2012 kawasaki ex250jc service repair manual

MODEL APPLICATION Year 2008 2009 2010 2011 2012

Model EX250J8 EX250J9 EX250JA EX250JB EX250JC

Beginning Frame No. JKAEXMJ1□8DA00001 JKAEXMJ1□9DA17355 JKAEXMJ1□ADA49773 JKAEXMJ1□BDA71588 JKAEXMJ1□CDA96621

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

Part No.99924-1391-05

Printed in Japan

Ninja 250R

Motorcycle 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

Cooling System

4 j

Engine Top End

5 j

Clutch

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

Ninja 250R

Motorcycle 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/Motorcycle & Engine 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 Motorcycle 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 2007 Kawasaki Heavy Industries, Ltd.

5th Edition (1): May 18, 2011

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) Celsius 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

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)

COUNTRY AND AREA CODES AU CA CAL CO

Australia Canada California Colombia

ID MY PH US

Indonesia Malaysia Philippines United States

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. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.

3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

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

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

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

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

NOTE

○The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows.

1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2. Tampering could include. a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. 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.

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 inlet 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 Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

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

Remember to keep complete records of maintenance and repair with dates 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 symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE NOTICE is used to address practices not related to personal injury.

This manual contains four more symbols 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 Table of Contents Before Servicing .....................................................................................................................

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

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

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

1 1-2 1-7 1-8 1-11

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, 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 motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) 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, cotter pins or self-looking nuts 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.

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 the old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling

Liquid Gasket, Non-permanent 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 the 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 Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires 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 adjustments.

GENERAL INFORMATION 1-7 Model Identification EX250J8 Left Side View (United States and Canada)

EX250J8 Right Side View (United States and Canada)

Frame Number

Engine Number

1-8 GENERAL INFORMATION General Specifications EX250J8 ∼ JC

Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass EX250J8 Curb Mass: EX250J9 ∼ JC 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 Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration

2 085 mm (82.1 in.), (AU) 2 080 mm (81.9 in.)

715 mm (28.1 in.)

1 110 mm (43.7 in.), (AU) 1 115 mm (43.9 in.)

1 400 mm (55.1 in.), (AU) 1 390 mm (54.7 in.)

130 mm (5.1 in.), (AU, ID) 140 mm (5.5 in.)

775 mm (30.5 in.)

152 kg (335 lb), (CAL) 153 kg (337 lb), (IN) 154 kg (340 lb) 170 kg (375 lb), (AU) 169 kg (373 lb) 82 kg (181 lb), (ID) 83 kg (183 lb) 88 kg (194 lb), (AU, ID) 87 kg (192 lb) 18 L (4.8 US gal.)

2.7 m (8.9 ft) 4-stroke, DOHC, 2-cylinder Liquid-cooled 62.0 × 41.2 mm (2.5 × 1.6 in.)

249 cm³ (15.2 cu in.)

11.6 24 kW (32.6 PS) @11 000 r/min (rpm) (ID) 23.4 kW (31.8 PS) @11 000 r/min (rpm) 22.0 N·m (2.24 kgf·m, 16.2 ft·lb) @9 500 r/min (rpm) Carburetor, Keihin CVK 30× 2 Electric starter Battery and coil (transistorized) Electronically advanced From 10° BTDC @1 300 r/min (rpm) to 35° BTDC @4 000 r/min (rpm) NGK CR8E or ND U24ESR-N Left to right, 1-2 1-2

36° BTDC 56° ABDC 272° 61° BBDC 31° ATDC 272°

GENERAL INFORMATION 1-9 General Specifications Items Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Caster (Rake Angle) Trail Front Wheel: Tire Type Tire Size: EX250J8 EX250J9 ∼ JC Rim Size Rear Wheel: Tire Type Tire Size: EX250J8 EX250J9 ∼ JC Rim Size Front Suspension: Type Wheel Travel

EX250J8 ∼ JC Forced lubrication (wet sump) API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE10W-40 1.7 L (1.80 US qt)

Gear 3.087 (71/23) Wet multi disc 6-speed, constant mesh, return shift 2.600 1.789 1.409 1.160 1.000 0.893

(39/15) (34/19) (31/22) (29/25) (27/27) (25/28)

Chain drive 3.214 (45/14), (AU) 3.071 (43/14) 8.859 @Top gear, (AU) 8.466 @Top gear Tubular, diamond 26° 82 mm (3.2 in.)

Tubeless 110/70-17M/C 54H 110/70-17M/C 54S 17 M/C × MT2.75 Tubeless 130/70-17M/C 62H 130/70-17M/C 62S 17 M/C × MT3.50 Telescopic fork 120 mm (4.7 in.)

1-10 GENERAL INFORMATION General Specifications Items Rear Suspension: Type Wheel Travel Brake Type: Front Rear Electrical Equipment Battery EX250J8 EX250J9 ∼ JC Headlight: Type Bulb: High Low Tail/brake Light Alternator: Type Rated Output EX250J8 ∼ JA EX250JB ∼ JC

EX250J8 ∼ JC Swingarm (uni-trak) 130 mm (5.1 in.)

Single disc Single disc

12 V 6 Ah 12 V 8 Ah Semi-sealed beam 12 V 55 W + 55 W (quartz-halogen) 12 V 55 W (quartz-halogen) 12 V 5/21 W Three-phase AC 19 A @5 000 r/min (rpm), 14 V 20 A @5 000 r/min (rpm), 14 V

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

AU: Australia Model ID: Indonesia Model

GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length: × × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

= = = = = = = = =

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

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 cm Hg 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 L L L L mL mL mL

× × × × × × × × ×

0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102

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

×

0.6214

Units of Force: N N kg kg

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

= = = =

kg lb N lb

Units of Power: kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

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

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

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

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

Periodic Maintenance Procedures..........................................................................................

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

Air Cleaner Element Cleaning...........................................................................................

Air Cleaner Element Installation........................................................................................

Throttle Control System Inspection...................................................................................

Choke Operation Inspection .............................................................................................

Engine Vacuum Synchronization Inspection.....................................................................

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

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

Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................

Evaporative Emission Control System (CAL Model) ...........................................................

Evaporative Emission Control System Inspection ............................................................

Cooling System....................................................................................................................

Coolant Level Inspection...................................................................................................

Radiator Hose Damage and Installation Condition Inspection..........................................

Coolant Filter Cleaning (Australia Model) .........................................................................

Air Suction System ..............................................................................................................

Air Suction System Damage Inspection............................................................................

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

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

Valve Clearance Adjustment.............................................................................................

Clutch...................................................................................................................................

Clutch Operation Inspection..............................................................................................

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

Air Pressure Inspection.....................................................................................................

Wheel/Tire Damage Inspection.........................................................................................

Tire Tread Wear, Abnormal Wear Inspection ....................................................................

Wheel Bearing Damage Inspection ..................................................................................

Drive Train ...........................................................................................................................

Drive Chain Lubrication Condition Inspection ...................................................................

Drive Chain Slack Inspection ............................................................................................

Drive Chain Slack Adjustment ..........................................................................................

Wheel Alignment Inspection .............................................................................................

Drive Chain Wear Inspection ............................................................................................

Chain Guide Inspection.....................................................................................................

Brake System ......................................................................................................................

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................

Brake Hose and Pipe Damage and Installation Condition Inspection...............................

Brake Operation Inspection ..............................................................................................

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

Brake Pad Wear Inspection ..............................................................................................

Brake Light Switch Operation Inspection ..........................................................................

Suspensions ........................................................................................................................

Front Forks/Rear Shock Absorber Operation Inspection ..................................................

Front Fork Oil Leak Inspection..........................................................................................

Rear Shock Absorber Oil Leak Inspection ........................................................................

2-3 2-7 2-12 2-14 2-15 2-15 2-15 2-16 2-16 2-18 2-18 2-19 2-19 2-20 2-20 2-20 2-21 2-21 2-22 2-22 2-22 2-22 2-23 2-23 2-24 2-26 2-26 2-27 2-27 2-27 2-27 2-28 2-29 2-29 2-29 2-30 2-31 2-31 2-32 2-32 2-32 2-32 2-33 2-33 2-34 2-34 2-35 2-35 2-35 2-35

2

2-2 PERIODIC MAINTENANCE Rocker Arm Operation Inspection.....................................................................................

Tie-Rod Operation Inspection ...........................................................................................

Swingarm Pivot Lubrication ..............................................................................................

Steering System ..................................................................................................................

Steering Play Inspection ...................................................................................................

Steering Play Adjustment..................................................................................................

Steering Stem Bearing Lubrication ...................................................................................

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

Lights and Switches Operation Inspection........................................................................

Headlight Aiming Inspection .............................................................................................

Sidestand Switch Operation Inspection ............................................................................

Engine Stop Switch Operation Inspection.........................................................................

Others ..................................................................................................................................

Chassis Parts Lubrication .................................................................................................

Bolts, Nuts and Fasteners Tightness Inspection...............................................................

Replacement Parts ..............................................................................................................

Air Cleaner Element Replacement....................................................................................

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

Coolant Change ................................................................................................................

Radiator Hose and O-ring Replacement...........................................................................

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

Oil Filter Replacement ......................................................................................................

Brake Hose and Pipe Replacement..................................................................................

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

Master Cylinder Rubber Parts Replacement ....................................................................

Caliper Rubber Parts Replacement ..................................................................................

Spark Plug Replacement ..................................................................................................

2-35 2-36 2-36 2-36 2-36 2-37 2-37 2-38 2-38 2-40 2-41 2-42 2-43 2-43 2-44 2-45 2-45 2-45 2-45 2-47 2-48 2-48 2-49 2-49 2-51 2-52 2-53

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection FREQUENCY Whichever comes first 1 INSPECTION Fuel System

Every

6

(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Air cleaner element - clean Throttle control system (play, smooth return, no drag) - inspect

year

Choke operation - inspect

year

• •

Engine vacuum synchronization - inspect Idle speed - inspect Fuel leak (fuel hose and pipe) inspect Fuel hose and pipe damage inspect Fuel hose and pipe installation condition - inspect Evaporative emission control system function (CAL) - inspect Cooling System

year year year

Coolant level - inspect Coolant leak (water hose and pipe) - inspect

year

Water hose damage - inspect

year

Water hose installation condition - inspect Coolant filter - clean Air Suction System Air suction system damage inspect Engine Top End

year

• • • • • • • • •

Clutch Clutch operation (play, disengagement, engagement) inspect Wheels and Tires

• • • •

•

• • • • • • • • • • • • •

•

• • • • • • • • •

2-15

• • • •

2-21

year

Tire tread wear, abnormal wear - inspect year

2-16 2-18 2-18 2-19 2-20 2-20 2-20 2-20

2-22 2-22 2-22 2-22

•

Wheel/tire damage - inspect

Wheel bearing damage - inspect

•

• • • • • • • • •

year

Valve clearance - inspect

Tire air pressure - inspect

12

* ODOMETER READING × 1 000 km (× 1 000 mile) See Page 18 24 30 36

•

•

•

2-22

•

•

•

2-23

•

•

•

2-26

• • • •

• • • •

• • • •

2-27 2-27 2-27 2-28

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first 1 INSPECTION Drive Train Drive chain lubrication condition - inspect # Drive chain slack - inspect #

Every

6

(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Every 600 km (375 mile)

2-29

Every 1 000 km (600 mile)

2-29

• •

Drive chain wear - inspect # Drive chain guide wear - inspect Brakes Brake fluid leak (brake hose and pipe) - inspect Brake hose and pipe damage inspect Brake hose and pipe installation condition - inspect Brake operation (effectiveness, play, no drag) - inspect Brake fluid level - inspect

year year year year 6 months

• • • • •

Brake pad wear - inspect # Brake light switch operation inspect Suspension Front forks/rear shock absorber operation (damping and smooth stroke) - inspect Front forks/rear shock absorber oil leak - inspect

12

* ODOMETER READING × 1 000 km (× 1 000 mile) See Page 18 24 30 36

•

year

Rocker arm operation - inspect Tie-rods operation - inspect

• • • • • • •

• • • • • • •

• • • • • • • • •

• • • • • • •

• • • • • • •

• •

2-31

• • • • • • •

2-32

2-32

2-32 2-32 2-33 2-33 2-34 2-34

•

•

•

2-35

• • •

• • • •

• • •

2-35

• •

•

• • • •

• • • •

Swingarm pivot - lubricate

2-35 2-36 2-36

Steering Steering play - inspect Steering stem bearings lubricate Electrical System Lights and switches operation inspect Headlight aiming - inspect Sidestand switch operation inspect Engine stop switch operation inspect

year

•

•

2 years

year year year year

• • • •

2-36 2-37

2-38 2-40 2-41 2-42

PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart FREQUENCY Whichever comes first 1 INSPECTION Others Chassis parts - lubricate Bolts and nuts tightness - inspect

Every

6

12

* ODOMETER READING × 1 000 km (× 1 000 mile) See Page 18 24 30 36

(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

year

•

• •

• •

• •

2-42 2-43

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever comes first

* ODOMETER READING × 1 000 km (× 1 000 mile) 1

CHANGE/REPLACE ITEM Air cleaner element # - replace Fuel hose - replace

Every 2 years 5 years

Coolant - change

3 years

Radiator hose and O-ring - replace

3 years

Engine oil # - change

year

Oil filter - replace

year

Brake hose and pipe - replace

4 years

Brake fluid - change

2 years

Rubber parts of master cylinder and caliper replace

4 years

Spark plug - replace

12

24

36

48

See Page

(0.6) (7.5) (15) (22.5) (30) 2-44 2-44

• •

• •

• •

• • • •

• •

•

•

2-44 2-46

• • • • • •

2-47 2-47 2-48 2-48 2-50 2-52

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is applied, the bolts and nuts could loosen and fall out. If too much torque is applied, the threads could be sheared off.

To tighten a bolt or a nut, or to check their torque, loosen the bolt or nut one-half turn before tightening it to the specified torque.

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

G: Apply grease.

L: Apply a non-permanent locking agent to the threads.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

R: Replacement Parts S: Tighten the fasteners following the specified sequence.

Si: Apply silicone grease.

SS: Apply silicone sealant.

Fastener Fuel System Fuel Tap Mounting Bolts Fuel Gauge Mounting Bolts Air Cleaner Housing Cap Bolts/Screws Air Cleaner Housing Screws Air Cleaner Housing Mounting Bolts Air Cleaner Housing Clamp Screws Separate Bracket Bolt Cooling System Water Temperature Switch Thermostat Cover Bolts Thermostat Housing Mounting Bolts Radiator Fan Switch Radiator Bolts Radiator Cap Bracket Bolt Water Pipe Bolts Water Hose Clamp Screws Drain Bolt Water Pump Cover Bolts Water Pump Bolts Reserve Tank Cap Reserve Tank Bolts Reserve Tank Bracket Bolt Engine Top End Cylinder Head Cover Bolts Camshaft Sprocket Bolts Chain Tensioner Cap Bolt Air Suction Cover Bolts Vacuum Switch Valve Bracket Bolts Rear Camshaft Chain Guide Bolt-Lower

N·m

Torque kgf·m

ft·lb

2.5 6.9 2.5 1.15 9.8 2.0 9.8

0.25 0.7 0.25 0.12 1.0 0.2 1.0

22 61 22 10 87 18 87

7.5 9.8 9.8 23.5 9.8 9.8 9.8 3.0 9.8 9.8 9.8 – 9.8 9.8

0.76 1.0 1.0 2.4 1.0 1.0 1.0 0.31 1.0 1.0 1.0 – 1.0 1.0

66 in·lb 87 in·lb 87 in·lb 17 87 in·lb 87 in·lb 87 in·lb 27 in·lb 87 in·lb 87 in·lb 87 in·lb – 87 in·lb 87 in·lb

9.8 15 5.0 9.8 9.8 17

1.0 1.5 0.5 1.0 1.0 1.7

87 in·lb 11 44 in·lb 87 in·lb 87 in·lb 13

Remarks

in·lb in·lb in·lb in·lb in·lb in·lb in·lb SS

Hand-Tighten

L

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Chain Tensioner Mounting Bolts Camshaft Cap Bolts Cylinder Head Bolt (M6) Cylinder Head Bolts (M8) Water Passage Plugs Carburetor Holder Clamp Screws Water Drain Bolt Muffler Body Rear Cover Bolts Muffler Body Mounting Bolt Muffler Body Clamp Bolt Muffler Cover Bolts Muffler Cover Clamp Screw Exhaust Pipe Mounting Bolt Exhaust Pipe Holder Nuts Clutch Clutch Lever Holder Clamp Bolts Clutch Spring Bolts Clutch Hub Nut Oil Filler Plug Clutch Cover Bolts Engine Lubrication System Oil Hose Banjo Bolts Oil Pressure Relief Valve Crankcase Oil Passage Plug Oil Passage Plugs for Oil Pump Oil Pipe Banjo Bolts Oil Drain Bolt Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oil Filter Mounting Bolts Oil Breather Mounting Bolts Oil Pump Mounting Bolts Oil Screen Cover Bolts Plug Breather Bolt Engine Removal/Installation Engine Mounting Bracket Bolts and Nuts Engine Mounting Nuts Crankshaft/Transmission Oil Breather Mounting Bolts Crankcase Bolts 6 Crankcase Bolts 8 (L = 90) Crankcase Bolts 8 (L = 73)

N·m 9.8 12 12 31.4 20 2.0 5.9 9.8 30 17 9.8 6.9 9.8 12

Torque kgf·m 1.0 1.2 1.2 3.2 2.0 0.2 0.6 1.0 3.1 1.7 1.0 0.70 1.0 1.2

ft·lb 87 in·lb 106 in·lb 106 in·lb 23 15 18 in·lb 52 in·lb 87 in·lb 22 13 87 in·lb 61 in·lb 87 in·lb 104 in·lb

8.8 8.8 132 – 9.8

0.9 0.9 13.5 – 1.0

78 in·lb 78 in·lb 97.4 – 87 in·lb

19.6 15 15 20 12 19.6 15 1.5 19.6 9.8 9.8 9.8 19.6 9.8

2.0 1.5 1.5 2.0 1.2 2.0 1.5 0.15 2.0 1.0 1.0 1.0 2.0 1.0

14.5 11 11 15 104 in·lb 14.5 11 13 in·lb 14.5 87 in·lb 87 in·lb 87 in·lb 14.5 87 in·lb

64 64

6.5 6.5

47 47

9.8 12 24 19

1.0 1.2 2.4 1.9

87 in·lb 104 in·lb 18 14

Remarks

S MO, S MO, S L

L

Hand-Tighten

L L

SS

L L

L MO, S MO, S

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Starter Motor Clutch Bolts Connecting Rod Big End Cap Nuts Shift Drum Bearing Holder Bolt Shift Drum Pin Plate Bolt Neutral Switch External Shift Mechanism Return Spring Pin Shift Drum Positioning Bolt Shift Lever Link Bolt Front Tie-Rod Locknut (Left-Hand Threads) Rear Tie-Rod Locknut (Right-Hand Threads) EX250J8 ∼ JB (with a non-permanent locking agent) Shift Pedal Mounting Bolt EX250JB ∼ JC (with a non-permanent locking agent) Shift Pedal Mounting Bolt Wheels/Tires Front Axle Nut Rear Axle Nut Final Drive Engine Sprocket Cover Bolts Engine Sprocket Nut Rear Sprocket Nuts Rear Sprocket Studs Brakes Brake Lever Pivot Bolt Locknut Bleed Valve Front Master Cylinder Clamp Bolts Brake Disc Mounting Bolts Brake Hose Banjo Bolts Front Caliper Mounting Bolts Front Brake Light Switch Screw Brake Lever Pivot Bolt Front Reservoir Cap Screws Reservoir Mounting Bolt Bleed Valve Brake Pedal Pivot Bolt Push Rod Locknut Brake Disc Mounting Bolts Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts

N·m 34.3 27.5 12 9.0 15 19.6 24.5 12 7.0 7.0

Torque kgf·m 3.5 2.8 1.2 0.9 1.5 2.0 2.5 1.2 0.7 0.7

ft·lb 25 20 104 in·lb 80 in·lb 11 14.5 18 104 in·lb 62 in·lb 62 in·lb

20

2.0

15

25

2.5

18

88 98

9.0 10.0

65 72

9.8 127 59 –

1.0 13 6.0 –

87 in·lb 94 44 –

5.9 5.5 8.8 27 25 25 1.0 1.0 1.5 6.9 5.5 8.8 18 27 25 25 25

0.6 0.55 0.9 2.8 2.5 2.5 0.1 0.1 0.15 0.7 0.55 0.9 1.8 2.8 2.5 2.5 2.5

52 in·lb 49 in·lb 78 in·lb 20 18 18 9 in·lb 9 in·lb 13 in·lb 61 in·lb 49 in·lb 78 in·lb 13 20 18 18 18

Remarks L MO L L L

L

MO R L

S L

L L

2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Suspension Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Front Fork Bottom Allen Bolts Rocker Arm Pivot Nut Tie-Rod Nuts Rear Shock Absorber Mounting Nuts Swingarm Pivot Nut Steering Steering Stem Nut Handlebar Holder Mounting Bolts Steering Stem Head Bolt Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Frame Sidestand Nut Front Footpeg Bracket Mounting Bolts Rear Footpeg Bracket Mounting Bolts Sidestand Switch Bolt Windshield Mounting Screws Electrical System Tail/Brake Light Mounting Bolts Plugs on Alternator Cover Alternator Cover Bolts Alternator Rotor Bolt Alternator Stator Bolts Regulator/Rectifier Bolts Starter Motor Clutch Bolts Crankshaft Sensor Screws Ignition Coil Bolts Spark Plugs Starter Motor Terminal Locknut Starter Motor Assembly Bolts Starter Motor Mounting Bolts Starter Relay Terminal Nut Oil Pressure Switch Neutral Switch

N·m

Torque kgf·m

ft·lb

21 30 20 59 59 59 98

2.1 3.1 2.0 6.0 6.0 6.0 10.0

15 22 15 44 44 44 72

4.9 25 44 20 30

0.5 2.5 4.5 2.0 3.1

43 in·lb 18 32 15 22

39 25 25 8.8 0.42

4.0 2.5 2.5 0.90 0.043

29 18 18 78 in·lb 3.7 in·lb

5.9 – 9.8 88.2 12 9.8 34.3 3.0 – 13 9.8 3.5 9.8 5.0 15 15

0.6 – 1.0 9.0 1.2 1.0 3.5 0.30 – 1.3 1.0 0.36 1.0 0.5 1.5 1.5

52 in·lb – 87 in·lb 65 104 in·lb 87 in·lb 25 27 in·lb – 115 in·lb 87 in·lb 31 in·lb 87 in·lb 44 in·lb 11 11

Remarks

L R R R

R

L

Hand-Tighten

L see text

SS

PERIODIC MAINTENANCE 2-11 Torque and Locking Agent The table 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 Threads dia. (mm) 5 6 8 10 12 14 16 18 20

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 ∼ 0.50 0.60 ∼ 0.80 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

2-12 PERIODIC MAINTENANCE Specifications Item Fuel System Throttle Grip Free Play Idle Speed Carburetor Synchronization Vacuum Air Cleaner Element Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Capacity Engine Top End Valve Clearance: Inlet Exhaust Clutch Clutch Lever Free Play Engine Lubrication System Engine Oil: Grade Viscosity Capacity Level Wheels/Tires Tread Depth: Front: BRIDGESTONE DUNLOP IRC Rear: BRIDGESTONE DUNLOP IRC Air pressure: (when Cold) Front Rear Final Drive Drive Chain Slack

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

1 300 ±50 r/min (rpm) Less than 2.7 kpa (2 cmHg) difference between two carburetors Polyurethane foam

– – – – – –

Permanent type antifreeze Green Soft water 50%, coolant 50% –35°C (–31°F) 1.5 L (1.59 US qt)

– – – – –

0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)

0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)

– – – – – –

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

– – –

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 1.3 L (1.4 US qt) (when filter is not removed) 1.6 L (1.7 US qt) (when filter is removed) Between upper and lower level lines (Wait 2 ∼ 3 minutes after idling or running)

– – – – – –

– – – – –

– – – – –

– – – – – – – – – – – –

4.6 mm (0.181 in.)

4.5 mm (0.177 in.)

4.2 mm (0.165 in.)

1 mm (0.04 in.)

7.0 mm (0.276 in.)

7.4 mm (0.291 in.)

6.5 mm (0.256 in.)

2 mm (0.08 in.) up to 130 km/h (80 mph) 3 mm (0.12 in.) over 130 km/h (80 mph)

Up to 170 kg (375 lb) load: 200 kPa (2.0 kgf/cm², 28 psi) Up to 170 kg (375 lb) load: 225 kPa (2.25 kgf/cm², 32 psi)

– – –

20 ∼ 30 mm (0.8 ∼ 1.2 in.)

– – –

– – –

PERIODIC MAINTENANCE 2-13 Specifications Item Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Brake Light Timing: Front Rear Electrical System Type

Standard

DOT4 4.5 mm (0.18 in.)

Service Limit

– – – 1 mm (0.04 in.)

– – –

Pulled ON ON after 10 mm (0.39 in.) of pedal travel CR8E, U24ESR-N

– – –

2-14 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: 57001-1100

Vacuum Gauge KEK-55-5: 57001-1369

Filler Cap Driver: 57001-1454

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System Air Cleaner Element Cleaning

• Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Air Cleaner Cap Bolts [A] Air Cleaner Cap [B]

• Pull out the air cleaner element [A].

• Separate the plastic holders [A].

WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maintenance chart.

NOTICE If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point solvents to clean the element. the element [A] in a bath of high-flash point solvent.

• Clean Squeeze it dry in a clean towel. Do not wring the element or blow it dry; the element can be damaged.

Check all the parts of the element for visible damage.

If any of the parts of the element are damaged, replace them.

After cleaning, saturate the element with a high-quality foam-air-filter oil, squeeze out the excess, then wrap it in a clean towel and squeeze it as dry as possible. ○Be careful not to tear the sponge filter.

• •

Air Cleaner Element Installation

the removed parts in reverse of removal.

• Install Torque the air cleaner cap bolts.

• Torque - Air Cleaner Cap Bolts: 2.5 N·m (0.25 kgf·m, 22 in·lb)

Throttle Control System Inspection

that the throttle grip moves smoothly from full open • Check to close [A], and the throttle closes quickly and completely by the return spring in all steering positions.

If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

the throttle grip free play [A].

• Check If the free play is incorrect, adjust the throttle cable.

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

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures the locknut [A], and screw accelerator cable ad• Loosen juster [B] in completely so as to give the throttle grip plenty

• •

• • • • •

of play.

Turn the accelerator cable adjuster until 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of throttle grip play is obtained.

Tighten the locknut.

If the throttle cables can not be adjusted by using the cable adjuster at the upper end of the throttle cable, use the cable adjusters at the lower ends of the throttle cables.

Remove: Side Cover (see Side Cover Removal in the Frame chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) To make service easy, unscrew the reserver tank bolts and remove the reserver tank with hoses Turn out both upper nuts [A] and turn in both lower nuts [B] as far as they will go so as to give the throttle grip plenty of play.

With the throttle grip completely closed, turn out the lower nut and turn in the upper nut of the decelerator cable [C] until the inner cable just becomes tight.

Turn out the lower nut and turn in the upper nut of the accelerator cable [D] until the correct free play is obtained.

that the throttle linkage lever [A] stops against the • Check idle adjusting screw [B] with the throttle grip closed.

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Choke Operation Inspection

• Remove: Front Seat (see Front Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) Side Covers (see Side Cover Removal in the Frame chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) Push the choke lever [A] back all the way to its released position.

Check choke cable free play [B]. ○Determine the amount of choke cable play at the choke lever.

If the free play is incorrect, adjust the choke cable.

• •

Choke Cable Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

the choke lever back all the way to its released po• Push sition. the choke lever until the starter plunger lever [A] at the • Pull carburetor touches the starter plunger [B]; the amount of choke lever travel is the amount of choke cable play.

the locknut [A], and turn the adjuster [B] until the • Loosen cable has the proper amount of free play.

• Tighten the locknut securely.

Engine Vacuum Synchronization Inspection

the motorcycle using the center stand so that it is • Situate perpendicular to the ground. the fuel tank, and connect the sub-fuel tank to • Remove supply the fuel. the right lower fairing.

• Remove Warm up engine.

• Check thethe idle and adjust if necessary.

• Pull the vacuumspeed hoses off, and attach vacuum gauge [A] • to the vacuum hose fittings on the carburetors.

Special Tool - Vacuum Gauge KEK-55-5: 57001-1369

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures the engine and let it idle to measure the carburetor • Start intake vacuum.

If the intake vacuum difference between the two cylinders exceeds the limit, adjust the synchronization.

Engine Vacuum Synchronization Less than 2.7 kPa (2 cmHg) difference between both cylinders

the adjusting screw [A] to synchronize the carbure• Turn tor.

•

If the carburetor synchronization cannot be obtained by using the adjusting screw, check for dirt or blockage, and then check the pilot screw settings.

Check the Carburetor Synchronization again.

NOTE

○Do not turn the pilot screws carelessly during carburetor synchronization. You may cause poor running at low engine speed.

Idle Speed Inspection

the engine and warm it up thoroughly.

• Start With the • [A]. engine idling, turn the handlebar to both sides If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Throttle Control System Inspection or Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding Condition. Follow the service manual to be make sure to correct any of these conditions. idle speed.

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

Idle Speed Standard:

1 300 ±50 r/min (rpm)

Idle Speed Adjustment

the engine and warm it up thoroughly.

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

•○Open andadjusting close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition)

○The fuel hose is designed to be used throughout the motorcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B], bulges [C] or ozone cracks [D] are noticed. that the hose [A] are securely connected and • Check clamps [B] are tightened correctly. that the hoses are routed according to Cable, Wire, • Check and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked.

Evaporative Emission Control System (CAL Model) Evaporative Emission Control System Inspection the canister as follows.

•○Inspect Remove:

Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) ○Remove the canister [A], and disconnect the hoses from the canister. ○Visually inspect the canister for cracks or other damage.

If the canister has any cracks or bad damage, replace it with a new one.

NOTE

○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under normal conditions.

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