2013 kawasaki kvf650dd service repair manual

MODEL APPLICATION Year

Model

2005

KVF650-D1

2005

KVF650-E1

2006

KVF650D6

2006

KVF650E6

2007

KVF650D7

2007

KVF650E7

2008

KVF650D8

2008

KVF650E8

2009

KVF650D9

2009

KVF650E9

2010

KVF650DA

2011

KVF650DB

2012 2013

KVF650DC KVF650DD

Beginning Frame No. JKAVFED1□5B500001 JKAVF650DDB600001 JKAVFEE1□5B500001 JKAVFED1□6B503001 JKAVF650DDB601110 JKAVFEE1□6B503001 JKAVFED1□7B515501 JKAVF650DDB602401 JKAVFEE1□7B505601 JKAVFED1□8B520300 JKAVF650DDB603400 JKAVFEE1□8B507500 JKAVFED1□9B525501 JKAVF650DDB604901 JKAVFEE1□9B508901 JKAVFED1□AB528001 JKAVF650DDB607001 JKAVFED1□BB529001 JKAVF650DDB607301 JKAVFED1□CB530801 JKAVFED1□DB532001

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

Part No.99924-1348-09

Printed in Japan

BRUTE FORCE 650 4×4 KVF650 4×4

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

Cooling System

4 j

Engine Top End

5 j

Converter System

6 j

Recoil Starter

7 j

Engine Lubrication System

8 j

Engine Removal/Installation

9 j

Crankshaft/Transmission

10 j

Wheels/Tires

11 j

Final Drive

12 j

Brakes

13 j

Suspension

14 j

Steering

15 j

Frame

16 j

Electrical System

17 j

Appendix

18 j

BRUTE FORCE 650 4×4 KVF650 4×4

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/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 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.

© 2004 Kawasaki Heavy Industries, Ltd.

9th Edition (0) : May 18, 2012

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)

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.

(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

â—‹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 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.

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 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 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 wires 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 flash-point solvent when cleaning parts. High flash-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 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 KVF650-D1 Left Side View

KVF650-D1 Right Side View

The KVF650-E1 is a camouflage-surface-treated model and identical to the KVF650-D1, the base model, in every other aspect: controls, features, and specifications.

1-8 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width

Overall Height

Wheelbase Ground Clearance: 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

KVF650-D1, E1

KVF650D6 ∼ DD, E6 ∼ E9

2 185 mm (86.02 in.)

1 209 mm (47.60 in.) (KVF650D6 ∼ DB/E6 ∼E9) 1 212 mm (47.72 in.)

(KVF650DC ∼) 1 210 mm (47.63 in.)

1 166 mm (45.91 in.) (KVF650D6 ∼ DB/E6 ∼E9) 1 164 mm (45.83 in.)

(KVF650DC ∼) 1 165 mm (45.87 in.)

(KVF650D6 ∼ DB/E6 ∼E9) 1 294 mm (50.94 in.)

(KVF650DC ∼) 1 295 mm (50.98 in.)

192 mm (7.56 in.)

185 mm (7.28 in.)

864 mm (34.02 in.)

862 mm (33.94 in.)

(KVF650-D1/D6 ∼ D8 (US, CA, AU)/E1 ∼ E8) 273 kg (602 lb) (KVF650D6 ∼ D8 (EUR)) 273.5 kg (603 lb) (KVF650D9 ∼ DD (US, CA, AU)/E9) 293 kg (646 lb) (KVF650D9 ∼ DB (EUR)) 294 kg (648 lb) 152 kg (335 lb) 154 kg (339.6 lb) (KVF650D6 ∼ D8 (EUR)) 154.2 kg (340 lb) (KVF650D9 ∼ DB (EUR)) 155 kg (342 lb) 141 kg (311 lb) 139 kg (306 lb) (KVF650D6 ∼ D8 (EUR)) 139.3 kg (307 lb) 17 L (4.5 US gal) 18 L (4.8 US gal) 3.1 m (10.17 ft)

4-stroke, SOHC, V-twin Liquid-cooled 80 × 63 mm (3.15 × 2.48 in.)

633 cm³ (38.6 cu in.)

9.9 : 1 30.9 kW (42.0 PS) @6 500 r/min (rpm), (US, CA) – 52.1 N·m (5.3 kgf·m, 38.0 ft·lb) @4 000 r/min (rpm), (US, CA) – Carburetor, Keihin CVKR-D32 Electric Starter & Recoil Starter (KVF650-D1 ∼ D9/E1 ∼ E9) Starting System Electric Starter (KVF650DA ∼ DD) Ignition System Digital DC-CDI Timing Advance Electronically advanced Ignition Timing From 5° BTDC @1 100 r/min (rpm) to 28° BTDC @5 000 r/min (rpm) Spark Plug NGK CR7E Cylinder Numbering Method Front to rear, 1-2 Firing Order 1-2

GENERAL INFORMATION 1-9 General Specifications Items Valve Timing: Intake: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine oil: Type 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 Front Final Gear Case Oil: Type Viscosity Capacity Rear Final Gear Case Oil: Type Capacity Frame Type Caster (Rake Angle)

KVF650D6 ∼ DD, E6 ∼ E9

KVF650-D1, E1

30° BTDC 34° ABDC 244° 54° BBDC 10° ATDC 244° Forced lubrication (wet sump) API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 2.05 L (2.17 US qt)

Belt converter 3.122 ∼ 0.635 2-speed and reverse

3.098 (30/26 × 29/18 × 20/12) 4.833 (36/20 × 29/18 × 20/12) 4.028 (16/12 × 18/16 × 29/18 × 20/12) Shaft 2WD/4WD 4.375 (35/8)

42.32 ∼ 8.61 66.02 ∼ 13.43 55.01 ∼ 11.19 API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE10W-40 0.43 L (0.45 US qt) MOBIL FLUID 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID, or EXXON HYDRAUL 560 0.9 L (0.95 US qt) Double tubular 3.5°

4.5°

1-10 GENERAL INFORMATION General Specifications Items Camber King Pin Angle Trail Tread: Front Rear Front tire: Type Size Rear tire: Type Size Rim Size: Front Rear Suspension: Front: Type Wheel Travel Rear: Type Wheel Travel Brake: Front Rear Parking Brake Electrical Equipment Battery Headlight: Type Bulb Tail/brake Light: Bulb Reverse Light: Bulb Alternator: Type Rated Output

KVF650D6 ∼ DD, E6 ∼ E9

KVF650-D1, E1 0° 11° 15 mm (0.59 in.)

16°

909 mm (35.79 in.)

910 mm (35.83 in.)

910 mm (35.83 in.)

909 mm (35.79 in.)

Tubeless AT25 × 8-12 Tubeless AT25 × 10-12 12 × 6 AT 12 × 7.5 AT

MacPherson strut 170 mm (6.69 in.)

Swingarm 184 mm (7.24 in.)

Disc × 2 Enclosed wet multi-plate Enclosed wet multi-plate 12 V 12 Ah Semi-sealed beam 12 V 45/45 W × 2 12 V 5/21 W (EUR) 12V 10W Three - phase AC 25 A, 14 V @6 000 r/min (rpm)

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

AU: Australia Model CA: Canada Model EUR: Europe Model US: United States Model

GENERAL INFORMATION 1-11 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

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

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature

× × ×

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 Pressure: = = = = = = = = =

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

Units of Force: N N kg kg

km m mm

= = = =

kg lb N lb

kPa kPa kPa kgf/cm² kgf/cm² cmHg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

Units of Speed: km/h

×

0.6214

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....................................

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

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

Choke Lever Free Play Inspection..................................

Choke Lever Free Play Adjustment ................................

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

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

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

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

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

Fuel Hose and Connection Inspection..................................

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

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

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

Radiator Cleaning ........................

Radiator Hose and Connection Inspection..................................

Coolant Filter Cleaning ................

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

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

Valve Clearance Adjustment........

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

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

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

Converter Drive Belt Deflection Inspection..................................

Converter Drive Belt Deflection Adjustment ................................

Converter Drive Belt Wear Inspection..................................

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

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

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

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

Spark Plug Cleaning/Inspection...

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

2-2 2-4 2-11 2-13 2-14 2-14 2-14 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-18 2-18 2-19 2-19 2-21 2-22 2-22 2-22 2-22 2-24 2-24 2-24

2-24 2-25 2-25 2-26 2-27 2-27 2-28 2-28 2-28 2-28

Drive Belt Failure Detection System Inspection.....................

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

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

Joint Boots Inspection.....................

Front Axle/Steering Knuckle Joint Boot Inspection .........................

Front Propeller Shaft Boot Inspection..................................

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

Tie-Rod End Boot Inspection .......

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

Variable Differential Control Lever Play Inspection..........................

Variable Differential Control Lever Play Adjustment ........................

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

Rear Final Gear Case Oil Change Brakes.............................................

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

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

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

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

Front Brake Caliper Dust Seal Replacement .............................

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

Front Brake Hose Replacement...

Rear Brake Lever Free Play Inspection..................................

Rear Brake Pedal Free Play Inspection..................................

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

Rear Brake Plates Replacement..

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

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

Switches .........................................

Brake Light Switch Inspection......

Brake Light Timing Adjustment ....

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

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

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

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

2-28 2-30 2-30 2-30 2-30 2-31 2-31 2-31 2-31 2-31 2-32 2-32 2-33 2-34 2-34 2-34

2-35 2-35 2-36 2-36 2-36 2-36 2-37 2-37 2-37 2-37 2-38 2-38 2-38 2-38 2-38 2-39 2-39 2-40 2-40

2

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

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

Every 90 days, 1 700 km (1 Every Every 100 mi.)

10 30 of use or days or days or Every See when belt 200 km 600 km year of indicator page (120 (360 use light turns mi.) of mi.) of on (100 use use hrs of use) whichever comes first

OPERATION ENGINE Throttle lever play-inspect Choke lever play-inspect

• •

• •

Idle speed-inspect Fuel system cleanliness-inspect * Air cleaner-inspect *

• •

2-14 2-14

•

•

Radiator-clean*

• •

•

2-18 2-19

•

2-21

• •

Coolant filter of carburetor-clean First 1 700 km (1 100 mi); thereafter every 3 400 km (2 200 mi)

Spark arrester-clean

• • • • • • •

Engine brake control lever-inspect * Converter drive belt deflection-inspect * Converter drive belt wear-inspect * Engine oil-change * Oil filter-replace * Spark plug cleaning and gap-inspect

• • •

Drive belt failure detection system function-inspect * CHASSIS Tire wear-inspect * Joint boots-inspect * Differential control lever play-inspect Front and rear final gear case oil-change Front brake fluid level-inspect

2-18

5 years 2 years

Radiator hoses and connections-inspect*

Valve clearance-inspect

2-16 2-17

Fuel hoses and connections-inspect Fuel hose-replace Coolant-change*

2-15

• • • •

• •

2-22 2-22 2-22

•

2-24 2-24 2-25 2-26 2-27 2-28 2-28 2-28

•

2-30 2-30 2-31

• •

2-32 2-33 2-34

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY

First Service

Regular Service

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

Every 90 days, 1 700 km (1 Every Every 100 mi.)

10 30 of use or Every days or days or when belt See year of 200 km 600 km indicator page use (120 (360 light turns mi.) of mi.) of on (100 use use hrs of use) whichever comes first

OPERATION

•

Front brake fluid-change Front brake master cylinder piston assembly and dust cover-replace Front brake caliper fluid seal and dust seal-replace Front brake pad wear-inspect *

•

2 years

2-35

2 years

2-35 2-36

•

Front brake hoses and connections-inspect Front brake hose-replace Rear brake pedal and lever play-inspect * Rear brake plates-replace * Steering-inspect Brake light switch-inspect *

•

2-37

every 10 000 km (6 000 mi.)

• • •

•

2-36 2-36

•

General lubrication * Bolts and nuts-tighten

2-36

4 years

•

2-34

• •

•

2-37 2-38 2-38 2-39 2-40

*: 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: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent.

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

Lh: Left-hand Threads LN: Apply a non-permanent locking agent (High Strength: Loctite 271 Equivalent).

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

R: Replacement Parts S: Follow the specific tightening sequence.

SS: Apply silicone sealant (Liquid Gasket, TB1211: 56019-120).

St: Stake the fasteners to prevent loosening.

Fastener Fuel System Throttle Limiter Screw Throttle Limiter Locknut Throttle Case Assembly Screws Choke Lever Mounting Screw Left Handlebar Switches Assembly Screws Heat Guard Plate Mounting Bolts Air Cleaner Housing Bolts (M5) Air Cleaner Housing Bolts (M6) 28.7 mm (1.13 in.)

Air Cleaner Housing Bolts (M6) 33 mm (1.30 in.)

Fuel Pump Mounting Nuts (On and after KVF650D6/E6) Fuel Pump Bracket Bolts (On and after KVF650D6/E6) Fuel Tap Plate Screws Fuel Tap Plate Screws (On and after KVF650D6/E6) Air Cleaner Element Bracket Screws Cooling System Radiator Fan Switch (KVF650-D1 ∼ DA/E1 ∼ E9) Radiator Fan Switch (KVF650DB ∼) Water Pump Cover Bolts Coolant Drain Plug Water Pump Fitting Bolt Water Pump Impeller Thermostat Housing Cover Bolts Coolant Temperature Warning Light Switch Radiator Fan Mounting Nut Radiator Fan Assembly Bolts Radiator Mounting Bolts Engine Top End Water Pipe Bolts Rocker Case Bolts 55 mm (2.2 in.)

N·m

Torque kgf·m

3.7 3.7 3.7 3.5 3.5 8.8 5.9 8.8 8.8

0.38 0.38 0.38 0.36 0.36 0.90 0.60 0.90 0.90

33 33 33 31 31 78 52 78 78

8.0

0.80

71 in·lb

8.0

0.80

71 in·lb

0.8 5.0 5.0

0.08 0.50 0.50

7 in·lb 44 in·lb 44 in·lb

18 23 8.8 8.8 9.8 7.9 8.8 6.9 2.7 8.8 8.8

1.8 2.3 0.90 0.90 1.0 0.80 0.90 0.70 0.28 0.90 0.90

13 17 78 in·lb 78 in·lb 87 in·lb 69 in·lb 78 in·lb 61 in·lb 24 in·lb 78 in·lb 78 in·lb

9.8 8.8

1.0 0.90

87 in·lb 78 in·lb

ft·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb in·lb

Remarks

L

SS L

S

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Fastener Rocker Case Bolts 130 mm (5.1 in.)

Rocker Case Bolts 30 mm (1.2 in.)

Rocker Case Bolts 25 mm (1.0 in.)

Cylinder Head Bolts (M10), First Torque Cylinder Head Bolt (M10), Final Torque Cylinder Head Bolts (M6) Cylinder Head Jacket Plugs Valve Adjusting Cap Bolts Valve Adjusting Screw Locknuts Rocker Shaft Plugs Chain Tensioner Mounting Bolts Chain Tensioner Cap Bolt Intermediate Shaft Chain Guide Bolts Intermediate Shaft Chain Tensioner Bolts Camshaft Sprocket Bolts Position Plate Bolts Cylinder Bolts 40 mm (1.6 in.)

Cylinder Bolts 30 mm (1.2 in.)

Front Cylinder Camshaft Chain Guide Bolt Rear Cylinder Camshaft Chain Guide Bolt Coolant Drain Plugs (Cylinder) Exhaust Pipe Cover Bolts Muffler Cover Bolts Muffler Mounting Bolts Heat Guard Plate Mounting Bolts Muffler Clamp Bolt Converter System Drive Pulley Bolt Driven Pulley Nut Drive Pulley Cover Bolts Ramp Weight Nuts Spider Torque Converter Cover Bolts Joint Duct Bolts Engine Brake Actuator Mounting Bolts Recoil Starter Recoil Starter Mounting Bolts Engine Lubrication System Oil Filter Oil Pressure Switch Oil Pipe Bolts Engine Drain Plug Oil Pressure Relief Valve

N·m 9.8 9.8 9.8 25 49 9.8 20 8.8 12 20 8.8 22 8.8 8.8 12 8.8 9.8 9.8 20 20 7.0 8.8 8.8 20 8.8 8.8

Torque kgf·m ft·lb 1.0 87 in·lb 1.0 87 in·lb 1.0 87 in·lb 2.5 18 5.0 36 1.0 87 in·lb 2.0 14 0.90 78 in·lb 1.2 104 in·lb 2.0 14 in·lb 0.90 78 in·lb 2.2 16 0.90 78 in·lb 0.90 78 in·lb 1.2 104 in·lb 0.90 78 in·lb 1.0 87 in·lb 1.0 87 in·lb 2.0 14 2.0 14 0.70 62 in·lb 0.90 78 in·lb 0.90 78 in·lb 2.0 14 0.90 78 in·lb 0.90 78 in·lb

Remarks S S S S, MO S L

L

L

93 93 13 6.9 275 8.8 8.8 8.8

9.5 9.5 1.3 0.70 28 0.90 0.90 0.90

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

R, Lh

5.9

0.60

52 in·lb

L

18 15 8.8 20 15

1.8 1.5 0.90 2.0 1.5

13 11 78 in·lb 14 11

R SS

Lh S

L

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Oil Pump Cover Bolts Chain Guide Bolts Oil Pump Drive Chain Tensioner Bolt Oil Filter Mounting Bolts Oil Pressure Switch Terminal Bolt Engine Removal/Installation Engine Mounting Bracket Bolts Engine Mounting Bolt Engine Mounting Nut Crankshaft/Transmission Connecting Rod Big End Cap Nuts Engine Drain Plug Crankcase Bolts (M8) 75 mm (2.95 in.)

Crankcase Bolts (M8) 110 mm (4.33 in.)

Crankcase Bolts (M6) 40 mm (1.57 in.)

Crankcase Bolts (M6) 65 mm (2.56 in.)

Bearing Position Plate Screws Grip Hold Nut Shift Lever Assembly Bracket Bolts Tie-Rod End Front Locknut Tie-Rod End Rear Locknut Tie-Rod End Nut Shift Lever Assembly Nut Tie-Rod End Bolt Shift Shaft Positioning Bolt Shift Shaft Spring Bolt Shift Shaft Cover Bolts Tie-Rod End Locknut Neutral Position Switch Reverse Position Switch Wheel/Tires Tie-Rod Adjusting Sleeve Locknuts Wheel Nuts Front Axle Nuts Rear Axle Nuts Final Drive (Output Bevel Gears) Output Driven Bevel Gear Housing Bolts Output Drive Bevel Gear Housing Bolts Bearing Holder Bevel Gear Holder Nut Bearing Holder Output Shaft Holder Nut

N·m 8.8 8.8 25 25 1.5

Torque kgf·m 0.90 0.90 2.5 2.5 0.15

ft·lb 78 in·lb 78 in·lb 18 18 13 in·lb

32 62 62

3.3 6.3 6.3

24 46 46

34.3 20 20 20 9.8 9.8 4.9 9.8 20 9.8 9.8 20 20 9.8 25 25 8.8 20 15 15

3.50 2.0 2.0 2.0 1.0 1.0 0.50 1.0 2.0 1.0 1.0 2.0 2.0 1.0 2.5 2.5 0.90 2.0 1.5 1.5

25.3 14 14 14 87 in·lb 87 in·lb 43 in·lb 87 in·lb 14 87 in·lb 87 in·lb 14 14 87 in·lb 18 18 78 in·lb 14 11 11

27 78 197 265

2.8 8.0 20 27

20 58 145 195

26 26 250 200 118 200

2.7 2.7 25.5 20.4 12 20.4

20 20 184 148 87 148

Remarks

L (15 mm)

MO S S, L(1)

L

Lh

LB

Lh (2)

L L L L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Rotor Mounting Bolts Output Drive Bevel Gear Cover Bolts Forward/Reverse Detecting Sensor Mounting Bolt (Front Final Gear Case) Variable Differential Control Shift Shaft Lever Bolt Front Final Gear Case Left Cover Bolts (M6) Ring Gear Bolts Front Final Gear Case Center Cover Bolts (M6) Oil Filler Cap Front Final Gear Case Center Cover Bolts (M8) Pinion Gear Bearing Holder Nut Pinion Gear Bearing Holder Front Final Gear Case Coupling Nut Oil Drain Plug 2WD/4WD Actuator Mounting Bolts Variable Differential Control Cable Locknut Variable Differential Control Lever Bolt Front Final Gear Case Bolts and Nuts (Rear Final Gear Case) Oil Filler Cap Oil Drain Plug Pinion Gear Bearing Holder Pinion Gear Bearing Holder Nut Rear Final Gear Case Right Cover Bolts (M8) Rear Final Gear Case Right Cover Bolts (M10) Rear Final Gear Case Right Cover Bolts (M12) Rear Final Gear Case Left Cover Bolts Rear Final Gear Case Bolts Brakes Reservoir Cap Screws Front Brake Lever Pivot Bolt Front Brake Lever Pivot Bolt Locknut Front Brake Master Cylinder Clamp Bolts Front Bake Hose Banjo Bolt Front Brake Caliper Mounting Bolts Bleed Valves Front Brake Disc Mounting Bolts Front Brake Light Switch Mounting Screw Variable Differential Control Lever Bolt Gasket Screws Rear (Parking) Brake Lever Pivot Bolt Rear Brake Lever Lock Screw

N·m 12 8.8 15

Torque kgf·m ft·lb 1.2 104 in·lb 0.90 78 in·lb 1.5 11

8.8 9.8 57 9.8 29 24 127 137 25 15 9.8 17 3.4 59

0.90 1.0 5.8 1.0 3.0 2.4 13 14 2.5 1.5 1.0 1.7 0.35 6.0

78 in·lb 87 in·lb 42 87 in·lb 22 17 94 101 18 11 87 in·lb 12 30 in·lb 43

29 20 137 157 24 49 93 49 42

3.0 2.0 14 16 2.4 5.0 9.5 5.0 4.3

22 14 101 116 17 36 69 36 31

1.5 5.9 5.9 8.8 34 25 7.8 37 1.2 3.4 – 2.4 2.4

0.15 0.60 0.60 0.90 3.5 2.5 0.80 3.8 0.12 0.35 – 0.24 0.24

13 in·lb 52 in·lb 52 in·lb 78 in·lb 25 18 69 in·lb 27 10 in·lb 30 in·lb – 21 in·lb 21 in·lb

Remarks

L (4), S LB L, S L, S St LN

L,S L

LB L L L L L S

L L L

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Suspension Suspension Arm Pivot Bolts Front Shock Absorber Mounting Nuts Front Shock Absorber Clamp Bolts and Nuts Steering Knuckle Joint Nut (KVF650-D1/E1) Steering Knuckle Joint Nut (On and after KVF650-D6/E6) Rear Shock Absorber Spring Locknut Rear Shock Absorber Mounting Nuts Swingarm Pivot Right Shaft Swingarm Pivot Left Shaft Swingarm Pivot Left Nut Steering Handlebar Holder Bolts Tie-Rod Adjusting Sleeve Locknuts Tie-Rod End Nuts Steering Stem Clamp Bolts Steering Stem Bottom End Nut Front Brake Master Cylinder Clamp Bolts Front Shock Absorber Clamp Nuts Steering Knuckle Joint Nut (KVF650-D1/E1) Steering Knuckle Joint Nut (On and after KVF650D6/E6) Throttle Case Assembly Screws Left Handlebar Switches Assembly Screws Frame Trailer Hitch Bracket Bolts (M8) Trailer Hitch Bracket Bolts (M10) Front Guard Bolts Front Carrier Bolts Rear Carrier Lower Bolts Rear Carrier Upper Bolts and Nuts Engine Mounting Bracket Bolts Engine Mounting Nuts Front Final Gear Case Bolts and Nuts Electrical System Starter Motor Mounting Bolts Starter Motor Terminal Nut Starter Motor Terminal Locknut Starter Motor Bolts Starter Motor Clutch Bolts Alternator Stator Bolts Crankshaft Sensor Mounting Bolts

N·m

Torque kgf·m

ft·lb

88 74 42 42

9.0 7.5 4.3 4.3

65 54 31 31

29

3.0

21

88 62 152 20 152

9.0 6.3 15.5 2.0 15.5

65 46 112 14 112

29 27 42 25 64 11 42 42

3.0 2.8 4.3 2.5 6.5 1.1 4.3 4.3

22 20 31 18 47 95 in·lb 31 31

29

3.0

21

3.7 3.5

0.38 0.36

33 in·lb 31 in·lb

24 49 29 32 54 32 32 62 59

2.4 5.0 3.0 3.3 5.5 3.3 3.3 6.3 6.0

17 36 22 24 40 24 24 46 43

8.8 4.9 6.9 4.9 34 13 5.9

0.90 0.50 0.70 5.0 3.5 1.3 0.60

78 in·lb 43 in·lb 61 in·lb 43 in·lb 25 113 in·lb 52 in·lb

Remarks

AL

L

S Lh (2)

AL

L L

L

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Alternator Cover Plugs Alternator Rotor Bolt Alternator Cover Bolts Starter Motor Terminal Locknut Starter Motor Through Bolts Alternator Outer Cover Bolts (KVF650DA ∼) Spark Plugs 2WD/4WD Actuator Mounting Bolts Engine Brake Actuator Mounting Bolts Forward/Reverse Detecting Sensor Mounting Bolt Speed Sensor Mounting Bolt Neutral Position Switch Reverse Position Switch Radiator Fan Switch (KVF650-D1 ∼ DA/E1 ∼ E9) Radiator Fan Switch (KVF650DB ∼) Coolant Temperature Warning Light Switch Oil Pressure Switch Oil Pressure Switch Terminal Bolt

Torque kgf·m ft·lb 1.8 13 13 94 0.90 78 in·lb 1.1 97 in·lb 0.51 44 in·lb 0.60 52 in·lb 1.3 113 in·lb 0.90 78 in·lb 0.90 78 in·lb 1.5 11 0.90 78 in·lb 1.5 11 1.5 11 1.8 13 2.3 17 0.70 61 in·lb 1.5 11 0.15 13 in·lb

N·m 18 127 8.8 11 5.0 5.9 13 8.8 8.8 15 8.8 15 15 18 23 6.9 15 1.5

Remarks

L,S

SS SS

The tables below, relating tightening torque to thread diameter, list 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

Mark of bolt head

5 6 6 6 8 8 10 10

4T 9T 7T 4T 7T 4T 7T 4T

N·m 2.2 ∼ 2.6 12 ∼ 15 7.8 ∼ 9.8 3.9 ∼ 4.9 18 ∼ 22 10 ∼ 14 39 ∼ 44 20 ∼ 24

Torque kgf·m 0.22 ∼ 0.27 1.2 ∼ 1.5 0.8 ∼ 1.0 0.4 ∼ 0.5 1.8 ∼ 2.2 1.0 ∼ 1.4 4.0 ∼ 4.5 2.0 ∼ 2.4

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

2-10 PERIODIC MAINTENANCE Torque and Locking Agent Basic Torque for General Fasteners of Frame Parts 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 ∼ 0.5 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 2-11 Specifications Item Fuel System Throttle Lever Free Play Choke Lever Free Play Idle Speed Air Cleaner Element Oil Cooling System Coolant: Type (Recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Intake Converter System Actuator Lever Guide Shoe Wear Belt Width Belt Deflection Engine Lubrication System Engine Oil: Type Capacity

Wheels/Tires Tire Tread Depth: Front Rear Standard Tire: Front

Rear

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

About 3 mm (0.12 in.)

1 100 ±50 r/min (rpm) High-quality foam air filter oil

– – – –

– – – –

– – – –

Permanent type antifreeze Green Soft water 50%, Coolant 50% –35°C (–31°F) 2.4 L (2.5 US qt.)

– – – – –

– – – – –

– – – – –

0.20 ∼ 0.25 mm (0.0079 ∼ 0.0098 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

– – – – – –

––– 29.7 ∼ 30.3 mm (1.169 ∼ 1.193 in.)

22 ∼ 27 mm (0.87 ∼ 1.06 in.)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 1.54 L (1.63 US qt) (When filter is not removed) 1.75 L (1.85 US qt) (When filter is removed) 2.05 L (2.17 US qt) (When engine is completely dry)

––– ––– AT 25 × 8-12 DUNLOP, KT121A, Tubeless DURO, DI-K211A, Tubeless AT 25 × 10-12 DUNLOP, KT127A, Tubeless DURO, DI-K721A, Tubeless

6 mm (0.24 in.)

28.0 mm (1.102 in.)

– – –

– – – – – – – – – – – –

3 mm (0.12 in.)

4 mm (0.16 in.)

– – – – – – – – – – – –

2-12 PERIODIC MAINTENANCE Specifications Item Final Drive Front Final Gear Case Oil: Gear Oil (Same engine oil) Type Viscosity Oil Level Capacity Rear Final Gear Case Oil: Gear Oil: Type

Oil Level Capacity Brakes Front Brake Fluid: Type 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

Standard

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 Filler opening bottom 0.43 L (0.45 US qt)

MOBIL Fluid 424, CITGO TRANSGARD TRACTOR HYDRAULIC FLUID or EXXON HYDRAUL 560 Filler opening bottom 0.9 L (0.95 US qt)

DOT 3 or DOT 4 4 mm (0.16 in.)

Service Limit

– – – – – – – – – – – –

– – – – – – – – –

– – – 1 mm (0.04 in.)

1 ∼ 2 mm (0.04 ∼ 0.08 in.)

15 ∼ 25 mm (0.6 ∼ 1.0 in.)

– – – – – –

0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

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

– – – – – –

PERIODIC MAINTENANCE 2-13 Special Tools Oil Filter Wrench: 57001-1249

Pulley Holder Attachment: 57001-1472

Carburetor Drain Plug Wrench, Hex 3: 57001-1269

Flywheel & Pulley Holder: 57001-1605

Filler Cap Driver: 57001-1454

Belt Measuring Gauge: 57001-1646

2-14 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 cable damage.

Then lubricate the throttle cable.

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

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

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

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

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

Throttle Lever Free Play Adjustment

the handle cover (see Multifunction Meter Unit • Remove Removal in the Electrical System chapter). 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.

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

Choke Lever Free Play Inspection

if the choke lever [A] returns properly and if the • Check inner cable slides smoothly. sure that the choke lever returns to its released po• Make sition all the way. determine the amount of choke cable play at the lever, • To pull the choke lever to the left until feeling the operation of

•

the lever tough; the amount of choke lever is equivalent to that of cable play.

The proper amount of play ranges about 3 mm (0.12 in.) at the choke lever.

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

Choke Lever Free Play [B] Standard: about 3 mm (0.12 in.)

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Choke Lever Free Play Adjustment

• Remove: Handlebar Cover Screws [A]

• Remove: Handlebar Cover Screws [A] Handlebar Cover Front [B]

the locknut [A] of the choke cable.

• Loosen Turn the • play. adjuster [B] until the cable has proper amount of • Tighten the locknut securely.

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.

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. Follow the service manual to be make sure to correct any of these conditions. idle speed with a suitable tachometer.

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

Idle Speed Standard: 1 100 ±50 r/min (rpm)

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