walls of the socket (8).
. Push the bulb in. turn it clockwIse. and release it. It should lock in
position .
• Tighten the two screws. Be careful not to overtighten them.
Regulator Removal
• Remove:
Side Covers
Seat
Regulator Connector [A]
• Unscrew the mounting bolts [8] and remove the regulator [C].
Regulator Inspection
e Disconnect the regulator connector.
• Set the hand tester x 1 kO range, connect it to the terminals in the
regulator connector, and check the resistance following the table.
Special Tool - Ha nd Tester: 57001·983
14-18 ELECTRICAL SYSTEM
CAI.ITlON
Use only the Kawasaki Hand Tester lor this test A muttl-meter other
than the Kawasaki Hand Tester may show different readings. II 8
megger or a meter with a large<apaclty battery is used, the regulator
unit will be damaged.
* ,r the readings do not correspond to the table, replace the regulator,
Regulator Internal Re. istance
Unit: k G
Meter Positive (+) lead Connections
l ead
BR
BKj Y
BR
-
15 .... 16
BK/Y
15 .... 60
-
(-r
-
( - ) : M eter Negative Lead Connections
Lighting Coil Inspection
• Remove the right side cover.
• Disconnect the magneto connector.
. Connect the hand tester as shown in the tabl e.
Special Tool - Hand Teater: 57001-983
Lighting Coli Winding Resistance
Connection.
: Y-8K
Reading
: 1.6 .... 2.4
n ( lC 1 0 )
*If there is mOfe resistance than shown in the table. or no hand tester
reading (infi nity), the coil has an open lead and must be replaced.
Much less than this resistance means the coil is shorted, and must be
replaced.
* Any hand tester reading less than infinity (00) indicates a short,
necessitating stator replacement.
>-
I
1
@)
>-
I
BI /Y
, ,>
~
D-- BK----".-=:i___
1. Lighting Switch
2. Magneto
3. Headlight
4. Regulator
~
~
~
~
ffi
5. Taillight
ELECTRICAL SYSTEM 14-19
Trip Meter
Removal
• Remove:
Headlig ht Unit
Meter Cable Upper End [A)
Handlebar Clamp Bolts [8]
• Remove the meter unit [C)
CAUTlON
Place Itte meter so thai the lace Is up. "ltte meier Is lett upside down
or sideways lor any length of lime, "will malfunction.
Installation
. Connect the meter cable upper end .
• Mount the handlebar clamps [AJ so thaI the arrow [BJ on the clamp
points to the fronl [C] .
• Install the longer clamp bolts (D) on the right side clamp
e Tighten the handlebar clamp bolts.
Torque - Handlebar Clamp Bolts: 25 N-m (2.5 kg-m, 18.0 n-Ib)
o Tighten the frOnl clamp bolts fi rst, and then the rear. If the handlebar
clamp is correctly installed, there will be no gap [8] at the front [Al
and a gap (C) at the rear aher tightening.
Meter Mounting Inspection
. Check to see that the rubber dampers [Al are installed at the meter
mounting bracket.
* Install a new damp., where it is absent.
• Check to see that the rubber dampers in the meter mounting bracket
are in good condition. They should not be hard or cracked.
* Replace any damaged rubber dampers with new on95 .
• Check to see that meter mounling nuts are tightened securely.
..
APPENDIX 15-1
Appendix
Table of Contents
Troubleshootmg Gu ide ., ..... ................... ,...............................................................15-2
General Lubrication ................................................................................ ................. .. 15·6
lubrication .................. ............................. ..... .......... ..... ..... ............................. .. 15-6
Nut. Bolt. and Fastener Tightness ............................................................................ 15-7
Tightness Inspection ............................................................................... ......... 15- 7
Unit Conversion Table ............................................... ...................................... .........15-8
15- 2 APPENDIX
Troubleshooting Guide
NOTE
o This
is not an exhaustive list. giving every possible
cause (or each problem listed. It is meant simply as a
rough guide to assist the troubleshooting for some
the more common difficulties.
o(
Engine Doesn't Start; Starting Difficulty:
Engine won't tum over:
CylindElf', piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big Bnd seizure
Transmission gear or bearing seizure
Kick shaft return spring broken
Kick ratchet not engaging
No tueillow:
No fuel in tank
Fuel tap turned off
Tank cap air vent obstructed
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded :
Fuel level too high in carburetor floal bowl
Float valve worn or stuck open
Starting technique fa ulty
(when flooded, kick with the throttle fully open to
allow more air to reach the engine.)
No apart; apart weak:
Spark plug dirty, broken, or gap maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap not in good contact
Spark plug incorrect
COl unit trouble
Ignition coil trouble
Flywheel magneto damaged
Wiring shorted or open
Fuel/air mixture Incorrect:
Throttle stop screw maladjusted
Pilot (slow) Jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter jet clogged
Compreulon Low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder nut loose
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Poor Running at Low Speed:
Spart week:
Spark plug dirty, broken, or gap maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
COl unit trouble
Igniuon coil trouble
Flywheel magneto damaged
Ignition coil or COl unit lead not in good contact
Fuel/air mixture Incorrect:
Throttle stop screw maladjusted
Pilot (slow) Jet or air passage clogged
Air cleaner element clogged, poorly sealed, or
missing
Starter plunger stuck open
Float level too high ()( too low in carburetor lloat
bowl
Fuel tank air vem obstructed
Carburetor holder loose
Air cleaner duct loose
Crankshaft oil seal deteriorated or damaged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder nut loose
Cylinder, piston worn
Piston ring bad (worn, weak, brokOfl, or sticking)
Piston ring / groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
KIPS ports stucK open:
K[PS e)(haust valve stuck open (valve seizure, or
carbon accumulation)
KIPS e)(hausl valves assembled incorrectly
KIPS ports clogged (carbon accumulation)
Exhaust valve advancer spring damaged
Exhaust valve rod seizure in cylinder
Main shaft seized in cylinder
Advancer shah seized in the right engine cover
Other:
Transmission oil viscosity 100 high
Brake dragging
Poor Running or No Power at High Speed:
Firing Incorrect
Spark plug dirty, damaged, or maladjusted
Spark plug cap or high tOflSlon wiring damaged
Spark plug cap shorted or not in good contact
Spark plug incorrect
COl unit trouble
Ignition coil trouble
Ftywheel magneto damaged
Ignition coil or COl unit lead not in good contact
Fuel/air mixture Incorrect:
Main jet clogged or wrong size
Jet needle or needle jet worn
Jet needle clip in wrong position
Fuel level too high or too [ow
Air Jet or air passage clogged
Air cleanef element clogged, poorlv sealed, or
missing
Starter plunger stuck open
Fuel to carburetor insufficient
Crankshaft oil seal deteriorated or damaged
Water or foreign matler in fuel
Fuel tank air vent obstructed
APPENDIX 15- 3
Carburetor holder loose
Air cleaner duct loose
Fuel tap clogged
Fuel line clogged
Comp ression low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder nut loose
Cylinder, piston worn
Piston ring bad (wom, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Engine rpm w ill not rise proper ly:
Starter plunger stuck open
Fuel level too high or too low
Compression high:
Carbon built up In combustion chamber
Engine load faulty:
Brake dragging
Clutch slipping
Transmission oil level too high
Transmission o il viscosity too high
Lubrication inadequate:
Transmission oil level too low
Transmission oil poor quality or incorrect
Coolant Incorrect:
Coolant level too low
Coolant deteriorated
Cooling system component Incorrect:
Radiator clogged
Radiator cap trouble
Water pump not rotating
Water pump impeller damaged
Main Jel clogged
Throttle valve does not fully open
Air cleaner element clogged
Muffler clogged
Water or foreign matter in fuel
Cylinder exhaust pon clogged
Brake dragging
Clutch slipping
Overheating
Transmission oil level too high
Transmission oil viscosity too high
Crankshaft bearing worn or damaged
KIPS ports stuck closed:
KIPS exhaust valves stuck closed (valve seizure,
or carbon accumulation)
KI PS exhaust valves assembled incorrectly
KIPS ports clogged (carbon accumulation)
Exhaust valve advancer spring damaged
Exhaust valve rod seized in cylinder
Main shaft seized in cylinder
Advancer shaft seized in the right engine cover
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
COl unit trouble
Ignition timing maladjusted
Overheating:
Firing Incorrect
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
COl unit trouble
Ignition timing maladjusted
Fuel/air mixture Incorrect:
Main jet clogged or wrong size
Fuelleve! too low in carburetor fioat bowl
Carburetor holder loose
Air cleaner element clogged, poorly sealed, or
missing
Air cleaner duct poorly sealed
Clutch Operation Faulty:
Clulch slipping:
No clutch lever play
Clutch cable maladju sted
Clutch inner cable catChing
Clutch plate worn or warped
Clutch spring broken or weak
Clutch release mechanism trou ble
Clu tch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever play excessive
Clutch plate warp ed or too rough
Clutch spring force uneven
Transmission oil deteriorated
Transmission oil viscosity too high
Transmission oil level too high
Clutch housing frozen on drive sh aft
Clutch release mechan ism trouble
Gear Shifting Faulty:
Doesn't g o into gear; shift pedal doesn' t return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear set lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift dru m broken
Jumps out of gear:
Shift fork worn
Gear groove worn
Gear d ogs and/or d og holes and recesses worn
Shift drum groove worn
Gear set lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear splines worn
Oversh lfts:
Gear set lever spring weak or broken
Shift mechan ism arm spring broken
15·4 APPENDIX
Abnormal Engine Noise:
Knocking:
Ignition timing maladjusted
COl unit trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/ piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin holes worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stuck
Piston seized or damaged
Cylinder head gasket leaking
Expansion chamber leaking at cylinder head
connection
Crankshaft runou! excessive
Engine mounts ioose
Crankshaft bearing worn
Primary gear worn or chipped
Abnormal Drive Train Noise:
ClullCh nol•• :
Clutch housing/friction plate clearance excessive
Clutch housing gear/primary gear backlash
excessive
Friction plates installed incorrectly
Metal chip jammed in clutch housing gear teeth
Transmlulon noise:
Crankcase bearing worn or damaged
Transmission gear worn or chipped
Metal chip jammed in gear teeth
Transmission oil insufficient or too thin
Kick ratchet not properly disengaging from kick
gear
Kick idle gear on output shaft worn or chipped
Drive chaIn noise:
Drive chain adjusted improperly
Chain worn
Rear and/or engine sprocket(s) worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front tortl. noise:
Oil insufficient or too thin
Spring weak or broken
Rear ahock absorber no... :
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Master cylinder damaged
Other noise
Bracket, nut, bolt, etc. not properly mounted or
tightened
Exhaust Smoke:
Excessive white smoke:
Crankshaft oil seal damaged
BrownIsh smoke:
Air cleaner element clogged
Main let too large or fallen out
Starter plunger stuck open
Fuel level too high in carburetor float bowl
Handling and/or Stability Unsatisfactory:
Handlebar hard to tum:
Cable or hose routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Bearing roller damaged
Bearing race dented or worn
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Spokes loose
Swingarm sleeve or needle bearing damaged
Rim warped, or not balanced
Front. rear axle runout excessive
Wheel bearing (hub bearing) worn
Handlebar clamp loose
Steering stem head nut loose
Handlebar pulls to one slda:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swingarm pivot shah runout excessive
Steering maladjusted
Steering stem bent
Front fork leg bent
Right/ left front fork oil level uneven
Sttock absorption unsallsfactory:
(Too hard )
Front fork maladjusted
Front fork oil excessive
Front fork oil viscosity too high
Front fork leg bent
Tire air pressure too high
Rear shock absorber maladjusted
Rear shock oil viSCOSity too high
(Too soh)
Front fork maladjusted
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Front fork, rear shock absorber spring weak
Tire air pressure too low
Rear shock absorber gas tea king
Rear shock absorber maladjusted
Rear shock oil viscosity too low
APPEN DIX 15- 5
Brakes Don 't Hold:
Air in the brake line
Pad or disc worn
Brake flUid leak
Disc warped
Contaminated pads
Brake flUid deteriorated
Primary or secondary cup damaged in the master
cyhnder
Master cylinder scratched Inside
Brake maladjustment (lever play excessive)
15-6 APPENDIX
General lubrication
Lubrication
• Before lubricat ing each part. clean off any rusty spots with rust remover
and wipe off any grease, oil, dirt, or grime.
• lubricate the points listed below with indicated lubricant.
NOTE
O Perform the general lubrication in accordance with the Periodic
Maintenance Chart or whenever the vehicle has been operated
under wet or rainy conditions, or especially after using 8
high-pressure water spray.
Pivots: Lubricate with Mot o r Oil.
Clutch lever
Side Stand
Kick Pedal
Shift Pedal
Drive Chain "
Apply heavy oil.
n:
Points: lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Thron le Inner Cable Upper End [A]
Brake Pedal
Trip Meter l ower End
Brake lever"
(00) : Apply silicone grease.
Ca bles: lubricate w ith Rust Inhibite r .
Throttle Cable
Clutch Cable
Special Tool - Pressure Cable Luber: K56019-021 [AJ
Aerosol Cable Lubricant [8]
. With the cable disconnected at the both end, the cable should move
freely [AI within the cable housing.
* 11 cable movement is not free after lubricating. if the cable is frayed, or
if the cable housing is kinked, replace the cable.
APPENDIX 15-7
Nut, Bolt, and Faste ner Tightness
Tightness Inspection
• Check the light ness of the bolts and nuts listed here In accordance
with the Periodic Maintenance Chart. Also, check to see that each
cotter pin is in place and in good condition.
NOTE
o Far the engine fasteners, check the tightness of them when the
engine is cold (at (oom temperature) .
* II there are loose fasteners, relorque them to the specified torque
following the specified tightening sequence. Ref8( to the Torque and
Locking Agent section 01 the General Information chapter for torque
specifications. For each fastener, first IOOSOfl II by 1/ 2 turn, then
lighten it.
*H co tter pins are damaged, replace them wi th new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Spoke Nipples
Front Axle
Front Axle Clamp Nuts
Rear Axle Nut
Rear Axle Nut Caner Pin
Final Driv~:
Rear Sprocket Nuts
Brakes:
Front M aster Cvlinder Clamp Bo lts
Caliper Mounting Bo lts
Rear Master Cylinder Screws
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Coner Pin
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolts
Swingarm Pivot Nut
Uni -trak link Nuts
Steering:
Stem Head Nut
Hand lebar Clamp Bolts
Engine:
Engine Mounting Bolts
Muffler Mounting Bolts
Exhaust Pipe Holder Nuts
Clutch Lever Pivot Nut
Others:
Side Stand Nul and Bracket Bolts
Rear Frame Pipe Bolts
15-8 APPEN DIX
Unit Conversion Table
Prefixes for Units'
Units of Torque:
Prefix
Symbol
Power
mega
M
k
• , ,000,000
kilo
centi
milli
micra
1,000
K 0.01
x 0.001
x 0.000001
K
c
m
"
•
•
•
•
•
•
N-m
N -m
N -m
kg - m
kg -m
kg - m
0.'020
0,7376
8.85'
kg -m
~
h -Ib
-
9,807
7.233
86.80
in - Ib
N -m
~
h -Ib
=
in -Ib
Units of Pressure:
Units of Mass:
kg
g
•
•
2.205
~
Ib
0.03527
==
oz
•
•
•
•
•
•
•
•
•
kg
kg
0,0'020
0.'450
0,750'
kg/em'
•
98 .07
,4.22
' _333
•
•
0.2642
0.2200
1.057
0.8799
2,113
, .8,6
0.0338,
0,028'6
0.06'02
em Hg
gal (US )
gal (imp)
ql (US)
qt (imp)
pint (US)
pint (imp)
02 (US)
az (imp)
cu in
~
~
=
=
=
•
•
0,'020
0,2248
•
•
9.807
2.205
•
km / h
psi
em Hg
~
kPa
psi
kPa
~
~
0,624'
~
, ,360
~
mph
Units of Power:
kW
kW
•
•
1.341
PS
PS
•
•
0,7355
0_9863
kg
Ib
~
kg/em'
~
Units of Speed:
Units of Force:
N
N
•
•
•
kg /cm ~
Units of Volume:
L
L
L
L
L
L
mL
mL
mL
kPa
kPa
kPa
PS
HP
kW
HP
~
N
Ib
~
Units of length:
•
•
km
m
mm
0.62'4
3.28'
0.03937
•
mile
~
h
~
in
Units of Temperature:
9(OC+40)
5( Or+40)
5
9
OF
-"
I
-4
-20
I
I
32
10I
Ij
-20 :
-17.8
20
I
I
I 40
i I
J!
4,4
68
60 : 80
I I I
I
iI
20 '
26.7
t04
lDO ! 120
, I'
I!
"
48.9
40 =
160
I ,Ii
60
71. 1
C
OF
176
'40
°
212
: 180 200 i 220
!I
I i I
,
80
I ,
r
! 100
93. J
248
284
240 ! 260 280 i 300
I : I
II
I
I :
I
! 120
116
I
!
I
, 140
138
I
320
I
160
°C
KDX220
Motorcycle
Service Manual
Supplement
I
Kawasaki
KDX220
Motorcycle
Service Manual
Supplement
This supplement is designed to be used inconjunction with the KDX200H Service Manual
(P/No.99924-1181-01 ).
The maintenance and repair procedures described in this supplement are only those that are unique to
KDX220A motorcycle. Most Service operations for this model remain identical to those described in the
Base Service Manual. Complete and proper servicing of the KDX220A motorcycle therefore requires this
Supplement and the Base Service Manual.
© 1996 Kawasaki Heavy Industries, Ltd.
Fifth Edition (1): Feb. 6, 2003 (K)
1
Table of Contents
General Information .......................•............................. 2
Model Identification' ...•................•.......................... " 2
General Specifications ............................................... 3
Fuel System···························································· 5
Specifications' .....•..•..................•...............••...•... " 5
Engine Top End' ......••................•..................•...•...... " 5
Specifications' ..•...•••...............••..................•....... " 5
Final Drive ...........•. - ••............•.....••....................... " 6
Specifications' .....•••.....................................•...... " 6
Supplement - 2002 Model- - ................•........................•.. 7-1
Foreword' . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . • . . . . .. 7-2
General Information ..............•....•..•........................ 7-3
CrankshaftfTransmission ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-5
Supplement - 2003 Model' • • . . . . . . . . . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-1
Foreword' . . . . . . . . • . . . . . . . . . . . . . . . . . . . • . . • • . . . . . . . . . . . . . . . . • . . . . .. 8-2
General Information ...................•..•........................ 8-3
WheelsfTires ..................................................... 8-5
Frame' .................................•.............•...•...... 8-6
T!
!
•
2
General Information
Model Identification
KDX220-A4 Left Side View
KDX220-A4 Right Side View
~
3
General Specifications
Items
KDX220-A4~ A8
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight
Front
Rear
Fuel tank capacity
2120 mm
890mm
1230mm
1 435 mm
340mm
920mm
101 kg
53 kg
57 kg
11 L
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing:
Inlet
2-stroke, single cylinder, piston reed valve
Liquid-cooled
69.0 x 58.0 mm
216 mL
7.2 : 1
27 kW (37 PS) @7 500 r/min (rpm)
35 N·m (3.55 kgf·m, 25.5 ft·lb)
Open
Close
Scavenging
Open
Exhaust
Close
Open
Close
Lubrication system (Gasoline: oil)
Drive Train:
Primary reduction system:
Type
Reduction ratio
Clutch type
Transmission:
Type
Gear ratios:
Final drive system:
Overall drive ratio
Transmission oil:
..
1st
2nd
3rd
4th
5th
6th
Type
Reduction ratio
Grade
Viscosity
Capacity
Carburetor, KEIHIN PWK33
Primary kick
COl
21 ° BTDC @6 000 r/min (rpm)
NGK BR8ES
Full open
56° BBDC
56° ABDC
79.1' BBDC (low speed), 90° BBDC (high speed)
79.1' ABDC (low speed), 90° ABDC (high speed)
Petrol mix (32:1)
Gear
2.864 (63/22)
Wet, multi disc
6-speed, constant mesh, return shift
2.692 (35/13)
2.000 (28/14)
1 .533 (23/15)
1.235 (21/17)
1 .042 (25/24)
0.870 (20/23)
Chain drive
3.615 (47/13)
9.002 @Top gear
SE, SF, or SG class
SAE 1OW-30 or 10W-40
0.7 L
(Continued on next page.)
---==-----
~~=--::;=~====
4
Items
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire:
Size
Make/Type
Rear tire:
Size
Make/Type
Front suspension:
Type
Wheel travel
Type
Rear suspension:
Wheel travel
Brake type:
Front and Rear
Effective disc diameter: Front
Rear
Electrical Equipment:
Headlight
Type
Bulb
Bulb
Taillight
Type
Magneto
Rated output
KDX220-A4~ AS
Tubular, semi-double cradle
45 to either side
26.5
108 mm
80/100-21 51 M
DUNLOP K490, Tube type
100/100-1859M
DUNLOP K695, Tube type
Telescopic fork
290mm
Swingarm (Uni-trak)
300mm
Single disc
220mm
190mm
0
0
Semi-sealed beam
12V30W
12V10W
Single-phase AC
Specifications are subject to change without notice, and may not apply to every country.
5
Fuel System
Specifications
Item
Throttle grip free play
Carburetor:
Make, type
Idle speed
Air screw (turns out)
Service fuel level
Float height
Main jet
Main air jet
Needle jet
Jet needle mark
Jet needle clip position
Pilot jet (slow jet)
Starter jet
Throttle valve cutaway
Air Cleaner Element Oil
Reed Valve
Reed warp
Standard
2 - 3 mm
KEIHIN, PWK33
Slowest smooth idle speed
1Yo ± %
o - 2 mm above the float bowl mating surface
16 ± 2 mm
#145
#200 (unremovable)
N426-24COO
R1173L2AFLP
3rd groove from the top
#42
I #78
I
I #5
High-quality-form-air filter oil
0.2 mm (service limit)
Engine Top End
Specifications
Standard
Item
Cylinder Head:
Cylinder compression
Cylinder head warp
Cylinder, Piston:
Cylinder inside diameter
Piston diameter
Piston/cylinder clearance
Piston ring/groove clearance:
Top
Second
Piston ring groove width:
Top
Second
Piston ring thickness:
Top
Second
Piston ring end gap:
Top
Second
KIPS Valve
KIPS valve opening
engine speed
(usable range)
655 - 1 040 kPa
(6.7~10.6 kgf/cni, 95~151 psi)
---
I
i Service Limit
I
I
---
0.05 mm
69.025 - 69.040 mm
68.925 - 68.940 mm
0.095 - 0.105 mm
69.1 mm
68.80 mm
---
--- (keystone)
0.025 - 0.08 mm
--0.18 mm
--- (keystone)
1.215 - 1.25 mm
--1.33 mm
1.17 - 1.19 mm
1.17 -1.19mm
1.1 mm
1.1 mm
0.30 - 0.50 mm
0.30 - 0.50 mm
0.8mm
0.8mm
about 6000
rim (rpm)
---
6
Final Drive
Specifications
Item
Standard
Service Limit
Drive Chain:
Standard chain
Make
Type
Link
Chain slack
20-link length
Sprockets:
Rear sprocket warp
DAIDO
Joint Endless, DlD520SR -02
108 links
55 - 65 mm
- -- -- --
317.5 - 318.2 mm
Too tight: less than 55 mm
Too loose: more than 70mm
323mm
TIR 0.4 mm or less
TIR 0.5 mm
SUPPLEMENT - 2002 MODEL 7-1
Supplement - 2002 Model
TABLE OF CONTENTS
Foreword .................................................................................................................................
How to Use this Manual .............. ......................................................................................... .
General Information ......... ........................................................................................................
General Specifications .. ........................................................................................................
Crankshaft/Transmission .........................................................................................................
Specifications .................. ......................................................................................................
Transmission Oil ...................................................................................................................
Oil Change .........................................................................................................................
7- 2
7- 2
7- 3
7- 3
7- 5
7- 5
7- 5
7- 5rn
7 -2 SUPPLEMENT - 2002 MODEL
Foreword
How to Use this Manual
This "Supplement 2002 Model" designed to be used in conjunction with the front part of this manual
(up to 6) and/or Base Manual KDX200H Service Manual Part No. 99924-1181-01. The specifications
and maintenance procedures described in this chapter are only those that are unique to the KDX220
-A9 model.
Complete and proper servicing of the KDX220-A9 model therefore requires mechanics to read both
this chapter and the front of this manual.
SUPPLEMENT - 2002 MODEL 7-3
General Information
General Specifications
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight:
KDX220-A9
Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Carburetion system
Starting system
Ignition timing
Ignition system
Spark plug
POI1 timing:
Inlet
Open
Close
Scavenging
Open
Close
Exhaust
Open
Close
Lubrication sy§tem (Gasoline: oil}
Drive Train:
Primary reduction system:
Type
Reduction ratio
Clutch type
Transmission:
Type
Gear ratios:
1st
2nd
3rd
4th
5th
6th
2 120 mm (83.5 in.)
890 mm (35.04 in.)
1 230 mm (48.4 in.)
1 435 mm (56.5 in.)
340 mm (13.4 in.)
920 mm (36.2 in.)
101 kg (222 Ib)
53 kg (116Ib)
57 kg (125 Ib)
11 L (2.9 US qal)
2-stroke, single cylinder, piston reed valve
Liquid-cooled
66.0 x 58.0 mm (2.59 x 2.28 in.)
216 mL (13.18 cu in.)
7.2 : 1
Carburetor, KEIHIN PWK33
Primary kick
21 ° BTDC @6 000 r/min (rpm)
COl
NGK BR8ES
Full open
56° BBDC
56° ABDC
79.7 BBDC (low speed), 90° BBDC (high speed)
79.7 ABDC (low speed), 90° ABDC (high speed)
Petrol mix (32 : 1)
Gear
2.864 (63/22)
Wet, multi disc
6-speed, constant mesh, return shift
2.692 (35/13)
2.000 (28/14)
1 .533 (23/15)
1.235 (21/17)
1.042 (25/24)
0.870 (20/23)
7-4 SUPPLEMENT - 2002 MODEL
General Information
KDX220-A9
Items
Final drive system:
Type
Reduction ratio
Overall drive ratio
Transmission oil:
Type
Viscosity
Capacity
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire:
Rear tire:
Front suspension:
Rear suspension:
Brake type:
Effective disc diameter:
Electrical Equipment:
Headlight:
Chain drive
3.615 (47/13)
9.002 @Top gear
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
0.7 L (0.74 US qt)
Tubular, semi-double cradle
45° to either side
26.5°
108 mm (4.3 in.)
80/100-21 51 M
Size
DUNLOP K490, Tube type
Make/Type
100/100-18 59M
Size
DUNLOP K695, Tube type
Make/Type
Telescopic
fork
Type
290 mm (11.4 in.)
Wheel travel
Swingarm (Uni-trak)
Type
300 mm (11.8 in.)
Wheel travel
Front and Rear Single disc
220 mm (8.7 in.)
Front
190 mm (7.5 in.)
Rear
Semi-sealed beam
Type
Bulb
12 V 30 W
12 V 10 W
Bulb
Taillight:
Single-phase AC
Magneto:
Type
Rated output
Specifications subject to change without notice, and may not apply to every country.
SUPPLEMENT - 2002 MODEL 7-5
eran kshaftfTransmission
Specifications
Item
Standard
Transmission Oil:
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
Type
Viscosity
0.65 L (0.69 US qt) (when changing oil)
0.7 L (0.74 US qt) (when engine is completely dry)
Between u per and lower level line
Capacity
Level
Transmission Oil
Oil Change
• Warm up the engine thoroughly so that the oil will pick up
any sediment and drain easily. Then stop the engine.
• Place an oil pan beneath the engine.
• Remove the transmission drain plug [A] on the bottom of
the engine, and let the oil drain completely.
NOTE
o Hold the motorcycle upright so that the oil may drain
completely.
• Check the gasket at the drain plug for damage.
*Replace the gasket with a new one if it is damaged.
• After the oil has completely drained out, install the drain
plug with the gasket, and torque it.
Torque - Transmission Drain Plug: 20 N·m (2.0 kgf.m, 14.5
ft·lb)
• Fill the engine with a good quality motor oil specified.
• Check the oil level.
CAUTION
Measure the oil amount correctly according to the
table and pour in the oil.
Recommended Transmission Oil
Type:
Viscosity:
Capacity:
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
0.65 L (0.69 US qt) (When charging oil)
0.7 L (0.74 US qt) (When engine is completely
dry)
Service Limit
7-6 SUPPLEMENT - 2002 MODEL
CrankshaftlTransmission
NOTE
o Depending on the atmospheric temperature of your rid-
SAE 20W-50
ing area, the engine oil viscosity should be changed according to the chart:
SAE 20W-40
1
1
I
I
I
I
I
I
I
I
SAE lOW-50
I
SAE lOW-40
-20
-10
I
I
-4
14
I
10
I
20
I
32
50
68
.
3040(C)
! !
8'6
1 ~4("F)
',----,-'_...L..'- - ' - ' - - - " - - - - ' - 1----,' GSa 9 0008 S,
C
SUPPLEMENT - 2003 MODEL 8-1
Supplement - 2003 Model
TABLE OF CONTENTS
Foreword.................................................................................................................................
How to Use this Manual.................. ........................................................................... ...........
General Information.................................................................................................................
General Specifications..........................................................................................................
WheelsfTires................................................................... ...... ...................................................
Specifications........................................................................................................................
888888-
2
2
3
3
5
5
Frame ......................................................................................................................................
8- 6
Exploded View ...................................................................................... ····· .. ······.··················
8- 6
8-2 SUPPLEMENT - 2003 MODEL
Foreword
How to Use this Manual
This "Supplement 2003 Model" designed to be used in conjunction with the front part of this manual
(up to 7-6) and/or Base Manual KDX200H Service Manual Part No. 99924-1181-01. The specifications and maintenance procedures described in this chapter are only those that are unique to the
KDX220-A 10 model.
Complete and proper servicing of the KDX220-A 10 model therefore requires mechanics to read
both this chapter and the front of this manual.
SUPPLEMENT - 2003 MODEL 8-3
General Information
General Specifications
KDX220-A10
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight:
Front
Rear
Fuel tank capacity
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Carburetion system
Starting system
Ignition timing
Ignition system
Spark plug
Port timing:
Inlet
Open
Close
Scavenging
Open
Close
Exhaust
Open
Close
Lubrication system (Gasoline: oil)
Drive Train:
Primary reduction system:
Type
Reduction ratio
Clutch type
Transmission:
Type
Gear ratios:
1st
2nd
3rd
4th
5th
6th
2 120 mm (83.5 in.)
890 mm (35.04 in.)
1 230 mm (48.4 in.)
1 435 mm (56.5 in.)
340 mm (13.4 in.)
920 mm (36.2 in.)
101 kg (222 Ib)
53 kg (116 Ib)
57 kg (125 Ib)
11 L (2.9 US aal)
2-stroke, single cylinder, piston reed valve
Liquid-cooled
69.0 x 58.0 mm (2.72 x 2.28 in.)
216 mL (13.18 cu in.)
7.2 : 1
Carburetor, KEIHIN PWK33
Primary kick
21 ° BTDC @6 000 r/min (rpm)
CDI
NGK BR8ES
Full open
56° BBDC
56° ABDC
90° BBDC
90° ABDC
Petrol mix (32 : 1)
Gear
2.864 (63/22)
Wet, multi disc
6-speed, constant mesh, return shift
2.692 (35/13)
2.000 (28/14)
1.533 (23/15)
1.235 (21/17)
1.042 (25/24)
0.870 (20/23)
8-4 SUPPLEMENT - 2003 MODEL
General Information
Items
KDX220-A10
Final drive system:
Type
Reduction ratio
Overall drive ratio
Transmission oil:
Type
Chain drive
3.615 (47/13)
9.002 @Top gear
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
0.7 L(0.74 USgtt
Viscosity
Capacity
Frame:
Type
Steering angle
Caster (rake angle)
Trail
Front tire:
Rear tire:
Front suspension:
Rear suspension:
Brake type:
Effective disc diameter:
Electrical Equipment:
Headlight:
Size
Make/Type
Size
Make/Type
Type
Wheel travel
Type
Wheel travel
Front and Rear
Front
Rear
Tubular, semi-double cradle
45° to either side
26.5°
108 mm (4.3 in.)
80/100-21 51 M
DUNLOP D739FA, Tube type
100/100-18 59M
DUNLOP 0739, Tube type
Telescopic fork
290 mm (11.4 in.)
Swingarm (Uni-trak)
300 mm (11.8 in.)
Single disc
220 mm (8.7 in.)
190 mm(7.5 inl
Type
Semi-sealed beam
Bulb
12 V 30 W
12 V
Taillight:
Bulb
Magneto:
Type
Single-phase AC
Rated output
Specifications subject to change without notice, and may not apply to every country.
SUPPLEMENT - 2003 MODEL 8-5
WheelslTires
Specifications
Item
Standard
Service Limit
Wheels:
Axial
Radial
Axle runoutJ100 mm
Rim runout:
Tires:
Tire air pressure:
TIR 0.5 mm (0.02 in.) or less
TIR 0.8 mm (0.03 in.) or less
TIR 0.10 mm (0.004 in.) or less
TIR 2 mm (0.079 in.)
TIR 2 mm (0.079 in.)
TIR 0.2 mm (0.008 in.)
80 kPa (0.8 kgf/cm 2 , 11 psi) - 100 kPa (1.0 kgf/cm 2 , 14 psi)
(to suit track conditions and rider preference)
Standard tires:
Front:
Rear:
Make
Type
DUNLOP
Size
D739FA Tube type
80/100-21 51 M
Make
DUNLOP
Type
Size
D739 Tube type
100/100-18 59M
Special Tools - Inside Circlip Pliers: 57001-143
Rim Protector: 57001-1063
Bead Breaker Assembly: 57001-1072
Bearing Driver Set: 57001-1129
Jack: 57001-1238
Bearing Remover Shaft, ¢9: 57001-1265
Bearing Remover Head, ¢15 x ¢17: 57001-1267
Bearing Remover Head, ¢ 20 x ¢22: 57001-1293
8-6 SUPPLEMENT - 2003 MODEL
Frame
Exploded View
G002071814
0: Apply oil.
T1: 59 N·m (6.0 kgf.m, 43 ft·lb)
T2: 44 N·m (4.5 kgf·m, 32 ft·lb)
C
SUPPLEMENT - 2003 MODEL 8-7
Frame
.~~~ ~­
~~~
G002072B"4 C
MODEL APPLICATION
Year
Model
Beginning Frame No.
1997
KDX220-A4
JKBDXBA 1DVA005001
2000
KDX220-A7
JKBDXBACDYA021 001
2001
KDX220-AB
JKBDXBACD 1A027001
2002
KDX220-A9
JKBDXBACD2DAOOO01
2003
KDX220-A10
JKBDXBACD3DA01565
D :This digit in the frame number changes from one machine to another.
~Kawasaki
KAWASAKI HEAVY INDUSTRIES, LTD.
Consumer Products & Machinery Company
Part No.99924-1204-55
Printed in Japan

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