2008 Kawasaki KVF360B6 Prairie Service Repair Manual 1

MODEL APPLICATION Year

Model

2003

KVF360-B1

2004

KVF360-B2

2005

KVF360-B3

2006

KVF360B6F

2007

KVF360B7F

2008

KVF360B8F

2009

KVF360B9F

Beginning Frame JKBVFHB1□3B500001 JKBVF360BBB600001 JKBVFHB1□4B505201 JKBVF360BBB601801 JKBVFHB1□5B507100 JKBVF360BBB602500 JKBVFHB1□6B510501 JKBVF360BBB602901 JKBVFHB1□7B512801 JKBVF360BB603601 JKBVFHB1□8B514900 JKBVF360BBB603900 JKBVFHB1□9B516601 JKBVF360BBB604501

No. or or or or or or or

□:This digit in the frame number changes from one machine to another.

Part No.99924-1302-07

Printed in Japan

PRAIRIE 360 KVF 360

All Terrain Vehicle Service Manual

Quick Reference Guide

This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System

3 j

Engine Top End

4 j

Converter System

5 j

Recoil Starter

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

PRAIRIE 360 KVF 360

All Terrain Vehicle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Š 2002 Kawasaki Heavy Industries, Ltd.

Seventh Edition (1) : May 30, 2008 (K)

LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celcius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

lb m min N Pa PS psi r rpm TDC TIR V W Ω

pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.

1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase.

2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

3. Evaporative Emission Control System The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."

NOTE The phrase "remove or render inoperative any device or element of design" has been generally â—‹ interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2. Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only) TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED: Federal regulations and California State law prohibit the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

• • • •

Do not tamper with the original emission related parts: Carburetor or internal parts Spark Plug Magneto ignition system Air Cleaner element

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below: * Replacement of the original exhaust system or muffler with a component not in compliance

with Federal regulations. * Removal of the muffler(s) or any internal portion of the muffler(s). * Removal of the air box or air box cover. * Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such

modifications result in increased noise levels.

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop.

However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual.

Be alert for problems and non-scheduled maintenance.

Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual carefully. Don’t take shortcuts.

Remember to keep complete records of maintenance and repair with dates and any new parts installed.

• • •

• •

How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference

Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance practices.

WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done.

○Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

1

Table of Contents Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1-2 1-7 1-8 1-14

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground Before completing any service on the vehicle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the negative cable (–) first and then the positive cable (+). When completed with the service, first connect the positive cable (+) cable to the positive (+) terminal of the battery then the negative terminal (–) cable to the negative terminal.

Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench.

Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Locking Agent For applications that require Liquid Gasket or a Non-Permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Leads A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to those of the same color.

Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustment.

GENERAL INFORMATION 1-7 Model Identification KVF360-B1 Left Side View

KVF360-B1 Right Side View

1-8 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance: Rear Final Gear Case Center of Frame Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine Oil: Grade Viscosity

KVF360-B1 ∼ B3 2 1 1 1

065 205 175 255

195 260 910 263

mm mm mm mm

(81.30 (47.44 (46.26 (49.41

KVF360B6F ∼

in.) in.) in.) in.)

mm (7.68 in.) mm (10.23 in.) mm (35.83 in.) kg (580 lb)

139.5 kg (308 lb) 135.5 kg (299 lb) 13.5 L (3.6 US gal)

263.5 kg (581 lb) 140 kg (309 lb)

3.2 m (10.50 ft) 4-stroke, SOHC, 1-cylinder Air-cooled 80.0 × 72.0 mm (3.15 × 2.83 in.)

362 cm³ (22.1 cu in.)

8.3 : 1 15.7 kW (21.4 PS) @7 000 r/min (rpm), (US) 26.1 N·m (2.66 kgf·m, 19.25 ft·lb) @4 500 r/min (rpm) Carburetor, Keihin CVK34 Electric Starter & Recoil Starter DC-CDI Electronically advanced From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @5 000 r/min (rpm) NGK DPR8EA-9

38° BTDC 58° ABDC 276° 68° BBDC 28° ATDC 276° Forced lubrication (wet sump) API SF or SG API SH, SJ or SL with JASO MA SAE 10W-40

GENERAL INFORMATION 1-9 General Specifications Items Capacity Drive Train Primary Reduction System: Type Reduction Ratio Transmission: Type Gear Ratios: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Forward: High Low Reverse Final Gear Case Oil: Type Capacity Frame Type Caster (Rake Angle) Camber King Pin Angle Trail Tread: Front Rear Front Tire: Type Size Rear Tire: Type Size Rim Size: Front Rear

KVF360-B1 ∼ B3 2.3 L (2.17 US qt)

KVF360B6F ∼

Belt converter 3.122 ∼ 0.635 2-speed automatic and reverse

3.548 (30/26 × 29/18 21/11) 5.536 (36/20 × 29/18 × 21/11) 4.613 (16/12 × 18/16 × 29/18 × 21/11) Shaft 4.375 (35/8)

48.474 ∼ 9.859 75.619 ∼ 15.380 63.016 ∼ 12.817 MOBILE Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID) or Exxon Hydvaul 560 900 mL (0.95 US qt) Double cradle, tubular steel 2.5° 0.5° 14.5° 15 mm (0.59 in.)

900 mm (35.43 in.)

895 mm (35.24 in.)

Tubeless AT25 × 8 - 12 Tubeless AT25 × 10 - 12 12 × 6.0 12 × 7.5

1-10 GENERAL INFORMATION General Specifications Items Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Brake/Tail Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output

KVF360-B1 ∼ B3

MacPherson strut 170 mm (6.69 in.)

Swingarm 180 mm (7.09 in.)

Disc × 2 Enclosed wet multi-plate 12 V 14 Ah Semi-sealed beam 12 V 30/30 W × 2 12 V 18/5 W (EUR) (GB) 12 V 10 W Three-phase AC 25 A, 14 V @8 000 r/min (rpm)

KVF360B6F ∼

GENERAL INFORMATION 1-11 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Ground Clearance: Rear Final Gear Case Center of Frame Seat Height Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine Oil: Grade

KVF360B9F 2 1 1 1

065 205 167 253

mm mm mm mm

(81.30 (47.44 (45.94 (49.33

in.) in.) in.) in.)

197 mm (7.76 in.)

252 mm (9.92 in.)

910 mm (35.83 in.)

KVF360B9F (US, AU) 276 kg (609 lb) KVF360B9F (EUR) 277 kg (611 lb) KVF360B9F (US, AU) 140 kg (309 lb) KVF360B9F (EUR) 141 kg (311 lb) 136 kg (300 lb) 13.5 L (3.6 US gal) 3.2 m (10.50 ft) 4-stroke, SOHC, 1-cylinder Air-cooled 80.0 × 72.0 mm (3.15 × 2.83 in.)

362 cm³ (22.1 cu in.)

8.3 : 1 15.7 kW (21.4 PS) @7 000 r/min (rpm), (US) 26.1 N·m (2.66 kgf·m, 19.25 ft·lb) @4 500 r/min (rpm) Carburetor, Keihin CVK34 Electric Starter & Recoil Starter DC-CDI Electronically advanced From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @5 000 r/min (rpm) NGK DPR8EA-9

38° BTDC 58° ABDC 276° 68° BBDC 28° ATDC 276° Forced lubrication (wet sump) API SF or SG API SH, SJ or SL with JASO MA

1-12 GENERAL INFORMATION General Specifications Items Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Transmission: Type Gear Ratios: Forward: High Low Reverse Final Drive System: Type Reduction Ratio Overall Drive Ratio: Forward: High Low Reverse Final Gear Case Oil: Type

Capacity Frame Type Caster (Rake Angle) Camber King Pin Angle Trail Tread: Front Rear Front Tire: Type Size Rear Tire: Type Size Rim Size: Front Rear

KVF360B9F SAE 10W-40 2.3 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed automatic and reverse

3.548 (30/26 × 29/18 21/11) 5.536 (36/20 × 29/18 × 21/11) 4.613 (16/12 × 18/16 × 29/18 × 21/11) Shaft 4.375 (35/8)

48.474 ∼ 9.859 75.619 ∼ 15.380 63.016 ∼ 12.817 MOBILE Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID) or Exxon Hydvaul 560 900 mL (0.95 US qt) Double cradle, tubular steel 3.1° 0.2° 14° 18 mm (0.71 in.)

905 mm (35.63 in.)

895 mm (35.24 in.)

Tubeless AT25 × 8 - 12 Tubeless AT25 × 10 - 12 12 × 6.0 12 × 7.5

GENERAL INFORMATION 1-13 General Specifications Items Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Electrical Equipment Battery Headlight: Type Bulb Brake/Tail Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output

KVF360B9F

MacPherson strut 170 mm (6.69 in.)

Swingarm 180 mm (7.09 in.)

Disc × 2 Enclosed wet multi-plate 12 V 14 Ah Semi-sealed beam 12 V 30/30 W × 2 12 V 18/5 W (EUR) (GB) 12 V 10 W Three-phase AC 25 A, 14 V @8 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country.

EUR: Europe Model GB: United Kingdom Model US: United States Model

1-14 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Units of Length:

Symbol M k c m μ

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

gal (US)

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

= = = = = =

kgf/cm² psi cmHg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

Units of Volume: L L

× ×

0.2642 0.2200

= =

L L L L mL mL mL

× × × × × × ×

1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

= = = = = = =

gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

Units of Pressure: kPa kPa kPa kgf/cm² kgf/cm² cm Hg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

Units of Force: N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

= = = =

kg lb N lb

×

0.6214

Units of Power: kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance 2

Table of Contents Periodic Maintenance Chart ..............

Torque and Locking Agent.................

Specifications ....................................

Special Tools .....................................

Periodic Maintenance Procedures.....

Fuel System....................................

Throttle Lever Free Play Inspection..................................

Throttle Lever Free Play Adjustment ................................

Idle Speed Inspection ..................

Idle Speed Adjustment.................

Fuel System Cleanliness Inspection..................................

Air Cleaner Element Cleaning and Inspection..................................

Air Cleaner Draining.....................

Fuel Hoses and Connections Inspection..................................

Fuel Hose Replacement ..............

Engine Top End ..............................

Valve Clearance Inspection .........

Valve Clearance Adjustment........

Spark Arrester Cleaning...............

Converter System ...........................

Actuator Lever (Engine Brake Control Lever) Assembly Inspection..................................

Drive Belt Inspection ....................

Drive Belt Deflection Inspection ...

Drive Belt Deflection Adjustment .

Engine Lubrication System .............

Engine Oil Change.......................

Oil Filter Change ..........................

Oil Cooler Cleanliness Inspection Oil Hoses and Connections Inspection..................................

Wheels/Tires...................................

Tire Inspection .............................

2-2 2-4 2-9 2-11 2-12 2-12 2-12 2-12 2-12 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-18

2-18 2-18 2-19 2-20 2-21 2-21 2-21 2-22 2-22 2-23 2-23

Final Drive.......................................

Final Gear Case Oil Change........

Propeller Shaft Joint Boot Inspection..................................

Brakes.............................................

Front Brake Pad Wear Inspection Front Brake Hoses and Connections Inspection.............

Front Brake Hose Replacement...

Front Brake Fluid Level Inspection..................................

Front Brake Fluid Change............

Brake Line Air Bleeding ...............

Front Brake Master Cylinder Piston Assembly and Dust Cover Replacement ..................

Front Brake Caliper Fluid Seal Replacement .............................

Front Brake Caliper Dust Seal and Rubber Boot, Dust Cover Replacement .............................

Rear Brake Plates Replacement..

Rear Brake Lever and Pedal Play Inspection..................................

Rear Brake Lever and Pedal Free Play Adjustment ........................

Steering ..........................................

Steering Inspection ......................

Electrical System ............................

Battery Inspection ........................

Spark Plug Cleaning/Inspection...

Spark Plug Gap Inspection ..........

Brake Light Switch Inspection......

Brake Light Timing Adjustment ....

General Lubrication ........................

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

Bolts and Nuts Tightening...............

Tightness Inspection ....................

2-23 2-23 2-24 2-24 2-24 2-24 2-24 2-25 2-25 2-26

2-27 2-27

2-27 2-27 2-27 2-28 2-28 2-28 2-29 2-29 2-29 2-29 2-30 2-30 2-30 2-30 2-31 2-31

2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY

First Service

Regular Service Every 90

After 10 hrs. or 100 km (60 mi.) of use

Every 10 days or 200 km (120 mi.) of use

Every 30 days, 1 700 days or km (1 100 600 km mi.) or 100 (360 mi.) hrs of use, whichever of use

OPERATION ENGINE

• • •

Converter drive belt deflection - inspect* Actuator lever (Engine brake control lever) - inspect* Throttle lever play - inspect

• •

• •

Idle speed - inspect Valve clearance - inspect Fuel system cleanliness - inspect* Engine oil - change* Oil filter - replace* Spark plug - clean and gap

• • • • • •

•

• • • • •

Bolts and nuts - tighten Front brake pad wear - inspect* Brake light switch - inspect* Battery - inspect Steering - inspect

• • •

Front brake fluid - change

2-21 2-21 2-29

• •

• • • • • • •

2-22 2-15

• • •

2-17

2-15

2-24 2-28

every 10 000 km (6 000 mi.)

General lubrication* Front brake fluid level - inspect

2-13

4 years

Tire wear - inspect* Final gear case oil - change

2-16

2-22

Fuel hoses and connections - inspect

Rear brake pedal and lever play inspect* Rear brake plates - change*

2-18

2-12

Oil hoses and connections - inspect*

Propeller shaft joint boot - inspect*

2-19

2-12

•

Fuel hose - replace CHASSIS

2-18

2-14

Spark arrester - clean Oil cooler cleanliness - inspect*

See Page

comes first

Converter drive belt wear - inspect*

Air cleaner - inspect*

Every year of use

2-27 2-31

• • • • • •

2-24 2-30 2-29

•

2-29 2-23

•

2-23 2-30 2-25

•

2-25

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY

First Service

Regular Service Every 90

After 10 hrs. or 100 km (60 mi.) of use

OPERATION Front brake master cylinder piston assembly and dust seal - replace Front brake caliper fluid seal and dust seal - replace Front brake hoses and connectionsinspect Front brake hose - replace

Every 10 days or 200 km (120 mi.) of use

Every 30 days, 1 700 days or km (1 100 600 km mi.) or 100 (360 mi.) hrs of use, whichever of use

Every year of use

See Page

comes first

2 years

2-27

2 years

2-27

• 4 years

2-24 2-24

*: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy loads or pulling a trailer. : Clean, adjust, lubricate, torque, or replace parts as necessary.

•

2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean: EO: Apply engine oil.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue).

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1).

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

Lh: Left-hand Threads R: Replacement Parts S: Follow the specific tightening sequence.

St: Stake the fasteners to prevent loosening.

Fastener Fuel System Throttle Cable Locknut Air Cleaner Duct Front Clamp Screw Air Cleaner Duct Rear Clamp Screw Air Cleaner Housing Mounting Bolts Air Cleaner Intake Duct Clamp Screws Engine Top End Valve Adjusting Cap Bolts Cylinder Head Bolts (M11), first torque Cylinder Head Bolts (M11), final torque Cylinder Head Bolts (M6) Camshaft Cover Bolts Engine Breather Plate Screws Camshaft Sprocket Bolts Bearing Retainer Bolts Rear Camshaft Chain Guide Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Chain Guard Bolts Valve Adjusting Screw Locknuts (KVF360-B1 ∼ B3, B6F) Valve Adjusting Screw Locknuts (KVF360-B7F) Rocker Shaft Holder Bolts Muffler Mounting Bolts Converter System Drive Pulley Bolt Driven Pulley Nut Drive Pulley Cover Bolts Ramp Weight Nuts Spider Converter Cover Bolts Engine Brake Actuator Mounting Bolts

N·m

Torque kgf·m

ft·lb

1.3

0.13

11 in·lb

1.4 4 6.9 1.4

0.14 0.41 0.70 0.14

12 36 61 12

8.8 25 44 12 8.8 4.4 14 12 9.8 8.8 8.8 12 8.8

0.90 2.5 4.5 1.2 0.90 0.45 1.4 1.2 1.0 0.90 0.90 1.2 0.90

78 in·lb 18 33 104 in·lb 78 in·lb 39 in·lb 10 104 in·lb 87 in·lb 78 in·lb 78 in·lb 104 in·lb 78 in·lb

8.8 26

0.90 2.7

78 in·lb 20

93 93 13 6.9 275 8.8 8.8

9.5 9.5 1.3 0.70 28 0.90 0.90

69 69 113 in·lb 61 in·lb 203 78 in·lb 78 in·lb

Remarks

in·lb in·lb in·lb in·lb

MO, S S S

L

(M6) (M5)

R, Lh

Lh S

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Converter Air Duct Bolts Recoil Starter Recoil Starter Mounting Bolts Engine Lubrication System Oil Cooler Mounting Bolts Oil Pipe Joint Nuts Oil Cooler Fan Switch Oil Temperature Warning Light Switch Oil Hose Banjo Bolts Oil Pipe Bolts Oil Filter (∼ KVF360B8F) Oil Filter (KVF360B9F) Oil Filter Mounting Bolt Oil Pressure Relief Valve Oil Pressure Switch Oil Pump Cover Bolt Oil Pump Cover Screws Oil Line Plugs Engine Oil Drain Plug Oil Pressure Switch Terminal Bolt Engine Removal/Installation Upper Engine Mounting Bracket Bolt Lower Engine Mounting Bracket Bolts Lower Engine Mounting Bolts Upper Engine Mounting Bolt Crankshaft/Transmission Camshaft Chain Guard Bolts Oil Line Plugs Engine Oil Drain Plug Crankcase Bolts (M8) Crankcase Bolts (M6) (∼ KVF360B8F) Crankcase Bolts (M6) (KVF360B9F) Bearing Position Plate Screws (KVF360-B3 ∼ ) Grip Hold Nut Shift Lever Assembly Bracket Bolts Tie-Rod End Bolt Tie-Rod End Locknut Shift Lever Assembly Nut Tie-Rod End Front Locknut Tie-Rod End Rear Locknut Tie-Rod End Nut Shift Shaft Cover Bolts Neutral Switch

N·m 8.8

Torque kgf·m ft·lb 0.9 78 in·lb

5.9

0.60

52 in·lb

8.8 29 16 16 29 8.8

0.90 3.0 1.6 1.6 3.0 0.90

78 in·lb 22 12 12 22 78 in·lb

18 17.5 25 15 15 20 5.4 23 20 1.5

1.8 1.8 2.5 1.5 1.5 2.0 0.55 2.3 2.0 0.15

13 13 18 11 11 14 48 in·lb 17 14 13 in·lb

42 25 42 25

4.3 2.5 4.3 2.5

31 18 31 18

8.8 23 20 20 8.8 9.8 4.9 9.8

0.90 2.3 2.0 2.0 0.90 1.0 0.50 1.0

78 in·lb 17 14 14 78 in·lb 87 in·lb 43 in·lb 87 in·lb

20 9.8 20 20 9.8 9.8 20 8.8 15

2.0 1.0 2.0 2.0 1.0 1.0 2.0 0.90 1.5

14 87 in·lb 14 14 87 in·lb 87 in·lb 14 78 in·lb 11

Remarks

L

R R L L SS

L

L S, L (1)

L

Lh

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Reverse Position Switch Shift Shaft Positioning Bolt Shift Shaft Spring Bolt Wheels/Tires Tire Rod End Nuts Tie-Rod Adjusting Sleeve Locknuts Wheel Nuts Front Axle Nuts Rear Axle Nuts Final Drive (Output Bevel Gears) Output Drive Bevel Gear Housing Bolts Rotor Mounting Bolts Output Drive Bevel Gear Cover Bolts Forward/Reverse Detecting Sensor Mounting Bolts Output Drive Bevel Gear Bearing Holder Bevel Gear Holder Nut Output Driven Bevel Gear Housing Bolts Output Driven Bevel Gear Bearing Holder Output Shaft Holder Nut (Final Gear Case) Oil Filler Cap Oil Drain Plug Final Gear Case Bolts Pinion Gear Bearing Holder Final Gear Case Left Cover Bolts (M10) Final Gear Case Right Cover Bolts (M10) Final Gear Case Right Cover Bolts (M8) Final Gear Case Right Cover Bolts (M12) Pinion Gear Bearing Holder Nut Brakes Reservoir Cap Screws Bleed Valves Master Cylinder Clamp Bolts Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Caliper Mounting Bolts Caliper Holder Shaft Caliper Holder Shaft (Allen Bolt) Pad Mounting Bolts Disc Mounting Bolts

15 25 25

Torque kgf·m 1.5 2.5 2.5

ft·lb 11 18 18

42 37 52 196 265

4.3 3.8 5.3 20 27

31 27 38 145 195

26 12 8.8 15 118 200 26

2.7 1.2 0.9 1.5 12 20 2.7

20 104 in·lb 78 in·lb 11 87 148 20

250 200

26 20

184 148

L L

29 20 42 137 49 49 24 93 157

3.0 2.0 4.3 14 5.0 5.0 2.4 9.5 16

22 14 31 101 36 36 17 69 116

S L L L L L L

1.5 7.8 8.8 34 5.9 5.9 25 18 23 18 37

0.15 0.80 0.90 3.5 0.60 0.60 2.5 1.8 2.3 1.8 3.8

13 in·lb 69 in·lb 78 in·lb 25 52 in·lb 52 in·lb 18 13 17 13 27

L

N·m

Remarks

L

L L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Suspension Front Shock Absorber Clamp Bolts and Nuts Front Shock Absorber Mounting Nuts Rear Shock Absorber Mounting Nuts Knuckle Joint Mounting Nuts (KVF360B6F ∼) Piston Rod Nut Suspension Arm Pivot Bolts Swingarm Pivot Right Shaft Swingarm Pivot Left Shaft Swingarm Pivot Left Nut Steering Parking Brake Lever Screw Steering Stem Bottom End Nut Steering Stem Clamp Bolts Tie-Rod End Nuts Steering Knuckle Joint Nuts Knuckle Joint Mounting Nuts (KVF360B6F ∼) Front Shock Absorber Clamp Bolts and Nuts Tie-Rod Adjusting Sleeve Locknuts Handlebar Lower Holder Nuts Handlebar Holder Bolts Frame Rear Carrier Bolts and Nuts Front Carrier Bolts Front Guard Bolts Footboard Mounting Nuts Electrical System Alternator Cover Bolts Alternator Rotor Bolts Alternator Stator Bolts Spark Plug Ignition Coil Mounting Bolt Crankshaft Sensor Mounting Bolts Starter Motor Mounting Bolts Starter Motor Terminal Nut (∼ KVF360B8F) Starter Motor Terminal Nut (KVF360B9F) Starter Motor Terminal Locknut (∼ KVF360B8F) Starter Motor Terminal Locknut (KVF360B9F) Starter Motor Bolts (∼ KVF360B8F) Starter Motor Bolts (KVF360B9F) Starter Motor Clutch Bolts Engine Brake Actuator Mounting Bolts Reverse Position Switch

N·m

Torque kgf·m

ft·lb

47 74 62 29 49 88 152 20 152

4.8 7.5 6.3 30 5.0 9.0 15.5 2.0 15.5

35 54 46 22 36 65 112 14 112

2.2 62

0.22 6.3

19 in·lb 46

25 42 42

2.5 4.3 4.3

18 31 31

29 47 37 37 27

30 4.8 3.8 3.8 2.8

22 35 27 27 20

25 – 20 -

2.5 – 2.0 -

18 – 14 -

8.8 127 14 14 8.8 5.9 8.8 4.9 6.8 6.9 11 3.4 5.0

0.90 13 1.4 1.4 0.90 0.60 0.90 0.5 0.69 0.7 1.1 0.3 0.51

78 in·lb 94 10 10 78 in·lb 52 in·lb 78 in·lb 43 in·lb 60 in·lb 61 in·lb 97 in·lb 30 in·lb 44 in·lb

34 8.8 15

3.5 0.90 1.5

25 78 in·lb 11

Remarks

L L

L

L S

L L

L S

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener

N·m

Neutral Switch Starter Relay Terminal Nuts Igniter Mounting Bolts Ignition Switch Nut Oil Pressure Switch Terminal Bolt Regulator/Rectifier Mounting Bolts

15 4.9 2.3 2.7 1.5 8.8

Torque kgf·m 1.5 0.50 0.23 0.28 0.15 0.90

ft·lb 11 43 in·lb 20 in·lb 24 in·lb 13 in·lb 78 in·lb

Remarks

The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners of Engine Parts Threads dia. mm (in.)

5 (0.20) 6 (0.24) 6 (0.24) 6 (0.24) 8 (0.31) 8 (0.31) 10 (0.39) 10 (0.39)

Mark of Bolt Head 4T 9T

N·m 2.2 ∼ 2.6 12 ∼ 15

7T 4T 7T 4T 7T 4T

7.8 3.9 18 10 39 20

∼ ∼ ∼ ∼ ∼ ∼

Torque kgf·m 0.22 ∼ 0.27 1.2 ∼ 1.5

ft·lb 19 ∼ 23 in·lb 104 ∼ 130 in·lb

∼ ∼ ∼ ∼ ∼ ∼

69 ∼ 87 in·lb 35 ∼ 43 in·lb 13 ∼ 16 87 ∼ 122 in·lb 29 ∼ 33 14 ∼ 17

9.8 4.9 22 14 44 24

0.8 0.4 1.8 1.0 4.0 2.0

1.0 0.5 2.2 1.4 4.5 2.4

Basic Torque for General Fasteners of Frame Parts Threads dia. mm (in.)

5 (0.20) 6 (0.24) 8 (0.31) 10 (0.39) 12 (0.47) 14 (0.55) 16 (0.63) 18 (0.71) 20 (0.79)

N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

Torque kgf·m 0.35 ∼ 0.5 0.6 ∼ 0.8 1.4 ∼ 1.9 2.6 ∼ 3.5 4.5 ∼ 6.2 7.4 ∼ 10.0 11.5 ∼ 16.0 17.0 ∼ 23.0 23 ∼ 33

ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10.0 ∼ 13.5 19.0 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240

PERIODIC MAINTENANCE 2-9 Specifications Item Fuel System Throttle Lever Free Play Air Cleaner Element Oil Engine Top End Valve Clearance: Exhaust Inlet Converter System Actuator Lever Guide Shoe Wear Belt Width (KVF360-B1 ∼ B2) (KVF360-B3 ∼) Belt Deflection Engine Lubrication System Engine Oil: Type Viscosity Capacity

Wheels/Tires Tire Tread Depth: Front Rear Standard Tire: Front Rear Final Drive Final Gear Case: Gear Case Oil: Type

Oil Level Capacity

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

High-quality foam air filter oil

– – – – – –

0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.)

0.08 ∼ 0.13 mm (0.0032 ∼ 0.0051 in.)

– – – – – –

––– 29.9 ∼ 31.1 mm (1.18 ∼ 1.22 in.)

29.7 ∼ 30.3 mm (1.17 ∼ 1.19 in.)

22 ∼ 27 mm (0.87 ∼ 1.06 in.)

API SF or SG API SH, SJ or SL with JASO MA SAE10W-40 1.50 L (1.59 US qt) (When filter is not removed) 1.74 L (1.84 US qt) (When filter is removed) 2.3 L (2.43 US qt) (When engine is completely dry)

––– –––

6 mm (0.24 in.)

29.4 mm (1.16 in.)

28.0 mm (1.10 in.)

– – –

– – – –

– – – –

– – – –

– – – – – –

3 mm (0.12 in.)

4 mm (0.16 in.)

AT 25 × 8-12 Dunlop, KT121, Tubeless AT 25 × 10-12 Dunlop, KT405C/KT127A, Tubeless

– – – –

– – – –

– – – –

MOBIL Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID) or Exxon Hydraul 560 Filler opening bottom 900 mL (0.95 US qt)

– – –

– – – – – –

2-10 PERIODIC MAINTENANCE Specifications Item

Standard

Service Limit

Brakes Front Brake Fluid: Grade Front Disc Brake: Pad lining Thickness Rear Brake Lever, Pedal and Cables: Rear Brake Lever Free Play Brake Pedal Free Play Electrical System Spark Plug Gap Rear Brake Light Switch Timing

DOT 3 or DOT 4

– – –

4.5 mm (0.18 in.)

1 mm (0.04 in.)

1 ∼ 2 mm (0.04 ∼ 0.08 in.)

15 ∼ 25 mm (0.6 ∼ 1.0 in.)

– – – – – –

0.8 ∼ 0.9 mm (0.031 ∼ 0.035 in.)

On after 10 mm (0.4 in.) of pedal travel

– – – – – –

PERIODIC MAINTENANCE 2-11 Special Tools Oil Filter Wrench: 57001-1249

Belt Measuring Gauge: 57001-1519

Carburetor Drain Plug Wrench, Hex 3: 57001-1269

Flywheel & Pulley Holder: 57001-1605

Filler Cap Driver: 57001-1454

Belt Measuring Gauge: 57001-1646

Pulley Holder Attachment: 57001-1472

Valve Adjusting Screw Holder: 57001-1217

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Throttle Lever Free Play Inspection

that the throttle lever [A] moves smoothly from full • Check open to close, and the throttle closes quickly and com-

• •

pletely in all steering positions by the return spring.

If the throttle lever does not return properly, check the throttle cable routing, lever free play, and possible cable damage. Then lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increases, check the throttle lever free play and the cable routing.

Stop the engine and check the throttle lever free play [B].

Throttle Lever Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play Adjustment

the rubber cover off the adjuster at the throttle case.

• Slide Loosen locknut [A] and turn the throttle cable upper • adjuster the [B] until the cable has proper amount of play.

• Tighten the locknut and reinstall the rubber cover.

Torque - Throttle Cable Locknut: 1.3 N·m (0.13 kgf·m, 11 in·lb)

If the free play cannot be adjusted by using the upper cable adjuster, remove the throttle cable pulley cover and then use the cable adjusting nuts [A] at the lower end of the throttle cable and make the necessary free play.

Idle Speed Inspection

the engine and warm it up thoroughly.

• Start With the idling, turn the handlebar to both sides to • check forengine any changes in the idle speed.

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted incorrectly routed, or damaged. Be sure to correct any of these conditions before riding.

WARNING Operation with improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition.

• Check idle speed with a suitable tachometer.

Idle Speed Standard:

1 300 ± 50 r/min (rpm)

If the idle speed is out of the specified range, adjust it.

Idle Speed Adjustment

the engine and warm it up thoroughly.

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

○Open and close the throttle a few times to make sure that the idle speed is within the specified range.

Fuel System Cleanliness Inspection

WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the fuel tap to the OFF position.

• Turn Remove check valve [A] at the end of the carburetor • overflow the hose.

Run the lower end of the carburetor overflow hose to a • suitable container. out the carburetor drain plug a few turns and drain • Turn the fuel system.

Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269 [A]

to see if water or dirt comes out.

• Check Tighten the drain plug.

• If any water or dirt appears during the above inspection, clean the fuel system (carburetor, tank, fuel hose).

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