Manual de taller kawasaki tengai kl500 kl650 web by Alberto Rivera

Kawasaki

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Motorcycle

Service Manual

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G e n e ra l

In fo rm a tio n

•• I

F u e l S y s te m C o o lin g S y s te m E n g in e T o p E n d E n g in e R ig h t S id e /L e ft E n g in e L u b ric a tio n

S id e

S y s te m

E n g in e R e m o v a l/ln s ta lla tio n C ra n k s h a ft/T ra n s m is s io n W h e e ls /T ire s

I F in a l D riv e B ra k e s S u s p e n s io n S te e rin g F ra m e E le c tric a l

S y s te m

Appendíx This quick reference guide will assist you in S u p p le m e n t-1 9 9 0 locating a desired topic or procedure. eSend the pages back oto match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. eRefer to the sectional table of contents for the exact pages to locate the specific topic required.dcbaZYXWVUTSRQPONMLKJIHGFEDCBA

M odel

Kaw asaki

TĂŠnga1

M o to rc y c le

S e rv ic e

M anual

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AII rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any rneans. electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer ProductsjihgfedcbaZYXWVUTS & Components Group/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. AII information contained in this publication is based on the latest product information available at the time of publication. IlIustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

ÂŠ Kawasaki Heavy Industries. Ltd. 1988, 1989

2nd Edition (1) : Sep. 5, 1989 (1)

L lS T O F A B B R E V IA T IO N S utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

ampere(s)

ABDC

after bottom

alternating

ATDC

after top dead center

newton(s)

BBDC

before bottom

pascal(s)

BDC

bottom

horsepower

BTDC

before top dead center

psi

pound(s)

째c

degree(s)

revolution

direct current

rpm

revolution(s)

farad(s)

TDC

top dead center

TIR

total indicator

lb dead center current dead center

dead center Celcius

pounds(s)

meter(s)

min

minute(s)

per square

per minute

째F

degree(s)

foot, feetjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA V SRQPONMLKJIHGFEDCBA v o lt ( s )

gram(s)

hour(s)

liter( s)

Fahrenheit

W O

inch

reading

watt(s) ohm(s)

This warning may apply to any of the following components or any assembly containing one or more of these components:Brake Shoes or Pads Clutch Friction Material Gaskets Insulators WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow salety in s tru c tio n s

SAFETY INSTRUCTIONS eOperate if possible out of doors or in a well ventilated place. e Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. elf possible, dampen before cutting or drilling. e Dampen dust and place it in properly closed receptacle and dispose of it safely.

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E M IS S IO N

CONTROL

IN F O R M A T IO N

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United States Environmental Protection Agency and California Air Resources Board. Additionally, has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System.. This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or sto red in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

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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 ..."

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A d d ítío n

ín o p e ra tív e

o f d e v íc e s o r

ín c lu d e : o f v e h íc le c o m p o n e n ts

s u c h th a t th e e m ís s io n s ta n d a r d s a r e e x -

a d v e r s e ly a ffe c t th e p e r fo r m a n c e

o f th e m o to r c y c le .

o f c o m p o n e n ts

o r a c c e s s o r íe s th a t r e s u lt ín th e

v e h íc le e x c e e d ín g

th e

~~ re m o v ín g ,

d ís c o n n e c tín g ,

o r re n d e rín g

ín o p e ra tív e

any com ponent

o r e le m e n t o f d e s íg n o f th e e m ís s ío n c o n tr o l s y s te m s .

~ WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EX-

CEEDING $10,000 PER VIOLATION.

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TAMPERING

WITH NOISE CONTROL SYSTEM

PROHIBITED

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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 :'!'J! to its sale or delivery to the untilmate purchaser or while it is in use, or (2) the use of the vehicle ~J~ after such device or element of design has been removed or rendered inoperative by any persono

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Among those acts presumed to constitute tampering are the acts listed below: e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations. e Removal of the muffler(s) or any internal portion of the muffler(s). e Removal of the air box or air box cover. e Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

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F o re w o rd utsrqponmlkjihgfedcbaZYXWVUTSRQPONM 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 arder 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. F o r th e d u ra tio n o f y o u r w a rra n ty

I f

p e rio d ,

especially, 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 Motorcycle: • 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 Special Tool 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.

H o w to U s e th is M a n u a l

In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. AII information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Ouick Reference Guide shows you all of the product's system and assists in locating their chapterso Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for exarnple. go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Ouick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

I o T h is w a rn in g

W ARNING

s y m b o l id e n tifie s s p e c ia l in -

s tru c tio n s o r p ro c e d u re s w h ic h , if n o t c o rre c tly

fo llo w e d ,

c o u ld

re s u lt

p e rs o n a l

in ju ry , o r lo s s o f Iife,

o T h is

c a u tio n

s tru c tio n s

s y m b o l id e n tifie s p ro c e d u re s

s p e c ia l in -

w h ic h ,

not

s tric tly o b s e rv e d , c o u ld re s u lt in d a m a g e to o r d e s tru c tio n o f e q u ip m e n t.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.dcbaZYXWVUTSRQPONMLKJIHGFEDCBA NOTE OSRQPONMLKJIHGFEDCBA T h ís n o te s y m b o / ín d íc a te s

p o ín ts

o f p s r tic -

u /a r ín te re s t fo r m o re e ffíc íe n t a n d c o n v e n íe n t o p e ra tío n .

elndicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. Indicates a conditional step or what action to take based on the results of the test or 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

IN F O R M A T IO N

1 -1

G e n e ra l In fo rm a tio n

T a b le 01 C o n te n ts utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHG

Before Servicing Model Identification General Specifications Periodic Maintenance Chart Technicallnformation Torque and Locking Agent.. Cable, Wire, and Hose Routing

1-2 1-4 1-6 1-8 1-9 1-15 1-18

1 -2

GENERAL

IN F O R M A T IO N

B e fo re S e rv ic in g utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detail account has limitations, a certain amount of basic knowledge is also required for successful work. E s p e c ia lly n o te th e fo llo w in g :

(1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead from the battery before performing any disassembly operations on the motorcycle. This prevents: (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (e) damage to electrical parts. (3) Tightening Sequence Generally, when installing a part with several bolts. nuts, or screws, they should all be started in their holes and tightened to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts. or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts. nuts, or screws must be tightened in the order and method indicated. (4) Torque The torque values given in this Service Manual should always be adhered to. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plasticfaced mallet. Use an impact driver for screws (particularly for the removal of screws heId by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it overo (7) High Flash-point Solvent A high flash-point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (8) Gasket, O-rjng Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Nonpermanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An examole of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue). (10) Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races. and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.

GENERAL

IN F O R M A T IO N

1 -3 utsrqponml

(12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones. as removal generally damages seals. When pressing in a seal which has manufacturer's marks. press it in with the marks facing out. Seal should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. (13) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seallips. Before a shaft passes through a seal. apply a little oil. preferably high temperature grease on the lips to reduce rubber to metal friction. (14) Circlip, Retaining Ring / Replace any circlips and retaining rings that were removed with new ones. as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15) Cotter Pin Replace any cotter pins that were removed with new ones. as removal deforms and breaks them. (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makers reference to molybdenum disulfide grease (MoS, ) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. (17) Electrical Wires AII the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For exarnple. a yellow wire with thin red stripes is referred to as a "vellow/red" wire; it would be a "red/vellow" wire if the colors were reversed to make red the main color.

Wire (cross-section)

Name of Wire Color

Red Wire strands

Yellow/red

Yellow ~

"'--

Red

(18) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (19) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of thern, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20) Service Data Numbers of service data in this text have following meanings: "Standard": Show dimensions or performances which brand-new parts or systems have. "Service Lirnit": Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

1 -4

GENERAL

IN F O R M A T IO N

M o d e l I d e n t if ic a t io n

K L 6 5 0 - B 1 L e f t S id e V ie w :

K L 6 5 0 - B 1 R ig h t

S id e V ie w :

"--~----_'/

GENERAL

Kl500- B1 left

Side View:

Kl500-B1 Right Side View:

IN F O R M A T IO N jihgfedcbaZYXWVU 1-5 utsrqponm

1 -6

GENERAL

IN F O R M A T IO N

G e n e ra l S p e c ific a tio n s

Ite m s

K L 5 0 0 -B 1

K L 6 5 0 -B 1

D im e n s io n s : utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight:

Front Rear

Fuel tank capacity

2220 mm, (SA) 2175 920 mm 1300mm 1 480 mm 210 mm 870 mm 159 kg 87 kg 97 kg 23 L

~---jihgfedcbaZYXWVUTSRQPON ~---

~--~--~--~--~--~--~---

P e rfo rm a n c e :

Braking distance Minimum turning radius

12.5 m from 50 krn/h 2.4 m

~--~---

E n g in e :

Type Cooling system Bore and str贸ke Displacement Compression ratio Maximum horsepower

Maximum torque

Carburetion system Starting system Ignition system Timing advance

4-stroke, DOHC, 4-valve, 1 -cylinder Liquid-cooled 100;0 x 83.0 mm 651mL 9.5: 1 35.3 kW (48 PS) @6 500 r/rnin (rpm) (F) 34.2 kW (46.5 PS) @6 500 r/rnin (rpm): UTAC's norms (G) 19.9 kW (27 PS) @5 500 r/rnin (rpm): DIN (S) 17.2 kW (23.4 PS) @4 500 r/min (rpm) 54.9 N-m (5.6 kg-m, 40.5 ft-Ib) @5 500 r/rnin (rpm) (G) 48.1 N-m (4.9 kg-m, 35.4 ft-Ib) @2 300 r/rnin (rpm) : DIN (S) 43.2 N-m, (4.4 kg-m, 31.8 ft-Ib) @3 000 r/min (rpm) Carburetor, Keihin CVK40 Electric Starter CDI Electronically advanced

~--~---

89.0 x 80.0 mm 497 mL ~---

29.4 kW (40 PS) @7 500 r/rnin (rpm)

38.2 N-m (3.9 kg-m, 28.2 ft-Ib) @6 000 r/min (rpm)

~--~--~---

~---

Ignition timing

From 10 BTDC @1 300 r/rnin (rpm) to

Spark plug

30 o BTDC @3 300 r/rnin (rpm) NGK DPR8EA-9 or ND X24EPR-U9 (I)(SA) NGK DP8EA-9, or ND X24EP-U9

~--~---

Valve timing: Inlet

Exhaust

Lubrication system Engine oil: Grade Viscosity Capacity

Open

19 (BTDC)

(ABDC) 0

Duration

268

Open

Duration

268 Forced lubrication (wet sump)

~--~--~---

(BBDC)

~---

(ATDC)

~---

SE or SF class SAE10W40, 10W50, 20W40, or20W50 2.5 L

~--~---

~--~--~---

GENERAL Ite m

IN F O R M A T IO N

K L 6 5 0 -B 1

K L 5 0 0 -B 1

D riv e T ra in : utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Final drive system: Type Reduction ratio Overall drive ratio

Gear 2.272 (75/33) Wet multi disc

+----

5-speed, constant mesh, return shift 2.266 (34/15) 1.529 (26/17) 1.181 (26/22) 0.954 (21/22) 0.791 (19/24)

+----

+---+----

+-- -+---+----

+---+----

Chain drive 2.866 (43/15) 5.157 @Top gear

3.133 (47/15) 5.637 @Top gear

Type

Tubular, semi-double cradle

+----

Caster (rake angle) Trail Front tire: Type Size Rear tire: Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake type: Front Rear

28째 113 mm

+----

F ra m e :

+----

Tube type 90/90-21 54S Tube type 130/80-17

+----

+---+----

65S

+----

Telescopic air fork (pneumatic) 220mm

+----

Swing arm (uni-trak) 200mm

+----

Single disc Single disc

+----

12 V 14 Ah

+----

Semi-sealed beam 12 V 60/55 W (quartz-halogen) 12 V 5/21 W, (SA) 12 V 8/27 W

+----

+--- -

E le c tric a l E q u ip m e n t:

Battery Headlight: Type Bulb Tail/brake light Alternator: Type Rated output

Three-phase AC 14 A @8 000 r/rnin (rpm). 14 V

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

A b b re v ia tio n

(F) (G) (1)

French Model Swiss Model (S) (SA) South African Model West German ModeljihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Italian Model

+---+---+----

+----

1 -7

1-8

GENERAL INFORMATION

Periodic Maintenance

Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle running condition. The initial maintenance is vitally important and must not be neglected.

Whichever..

tODOMETER

in good

READING

FREQUENCYjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

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'*-~ '*-~ '*-~ '*-~ '*-~

~ '*-~ C~

C~ C~ C~ < o ~ ~<o'(\S ,~~ ,<o~ "'~ ~

OPERATIONSRQPONMLKJIHGFEDCBA Every Spark plug - clean Spark plug - check* Valve clearance - check" Air cleaner element - clean Air cleaner element - replace Throttle grip play - check* Idle speed - check* Fuel system - check" Spark arrestor ( C, US) - clean Evaporative emission control system (Cal) - charige* Engine oil - change Oil filter - replace Radiator hoses, connections - check* Coolant - change Fuel hose - replace Balancer chain tension - adjust Clutch - adjust Drive chain wear - check" Drive chain - lubricate Drive chain slack - check" Brake lining or pad wear - check* Brake fluid level - check" Brake flu id - change Brake hose - replace Brake master cylinder cup and dust seal - replace Caliper piston seal and dust seal - replace Brake light switch - check * Steering - check * Steering stem bearing - lubricate Front fork oil - change Tire wear - check" Spoke tightness and rim runout - check" Swing arm pivot, uni-trak linkage - lubricate Battery electrolyte level - check * General lubrication - perform Nut, bolt, and fastener tightness - check"

•

• •

•

5 cleanings

•

year year 2 years 4 years

• •

• • • • • • •

•

• •

• • • • • • • • • •

•

• •

•

• •

See Page 15-21 15-21 4-16 2-15 2-15 2-6 2-9 2-11 -

• • • •

6-6 6-6 3-13 3-5

•

• • •

•

• •

•

• • •

11-8 11-13 11-13 11-16

300 km 800 km

•

• •

•

• • • • • • • •

O:J~ ~

5-17 5-6 10-5 10-5 10-4

•

month 2 years 4 years

• • •

• • • • •

1>~

• •

•

• •

•

2 years

11-11

2 years

11-8 15-34 13-4

•

2 years

•

• • • • • •

•

• •

•

• •

•

• • • • month

•

• •

• • •

• •

•

• • •

: For higher odometer readings, repeat at the frequency interval established here.

: Replace, add. adjust. clean, or torque if necessary. (C) : Canadian Model (Cal) : California Vehicle

•

(US) : US Model

•

• • • • • • •

13-7 12-5 9-9 9-6 12-3 15-11 16-8 1-15

GENERAL

T e c h n ic a l

IN F O R M A T IO N

1 -9

In fo rm a tio n

Side Stand Switch (lnter lock)

Torque limiter BAC

K A C R (K a w a s a k i A u to m a tic C o m p re s s io n R e le a s e ) utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCB TheSRQPONMLKJIHGFEDCBA d e v ic e momentarily opens one of the exhaust v a lv e s on the compression stroke at v e r y low speeds. This allows some of the compression pressure to escape, making it easy to turn o v e r the engine during starting. Due to the simplicity of the mechanism, no periodic maintenance is needed.

A. Right Hand Exhaust V a lv e B. Front

C. Exhaust Cam Lobe D. KACR Unit

1 -1 0

GENERAL

IN F O R M A T IO N

OperetionutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

The KACR mechanism is fixed to the end of the exhaust camshaft and rotates with it. When the engine is turning at very low speeds (cranking speeds), the weights are pulled together by the spring.jihgfedcbaZYXWVUTSRQPONMLKJIHGF

Release Cam Protrusion (exaggerated for illustration)

Plate

Exhaust

Cam

1111111111111111111111

Spring

IlIIlun

1111111111111111111

111111111111111111

1111111111111111111

111111111111111111 1111111111111111111111

Weight (A)

Release Cam Pivot

Tappet

The release cam on weight (B) protrudes beyond the base circle (heel) of the exhaust cam lobe. Weight (B) resets against a stopper pin mounted on the KACR plate, so that when the release cam forces the right hand exhaust valve open the weights don't fly aparto Since the release cam is very small, it opens the exhaust valve only for a very short part of the compression stroke before top dead center. Weight (A) pivots on the KACR plate and weight (B) pivots on weight (A). When the engine starts weight (B) swings away from the center of the KACR plate until it is free of the stopper pino This allows weight (A) to swing out and move the pivot of weight (B) toward the center of the cam lobe.

IlllIlllIl1llllilll

This in turn moves the release cam inside the base. circle of the cam lobe where it no longer opens the right hand exhaust valve. The stopper pin holds weight (B) from going too far out. Of course, when the engine slows to a stop, the weights return to their original positions and the release cam can again hold open the valve.

GENERAL

IN F O R M A T IO N

1 -1 1 utsrqponmlk

The release cam operates following after the piston movement and the exhaust cam movement as shown in the figure below.jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Cylinder Head Upper Surface

Release Cam

Cam Lobe

Effective Compression Period

KA-C-R-o-p-e-ra-t-in-g-pl~n Stroke

period

:~ ~ t.~ ;= = ~ ~ = = = = = = ~ = ~ ~ t= = = = = ~ t_ 5 = ----

1 2 3 4

2: 3: -+ 4: -+ 1: -+ -+

Power Stroke Exhaust Stroke Intake Stroke Compression Stroke

TDC

L _

SRQPONMLKJIHGFEDCBA

BDC

1 -1 2

GENERAL

B A C (B a la n c e d

IN F O R M A T IO N A c tu a tio n

C a lip e r) utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

The front disc brake employs the BAC (Balanced Actuation Caliper) system. The disc brake caliper has one small piston and one large one. The small piston is on leading edge of the pad, where less pressure is needed beca use the leading edge tries to "dig in" by itself when the brake is applied.

1. Caliper Body 2. Pistons 3. Pads

1. 2. 3. 4. 5.

Conventional Type Caliper 2-piston Type Caliper Trailing-side Piston Leading-side Piston Conventional Type Piston

6. 2-piston Type Pad 7. Conventional Type Pad 8. Disc .9. Reduceable Disc Area 10. Disc Rotational Direction

Balanced actuation means better pad wear, and better brake feel under extreme racing conditions.

GENERAL

IN F O R M A T IO N

1 -1 3

L im ite r utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

T o rq u e

The crankshaft is likely to rotate in the opposite direction during engine starting due to reduce the engine rpm by compression pressure or firing pressure at the BTDC in the compression stoke. In this case, starter mechanism may be damaged by large back torque from the crankshaft. To prevent this damage, the starter mechanism employs the torque limiter. The torque limiter is a kind of friction clutch which consists of a shaft, large gear, small gear, conical spring washer and shim(s).

Operation When

engine

The driving through When

starting: force of the starter motor

the shaft and small gear.

from the large gear of the torque

limiter

to the idle gear

to the starter gear, rotates the crankshaft.

crankshaftjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA roiatinq in the opposite:

The back torque torque

is transmitted

And the force is transmitted

limiter

not transmitted

from

through

the crankshaft

the idle gear.

is transmitted

If the torque

from

the starter gear to the shaft and small

is over the clutch

to the large gear beca use of the slip between

capacity

limiter,

gear of the the torque

the shaft and the large gear.

When crankshaft rotating in the opposite.

When engine starting: Starter Motor Gear

of the torque

Driving Force

.ยก,

Stop . Slip.

Large Gear Conical Spring Washer ---'--+ยกI'r:~

Rotate.

Shim _---jยก---UJJ Shaft--:::::::ยก~--

Small Gear

ldle Gear

Back Torque

To Idle Gear

Starter Gear -----'t"-

1 -1 4

GENERAL

IN F O R M A T IO N

S id e S ta n d S w itc h (In te r L o c k ) utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Side stand switch is designed so that the motorcycle does not run when side stand is up. The side stand switch is operated by the side stand, and kills the engine by stopping ignition sparks.

Operstion Side stand switch is closely related with starter lockout switch and neutral switch as inter lock system. These switches are connected with ignition circuir. and control the ignition system as follows (see Ignition System Wiring Diagram in the Electrical System chapter). Side Stand Switch When side stand is down

Starter Lockout Switch When clutch lever is pulled in

When clutch lever is released

Neutral Switch

Starter Starting

Engine Ignition

OFF

X OFFjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA X When side stand is up

When clutch lever is pulled in

When clutch lever is released

OFF

GENERAL

IN F O R M A T IO N

1 -1 5

T o rq u e a n d L o c k in g A g e n t utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Tighten al! bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket. When checking the tighening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten it to the specified torque. Letters used in the "Rernarks" column mean: L Applya non-permanent locking agent to the threads. LG : Apply liquid gasket to the threads. SS : Apply silicone sealant to the threads. S Tighten the fasteners following the specified sequence.

F a s te n e r

T o rq u e

R e m a rk s

N -m

k g -m

ft-Ib

7.4 15 9.8 9.8

0.75 1.5 1.0 1.0

65 in-lb 11.0 7.0 7.0

7.8 15 12 49 65 9.8 25 18 25 9.8

0.8 1.5 1.2 5.0 6.6 1.0 2.5 1.8 2.5 1.0

69 in-lb 11.0 8.5 36 48 7.0 18.0 13.0 18.0 7.0

23 130 9.8 9.8 12 25 120 9.8 195 9.8 34 25 12 44

2.3 13.5 1.0 1.0 1.2 2.5 12.0 1.0 20 1.0 3.5 2.5 1.2 4.5

16.5 98 7.0 7.0 8.5 18.0 87 7.0 145 7.0 25 18.0 8.5 33

C o o lin g S y s te m :

Fan Switch Water Temperature Sensor Water Pump Impeller Nut Coolant Drain Plug

E n g in e T o p E n d :

Cylinder Head Cover Bolts Water Temperature Sensor Camshaft Cap Bolts Camshaft Sprocket Bolts Cylinder Head Bolts (10 mm) Cylinder Head Bolts (6 mm) Cylinder Head Nuts (8 mm) Cylinder Head Allen Bolt (8 mm) Cylinder Nuts Cylinder Bolt E n g in e R ig h t S id e /L e ft

SS S L S S S S S S

S id e :

Oil Passage plug Clutch Hub Nut Clutch Spring Bolts Clutch Cover Damper Mounting Bolts Shift Drum Cam Allen Bolt Return Spring Pin Primary Gear Nut Magneto Cover Damper Mounting Bolts Magnet Flywheel Bolt Starter Motor Mounting Bolts Starter Clutch Allen Bolts Balancer Inside Chain Guide Bolt (8 mm) Balancer Inside Chain Guide Bolt (6 mm) Balancer Front Right Weight Nut

L L L L

L L L

1 -1 6

GENERAL

IN F O R M A T IO N

F a s te n e r

R e m a rk s

T o rq u e N -m

k g -m

ft-Ib

E n g in e L u b ric a tio n S y s te m : utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Camshaft Cap Bolts 1.2 8.5 12 S 14.5 Oil Pipe Banjo Bolts 20 2.0 Oil Passage Plug 2.3 16.5 23 L 1.5 11.0 Oil Pressure Relief Valve 15 Engine Oil Drain Plug 16.5 23 2.3 L Oil Pump Cover ScrewjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA E n g in e R e m o v a l/ln s ta lla tio n :

Swing Arm Pivot Nut Engine Mounting Nuts Engine Bracket Nuts Cylinder Head Bracket Bolt Cylinder Head Bracket Nuts

98 44 25 25 25

10.0 4.5 2.5 2.5 2.5

72 33 18.0 18.0 18.0

78 93 2.0 - 3.9

8.0 9.5 0.2 - 0.4

58 69 17 - 35 in-lb

9.8 32 -

1.0 3.3 -

7.0 24 -

98 98 93

10.0 10.0 9.5

72 72 69

25 1.5 5.9 8.8 1.3 33 7.8 23 5.9 8.8 17.2 5.9 5.9 23 23 5.9

2.5 0.15 0.6 0.9 0.13 3.3 0.8 2.3 0.6 0.9 1.75 0.6 0.6 2.3 2.3 0.6

18.0 13 in-lb 52 in-lb 78 in-lb 11 in-lb 25 69 in-lb 16.5 52 in-lb 78 in-lb 152 in-lb 52 in-lb 52 in-lb 16.5 16.5 52 in-lb

C ra n k s h a ft/T ra n s m is s io n :

Bearing Holding Plate Mounting Screws (for crankshaft bearings in both crankcase halves and driveshaft bearing and shift drum bearing in right crankcase half)

W h e e ls /T ire s :

Front Axle Nut Rear Axle Nut Spoke Nipples F in a l D riv e :

Engine Sprocket Bolts Rear Sprocket Nuts Rear Coupling Studs Swing Arm Pivot Nut Tie-Rod Upper Mounting Rear Axle Nut

Nut

B ra k e s :

Brake Hose Banjo Bolts Front Reservoir Cap Screws Brake Lever Pivot Locknut Front Master Cylinder Clamp Bolts Front Brake Light Switch Mounting Screw Front Caliper Mounting Bolts Caliper Bleed Valves (Front. Rear) Brake Disc Mounting Bolts (Front, Rear) Brake Disc Cover Bolts (Front. Rear) Brake Pedal Mounting Bolt Brake Pedal Adjuster Locknut Rear Brake Hose Clamp Mounting Screw Rear Reservoir Mounting Bolt Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts Rear Disc Cover Bracket Bolts

1 -1 7 utsrqponm

G E N E R A llN F O R M A T IO N

Fastener N-m Suspension: Front Fork Air Valves 12 Front Top Bolts 29 Front Fork Upper Clamp Bolts 25 Front Fork Lower Clamp Nuts 25 Front Fork Oil Drain Screws 1.5 Front Fork Bottom Allen Bolts 39 Rear Shock Absorber Upper Mounting Bolt 59 Rear Shock Absorber Lower Mounting Nut 98 Swing Arm Pivot Nut 98 Tie- Rod Mounting Nuts (Upper, Lower) 98 Rocker Arm Pivot Nut 98 Steering: Handlebar Clamp Bolts 24 Steering Stem Head Nut 39 Front Fork Upper Clamp Bolts 25 Front Fork Lower Clamp Nuts 25 Steering Stem Locknut Hand- Tighten (about 4.9) Frame: Rear Frame Upper Mounting Bolts 25 Rear Frame Lower Mounting Bolts 25 Electrical System: Front Brake Light Switch Mounting Screw 1.3 Water Temperature Sensor 15 7.4 Fan Switch Spark Plug Magneto Flywheel Bolt Starter Motor Mounting Bolts Neutral Switch

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. AII of the values are for use with dry solvent-cleaned threads.

Remarks

Torque kg-m

ft-Ib

1.2 3.0 2.5 2.5 0.15 4.0 6.0 10.0 10.0 10.0 10.0

8.5 22 18.0 18.0 13 in-lb 29 43 72 72 72 72

2.4 4.0 2.5 2.5 Hand-Tighten (about 0.5)

17.5 29 18.0 18.0 Hand- Tighten (about 43 in-lb

14 195 9.8 15

General

2.5 2.5

18.0 18.0

0.13 1.5 0.75 1.4 20 1.0 1.5

11 in-lb 11.0 65 in-lb 10.0 145 7.0 11.0

LG L

Fasteners

Threads dia.

Torque

(mm)

N-m

kg-m

ft-Ib

3.4 ~ 4.9

0.35 ~ 0.50

30 ~ 43 in-lb

5.9 ~ 7.8

0.60 ~ 0.80

52 ~ 69 in-lb

14 ~ 19

1.4 ~ 1.9

10.0 ~ 13.5

25 ~ 34

2.6 ~ 3.5

19.0 ~ 25

44 ~ 61

4.5 ~ 6.2

33 ~ 45

73 ~ 98

7.4 ~ 10.0

54 ~ 72

115 ~ 155

11.5 ~ 16.0

83 ~ 115

165 ~ 225

17.0 ~ 23.0

225 ~ 325

23 ~ 33

125 ~ 165

165 ~ 240jihgfedcbaZYXWV

1 -1 8

GENERAL

IN F O R M A T IO N A B a c k V ie w

C a b le , W ire , a n d H o s e R o u tin g

B A rro w

速

utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA V ie w jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

速

Clamp turn signal leads. Tie Band Place at headlight back. Clamp with brake hose and left grip harness. 5. Place at main pipe back. 1. 2. 3. 4.

6. Insert and connect into bracket. 7. Speedometer Cable 8. Brake Hose 9. Throttle Cables 10. Clamp 11. Clutch Cable

12. lnsert clamp into head gusset. 13. Clamp on ignition switch mounting boss. 14. Run inside of stay. 15. Fan Lead

16. Fan Ground Lead 17. Fan Switch Lead

G E N E R A llN F O R M A T IO N

1 -1 9

M a in H a rn e s s

e A rro w

1. T o meter Bracket 2. To Headlight 3. To Turn Signal Light 4. To City Light 5. Ground Lead 6. To Diode Assembly 7. To Turn Signal Relay 8. To Horn 9. To CDI Unit 10. To Water Temperature Sensor 11. To Ignition Coil

12. To Magneto 13. To Neutral Switch and Pickup Coil 14. To Fan Relay 15. To Radiator Fan 16. To Fan Switch 17. Main Harness 18. Harness Position Mark 19. Rear Brake Light Switch 20. To Starter Relay 21. To Starter Circuit Relay 22. To Side Stand Switch

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

To Fuses To Battery To Regulator/Rectifier To Rear Harness Tie Band Reservoir Air Vent Hose Magneto Leads Main Harness Ground Lead Horn To Water Temperature Sensor 34. Spark Plug Cap

V ie w utsrqponmlkjihgfedcbaZYXWVUTSRQ

35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47.

Ignition Coil Fuse (for Fan) Main Pipe Radiator Fan Connector Turn Signal Relay Fan Relay CDI Unit 2P Connector Magneto Lead 3P Connector CDI Unit 1 P Connector Magneto Lead 6P Connector CDI Unit 6P Connector CDI Unit Diode Assembly

1 -2 0

GENERAL

IN F O R M A T IO N jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

速

R e a r H a rn e s s utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDC

1. 2. 3. 4. 5. 6.

Main Harness Starter Relay Ground Lead Starter Motor Lead Starter Circuit Relay Side Stand Switch

7. To Fuses 8. T o Battery 9. Battery (+) Lead 10. To Regulator/Rectifier 11. To Rear Harness 12. Battery (-) Lead

13. 14. 15. 16. 17. 18.

Brake Light Switch Lead Rear Brake Light Switch Tie Band Magneto Leads Side Stand Switch Cable Clamp

19. 20. 21. 22. 23. 24.

Fit into groove. Neutral Switch Connector Turn Signal Light Leads Tail/Brake Light Leads Rear Harness License Plate Light Lead

GENERAL

IN F O R M A T IO N

Hoses

11jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

1. Coolant Reservoir Tank 2. Reservoir Air Vent Hose 3. Fuel Tank Breather Hose 4. Crankcase Breather Hose

5. Carburetor Air Vent Hose 6. Carburetor Over Flow Tube 7. Ground Lead 8. Battery Vent Hose

9. Air Cleaner Drain Hose 10. Oil Reservoir

11. Plug

1 -2 1 utsrqponmlkjihgfed

1 -2 2

GENERAL

C o o lin g

IN F O R M A T IO N

H o s e s jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

速

速O速速~ D A rro w V ie w

6 B ra k e H o s e s utsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

1. 2. 3. 4.

Reservoir Hose Water Hose Reservoir Air Vent Hose Radiator

5. 6. 7. 8.

Radiator Hose Water Pump Hose Coolant Reservoir Tank Clutch Cable

9. Exhaust Pipe 10. Tie Band 11. Brake Hose 12. Clamp

13. 14. 15. 16.

Caliper Master Cylinder Reservoir Hose Rear Brake Reservoir

FUEL

SYSTEM

2 -1

F u e l S y s te m

T a b le 0 1 C o n le n ls ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFED

Exploded View

2-2

Specifications Special Tools Throttle Grip and Cables

2-4 2-5 2-6

Free Play Inspection

2-6

Free Play Adjustment

.2-6

Cable Installation Notes

2-6

Cable Lubrication

2-6

Cable Inspection Choke Cable

2-7 2-8

Free Play Inspection

2-8

Adjustment

2-8

Installation Notes

2-8

Lubrication

2-8

Inspection

2-8

Carburetor Idle Speed Inspection

2-9 .2-9

Idle Speed Adjustment

2-9

Service Fuel Level Inspection

2 -10

Service Fuel Level Adjustment

2-1 O

Fuel System Cleanliness Inspection

2-11

Removal

2-11

Installation Notes DisassemblyjAssembly

2-12 2-12

Notes

Cleaning

2-13

Inspection

2-13

Air Cleaner

2-14

Housing Removal

2-14

Housing Installation Notes Element Removal

2-15 2-15

Element Installation Notes

2-15

Element Cleaning and Inspection

2-15

Oil Draining

.2-16

Fuel Tank Removal

2-17 2-17

Installation Notes

.2-17

Inspection Cleaning

2-17 2-18

Fuel Tap Removal

2-18

Fuel Tap Installation Notes

2-18

Fuel Tap Inspection

2-18

2-2

FUEL SYSTEM

Exploded View ZYXWVUTSRQPONMLKJIHGFEDCBA

Q ยง

m ~

W -o

-o

1 . J e t N e e d le 2 . P ilo t S c re w 3 . P ilo t J e t 4 . N e e d le J e t 5 . N e e d le J e t H o ld e r 6 . M a in J e t O

: A p p ly o il.

: A p p ly g re a s e .

A D : A p p ly a d h e s iv e c e m e n to

FUEL

SYSTEM

2 ponmlkjihgfed -3 ZYXWV

2 -4

FUEL SYSTEM

S p e c ific a tio n s

It e m T h r o t t le

K L 6 5 0 -B 1

G r ip F r e e P la y ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 2 - 3mm

C h o k e C a b le F r e e P la y

2 -

Id le S p e e d

1 300 ± 50 r/rnin (rpm)

C a rb u re to r

3mm

K L 5 0 0 -B 1 ~--~--~---

S p e c if ic a t io n s :

Make/type

~ --Keihin/CVK40 ZYXWVUTSRQPONMLKJIHGFEDCBA

Main jet

#145, (S) #148

#148

Main air jet

#50

~---

Needle jet

#6 N74C, (S) N60N

~---

#40

~---

#70 1 % , (S) 1 % (turns out)

1 % (turns out)

Jet needle Pilot jet Pilot air jet Pilot screw Starter jet

N54G ~---

#52 0.5 ± 1 mm

~---

17.5 mm

~---

Grade

SE class

~---

Viscosity

SAE 30

~---

Service fuel level

~---

(above the bottom edge of the carburetor body) Float height A ir C le a n e r :

Air cleaner element oil:

(S) : Swiss Model

c.... Q)

::9.

'TI

o KJIHGFEDCBA ;¡::-

[

6t ::s ~

0'1

8...•,

..• o

~ EDCBA l>

.E : e

...•

(1)

0'1

8...•, ...•

i G> Q)

c: te !11

!ª

0'1

...•,

9 ...,¡

...'"O

~ ZYXWVUTSRQPONMLKJ

..•

c: (1)

o Q)

C'"

C'" (1)

§" (1)

e m

-i m

s: N I

(1'1

2-6

FUEL SYSTEM eTurn

Throttle

Grip and Cables KJIHGFEDCBA

the adjusting

nut

until

the

proper amount

throttle grip free play is obtained.

F r e e P la y In s p e c tio n eCheck the throttle grip free play.

A. Locknut

C. Accelerator Cable

B. Adjusting Nut A. Throtfle Grip Free Play eTighten Throttle Grip Free Play Standard: *If

2 -

the locknut securely.

* If the proper amount of free play can not be obtained in 3 mm

the free play is incorrect, adjust the throttle cable.

the adjustable range of the adjusting nut, use the adjuster screwed fully at the upper end of the accelerator cable again.

F r e e P la y Ad ju s tm e n t e Loosen the lockn ut. eTurn the adjuster until the proper amount of throttle grip free play can be obtained.

C a b le In s ta lla tio n N o te s elnstall

the throttle cables in accordance with the Cable

Routing section in the General Information chapter. elnstall

the lower ends of the throttle cable in the cable

bracket on the carburetor after installing the upper ends of the throttle cable in the grip. e After the installation, adjust each cable properly.

I WARNING' o O peration

with

incorrectly

routed or im proper adjusted

cables could result in an unsafe riding condition.

A. Locknut

B. Adjuster

C a b le L u b r ic a tio n eTighten the locknut securely. * If the proper amount of free play can not be obtained by using the adjuster only, use the adjusting nut at the lower part of the accelerator cable, too.

W henever the cable is removed, and in accordance with the Periodic Maintenance Chart (see General Informatian chapter), do the follawing. eApplya

thin coating of grease to the cable upper end. ZYXWVUTSRQPONMLKJIHGFEDCBA

e Loosen the locknut, and screw the adjuster in fully at the upper end of the accelerator cable. eTighten the locknut securely. e Remove the fuel tank (see Fuel Tank Removal). e Loosen the locknut at the lower part of the accelerator cable.

FUEl

If cable movement is not free after lubricating, ble is frayed, or if the housing ble.

1. Apply grease .

â&#x20AC;˘ Lubricate the cable with a penetrating rust inhibitor through the Pressure Cable Luber (special tool).

1. Cable 2. Pressure Cable Luber: K56019-021

Cable InspectĂon .With the throttle cable disconnected cable should move freely within

1. Cable

at both ends, the

the cable housing.

SYSTEM

2 - 7 ponmlkjihgf

if the ca-

is kinked, replace the ca-

2-8

FUEl SYSTEM L u b r íc a tío n

Choke Cable KJIHGFEDCBA

W henever

the

choke

cable

removed,

lubricate

the

choke cable as follows. eAfter

F r e e P la y In s p e c tío n eCheck

that the choke

inner cable slides smoothly

a thin coating of grease to the cable upper end.

moving the choke lever to the front and rear.

* If there is any irregularity,

check the choke cable play. e Push the choke lever all the way to the front. e Determine the amount of choke cable play at the adjuster of the choke cable. Pull out and push in the outer cable; the amount of cable travel is the amount of choke cable free play.

1 . Apply grease.

e Lubricate

the cable with

through the Pressure Cable A. Choke Cable

C. Adjuster

B. Locknut

D. Free Play

a penetrating

rust inhibitor

Luber (special tool).

* If the free play is not correct, adjust the choke cable. Choke Cable Free Play

2'"

3m m

Ad ju s tm e n t e Loosen the locknut, and turn the adjuster until the cable has the proper amount of free play. eTighten

the locknut securely.

In s ta lla tío n N o te s elnstall

the choke cable in accordance

with

Routing section in the General Information eAfter

the Cable

chapter.

1. Cable 2. Pressure Cable Luber: K56019-021

In s p e c tío n eW ith

installation, adjust the cable properly.

I WARNING RQPONMLKJIHGFEDCBA I O O peration

with

incorrectly

routed

or im properly

the choke cable disconnected

at the both ends,

the cable should move freely within the cable housing.

ad-

justed cable could result in an unsafe riding condition.

FUEL SYSTEM

2-9

Carburetor KJIHGFEDCBA

Id le Sp e e d

In s p e c tio n

eStart the engine and warm it up thoroughly. eW ith *If

the engine idling, turn the handlebar to both sides.

handlebar movement

changes the idle speed, the

throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged.

Be sure to correct any

of these conditions before riding (see Cable Routing in the General Information chapter).

CD ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

I o O peration

WARNING RQPONMLKJIHGFEDCBA

1 Choke Cable

with im properly adjusted, incorrectly

or a dam aged cable could result condition.

* If cable movement is not free after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable.

routed,

in an unsafe riding

e Check idle speed. *If

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

Id le Speed 1 300

Âą

5 0 r/m in (rpm )

Id le Sp e e d Ad ju s tm e n t eStart the engine and warm it up thoroughly. eTurn the adjusting screw until the idle speed is correct.

A. Id le Adjusting Screw

eOpen

and close the throttle a few times to make sure

that the idle speed is within the specified range. Readjust if necessary.

2 - 1 0 RQPONMLKJIHGFEDCBA F U E L S Y S T E M KJIHGFEDCBA Se r víc e

NOTE EDCBA

F u e ! L e v e ! ! n s p e c t í o n ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA ODo

I o G asoline

is extrem ely

WARNING flam m able

under certain conditions. Do not sm oke. and free from

n o t / o w e r t h e " z e r o " / in e b e / o w

th e c a rb u re to r b o d y .

r a is e d a g a in , t h e f u e / / e v e /

m e a s u re d s h o w s

h ig h e r t h a n t h e a c t u a l f u e / le v e / o to a

and can be explosive

te r. d u m p

edge of a n d th e n

som ew hat

I f t h e g a u g e is / o w e r e d

t h e f u e / o u t o f it in t o

a n d s ta rt th e p ro c e d u re

Turn the ignition switch O FF.

th e b o tto m

I f t h e g a u g e is / o w e r e d

s u it a b / e

c o n t a in e r

o v e r a g a in .

M ake sure the area is well-ventilated any source of flam e or sparks; this

eludes any appliance with

in-

a pilot light.

• Remove the carburetor, and hold them stand (see Carburetor Removal).

upright

on a

If the fuel level is incorrect, adjust it (see Service Fuel Level Adjustment).

• Prepare an auxiliary fuel tank and connect the fuel hose to the carburetor. • Prepare a fuel hose (6 mm in diameter and about 300 mm long). • Connect a fuel level gauge (special carburetor float bowl with the fuel hose.

• Read the fuel level in the gauge compare it to the specification. Screw in the carburetor drain plug . • Stop feeding and remove the fuellevel gauge.

tool)

Service Fuel Level (above the bottom

edge of the carburetor

body)

0.5 ± 1 m m

the

• Hold the gauge vertically against the side of the carburetor body so that the "zero" line is several millimeters higher than the bottom

edge of the carburetor Se r víc e

body.

F u e ! L e ve ! Ad ju s tm e n t

• Feed fuel to the cárbu retor, then tu rn out the carbu retor drain plug a few turns. .W ait until the fuellevel in the gauge settles. • Keeping the gauge vertical, slowly lower the gauge until the "zero" line is even with the bottom edge of the carburetor body.

I o G asoline

WARNING

is extrem ely flam m able

under certain conditions. Do not sm oke. and free from

and can be explosive

Turn the ignition switch O FF.

M ake sure the area is well ventilated any source of flam e or sparks; this in-

eludes any appliance with a pilot light.

• Remove the carburetor, and drain the fuel into a suitable container. • Remove the float bowl. • Drive out the pivot pin and remove the float.

A. Pivot Pin

1. Fuel Level Gauge: 57001 -1017 2. Carburetor Body Bottom 3. Zero Line

Edge

B. Drive out the pino

• Bend the tang on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

4. Fuel Level 5. Drain plug Float Height 1 7 .5 m m

FUEL

SYSTEM

e Put the lower end of the overflow bowl into a suitable container.

2 -1 1

tube from the float

eTurn out the drain screw a few turns to drain some fuel from the carburetor, and check for water or dirt in the fue!.

A. Tang

A. Drain Screw

* If any water

or dirt comes out, clean the carburetor, fuel tap and fuel tank (see Fuel Tank).

eTighten the drain screw securely, and turn the fuel tap to the OFF position.

R em o va/

1 . Float Bowl Mating Surface 2. Float Valve Needle Rod 3. Float

4. Float Height RQPONMLKJIHGFEDCBA

o G asoline

is extrem ely flam m able

under certain conditions.

NOTE

Do not sm oke.

o EDCBA D o not push

t h e n e e d le r o d in

d u r in g

t h e f lo a t h e ig h t

eAssemble

and free from

I and can be explosive

Turn the ignition switch O FF.

M ake sure the area is well ventilated any source of flam e or sparks; this in-

eludes any appliance with a pilot light.

m e a s u re m e n t.

W A R N IN G

the carburetor, and recheck the fuel leve!.

e Remove the fuel tank (see Fuel Tank Removal).

If the fuel level can not be adj usted by th is method, the float or the float valve is damaged.

e Run the overflow

tube into a suitable container.

e Drain the fuel from the carburetor drain screw a few turns.

by turning

out the

e Remove the throttle cable lower ends. e Loosen the clamps, and remove the carburetor from the end of the air cleaner duct to the right side, and then F u e / S y s te m

C / e a n / in e s s

pull it out of the carburetor

/ n s p e c t io n

fuel tap vacuum attached.

I W A R N IN G I o G asoline

is extrem ely

flam m able

under certain conditions. Do not sm oke.

and can be explosive

Turn the ignition switch O FF.

M ake sure the area is well-ventilated

and free from any source of flam e or sparks; this eludes any appliance with a pilot light.

in-

holder with

hose, overflow

the fuel hose,

tube and air vent hose

2 -1 2

FUEL

S Y S T E M ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA In s ta //a tĂo n

eW hen

N o te s

installing

the

carburetor

into

the

carburetor

holder, fit the ridge into the notch.

A. Throttle Cables

eUnscrew

B. Clamp

the guide holder at the choke cable lower end,

and pull out the starter plunger assembly.

A. Ridge

B. Notch

e Route the air vent hose and overflow

tube through

the

rubber clamp on the breather hose (see Hose Routing in the General Information

o Always

chapter).

keep the tubes free of obstruction,

and m ake

sure they do not get pinched by the chain or shock absorber.

eAdjust: Throttle Grip Free Play Choke Cable Free Play Idle Speed A. Guide Holder

B. Starter Plunger

D Ăs a s s e m b /y / A s s e m b /y

o If

N o te s

I W A R N IN G '

the starter plunger is not rem oved from the the cable,

wrap it in a elean eloth to avoid dam age.

G asoline is extrem ely flam m able and can be explosive under certain conditions.

e Pull the hoses and tube off the carburetor.

Do not sm oke.

eAfter

and free from

removing the carburetor, stuff pieces of lint- free,

clean cloth into the carburetor holder and the air cleaner

Turn the ignition switch O FF.

M ake sure the area is well ventilated any source of flam e or sparks; this in-

eludes any appliance with a pilot light.

duct to keep dirt out of the engine and air cleaner.

I o If

dirt

W A R N IN G

or dust is allowed

carburetor, the throttle

I pass through

m ay becom e stuck,

o During

carburetor disassem bly, be careful not to dam -

age the diaphragm . into

the

Never use a sharp edge to rem ove

the diaphragm .

possibly

eTurn in the pilot screw and count the number of turns causinq an acciderit. ZYXWVUTSRQPONMLKJIHGFEDCBA until it seats fully but not tightly,

.- /

.-~

/../

screw.

and then remove the

This is to set the screw to its original position

when assembling. eTurn in the pilot screw fully but not tightly,

o If

dirt gets through

into the engine, excessive engine

wear and possibly engine dam age will occur. EDCBA

and then

back it out the same number of turns counted disassembly.

during

FUEL SYSTEM eTurn

the carburetor

body upside down,

2 -1 3

and drop the

needle jet into place so that the smaller diameter end of the jet goes in first.

o Do

not use com pressed air on an assem bled carburetor.

or the floats

m ay be crushed by the pressure and the

vacuum piston diaphragm s m ay be dam aged. O Rem ove as m any carburetor with

rubber

a cleaning solution.

deterioration

ution

plastic

parts

from

the

This will

prevent dam age or

of the parts.

O The carburetor rem oved.

as possible before cleaning the carburetor

body has plastic

parts that

Do not use a strong carburetor

which

could

attack

cannot be

cleaning sol-

these parts; instead. use a

m i Id high flash point cleaning solution parts.

safe for plastic

O Do not use wire or any other hard instrum ent to clean carburetor

parts. especially [ets, as they m ay be dam -

aged.

e Disassemble the carburetor. elmmerse 1. Needle Jet

all the metal parts in a carburetor cleaning sol-

ution. e Rinse the parts in water.

2. Smaller Diameter End

eW hen

the parts are clean, dry them with compressed air.

e Blow through pressed air. eAssemble

the air and fuel passages with

com-

the carburetor.

Do not force the needle jet holder (air bleed pipe) and m ain jet of overtighten requiring replacem ent.

them . They could be dam aged

In s p e c tĂo n

W A R N IN G

O G asoline is extrem ely

flam m able and can be explosive

under certain conditions. Do not sm oke. and free from

Turn the ignition switch O FF.

M ake sure the area is well ventilated any source of flam e or sparks; this in-

eludes any appliance with a pilot light.

1. Main Jet EDCBA

2. Needle Jet Holder eTurn

the throttle

butterfly tension.

cable pulley to check that the throttle

valve moves smoothly

and return

* If the throttle valve does not move smoothly, carburetor. eCheck

*If

IRQPONMLKJIHGFEDCBA W A R N IN G I o Clean

carburetors

in a well-ventilated

area, and

take care that there is no spark or flam e anywhere near the working pilot light.

area; this

includes any appliance with

piston are in good are not in good

the plastic tip of the float valve needle.

be smooth, without the

on the vacuum

any of the O-rings or diaphragms condition, replace them.

eCheck

replace the

that the O-rings on the float bowl and drain plug

and the diaphragm condition.

C le a n Ă n g

by spring

Because of the danger of highly flam m able

liquids. do not use gasoline or low flash point solvents to clean the carburetors.

It should

any grooves, scratches, or tears.

2 -1 4

FUEl

S Y S T E M ZYXWVUTSRQPONMLKJIHGFEDCBA

A ir C le a n e r KJIHGFEDCBA

H o u s in g R e m o va / • Remove the lower tairing, and set the jack stand (special tool:

57001 -1238)

under the trame .

• Remove: - + - - - - 1 2 ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Upper Fairing Seat Covers Seat FuelTank Muffler Fuse Box

Push and release

Battery 1. Rod 2. Valve Needle

3. Valve Needle W ear

Main Harness Connectors and Clamp

* It the plastic tip is damaged, replace the needle . • Check the tapered portion or damage.

of the pilot screw tor wear

A. Fuse Box B. Battery Cover Screw

C. Connectors D. Clamp

• Pull the air cleaner duct out of the carburetor. 1. Pilot Screw

2. Tapered Portion

• Pull the engine breather hose upper end off the housing. • Pull the drain hose off the housing.

*It

the pilot screw is worn or damaged on the tapered portion, it will prevent the engine trom idling smoothly. Replace it.

A. Engine Breather Hose Upper End B. Drain Hose C. Rear Frame Mounting

Bolts

• Remove the rear trame mounting rear trame assembly.

bolts, and take off the

• Remove the mounting boss and mounting bolt, and take the housing out of the rear frame assembly.

FUEl E le m e n t

.Coat

In s ta lla tio n

SYSTEM

2 -1 5

N o te s

the element lip with a layer of all purpose grease

to assure a complete seal against the cleaner case . • Be sure the foam gasket is in place in the groove in the element cap.

A. Mounting

Boss

C. Air Cleaner Housing

B. Mounting

Bolt

D. Rear Frame Assembly KJIHGFEDCBA

A. Foam Gasket

H o u s in g

In s ta lla tio n

N o te s

• Route harness/lead and hose/tu be in accordance with the W ire/Hose Routing in the General Information chapter. .Tighten the following to the specified torque ploded View in the Frame chapter). Rear Frame Upper Mounting

Bolts

Rear Frame Lower Mounting

Bolts

(see Ex-

E le m e n t

C le a n in g

a n d In s p e c tio n

NOTE

o In

d u s tya r e a s ,

t h e e l e m e n t s h o u l d h e e l e a n e d m o r e fr e -

q u e n tly th a n th e r e e o m m e n d e d O A ft e r

r id in g th r o u g h

m e n t s h o u ld

R e m o va l

c le a n in g o p e n s th e p a r e s o f th e e le m e n t,

r e p la e e it w ith a n e w

• Remove the right side cover. .Take off the air cleaner element cap.

o d ie M a in te n a n e e e le m e n t

r o a d s , th e e le -

b e c l e a n e d i m m e d i a t e l y . ZYXWVUTSRQPONMLKJIH

O Sin e e r e p e a te d

E le m e n t

in te r va l.

r a in o r o n m u d d y

o n e in a e e o r d a n e e

m a te r ia l o r a n y o th e r d a m a g e

r e p la e e th e e le m e n t

w ith th e P e r i-

C h a r t. Als o , if th e r e is a b r e a k in th e w ith a n e w

to th e

e le m e n t,

one.

I W A R N IN G I O Clean the elem ent

in a well-ventilated

area, and take

am ple care that there are no sparks or flam e anywhere near the working area. O Because of the danger of highly flam m able

liquids, do

not use gasoline or a low flash point solvent to clean the elem ent .

• Remove the air cleaner element, and separate the element from the element frame. A. Element Cap

C. W ing

Head Bolt

B. Element

• Remove the wing head bolt and take off the air cleaner element. RQPONMLKJIHGFEDCBA

2 -1 6

FUEL

S Y S T E M ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

I W A R N IN G I o Be sure

to install the plug in the drain hose after drain-

ing. O il on tires will m ake them slippery and can cause an accident and injury.

A. Filter

.Clean

B. Frame

the element in a bath of a high flash-point

sol-

vent, and then dry it with compressed air or by shaking it. .Check

all the parts of the element for visible damage.

* If any of the parts of the element are damaged, replace them . â&#x20AC;˘ After cleaning, saturate the sponge filter with

SE class

3 0 oil, squeeze out the excess, then wrap it in a SAE ZYXWVUTSRQPONMLKJIHGFEDCBA

clean rag and squeeze it dry as possible. to tear the sponge filter. .Assemble

Be careful not

the element, and install it. EDCBA

O il D r a in in g A drain hose is connected

to the bottom

cleaner housing to drain oil accumulated the housing . â&#x20AC;˘ Visually check the translucent

catch-tank

of the drain hose if the oil accumulates *If

of the air

at the bottom

at the middle

in the reservo ir.

any oil accumulates in the catch-tank, drain it by taking off the plug at the lower end of the drain hose.

A. Plug B. Catch- Tank

C. Drain Hose

FUEl

SYSTEM

2 -1 7

F u e lT a n k KJIHGFEDCBA

R e m o v a l ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA e Remove : Side Covers Seat eTurn the fuel tap to the OFF position. e Pull the fuel hose and the fuel tap vacuum

hose off the

fuel tapo e Pull the breather hose off the fuel tank.

I W A R N IN G I o G asoline

is extrem ely

flam m able

under certain conditions. O FF.

not

well-ventilated

sm oke.

A. Rubber Dampers and can be explosive

Turn the engine stop switch M ake

and free from

sure

the

area

any source of flam e or

sparks; this includes any appliance with a pilot light.

e Remove the upper fairing the upper.fairing mounting

If the dampers

are damaged

or deteriorated,

replace

them. e Be sure the fuel hose is c1amped to the fuel tap to prevent leak.

mounting screws, and pull bosses off the fuel tank.

e Remove the fuel tank mounting bolts. and take off the tank. ZYXWVUTSRQPONMLKJIHGFEDCBA

In s p e c tio n eVisually

* A

inspect

the gasket on the tank cap for any

damage.

Replace the gasket if it is damaged. eRemove the hose(s) from the fuel tank, and open the tank cap. eCheck

* *

to see if the breather and water drain pipes in the

tank are not clogged.

Check the tank cap breather too.

If the tank pipes are c1ogged, remove the tank and drain it and then blow the pipes free with compressed air. If the tank cap breather is c1ogged, replace it.

~ A. Breather Hose

C. Mounting

Bosses

B. Mounting

D. Mounting

Bolts

Screws

o Do

not apply com pressed air to the air vent holes on the

tank cap. This could cause dam age and clogging of the labyrinth

In s ta lla tio n

in the cap.

N o te s

e Check the rubber dampers.

A. Air Vent Holes

, '1

2 -1 8

F U E L S Y S T E M KJIHGFEDCBA

C ! e a n i n g ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA e Remove the fuel tank and drain it. e Pour some high flash point solvent into the

fuel tank

and shake the tank to remove dirt and fuel deposits.

I W A R N .lN G I o Clean the that

tank in a well-ventilated

there

working

is no spark or flam e

area.

Because of

the

area, and take care anywhere danger

near the of

highly

flam m able liquids, do not use gasoline or low point solvents to clean the tank.

flash

e Pour the solvent out of the tank. e Remove the fuel tap from the tank by taking

out the

bolts with nylon washers. eClean the fuel tap filter screens in a high flash-point solvent. e Pour high flash-point positions.

solvent through the tap in alllever

e Dry the tank and tap with compressed air. elnstall

the tap in the tank.

elnstall

the fuel tank.

1. O-ring

3. Gasket

2. Filter Screens

4. Nylon W asher

* F u e ! T a p R e m o va ! e Remove the fuel tank and

drain it.

e Remove the bolts with nylon flat washers and take out the fuel tapo

e Be sure the O-ring is in good condition

to prevent leaks.

e Be sure to clamp the fuel hose to the tap to prevent leaks. washers

are in good

condition

O Do not use steel washers in place of the nylon washers, because they will willleak.

If the fuel tap leaks, or allows fuel to flow when it is at ON or RES position without engine running, replace the damaged gasket or O-ring. If the fuel tap leaks, or allows fuel to flow when it is at OFF position with or without engine running, replace the damaged gasket or O-ring.

F u e ! T a p !n s ta lla tio n N o te s

e Be sure the nylon prevent leaks.

If the fuel tap screens have any breaks or are deteriorated, it may allow dirt to reach the carburetor, causing poor running. Replace the ZYXWVUTSRQPONMLKJIHGFEDCBA fu e l tapo

not seal the bolts properly

and fuel

F u e ! T a p !n s p e c tio n e Remove the fuel tapo eCheck the fuel tap filter screens for any breaks or deterioration.

C O O llN G

SYSTEM

3 -1

C o o lin g S y s te m T a b le

o f C o n te n ts lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View

3-2

Specifications

3-3

Removal

Special Tool

3-3

Installation

Sealant

3-3

Radiator Inspection

3-12

Cooling System

3-4

Cap Inspection

3-13

Coolant

3-5

Filler Neck Inspection

3-13

Inspection

3-5

Radiator Hose, Water Hose,

Change

3-5

Air Bleeding

3- 7

Visual Leak Inspection

3- 7

Cooling System Pressure Testing

3-7

Cooling System Flushing

3-8

Radiator, Radiator Fan Notes

Air Vent Hose Inspection Reservoir Tank Hose, Air Vent Hose Installation Removal

3-9

Installation

3-9

Inspection

3-9

Thermostatic

3-9

Water Temperature Sensor

Impeller Installation

Notes

Impeller Assembly Notes

3-13 3-14

3-9

Impeller Removal

Notes

Thermostat..

Water Pump Notes

3-13

Radiator Hose, Water Hose,

3-8

Cover Installation

3-12

Reservoir Tank Hose,

Disassembly and Assembly Precautions Cover Removal

3-11 3-11

3-14 Note

3-14 3-15

Fan Switch, 3-15

3-9

Thermostatic

Fan Switch

Removal

3-15

Impeller Inspection

3-10

Thermostatic

Fan Switch

Installation Note

3-15

Mechanical

Seal, Gil Seal Removal

3-10

Thermostatic

Fan Switch

Inspection

Mechanical

Seal, Gil Seal

Installation Mechanical

Notes Seal Inspection

Hose Inspection

Water Temperature Sensor Removal. 3-1 O 3-11 3-11

3-15 3-15

Water Temperature Sensor Installation

Notes

Water Temperature Serisor Inspection

3-16 3-16

3-2

COOLlNG

SYSTEM

Exploded View

Mark (white) ZYXWVUTSRQP '- - - - - - ~ ~ @Âť

Mark (white)

1 . F a n S w itc h 2 . W a t~ r T e m p e r a tu r e

S ensor

@ I ~

3 . T h e r m o s ta t 4 . C o o la n t D r a in P lu g S S : A p p ly s ilic o n e s e a la n t ( K a w a s a k i B o n d : 5 6 0 1 9 -1 2 0 )

to th e th r e a d s .

T 1 : 7 .4 N - m ( 0 .7 5 k q - m , 6 5 in - lb ) T 2 : 1 5 N - m ( 1 .5 k q - m , 1 1 .0 f t- lb )

T 3 : 9 .8 N - m ( 1 .0 k g - m , 7 .0 f t- lb )

~ ;5 '

COOllNGONMLKJIHGFEDCBA S Y S T E M ZYXWVUTSRQP 3 -3 S p e c ific a tio n s lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Items Coolant: Type

Standard

Permanent type of antifreeze for aluminum

Color Mixed ratio

engines and radiators Green Soft water 50%, coolant 50%

Freezing point Total amount

1.3 L (reservoir tank full level)

-35°C

(-31°F)

Radiator: Cap relief pressure

93 -

123 kPa (0.95 -

1.25 kq/crn". 14 -

18 psi)

Thermostat: Valve opening temperature

69.5 -

72.5°C (157 _ 162°F)

Valve full opening lift

Not less than 3mm @ 85°C (185°F)

S p e c ia l T o o l

S e a la n t

Bearing Driver Set: 5 7 0 0 1 - 1 1 2 9

Kawasaki Bond (Silicone Sealant): 5 6 0 1 9 - 1 2 0

3 -4

C O O L lN G

SYSTEM

S y s te m lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

C o o lin g

o ZYXWVUTSRQPONMLKJIHGFEDCBA C o ld

••

H ot

R a d ia to r

W a te r

5. To 6.

C ap

R e s e r v o ir

Pum p

C y lin d e r

F ro m

T ank

Jacket

C y lin d e r

H ead

7 . T h e r m o s ta t 8.

T h ro u g h

T h e r m o s ta t

A ir

T h ro u g h

T h e r m o s ta t

V a lv e

B le e d e r

H o le

C O O L lN G

* If the

amount

of coolant

3-5

SYSTEM

is insufficient,

add coolant

C o o la n t lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA through the filler opening to the FULL mark.

Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change

the

coolant

Maintenance

in accordance

with

the

Chart (see the Generallnformation

Periodic O For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and chapter).MLKJIHGFEDCBA degrades coolant

its

anticorrosion

emergency, soft water

The

O If coolant

Deterioration:

can be added.

must be added often,

has run completely

inspect the coolant in the reservoir tank.

cooling system.

diluted

engine parts.

In an

But the diluted

coolant must be returned to the correct within a few days.

/n s p e c tio n .Visually

properties.

can attack the aluminum

mixture

ratio

or the reservoir tank

dry, there is probably leakage in the

Check the system for leaks (see Visual

Leak Inspection, and Cooling System Pressure Testing).

NOTE o Be

s u r e to in s p e c t

th e c o o la n t a t th e r e s e r vo ir ta n k.

th e c o o la n t is c h e c ke d

a t th e r a d ia to r b y r e m o vin g

r a d i a t o r c a p , t h e a i r m u s t b e b l e d fo r m t h e c o o l i n g

If th e

sys-

te m o

C hange The coolant should

be changed periodically

to ensure

long engine life.

o If whitish

cotton-like

wafts

are observed,

parts in the cooling system are corroded.

aluminum

If the coolant

is brown, iron or steel parts are rusting. In either case, Draining: flush the cooling system.ZYXWVUTSRQPONMLKJIHGFEDCBA O

If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas

WARNING

leaking into the cooling system. OTo avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot.

W ait

until it cools down. O Coolant on tires will

.Situate the motorcycle ground. .Check

make them slippery and can cause

an accident and injury.

Level: so that it is perpendicular

to the

that

the level through

the coolant level gauge on the

NOTE

other painted parts.

th e e n g in e

is c o ld

(r o o m

or am-

for drinking.

• Remove the lower fairing . • Place a container under the water pump . • Drain the coolant from the radiator and engine by removing the drain plug at the bottom of the water pump.

b ie n t te m p e r a tu r e ). O D o not check

m o vin g

th e le ve l th r o u g h

th e c a p .

Immediately wipe up or wash spills on the frame, engine or

O Since coolant is harmful to the human body. do not use

reservo ir tank. The coolant level should be between the FULL and LOW marks.

O C h e c k th e le ve l w h e n

away any coolant

NOTE

t h e r a d i a t o r fi l l e r b y r e -

If th e c a p is r e m o ve d , a ir m a y g e t in to

th e c o o la n t, a n d lo w e r th e c o o lin g

e ffi c i e n c y .

O P o s itio n

th e m o to r c yc /e

u p r ig h t s o th a t th e c o o la n t m a y

b e d r a in e d e a s ily.

t A. FULL Mark

B. LOW Mark

A. Water Pump

B. Drain Plug

3-6

COOLlNG

SYSTEM O If hard water

• Remove the radiator cap for fast draining.

cumulation

is used in the system, it causes scales ac-

in the water passages, and considerably

duces the efficiency

re-

of the cooling system.

NOTE OA R e

v e

t h e

r a d ia t o r

c o u n t e r c / o c k w f e w

is e

s e c o n d s .

d ir e c t io n

T h e n

a n d

r e m

c a p

t o

t h e p u s h

v e

t h e

t w

f ir s t a n d

s t e p s .

s t o p t u r n

a n d it

F ir s t w

t u r n

a it

f u r t h e r

t h e

t h e r e in

t h e

c a p f o r

s a m

NOTE ZYXWVUTSRQPONMLKJIHGFEDCBA O

c a p .

h o o s e

c o o la n t

a m

s u it a b le

ix t u r e

u n u f a c t u r e r '

r a t io

b y

r e f e r r in g

t o

t h e

d ir e c t io n s .

Coolant Provided W hen Shipping Type

Permanent

type

aluminum

antifreeze

engines

and

for radi-

ators Color

Green

Mixed ratio

Soft water 50% , coolant 50%

Freezing point

-35°C (-31°F)

Total amount

1.3L (reservoir tank full level)

A. Radiator Cap

.Install

• Remove the reservoir tank cover. • Pull off the air vent hose and remove the mounting bolts from the reservoir tank, and take out the tank with the reservoir tank hose attached.

the drain plug.

Always replace the gasket with a

new one, if it is damaged . • Tighten the drain plug to the specified torque (see Exploded View). .Install the lower fairing . • Fill the radiator up to the bottom

of the radiator filler

neck with coolant. and install the cap turning

it clock-

wise about 1/4 turno

NOTE O

P o u r

f r a m

t h e

T h e

c o o la n t

e n g in e

r a d ia t o r

t u r n d o w

t h e

t h e n

o n

c a p

c a p it

s lo w

a n d m

u s t

c / o c k w

a n d

t u r n

s o

t h a t

c a n

e x p e l

t h e

a ir

r a d ia t o r . b e

is e it

t h e

t o

in s t a lle d t h e r e s t

f ir s t o f

t h e

s t e p s .

s t o p .

t w

T h e n

F ir s t p u s h

a y .

A. Mounting

Bolts

B. Reservoir Tank

• Unscrew the cap and pour the coolant into a container . • Inspect the old coolant for visual evidence of corrosion and abnormal smell (see Coolant Deterioration).

Filling:

1. Reservoir Tank Hose

o Use

coolant

cifically

containing

for aluminum

corrosion

ance with the manufacturer's O Soft or distilled

inhibitors

engines and radiators

made spein accord-

instructions.

water must be used with the antifreeze

in the cooling system.

2. Coolant Level

.Install the reservoir tank cover. • Fill the reservoir tank up to the FU LL mark with coolant, and install the cap.

C O O L lN G A i r B l e e d i n g lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA C o o lin g

Before putting trapped lows.

the motorcycle

in the cooling

into operation,

S ys te m

P r essur e

SYSTEM

3 -7

Te s tin g

any air

system must be removed as fol-

e Remove the radiator cap. e Fill the

radiator

the

radiator

filler

neck

with

coolant, and install the radiator cap. eCheck

The maximum pressure

.18 psi). is 123 kPa (1.25 kgfcm 2ZYXWVUTSRQPONMLKJIHGFEDC

and then stop

eCheck the coolant level in the reservoir tank after the engine cools down. *If

During pressure testing, do not exceed the pressure for which the system is desiqned.

the cooling system for leaks.

eStart the engine, warm it up thoroughly, it.

e Remove the radiator cap, and install a cooling pressure tester on the radiator filler neck.

system

the coolant level is low, add coolant up to the Full mark through the reservoir tank opening. NOTE

oA W

e t

th e

c o o la n t

Vis u a l L e a k In s p e c tío n

Any time the system slowly

a d a p te r to

p r e v e n t

c a p

s e a fín g

p r e s s u r e

s u r fa c e s

íth

a te r

o r

fe a k s .

e Build up pressure in the system carefully until the presloses coolant,

inspect for

leaks. eVisually check the water pump drainage outlet passage for coolant leaks.

sure reaches 123 kPa (1.25 kq/crn", 18 psi). eWatch the gauge for at least 6 seconds. If the pressure holds steady, the cooling system is all right.

* If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Replace the mechanical seal as a unit with a new one.

OW henever the mechanical seal is replaced. the oil seal and the ball bearing must be replaced with new ones too.

*If

there are no apparent leaks, pressure test the cooling system.

A. Pressure Tester

B. Adapter

e Remove the pressure tester, replenish the coolant, and install the radiator cap. * If the pressure drops and no external source is found, check for internalleaks. for leaks.

A. Drainage Outlet Passage : at the bottom of water pump ONMLKJIHGFEDCBA

Check the cylinder head gasket

3 -8

S Y S T E M MLKJIHGFEDCBA

C O O L lN G

C o o lin g S ys te m

F l u s h i n g lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA D is a s s e m b ly a n d A s s e m b ly

Over a period of time, the cooling system accumulates

rust, seale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system.

If this accumulation

is not removed,

it will clog up the water passage and considerably reduce the efficiency of the cooling system. e Fill the cooling system with fresh water mixed with a flushing compound.

Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator. the instructions supplied cleaning producto

eWarm

b y the

Carefully follow

manufacturer

of the

up the engine, and run it at normal operating

temperature for about ten minutes. eStop the engine, and drain the cooling system. e Fill the system with fresh water. eWarm up the enqine and drain the system. e Repeat the previous two steps once more. e Fill the system with

e Prior to disassembly of cooling system parts (radiator, pump, sensors. etc), wait until the coolant cools down, and then drain the coolant. eAfter

e Drain the cooling system.

a permanent type coolant.

bleed the air from the system (see Air Bleeding).

and

P r e c a u tio n s

assembling and filling

the system with

coolant.

bleed any air from the system.ZYXWVUTSRQPONMLKJIHGFEDCBA

C O O L lN G

SYSTEM

3 -9

W a te r P u m p MLKJIHGFEDCBA

C o v e r R e m o v a / lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

• Drain the coolant

(see Coolant Draining).

• Loosen the clamps, and pull the water pump hose and the radiator hose lower ends off the pump ports. • Remove the cover bolts and remove the water pump cover.

A. Impeller

B. Impeller Nut

/m p e lle r

/n s ta lla tio n

• Before

installing

N o te s

the

impeller,

fit

the

O-ring

in the

impeller. O Check that the O-ring is in good condition.

* If it is damaged, A. Cover Bolts

D. Arrow "CYL" Mark

B. Water Pump Cover

E. Radiator Hose

replace it with a new one.

C. Water Pump Hose

C o ve r /n s ta lla tio n

N o te s

• Be careful not to mix up the water pump hose and the radiator hose when connecting them with the pump ports. For the water pump hose, the port has the arrow "CYL" mark. • Replace the pump cover gasket with a new one . • Tighten the hose clamp bolts so that they are positioned on the right as one faces the cover.

A. Impeller .Tighten

B. O-ring the impeller nut to the specified

torque

(see

Exploded View).

• Fill the cooling system (see Coolant Filling).

O Be careful not to dam age the sealing surface of the m echanical sea!. OTurn the im peller clockwise at installation. prevent

/m p e lle r

im peller

O-ring

dam age b y

the

This is to shaft

screw

threads.

R e m o va /

• Drain the coolant (see Coolant Draining) . • Remove the cover bolts and turn up the water pump cover with the radiator hose attached. • Remove the impeller nut and washer, and pull out the Q - ring and the shim. impeller,ZYXWVUTSRQPONMLKJIHGFEDCBA

/m p e lle r

As s e m b /y

O Be careful

N o te s

not to dam age the sealing surface of the

m echanical sea!. OTurn the im peller counterclockwise

at rem ova!. This is

to prevent im peller O-ring dam age b y the shaft screw threads.

.Clean the sliding surface of the mechanical seal with a high flash point solvent, and apply a little coolant to the

3 -1 0

C O O L lN G

S Y S T E M lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

sliding surface to give the mechanical seal initial lubrication. eApply

coolant

to the surfaces of the rubber seal and

sealing seat, and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole.

1 . Bearing Driver Set: 5 7 0 0 1 - 1 1 2 9 2. Oil Seal

3. Mechanical Seal A. Sealing Seat

C. Apply coolant to the surfaces.MLKJIHGFEDCBA

B. Rubber Seal

M e c h a n ic a l

S e a /, O il S e a lln s ta lla tio n

N o te s

e Be sure to replace the mechanical seal and the oil seal, eApply lips.

Im p e lle r In s p e c tio n

eVisually

grease to the oil seal

e Press the oil seal into the ha le from the outside of the

check the impeller.

* If the surface is corroded,

plenty of high temperature

right engine cover with a bearing driver set (special tool:

or if the blades are damaged,

replace the impeller.

so that the spring side of the seal lips are toward the inside of the cover. 5 7 0 0 1 -1 1 2 9 )

eAfter

pressing the oil seal, press the mechanical seal into

the hole with a bearing driver flange touches the step.

o Never

(special tool)

until its

tap on the mechanical seal. use a press only.

O Be careful not to mechanical seal,

damage the sealing surface of the

D riv e r (5 7 0 0 1 -1 1 2 9 )

A. Impeller

B. Blades

Seat

M e c h a n ic a l

S e a /, O il S e a l R e m o va l

e Remove : Impeller Right Engine Cover (see Right Engine Cover Removal in the Engine Right Side/Left

Side chapter)

ePress out the mechanical seal and oil seal from the inside of the right engine cover with a bearing driver set (special tool).ZYXWVUTSRQPONMLKJIHGFEDCBA

O il s e a l G re a s e

COOLlNG M e c h a n íc a /

.VisuaJly

* If any

SYSTEM

3-11

S e a / / n s p e c t í o n lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Radiator, Radiator Fan

inspect the mechanical sea!.

one of the parts is damaged, chanical seal as a unit.

replace the meR e m o va /

.Remove: Lower Fairing Coolant (drain) Upper Fairing Side Covers Seat FuelTank • Disconnect : Fan Motor Lead Connector Fan Switch

Lead Connector

A. Impeller Sealing Seat Surface B. Rubber Seal C. Mechanical

H ose

.In

Seal Diaphragm

In s p e c tío n

accordance

Visually

inspect

with

the

Periodic

Maintenance

Chart,

the hoses for signs of deterioration.

Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen . • Replace any damaged hose.

A. Fan Motor Lead Connector B. Fan Switch

Lead Connector

I WARf\LINGONMLKJIHGFEDCBA I OThe radiator

fan and fan switch

to the battery. ignition switch

are connected

directly

The radiator fan may start even if the is off. NEVER TOUCH THE RADIATOR

FAN UNTIL THE ENGINE COMPLETELY COOLS OFF. TOUCHING

THE

FAN

BEFORE THE

ENGINE COOLS

COULD CAUSE INJURY FROM THE FAN BLADES .

• Remove the fan motor mounting fan motor.

bolts, and take off the

A. Water Pump Hose

A. Mounting

Bolts

B. Fan Motor ZYXWVUTSRQPON

3 -1 2

C O O L lN G

S Y S T E M lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

• Pull off the reservoir tank hose, the water hose and the radiator hose from the radiator.

A. Ground Lead

A. Reservoir Tank Hose

B. Mounting

Bolt

C. Radiator Hose

B. Water Hose

R a d ia to r In s p e c tio n • Check the radiator coreo

• Remove the radiator mounting bolts, and take off the radiator taking care not to damage the radiator coreo

* If there are obstructions to air flow, remove them. * If the corrugated fins are deformed, carefully straighten them with the blade of a thin screw driver.

o Do

A. Mounting

Bolts

B. Radiator Core

.Separate

not tear the radiator tubes while straightening

the

C. Grill D. Mounting

Screw

the grill from the radiator.MLKJIHGFEDCBA A. Thin Screwdriver

* If the air passages of the radiator core are blocked than 20% by unremovable

obstructions

more or irreparably

deformed fins, replace the radiator with a new one.

In s ta lla tio n N o te s • Be sure to install the fan switch ground mounting bolt.

lead on the fan

• Route the fan motor lead and the fan switch lead in eccordance with the Wire Routing in the General Information chapter.

OW hen

cleaning

the

radiator

careful of the following

with

compressed air, be

to avoid damage to the fins.

O Keep the air nozzle over 0.5 m (20 in.) away form the radiator. O Blow air perpendicularly

to the radiator coreo

O Never blow air at an angle against the fins but straight through them in the direction

of natural air flow.

O Never shake the air nozzle at a right angle against the fins, be sure to move it at a level with the fins.

COOLlNG Radiator (obliquity)

Cap Relief

93 -

SYSTEM

3-13

1 .2 5 k g / c m ', 1 4 -

1 8 psi)

Pressure

1 2 3 k P a ( 0 .9 5 -

OAlso, the cap must hold any pressure less than the relief

(perpendicular)

pressure for at least 6 seconds. If the cap cannot hold the pressure, or if the relief pressure is too high ~r too low, replace the cap with a new one.

OK MLKJIHGFEDCBA more than ZYXWVUTSRQPONMLKJIHGFEDCBA 0 .5 m

F ille r N e c k

/n s p e c tio n

• Check the radiator filler neck for signs of damage . • Check the condition

C a p In s p e c tio n • Check the condition

of the top and bottom sealing seats

in the filler neck. They must be smooth the radiator cap to function properly .

and clean for

of the valve spring, and the top and

bottom valve seals of the radiator cap. If any one of them shows visible damage, replace the cap.

A. Top Sealing Seat

A. Valve Spring

B. Top and Bottom Valve Seals

.Wet the cap sealing surfaces with prevent pressure leaks. .Install

water or coolant

R a d ia to r H o s e ,

the cap on a cooling system pressure tester.

.Watching

B. Bottom Sealing Seat

the pressure gauge, pump the tester to build

up the test pressure. The cap must open at the specified relief pressure (the gauge hand flicks down).

W a te r H o s e , R e s e r vo ir

Ta nk H ose,

Air Ve n t H o s e /n s p e c tio n .In

accordance

visually

with

inspect

the Periodic

Maintenance

the hoses for signs

Chart,

of deterioration.

Squeeze the hose. A hose should not be hard and brittle, nor should it be soft or swollen . • Replace any damaged hose.

R a d ia to r

H o s e , W a te r H o s e , R e s e r vo ir

Air Ve n t H o s e .Install

In s ta lla tio n

Ta nk H ose,

N o te s

the radiator hose, water hose, reservoir tank hose

or air vent hose being careful to follow

the performed

bends (see Exploded View, Hose Routing eral A. Pressure Tester

B. Radiator Cap

Information

chapter).

Avoid

kinking, flattening, or twisting. .Tighten the hose clamps securely.

in the Gen-

sharp

bending,

3 -1 4

C O O L lN G

S Y S T E M lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

T h e r m o s ta t MLKJIHGFEDCBA

R e m o v a / ZYXWVUTSRQPONMLKJIHGFEDCBA

e Remove : Lower Fairing Coolant (drain) Side Covers Seat FuelTank

e Remove the thermostat housing cap bolt, and take the A. Radiator Hose

C. Reservoir Tank Hose

B. Water Hose

D. Air Vent Hose

thermostat out of housing.

A. Thermostat

/n s ta l/a tio n

Housing Cap B. Thermostat

N o te

e Put the thermostat

into the housing

bleeder hole is positioned gine.

A. Thermostat

toward

so that the air

the upper of the en-

B. Air Bleeder Hole

C O O L lN G

SYSTEM

3 -1 5

I n s p e c t í o n lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

e Remove

the therrnostat.

and

inspect

the thermostat

T h e r m o s ta tic

F a n S w itc h ,

W a te r

T e m p e r-

a tu r e S e n s o r

valve at room temperature.

* If the valve is open. replace the valve with

a new one. eTo check valve opening temperature, suspend the thermostat and an accurate thermometer water.

in a container

F a n S w ítc h

e Drain the coolant

e Place the container over a source of heat and gradually raise the temperature of the water water gently.ZYXWVUTSRQPONMLKJIHGFEDCBA

T h e r m o s ta tíc

while

stirring

the

R e m o va l

(see Coolant Draining).

e Disconnect the thermostatic

fan switch lead connector.

e Unscrew the sensor and remove it.

OThe fan switch should never be allowed to fall on a hard surface.

Such a shock to this part can damage it.

Must be completely submerged.

They must not touch the container sides or bottom.

A. Connector 1 . Thermometer

* If it is out of the specified 6 9 .5

Fan Switch

2. Thermostat

eWatch the valve. As soon as the valve starts to open, note the temperature.

Thermostat

B. Thermostatic

range, replace the thermostat.

T h e r m o s ta tíc

eTighten

F a n S w itc h

the thermostatic

In s ta lla tío n

fan switch

N o te

to the specified

torque (see Exploded View).

Valve Opening Temperature 7 2 .5 ° C

(1 5 7

1 6 2 ° F ) ONMLKJIHGFEDCBA

T h e r m o s ta tíc

F a n S w ítc h

In s p e c tío n

e Refer to the Electrical System chapter.

W a te r

Te m p e r a tu r e

Sen so r

R e m o va l

eRemove: Lower Fairing Coolant (drain) Side Covers Seat FuelTank e Disconnect the water temperature sensor connector. e Unscrew the sensor and remove it. .

OThe water temperature

sensor should never be allowed

to fall on a hard surface. damage it.

Such a shock to this part can

3 -1 6

C O O L lN G

A. Connector

W a te r

eApply

T e m p e r a tu r e

S Y S T E M lkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

B. Water Temperature Sensor MLKJIHGFEDCBA

Sen so r

In s ta lla tio n

N o te s

silicone sealant (Kawasaki Bond: 56019-120)

the threads before installing the water temperature sensor. eTighten the water temperature torque (see Exploded View).

W a te r

T e m p e r a tu r e

Sen so r

sensor to the specified

In s p e c tio n

e Refer to the Electrical System chapter.

'".

E N G IN E

TOP

END

4 -1

E n g in e T o p E n d

T a b le o f C o n te n ts tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFE

Exploded View Specifications Special Tools Sealant Cylinder Head Cover Removal Installation Notes Camshaft Chain Tensioner Removal路 Installation Notes Camshaft, Camshaft Chain Camshaft Removal Camshaft Installation Notes (Including Camshaft Chain Timing Procedure) Camshaft and Sprocket Assembly Notes Camshaft Bearing Oil Clearance Inspection Camshaft Chain Wear Camshaft Chain Guide Wear KAWASAKI Automatic Compression Release (KACR) Cylinder Head Compression Measurement.. Removal Installation Notes Disassembly and Assembly (Valve Mechanism Removal and Installation) Warp Cleaning

Valves Clearance Inspection Clearance Adjustment.. Installed Height Valve Seat Inspection Valve Seat Repair Measuring Valve-to-Guide Clearance (Wobble Method) Cylinder, Piston Cylinder Removal Cylinder Installation Notes Piston Removal Piston Installation Notes Piston Ring, Piston Ring Groove Wear Piston Ring End Gap 4-8 Cylinder Inside Diameter .4-1onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA O Piston Diameter .4-11 Boring, Honing Exhaust Pipe, Muffler 4-11 .4-11 Exhaust Pipe Removal Muffler Removal Exhaust Pipe, Muffler Installation Notes 4-12 4-13 .4-13 .4-13 .4-14 .4-2 .4-4 .4-5 4-6 .4- 7 4- 7 4-7 .4-7 .4- 7 .4-7 .4-8 .4-8

.4-14 4-15 4-16

.4-16 ..4-16 .4-17 .4-20 .4-20 .4-21 .4-24 4-24 .4-24 4-25 4-25 4-25 .4-26 4-27 .4-27 .4-27 .4-27 4-28 4-28 .4-28 4-29

4-2

ENGINE TOP END

Exploded ViewonmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

f" ¡ ° l@ .. o ~~~

1. Cylinder Head Bolts (6 mm) 2. Cylinder Head Bolts (10 mm)

3. Cylinder Head Allen Bolt (8 mm] 4. Cylinder Head Nuts (8 mm) 5. KACR Unit

SS: Apply silicone sealant (Kawasaki Bond: 56019-120) to the gaskets and the threads. L : Apply a non-permanent locking agent to the threads. M : Apply a thin coat of a molybdenum O : Apply engine oil to the surface. S

disulfide grease.

: Follow the specific tightening sequence.

T1: 7.8 N-m (0.8 kq-rn, 69 in-lb) T2: 9.8 N-m (1.0 kq-m, 7.0 ft-lb] T3: 12 N-m (1.2 kq-m, 8.5 ft-Ib) T4: 15 N-m (1.5 kq-m, 11.0 ft-lb] T5: 18 N-m (1.8 kg-m.13.0ft-lb) T6: T7: T8: T9:

20 25 49 65

N-m N-m N-m N-m

(2.0 (2.5 (5.0 (6.6

kq-rn, kq-m, kq-m, kq-m,

14.5 ft-Ib) 18.0 ft-Ib) 36 ft-Ib) 48 in-lb) XWVUTSRQPONMLKJIHGFEDCBA

.RQPONMLKJIHGFEDCBA

l ,

E N G IN E

TOP

END

4-3

~'Q

tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIH ~

~~ ~

~ \ @

~ .~

t -: @

iMbaZYXWVUTSRQPON

4 -4

E N G IN E

TOP

END

S p e c ific a tio n s

Ite m C a m s h a ft,

C h a in : tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Cam height: Camshaft Camshaft Camshaft Camshaft

S e rv ic e L im it

S ta n d a rd

Inlet Exhaust

36.75 36.25 0.030 22.949 23.000 127.0 -

bearing oil clearance journal diameter bearing inside diameter chain 20-link length

36.85 mm 36.35 mm 0.064 mm 22.970 mm 23.013 mm 127.4 mm

Cylinder compression

(Usable Range) 530 - 855 kPa (5.4 - 8.7 kq/cm-, 77 - 124 psi)

Cylinder head warp

- --

C y lin d e r H e a d :

36.65 mm 36.15 mm 0.15 mm 22.92 mm 23.07 mm 128.9 mm

0.05mm

V a lv e s :

Valve c\earance (when cold): Valve head thickness: Valve stem bend Valve stem diameter: Valve guide inside diameter Valve guide/valve clearance (wobble method): Valve seating surface: Outside diameter Width Valve seating area width Valve spring free length

Inlet Exhaust Inlet Exhaust

-onmlkjihgfedcbaZYXWVUTSRQP --

0.10 - 0.20 mm 0.15 - 0.25 mm 1.0 mm 1.0 mm Less than 0.01 mm TI R 6.965 - 6.980 mm 6.955 - 6.970 mm 7.000 - 7.015 mm

0.5mm 0.7 mm 0.05 mm TIR 6.95 mm 6.94 mm 7.08 mm

Inlet Exhaust

0.04 - 0.11 mm 0.05 - 0.12 mm

0.24 mm 0.24 mm

Inlet Exhaust Inlet Exhaust

36.9 - 37.1 mm 31.9 - 32.1 mm 0.8 - 1.2 mm 0.8 - 1.2 mm 0.8 - 1.2 mm 37.6 mm 40.5 mm

Inlet Exhaust

Inner Outer

- --

- -- -- -- -- --

36.2 mm 39.0 mm

C y lin d e r, P is to n :

Cylinder inside diameter: Piston diameter: Piston/cylinder c\earance Oversize piston and rings Piston ring/groove c\earance: Piston ring groove width:

KL650-B1 KL500-B1 KL650-B1 KL500-B1

100.10mm 89.10 mm 99.80 mm 88.80 mm

Top 2nd Top 2nd Oil

100.000 - 100.012 mm 89.000 - 89.012 mm 99.942 - 99.957 mm 88.942 - 88.957 mm 0.043 - 0.070 mm +0.5 mm and +1.0 mm 0.03 - 0.07 mm 0.02 - 0.06 mm 1.22 - 1 .24 mm 1 .21 - 1 .23 mm 2.81 - 2.83 mm

0.17 0.16 1.32 1.31 2.91

Top & 2nd

1.17 -

1.10 mm

Top & 2nd

0.2 - 0.4 mm

- --

mm mm mm mm mm

Piston ring thickness: 1.19 mm

Piston ring end gap:

!el

0.7 mm

E N G IN E Cam Height

TOP

END

Measurement

Special Tools Compression

Gauge:

57001-221

Compression

Gauge Adapter

Cam Height

Hose: 57001-1183

Valve HeadonmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Valve Spring Compressor Assembly:

57001-241

Valve head thickness

Valve Spring Compressor

Adapter:

57001-243

Valve Stem BendbaZYXWVUTSRQPONMLKJIHGFEDCBA

Valve Guide Arbor:

Valve Guide Reamer:

57001-163

57001-162

Valve Seat Cutter Holder. 4>7: 57001-1126

4-5

4-6

ENGINE TOP END

Valve Seat Cutter Holder Bar:onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 57001-1128

Sealant Kawasaki Bond (Silicone Sealant):

Valve Seat Cutter, 45° - <t>35.0: 57001-1116

Valve Seat Cutter, 45° - <P41.5: 57001-1117

Valve Seat Cutter, 32° - <t>35.0: 57001-1121

Valve Seat Cutter, 32° - <t>38.5: 57001-1122

Valve Seat Cutter, 60° - <P41.0: 57001-1124

57001-910 XWVUTSRQPONMLKJIHGFEDCBA

Piston Pin Puller Assembly:

e O

r .~

O Piston Pin Puller Adapter:

57001-1211

Piston Ring Pliers: 57001-115

56019-120

E N G IN E

C y lin d e r

H e a d C o v e r XWVUTSRQPONMLKJIHGFEDCBA C a m s h a ft

TOP

END

4 -7

C h a in T e n s io n e r

R e m o v a l tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA R em o va l

e Remove : Side Covers Seat FuelTank Radiator Fan Ignition Coil Water Temperature Sensor Connector e Remove the cylinder head cover bolts, and take off the cover toward the left side.

o Be careful

not to damage the radiator coreo

This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: OWhen removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in "Installation". O Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.

e Remove the cap bolt, washer and spring. e Remove the mounting bolts. and take off the chain tensioner.

A. Cover Bolts B. Cover

C. Radiator Core

A. Cap Bolt

In s ta lla tio n

8. Mounting

Bolts

N o te s

eApply silicone sealant (Kawasaki to the cylinder head as shown.

Bond:

56019-120)

In s ta lla tio n

N o te s

eUnlock the ratchet stopper and push the rod into the tensioner body.

1. Silicone Sealant Applied Area

eTighten the cover bolts to the specified torque (see Exploded View).

A. Ratchet Stopper

8. Push Rod

4 -8

E N G IN E

TOP

E N D tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

elnstall the chain tensioner pointing downwards.

body with

the arrow on it

C a m s h a ft, C a m s h a ft C h a in RQPONMLKJIHGFEDCBA

C a m s h a ft R e m o v a l

eRemove: Cylinder Head Cover Camshaft Chain Tensioner Camshaft Caps. Oil Pipe and O-rings

A. Arrow

A. Cap Bolts

B. Oil Pipe

e Remove the camshafts.

OThe crankshaft may be turned. while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.

C a m s h a f t I n s t a lla t io n N o t e s ( I n c lu d in g

C a m s h a ft

C h a in T im in g P r o c e d u r e )

eApply engine oil to all cam parts. If the camshaft(s) and/or cylinder head are replaced with new ones, apply a thin coat of molybdenum disulfide grease to the new carn part surfaces.

NOTE

o The

exhaust

m e c h a n is m . in s t a llin g .

c a m s h a ft

has

th e

c o m p r e s s io n

r e le a s e

B e c a r e f u l n o t t o m ix u p t h e s e s h a f t s w h e n

E N G IN E

A. Exhaust Camshaft

A. Rotation Bolt B. Compression Release MechanismbaZYXWVUTSRQPONMLKJIHGFEDCBA B. Counterclockwise

N O T E RQPONMLKJIHGFEDCBA O B e s u r e t o s e t p r o p e r ly in s t a llin g

t h e c a m s h a f t c h a in t im in g

when

th e c a m s h a ft.

e Remove. the two caps on the alternator cover. e Position the crankshaft at TDC. o Using a wrench on the crankshaft rotation bolt, turn the crankshaft counterclockwise until the "T" TDC mark on the rotor is aligned with the notch in the edge of the upper hole in the magneto cover.GFEDCBA

TOP

END

4 -9

C. "T" TDC Mark D. Notch

e Engage the camshaft chain with the camshaft sprockets. o Pul! the tension side (exhaust side) of the chain taut to instal! the chain. OThe timing marks on the exhaust sprocket must be aligned with the cylinder head upper surface and pointed toward the front. e Pul! the chain taut and fit it onto the camshaft sprocket. eStarting with the timing mark on the front of the exhaust sprocket, count to the 46th pino Feed the exhaust camshaft through the chain and align that 46th pin with the timing mark on the inlet camshaft sprocket. e Flush out the cylinder head oil pipe with a high flash point solvent. eFil1 the oil pipe with engine oil, This shortens air bleeding time and prevents engine damage. eCheck that the O-rings are in good condition.

* If they are damaged,

replace them with new ones. eApply engine oil to both ends of the head oil pipe to prevent damage to the O-rings in the camshaft caps.onmlkjihgfedcba

(L e ft

S id e

View)

Cylinder head upper surface

I n le t

C a m sh a ft

1st

Timing Mark Timing Mark Turning Tension Side

Direction

---~-~Inlet Side

4-10 baZYXWVUTSRQPONMLKJIHGFEDCBA E N G IN E T O P E N D

Front

2 tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

)~"~

1. Camshaft Cap 2.0-ring

3. Oil Pipe 4. Apply engine oil.

~~ @

eApply engine oil to the camshaft bearing portion. elnstail the camshaft caps in the correct locations as shown in the figure below. Location alphabets are marked on the each caps.

RearRQPONMLKJIHGFEDCBA

OThe camshaft caps are machined with the cylinder head. So, if cap is installed in a wrong location, the camshaft may seize because of improper oil clearance in the bearings. C a m s h a ft

and

S p ro c k e t

A s s e m b /y

N o te s

The inlet and exhaust sprockets are identical. elnstall the sprockets so that the marked side faces outwards. Fit the knock pin into the camshaft hole.

Rear

GFEDCBA C a m sh a ft c a p

Hntet. M lr k :

m u ft

b e fa c e d

r ig h t)

fo rw a rd

A. Knock Pin e First tighten down the two camshaft cap bolts (#1 and #2 bolts in the figure) evenly to seat the camshafts in place, then tighten all bolts to the specified torque (see Exploded View), following the specified tightening sequence.

OAfter this procedure, if any resistance is felt while turning over the crankshaft, stop immediately, and check the camshaft chain timing. Valves will be bent if the timing is not properly seto

B. Mark

eApply a non-permanent locking agent to the camshaft sprocket bolts and tighten them to the specified torque (see Exploded View). elf a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces.

ENGINE TOP END C a m s h a ft

B e a r in g

O il C le a r a n c e

4-11

Camshaft Chain 20-Link Length I n s p e c t io n tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

The journal wear is measured using plastigauge (press gauge), which is inserted into the clearance to be measured. The plastigauge indicates the clearance by the amount it is compressed añd widened when the parts are assembled. • Cut strips of plastigauge to journal width. Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position and so that the plastigauge will be compressed between the journal and camshaft cap . • Install the camshaft caps, tightening the bolts in the correct sequence to the specified torque.

Standard: Service Limit:

127.0 '" 127.4 mm 128.9 mm

20-Link

Length 1st

21st

NOTE

oDo

n o t tu rn th e c a m s h a ft w h e n

t h e p la s t ig a u g e is b e -

t w e e n t h e jo u r n a l a n d c a m s h a f t c a p .

• Remove the camshaft caps again, and measure the plastigauge width to determine the clearance between each journal and the camshaft cap. O Measure the widest portion of the plastigauge.

C a m s h a ft

.Visually

C h a in

* If any clearance exceeds the service limit, replace the

camshaft with a new one and measure the clearance again.

* If the clearance still remains out of the limit, replace the cylinder head unit.

Camshaft Bearing Oil Clearance Standard: Service Limit:

C a m s h a ft

C h e in

0.030 '" 0.064 mm 0.15 mm

W ear

• Hold the chain taut with a force of about 5 kg in some manner, and measure a 20-link length. Since the chain may wear unevenly, take measurements at several places.

* If any measurement the chain.

exceeds the service limit, replace

W ear

* If the rubber is damaged, cut, or is missing pieces, replace the guides.

A. Plastigauge Width

G u id e

inspect the rubber on the guides.

4 -1 2

E N G IN E

KAW ASAKI

TOP

END

A u to m a tic

C o m p re s s io n

Retracted leased)

or Rest Position

(compression

R e le a s e (K A C R ) tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Due to the simplicity of the mechanism, no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism: compression is not released during starting, and compression is released during running. (1) If compression is not released during starting, the weights are not returning to their rest position. e Remove the cylinder head cover. eVisually inspect the spring. * If the spring is damaged, deformed, or missing, replace it. eRemove the spring and move the weights back and forth. *If

the weights do not move smoothly all the way, replace the exhaust camshaft.

Running Position (compression is not released) Weight (Al

Stopper

Spring

(2)

If compression is released while the engine is running, the weights are not swinging out. e Remove the spring andmove the weights back and forth.

*If

the weights do not move easily from the retracted position, replace the exhaust camshaft.RQPONMLKJIHGFEDCBA

is re-

E N G IN E

TOP

END

4 -1 3

* If cylinder compression lower than the usable range, check the following: (1) Gas leakage around the cylinder head - replace the damaged gasket and check the cylinder head warp. C o m p r e s s io n M e a s u r e m e n t tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA (2) Condition of the valve seating. e Remove : (3) Valve clearance. Upper Fairing (4) Piston/cylinder clearance, piston seizure. Side Covers (5) Piston ring, piston ring groove. Seat (6) Compression release weights do not move smoothly. eThoroughly warm up the engine so that engine oil between the prston and cylinder wall will help seal compression as it does during normal running. eStop the enqine. remove the fuel tank and the spark plug, and attach the compression gauge (special tool) and the adapter hose (special tool) firmly into the spark plug hole.

C y lin d e r

H e a d XWVUTSRQPONMLKJIHGFEDCBA

R em o va /

~ A. Compression Gauge: 57001-221 B. Compression Gauge Adapter Hose: 57001 -1183 I â&#x20AC;˘

e Using the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable.

C y lin d e r 530 -

(5.4 -

C o m p re s s io n (U s a b le

e Remove : Fairings Coolant (drain) Exhaust Pipe Side Covers Seat FuelTank Carburetor Water Hose Radiator Fan Ignition Coil Water Temperature Sensor Connector (disconnect) Cylinder Head Cover Camshaft Chain Tensioner Camshafts Cylinder Head Bracket Main Oil Pipe Mounting Bolt (Ioosen) Main Oil Pipe Upper Banjo Bolt Left Rubber Damper for Fuel Tank e Remove the cylinder head bolts and nuts in following order. 1.6 mm Bolts 2. 8mm Allen Bolt 3.8 mm Nuts 4. 1 O mm Bolts

Range)

855 kPa 2 8.7 kg/cmonmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA , 77 - 1 2 4 p s i)

*If

cylinder compression is higher than the usable range, check the following: (1) Carbon build-up on the piston head and cylinder head - clean off any carbon on the piston head and cylinder head. (2) Cylinder head gasket, cylinder base gasket - use only the proper gaskets. The use of a gasket of incorrect thickness will change the compression. (3) Valve stern oil seals and piston rings - rapid carbon accumulation in the combustion chamber may be caused by damaged valve stem oil seals and/or damaged piston oil rings. This may be indicated by white exhaust smoke. (4) Compression release cam spring is damaged, deformed, missing, or weights do not move smoothly.

A. 6 mm Bolts

B. 10 mm Bolts

4 -1 4

E N G IN E

TOP

A. 8 mm Allen Bolt

E N D tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

B. 8 mm Nuts

e Lift off the cylinder head toward move the cylinder head gasket.

the left side, and re1-+4

Cylinder Head Bolts (10 mm) Torque them first to 20 N-m (2.0 kg-m, 14.5 ft-Ib) and then to 65 N-m (6.6 kg-m, 48 ft-Ib)

5-+6

Cylinder Head Nuts (8 mm) 25 N-m (2.5 kg-m, 18.0 ft-lb)

NOTE

oRQPONMLKJIHGFEDCBA T a p lig h t ly u p t h e c y lin d e r h e a d w it h

a r u b b e r m a l/ e t t o

s e p a r a t e f r o m t h e c y lin d e r .

o Be careful

not to damage the radiator coreo

7-+8onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Cylinder Head Nuts (Retighten) 25 N-m (2.5 kg-m, 18.0 ft-lb) Cylinder Head Allen Bolt (8 mm) 9 18 N-m (1.8 kg-m, 13.0 ft-Ib) 10-+11

D ís a s s e m b ly

Cylinder Head Bolts (6 mm) 9.8 N-m (1.0 kg-m, 87 in-lb)

and

A s s e m b ly

(V a lve

M e c h a n ís m

R e m o va l a n d In s ta lla tío n )

e Use the valve spring compressor assembly (special tool) and the adapter (special tool) to press down the valve spring retainer, and remove the split keepers. O Be careful not to damage the studs on the cylinder surface. A. Rubber MalletXWVUTSRQPONMLKJIHGFEDCBA

In s ta lla tío n N o te s

e-rhe camshaft caps are machined together with the cylinder head, so if a new cylinder head is installed, use the caps that are supplied with the new head. eApply a molybdenum disulfide grease to the cylinder head bolts (10 mm) seating surface and threads. eTighten the cylinder head bolts and nuts to the specified torque in following order. eThroughly warm up the engine, and then let it cool completely. Now retighten the cylinder head nuts and Allen bolt to the specified torque.

A. Valve Spring Compressor Assembly: B. Adapter: 57001 -243

57001-241

E N G IN E

TOP

END

4 -1 5

e Heat the area around the valve guide to about 120 150°C (248 - 302°F), and hammer lightly on valve guide arbor (special tool) to remove the guide from the top of the head.

A. Valve Guide Arbor: 57001-163

eValve Guide Installation: OApply oil to the valve guide outer surface before installation. o Heat the area around the valve guide hole to about 120 -

150°C (248 -

302°F).

o Drive the valve guide in from the top of the head using the valve guide circlip stops the O Ream the valve tool) even if the

arbor (special tool: 57001 -163). The guide from going in too faro guide with valve guide reamer (special 1. Shim old guide is re-used.onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 2. Valve Lifter 3. Split Keeper 4. Spring Retainer 5. Valve Spring, Outer 6. Valve Spring, Inner

7. 8. 9. 10. 11.

Oil Seal Spring Seat Valve, Inlet Valve, Exhaust Closed Coil End

Warp

••• --

A. Valve Guide Reamer: 57001-162

eValve Installation: O Check to see that the valve moves smoothly up and down in the guide. O Check to see that the valve seats properly in the valve seat. If it does not, repair the valve seat. Check the valve installed height. OApply a thin coat of molybdenum disulfide grease to the valve stem before valve installation. Olnstall the springs so that the closed coil end is facing toward the valve seat (downwards).

,baZYXWVUTSRQPONMLKJIHGFEDCBA

e Laya straightedge across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge between the straightedge and the head .

* If warp

exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.

4 -1 6

E N G IN E

TOP

E N D tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

V a lv e s

C le a r a n c e

In s p e c tio n

NOTE O lf th e e n g in e c le a r a n c e (r o o m

is h o t,

m ust

w a it u n ti/ th e e n g in e ch ecked

when

th e

c o o /s .

e n g in e

V a /ve is

c o /d

te m p e r a tu r e ).

• Remove the cylinder Cover Removal).

head cover (see Cylinder

Head

• Unscrew the two caps on the alternator cover. A Straightedge

C y lin d e r

B. Thickness Gauge

H e a d W a rp

S e rv ic e

0.05 m m XWVUTSRQPONMLKJIHGFEDCBA L im it: onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

C le a n in g

• Before installation, compressed air.

blow the oil passages cleari with

AUpper

Cap

B. Lower Cap

.Check the valve clearance when piston is at TDC. • Using a wrench on the crankshaft rotation bolt, turn the crankshaft counterclockwise while watching the movement of inlet valves (valves to rear). When the valves have just finished opening and closing (moving downwards and returning upwards), turn the crankshaft in the same direction for about another 1/2 turn until the "1" mark on the magneto flywheel is aligned with the notch on the upper hole of the magneto cover. OAt this point, the marks on the camshaft sprockets point forward and line up with the surface of the cylinder head. A. Oil Passage

A Oil Passage

A B. C. D.

Notch ''1'' Mark Normal Direction of Crankshaft Rotation Crankshaft Rotation Bolt

E N G IN E

TOP

E N D onmlkjihgfedcbaZY 4-17

NOTE

oRQPONMLKJIHGFEDCBA C h e c k th e v a /v e c /e a ra n c e u s in g C h e c k in g

th e c /e a ra n c e

r e s u / t in im p r o p e r

a t a n y o th e r

t h is

m e th o d

c a m p o s it io n

o n /y . m ay

v a /v e c /e a ra n c e .

• Measure the clearance between the cam and shirn, for all four valves.

* If the valve clearance is incorrect, adjust it.

o Do not

put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. O Do not grind the shim. This may cause it to fracture, causing extensive engine damage. O Do not grind the valve stem end to repair it or to permit additional valve clearance. If the valve end is ground, the lifter may contact the spring retainer and/or split keepers during operation, allowing the keeper to loosen. Consequently, the valve may drop into the engine, causing serious damage.

A. Insert the thickness gauge. Valve Clearance (when cold) Inlet

0.10 '" 0.20 mm

Exhaust

0.15 '" 0.25 mmXWVUTSRQPONMLKJIHGFEDCBA

C le a r a n c e

A d ju s tm e n t

.To change the valve clearance, remove the chain tensioner, the camshaft and the shim . • To select a new shim which brings valve clearance within the specification, refer to the Valve Clearance Adjustment Charts. • Position the lifter notch so that if faces upwards. allows the shim to be lifted and removed.

This

A. Notch .Install the camshafts. properly.

Be sure to time the camshafts

• Remeasure the valve clearance that was adjusted. Readjust if necessary.baZYXWVUTSRQPONMLKJIHGFEDCBA

" GFEDCBA I n le t V a lv e

C le a r a n c e

A d ju stm e n t

C hart

baZYXWVUTSRQPONMLKJIHGFEDCBA

~ ~ I

PRESENT PART NUMBER

T H IC K N E S S

(1 2 0 3 7 -

(m m l

001 200

1002

003

205

210

0.00 - 0.02

003 - 007

008 - O 09

2.00

S H IM

004100510061007100810091010101110121013101410151 215

2.20

2.25

1 2.301

2.35 1 2.40

1 2.451

0161

0171

2.50 1 255

1 260

1 265

1 270

1 275

1 280

1 2.85 1

2.90 1

295

305

310

1 315

2.20

2.25

2.30

235

240

245

250

255

260

265

2 70

275

2.80

285

290

295

300

305

2.00

205

210

2 15

220

2.25

230

2.35

240

245

250

255

260

265

2 70

2 75

2.80

285

290

295

300

305

310

205

210

2 15

2.20

225

230

2.35

2.40

245

250

255

260

265

270

275

280

285

290

295

300

305

310

3 15

SPECI FI ED

CLEARANCE

/ NO

205

210

215

220

225

2.30

235

2.40

2.45

250

255

260

265

270

2 75

280

285

290

295

300

305

310

315

023-027

210

2 15

220

225

230

235

240

2.45

250

255

260

265

270

2 75

280

285

290

295

300

305

310

315

320

028 - 032

2 15

220

225

230

235

2.40

245

2.50

255

260

265

270

2 75

280

285

290

295

300

305

3 10

315

320

290

295

300

305

310

3 15

320

3 20

235

240

245

250

255

2.60

265

270

2 75

280

285

0.38-042

2.25

2.30

235

240

245

2.50

2.55

2.60

2.65

270

275

280

285

290

295

300

305

310

3 15

E E

043-047

230

235

240

245

250

255

2.60

265

2 70

2 75

280

285

290

295

300

305

3 10

3 15

320

048 - 052

235

240

245

250

255

260

265

270

2 75

280

285

290

295

300

305

310

3 15

320

053-057

240

245

U Z

250

255

260

265

270

275

2 80

2 85

2 90

2 95

3 00

3 05

3 10

3 15

3 20

058 - 062

245

250

255

2.60

265

270

2 75

280

285290

063-067

250

255

260

2.65

270

275

280

2.85

2 90

2 95

3 00

3 05

3 10

3 15

068-072

2.55

2 60

2 65

2 70

2 75

2.80

2 85

2.90

295

300

305

310

315

320

073-077

2.60

265

270

2.75

280

285

2.90

2.95

300

305

310

315

320

078 - O 82

2.65

2 .1 0

275

2.80

2.85

2.90

2.95

300

3.05

310

315

320

0.83 -O 87

270

275

2.80

2.85

2.90

2.95

3.00

3.05

310

315

3.20

0.88 - 0.92

275

280

285

290

295

3.00

3.05

3.10

315

3.20

093 - 097

280

285

2.90

2.95

300

305

3.10

3 15

320

0.98 - 1 02

285

290

295

300

305

3.10

315

3.20

1 03 - 1 07

2.90

295

300

305

310

315

3.20

108 - 1 12

295

300

305

310

3 15

320

1 13 - 1 17

300

305

3 10

3 15

320

1 18- 122

305

310

315

320

123-1.27

310

3.15

320

1 28 - 1 32

315

320

~RQPONMLKJIHGFEDCBA

295300305310315

\.~~

'f.~« , S S

3 20

In le tV a lv e

,' ( ,: ( \ ,G

...J

1 33 - 1 40

~y..\S o<C

sy..\~· ~y..«,

\,..\,..

S~~ \~

XWVUTSRQPONMLKJIHGFEDCBA 320

320

1 . M e a s u re

th e

c le a ra n c e

(w h e n

e n g in e

c o ld ) .

c o lu m n

w ith

2 . C h e c k p re s e n t s h im s ize . 3 . M a tc h p re s e n t

c le a ra n c e s h im

s ize

v e rtic a l in

h o rizo n ta l

c o lu m n .

4 . T h e s h im s p e c ifie d w h e re th e lin e s in te rs e c t is th e

2: m

-1 O

021-022

~onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

R E Q U IR E D

CHANGE

230

2 15

225

300

2.10

220

> ...J

3.20

2.05

033 - 037

025

018101910201021102210231024

200

010-020

o n e th a t

w ill

g iv e y o u th e

p ro p e r

c le a r-

ance. NOTE

olf there is no clearance, se/ect a shim which is severa/ s i z e s sma//er and then measure the c/earance.

E xh au st

onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Val ve C l e a r a n c e A d j u s t m e n t C h a r t baZYXWVUTSRQPONMLKJIHGFEDCBA PRESENT

PART NUMBER

T H IC K N E S S

(1 2 0 3 7 -

!m m )

0011002100310041005100610071008100910101011 2.00

1 2.05

1 2.10 1 2.15

1 2.20

1 2.25

1 2.30

U Z

- > 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 /"RQPONMLKJIHGFEDCBA

0.03 -0.07

0.08 -0.1 2

0.13-0.14

2.00

2.05

2.10

1 2.80 1 2.85

0241025

1 2.90

1 2.95

1 3.00

1 3.05

1 3.10 1 3.15 1 3.20

2.45

2.50

2.55

2.60

2.65

2 70

2 75

2.80

2.85

2 90

2.95

3.00

2.10

2.35

2.40

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2 95

3.00

3.05

2.15

2.20

2.25

2.30

2.35

2.40

2.45

2.50

2.55

2.60

2.65

270

275

2.80

2.85

2 90

2 95

300

3'05

3 10

2.35

2.40

2.45

2.50

2.65

2 70

2 75

285

2.90

2 95

300

3 05

3 10

3 15

320

2.20

2.25

2.30

S P E C IF IE D

CLEARANCE

2.55

2.60

/ NO

CHANGE

2 80

R E Q U IR E D

0.26 -0.27

2.05

2.10

2 15

2.20

2.25

2.30

2.35

2.40

2.45

2.50

2.55

2.60

2.65

270

275

2.80

2.85

2.90

295

3.00

3.05

310

315

0.28 -0.32

2.10

2.15

2.20

2.25

2.30

2.35

2.40

2.45

2.50

2.55

2.60

2.65

2.70

275

2.80

285

2.90

2.95

3.00

305

3 10

3.15

320

0.33 -0.37

2.15

2.20

2.25

2.30

2.35

2.40

2.45

2.50

2.55

2.60

2.65

270

2.75

2.80

2.85

2.90

2.95

3.00

3.05

310

3.15

320

2.25

2.30

2.35

2.40

2.45

2.50

2.55

2.60

2.65

270

2.75

2.80

285

2.90

2.95

3.00

3.05

310

315

320

270

2.75

2.80

285

2.90

2.95

3.00

305

3.10

3 15

320

3.20

2.20

2.40 tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 2.45 2.25 2.35 2.50 2.55 2.60 2.65 2.30

0.48 -0.52

2.30

2.35

2.40

0.53 -0.57

2.35

2.40

2.45

2.50

2.55

260

265

2.70

275

2.80

2.85

2.90

2.95

3.00

3.05

3 lO

315

2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3 10

3.15

3.20

2.70

275

2.80

2.85

2902953.003.053.10315

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

295

3.00

3.05

~1O

3.15

2.50

2.55

2.60

2.65

270

2.75

280

2.85

2.90

295

3.00

305

3 lO

3 15

3.20

3 20

2.45

2.50

2.55

2.60

0.68 -0.72

2.50

2.55

260

265

0.73 -0.77

2.55

2.60

2.65

270

2.75

2.80

2.85

2.90

2.95

0.78 -0.82

2.60

265

2.70

275

2.80

2.85

2.90

2.95

3.003.05

> ...J

0.83 -O 87

265

2.70

275

2.80

2.85

290

2.95

3.00

3.05

0.88 -O 92

270

2.75

2.80

2.85

2.90

2.95

3.00

3.05

0.93 - 0.97

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10

0.98 - 102

280

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

1.03 - 1.07

2.85

290

295

3.00

3.05

3.10

3 15

3.20

3.00

3.10

315

3.1C

3.15

320

310

3.15

3.20

3.10

315

3.20

3.15

3.20

1 12

2.90

295

3.00

3.05

3.10

315

1 ;J - 1 17

2.95

300

3.05

310

315

320

1 18 - 122

3.00

3.05

3.10

3.15

3.20

1 23 - 1 27

3.05

310

315

3.20

1.28 - 1 32

3.10

315

320

1.33-

3.15

3.20

1 37

138-145

3.20

y ..'\(j~

au st

a ve

,y ..\S 0'«

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3.20

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3.20

3.05

1 . M e a s u re

th e

c le a ra n c e

(w h e n

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cold).

c o lu m n

w ith

2 . C h e c k p re s e n t s h im s ize . 3 . M a tc h

~ ,~ \~

108-

XWVUTS

2.40

2.30

2.15

2.40

1 2.75

2.25

2.10

0.63 -0.67

1 2.65 1.270

2.20

2.05

0.58 - 0.62

UJ ...J

1 2.60

2.15

2.00

ex:

1 2.55

/" /

0.43 -0.47

1 2.50

0.38-0.42

1 2.40 1 2.45

0.00 -0.02

0.15-0.25

E E

1 2.35

S H IM

1012101310141015101610171018101910201021102210231

p re s e n t

c le a ra n c e s h im

s ize

v e rtic a l in

h o rizo n ta l

colurnn.

4 . T h e s h im s p e c ifie d w h e re th e lin e s in te rs e c t is

3.20

th e

o n e th a t

w ill

g iv e y o u th e

p ro p e r c le a r-

ance. NOTE

there is no clearance, select a shim which is several sizes smaller and then measure the clearance.

o tt

m Z

G')

Z m -t O "O

m Z

e ,J::lo I ....Jo

c.o

4-20

ENGINE TOP ENDXWVUTSRQPONMLKJIHGFEDCBA

/n s ta lle d

NOTE

H e ig h t

elnstall the valve in the cylinder head. e Pushing up on the valve so that it seats firmly in the valve seat, measure the valve installed height with vernier calipers. The valve installed height is the distance from the bottom of the cylinder head lifter hole to the end of the valve stem.

V a /ve S e a t

o The

va /ve s te m

th is c h e c k

a n d g u id e

m ust

b e in g o o d

c o n d itio n

w ill n o t b e va /id .

If the valve seating pattern is not correct, repair the seat.

1. 2. 3. 4.

ValveonmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Valve Seat Seating Surface Outside Diameter Seating Surface Width

Good

Too Wide

Too Narrow

Uneven

/n s p e c tio n

e Remove the valve. eCoat valve seat with machinist's dye. epush the valve into the guide. e Rotate the valve against the seat with a lapping tool. e Pull the valve out, and check the seating pattern on the valve head. It must be the correct width and even all the wayaround.

Valve Seating

Surface

Width

Inlet

0.8 .••. 1.2 mm

Exhaust

Valve Installed

e Measure the outside diameter of the seating pattern on the valve seat.

0.8 .••. 1.2 mm

Height

(mm)

Inlet

Exhaust

less than

37.13

less than 37.08

37.13 .••.37.97

37.08 .••.37.92

More than 37.97

More than 37.92

Probable

Cause

Recommendation

e Move valve to deeper cut seat. Remeasure. e Replace valve. Remeasure. e Replace cylinder head. Remeasure. Normal/acceptable

eAfter assembling, ance.

check and adjust valve clear

Valve face or seat worn out, or ground excessively.

e Move valve to shallower cut seat. Remeasure. e Replace valve. Remeasure. e Replace cylinder head. Remeasure.

E N G IN E

TOP

END

4 -2 1

* If the outside diameter of the valve seating pattern is too large or too small, repair the seat. Valve Seating

Surface

Outside

Diameter

Inlet

36.9 '" 37.1 mm

Exhaust

31.9 '" 32.1 mmXWVUTSRQPONMLKJIHGFEDCBA

V a /ve S e a t

R e p a ir

• Follow the manufacturer's instructions seat cutters (special tools).

for use of valve

Use these Cutters

1. Cutter

2. Cutter Holder

Intake Valve Seat Cutter

45° - <1>30.0

57001-1117

Outside

32° - <1>38.5

57001-1122

60° - <1>41.0

57001-1124

Seat Cutter

45° - <1>35.0

57001-1116

Outside

32° - <1>35.0

57001-1121

60° - <1>41.0

57001-1124

cutter

Inside Cutter

3. Bar 5. After use wash the cutter with washing oil and apply a thin layer of engine oil before storing.

Exhaust Valve

Cutter

Inside Cutter

Marks Stamped on the Cutter: The marks stamped on the back of the cutter represent the following. 1 Cutter number, selected from 1 to 12

Use this Holder and Bar Holder

- <1>7.0

57001-1126

Bar *If

57001-1128

the manufacturer's instructions the following procedure.

are not available, use

45° 24.5<1> KSOO

Cutter angle Outer diameter of cutter Manufactured lot number

Seat Cutter Operating Cares: Outer Diameter of Cutter 1. This valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil,baZYXWVUTSRQPONMLKJIHGFEDCBA Angle of Cutter

NOTE

oRQPONMLKJIHGFEDCBA D o n o t u s e a w ir e b r u s h t o r e m o v e fro m th e c u tte r.

t h e m e t a l p a r t ic le s

I t w ill t a k e o f f t h e d ia m o n d p a r t ic le s .

4. Setting the grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil, NOTE

o P r io r d u r in g

g r in d in g , th e

a p p ly

o p e r e t io n ,

e n g in e

w ash

s t í c k í n g t o t h e c u t t e r w it h

o ff

o íl

any

w a s h í n g o il.

th e

c u tte r

g ro u n d

and

p a r t í c le s

Operating Proced u res: .Clean the seat area carefully . • Coat the seat with machinist's dye. • Fit a 45° cutter to the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.

4-22baZYXWVUTSRQPONMLKJIHGFEDCBA E N G IN E T O P E N D *If

o Do

not grind the seat too mucho Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head. it will be impossible to adjust the clearance. and the cylinder head must be replaced.

e Measure the outside diameter of the seating surface with a vernier caliper. * If the outside diameter of the seating surface is too srnall. repeat the 45° grind until the diameter is within the specified range. * If the outside diameter of the seating surface is too large. make the 32° grind described below. * If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. eGrind the seat at a 32° angle until the seat 0.0. is within the specified range.

the seat width is too wide, make the 60° grind described below.

* If the seat width is within the specified range, lap the valve to the seat as described below. eGrind the seat at a 60° angle until the seat width is within the specified range. O lo make the 60° grind, fit a 60° cutter to the holder, and slide it into the valve guide. Olurn the holder, while pressing down lightly. O After making the 60° grind, return to the seat width measurement step above. eLap the valve to the seat, once the seat width and 0.0. are within the ranges specified above. O Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. O Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. O Repeat the process with afine grinding compound.

O lo make the 32° grind, fit a 32° cutter to the holder, and slide it into the valve guide. Olurn the holder one turn at a time while pressing down very lightly. Check the seat after each turno

(1 )-----1

OThe 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent over grinding.

2 OAfter making the 32° grind, return to the seat 0.0. measurement step above. Widened width of Ground volume engagementonmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA by machining by 32° cutter with 45° cutter

1. Lapper 2. Valve Seat 3. Valve

elhe seating area should be marked about in the middle of the valve face. * If the seat area is not in the right place on the valve, check to be sure the valve is the correct parto If it is, it may have been refaced too much; replace it. e Be sure to remove all grinding compound before assembly. eWhen the engine is assembled, be sure to adjust the valve clearances (see Valve Clearance Adjustment).

elo

measure the seat width,

use a vernier caliper to

measure the width of the 45° angle portion of the seat at several places around the seat. * If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat 0.0. measurement step above.

E N G IN E

TOP

END

V a lv e S e a t R e p a ir tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Machinist', START (onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA )

dyc on scat

45° Grind Too!: Purpose:

45° Cutter make sea ting area smooth and round

Measurc Seating Arca 0.0.

, Tool small

Tool Purpose:

Vernier Caliper check seat 0.0. agai ns t spec.

, ,

I Results

45° Grind Tool: Purpose:

45°Cutter increase O. D. of seat area to spec.

Too big

Machinist's dve on seat

32° Grind Tool: Purpose:

32°Cutter reduce O. D. of seat area to spec,

Measure Seat Width

, 00

narrow

Tool: Purpose:

Vernier Caliper check seat width against spec.

•

45° Grind Tool: Purpose:

I Res,lts

45° Cutter increase width of seat area beyond spec. to increase O. D.

Too wide

•

Machinist's dye on seat

60° Grind

Tool: Purpose:

60° Cutter reduce seat width to spec.

Lap Valve Tools: Pu rpose:

Valve lapper, grinding compound perfectly match valve and seat area; check valve head for damage I

(

FINISHED

4 -2 3

4-24

ENGINE TOP ENDXWVUTSRQPONMLKJIHGFEDCBA

M e a s u r in g V a lve -to -G u id e (W o b b le

C le a r a n c e

Cylinder, Piston

M e th o d )

If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide olearance with the wobble method, as indicated below. elnsert a new valve into the guide so that the end of the stem is flush with the end of the guide. eSet a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. e Move the stem back and forth to measure valve/valve guide clearance. e Repeat the measurement in a direction at a right angle to the first.

C ylin d e r R e m o va l

e Remove the cylinder head. e Remove the mounting bolts, and motor. e Remove the main oil pipe mounting e Pull off the water pump hose upper e Pull out the chain guide holder and e Remove the cylinder bolt. e Remove the cylinder nuts.

slide off the starter bolt. end. guide.

If the reading exceeds the service limit, replace the guide.

NOTEonmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

T h e r e a d in g beca use

is n o t

a c tu a l

th e m e a s u r in g

va lve /va lve

p o in t

is e b o ve

g u id e

c le a r a n c e

th e g u id e .

Valve/Valve Guide Clearance (Wobble Method) Standard

Service Limit

Inlet

0.04 -

0.11 mm

0.24 mm

Exhaust

0.05 -

0.12 mm

0.24 mm A. Cylinder Bolt

--,

Valve guide

New valve

A. Cylinder Nuts

e Lift off the cylinder so as not to damage the main oil pipe.

NOTE

o Ta p

lig h tly a r o u n d

th e b a s e o f th e c ylin d e r w ith a r u b b e r

m a lle t.

e Remove the cylinder base gasket.

E N G IN E C y /ín d e r

/n s ta //a tío n

TOP

END

4 -2 5

N o t e s tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

eReplace the cylinder base gasket with a new one. eApply engine oil to the piston surface, piston rings and cylinder bore. elnstall the cylinder so as not to damage the main oil pipe. eTighten the following to the specified torque in following order. 1. Cylinder Nuts

2. Cylinder Bolt eAfter setting the chain guide into the crankcase and cylinder concavity securely, fit the guide holder into the cylinder concavity securely. A. Piston Ring Pliers: 57001 -115

P ís to n

R em ova/

e Remove the cylinder. eStuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase. e Remove 'one of the pisto n pin snap rings with needle nose pliers. e Remove the piston by pushing the piston pin out the side from which the snap ring was removed. Use a piston pin puller assembly and adapter (special tools), if the pin is tight.

P ís to n

In s ta //a tío n

N o te s

eThe arrow on the top of the piston must point toward the front. eWhen installing a piston pin snap ring, compress it only enough to install it and no more.

o Do

not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

e Fit a new piston pin snap ring into the side of the piston so that the ring opening does not coincide with the notch in the edge of the piston pin hole.

A. Piston Pin Puller Assembly: 57001 -910 B. Adapter: 57001 -1211

e Remove the top and second rings with piston ring pliers (special tool). If the special tool is not available, carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring to remove it.

A. Arrow

B. Snap Ring eRemove the 3-piece oil ring with your thumbs in the same rnanner.baZYXWVUTSRQPONMLKJIHGFEDCBA

C. Ring Opening D. Notch

eOil Ring Installation:onmlkjihgfedcbaZYXWVUTSRQPONMLK O First install the expander in the piston oil ring groove so

that the expander ends but together, never overlap. O Install the upper and lower steel rails. There is no UP

or DOWN to the rails. They can be installed either way.

4-26baZYXWVUTSRQPONMLKJIHGFEDCBA E N G IN E T O P E N D ( j) .- ~

2NMarkRQPONMLKJIHGFEDCBA ~ ~ ¿ J onmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFE

®~

Front

Arrow

• Do not mix up the top and second rings. The top and second rings are not symmetrical and must be installed with the marked side facing up.

N Mark 1. Top Ring 2. Second Ring 3. Steel Rail, Oil Ring 4. Expander, Oil Ring

Top Ring

P is to n R in g , P is to n R in g G r o o ve W e a r

.Check for uneven groove wear by inspectipq seating. Second 2N Mark

Ring

• Position each piston ring so that the opening in the ring and oil ring steel rails are facing forwards, and second ring and oil ring expander openings face rear. The openings of the oil ring steel rails must

top the the be

the ring

*The rings should fit perfectly parallel to the groove surfaces. If not, the piston must be replaced. .With the piston rings in their grooves, make several measurements with a thickness gauge to determine piston ring/groove c1earance.

Piston

Ring/Groove

Clearance Standard

Service

limit

Top

0.03 -

0.07 mm

0.17mm

Second

0.02 -

0.06 mm

0.16 mm

about 30° ;...,40° of angle from the opening of the top ring to either side.XWVUTSRQPONMLKJIHGFEDCBA

A. Thickness Gauge

E N G IN E P is to n

R in g

End

TOP

END

4-27

G a p tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

• Place the piston ring inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low . • Measure the gap between the ends of the ring with a thickness gauge.

Piston Ring End Gap Top

Standard 0.2 0.4 mm

Second

0.2

0.4 mm

Service Limit

60mm

0.7mm 0.7mm

Piston Ring

P is to n

D ia m e te r

• Measure the outside diameter of each piston 5 mm up from the bottom of the piston at a right angle to the direction of the piston pino * If the measurement is under the service lirnit, replace the piston. Piston Diameter Standard: Service Limit:

C y/in d e r /n s id e

KL650-B1 99.942

99.957 mm

KL500-B1

88.942

88.957 mm

KL650-B1 KL500-B1

99.80 mm 88.80 mm

D ia m e te r

.Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure. *If

any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be bored to oversize and then honed.

B o r in g ,

H o n in g

When boring and honing a cylinder, note the following: OThere are two sizes of oversize pistons available. OverCylinder Inside Diameter size pistons require oversize rings. Standard: KL650-B1 100.000 100.Q12 mm Oversize Pistons and Rings KL500-B1 89.000 89.012 mm 0.5 mm Oversize and less than·O.01 mm difference be1 .0 mm Oversize tween any two measurements O Before boring a cylinder, first measure the exact diamService Limit: KL650-B1 100.10 mm eter of the oversize piston, and then, according to the KL500-B1 89.10 mm standard clearance in the Specifications, determine the or more than 0.05 mm difference rebore diameter. However, if the amount of boring between any two measurementsbaZYXWVUTSRQPONMLKJIHGFEDCBA necessary would make the inside diameter greater than 1 .0 mm, the cylinder block must be replaced.

4 -2 8

E N G IN E

TOP

E N D tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

OCylinder inside diameter must not vary more than 0.01 mm at any point. O Be wary of measurements taken immediately after boring since the heat affects cylinder diameter. O In the case of a rebored cylinder and oversize pistón, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm and the service limit for the piston is the oversize piston original diameter minus 0.15 mm. If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder.

E x h a u s t P ip e , M u ffle r RQPONMLKJIHGFEDCBA

E x h a u s t P ip e R e m o v a l

• Remove the following. Upper Fairing Lower Fairing Rear Brake Reservoir Cover • • • •

Loosen the clamp bolt. Remove the mounting bolt. Remove the exhaust pipe holder nuts. Pull off the exhaust pipe to the frontward.onmlkjihgfedcbaZYXWVUTSRQPON

A. Clamp Bolt

B. Mounting

Bolt

""A. Holder Nuts

M u f f le r R e m o v a l

• Remove the following. Right Side Cover Rear Brake Reservoir Cover • Loosen the clamp bolt. .Remove the mounting bolts and pull off the muffler to the rearward.

E N G IN E

A. Mounting BoltsRQPONMLKJIHGFEDCBA

E x h a u s t P ip e . M u f f le r I n s t a lla t io n N o t e s

.Check the exhaust gasket tor signs of damage. It necessary, replace it with a new one . â&#x20AC;˘ Thoroughly warm up the engine, wait until the engine cools down, and then retighten the clamp bolt and holder nuts.

TOP

END

4 -2 9 tsrqponmlkjih

E N G IN E

E n g in e R ig h t S id e

R IG H T

S ID E

/ lE F T

S ID E

5 -1

L e ft S id e

T a b le o f C o n te n ts kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View

5-2

Specifications

5-4

Rem oval

Special Tools

5-4

Installation

Right Engine Cover

5-5

Rem oval Installation

Notes

Clutch Adjustm ent

Check

Adjustm ent

M agneto

Flywheel

5-13 5-13

Notes

5-13

Starter M echanism

5-14

5-5

Starter M otor Rem oval

5-5

Starter M otor Installation

5-5

Starter M otor Disassem blyj

5-5

5-14 Notes

5-14

Assem blyjlnspection

5-15

5-6

Starter Clutch Installation

Release Shaft Rem oval

5-6

Starter Clutch Inspection

5-15

Release Shaft Installation

5-7

Starter Clutch G ear Rem oval.

5-1 5

Rem oval

5- 7

Starter Clutch G ear Installation

5-8

Starter T orque Lirniter Rem oval

Friction Plate W ear, Dam age Inspection

5-8

Starter Torque Lim iter Installation

Friction and Steel Plate W arp Inspection

5-8

Clutch Spring Free Length M easurem ent

5-9

Rem oval

Clutch Housing

5-9

Installation

Notes

Finger Inspection

External Shift M echanism Rem oval Installation

Notes

5-1 O

Note

5-15

Notes

5-16 Notes

5-17

8alancer M echanism

5-17

5-10

8alancer Chain Tension Adjustm ent

5-17

5-10

Rem oval

5 -17

5-10

Installation

5-11

Sprocket and Coupling

5-11

Right W eight

Rem oval

5-11

Right W eight

Installation

5-12

Right W eight and 8alancer Shaft

M agneto

Notes

Cover

Rem oval

5-16 5-16

Inspection

Installation

5-16 Note

Left Engine Cover

Prim ary G ear Rem oval

5-15

Notes

5-18 Assem bly Notes

5-20 5-20

Notes

5-20

5-12

Rem ovaljlnstallation

Note

5-12

8alancer Chain W ear

5-21

j Assem bly Disassem bly MLKJIHGFEDCBA

5-12

Cam shaft Chain, 8alancer Chain G uide W ear

5-21

Installation

5-21

5-2 WVUTSRQPONMLKJIHGFEDCBA E N G IN E R IG H T S ID E / L E F T S ID E Exploded View MLKJIHGFEDCBA

- ,r ' • ..•,

.. \i')'

~ .0 O

";'

~:'. !: ~::.::~ A ~ ~ ~ :t

~. ~

''',

S w itc h

&) ~

: Apply a non-perm anent locking agent to the threads.

M : Apply

m olybdenum

disulfide grease.

T1 KJIHGFEDCBA f[\ ;SJ G : Apply high tem perature grease. \b I

: Apply engine oil.

T1 : 9.8 N -m (1.0 kq-rn, 7.0 ft-lb] T2: 12N -m

(1.2 kq-m , 8.5 ft-lb]

T3: 34 N -m (3.5 kq-m , 25 ft-lb] T4: 195 N -m (20 kq-rn, 145 ft-lb] T5: 23 N -m (2.3 kq-m , 16.5 ft-lb] T6: 25 N -m (2.5 kq-m , 18.0 ft-lb] T7: 44 N -m (4.5 kq-rn, 33 ft-lb) T8: 120 N -m (12.0 kq-rn, 87 ft-lb] T9: 130 N -m (13.5 kq-m , 98 ft-Ib)

EN G IN E

R IG H T

SID E / LEFT SID E

5-3

5 -4

E N G IN E

R IG H T

S ID E

/ L E F T S ID E

S p e c ific a tio n s

Ite m

S ta n d a rd

S e rv ic e L im it

C lu tc h : kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Clutch lever free play Clutch spring free length Friction plate thickness Friction and steel plate warp

2 - 3m m A 34.2 m m

- - -

33.1 m m 2.8 m m

2.9 - 3.1 m m Not m ore than 0.2 m m

0.3m m

B a la n c e r M e c h a n is m :

8alancer chain 20-link

length

190.5 -

O u ts id e

S p e c ia l T o o ls

C lu tc h

H o ld e r:

R o to r

H o ld e r:

R o to r

P u lle r:

5 7 0 0 1 -1 2 4 3

5 7 0 0 1 -1 1 8 4

5 7 0 0 1 -1 2 1 6

193.4 m m

190.9 m m

C irclip P lie rs :

5 7 0 0 1 -1 4 4

E N G IN E

R ig h t E n g in e C o v e r MLKJIHGFEDCBA

R IG H T

S ID E

/ LEFT

S ID E

5 -5

C lu tc h

R e m o v a l kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Due to friction

e Rem ove :

plate wear and clutch cable stretch over

Engine O il (drain)

a long period of use, the clutch

Fairings

cordance with the Periodic M aintenance

m ust be adjusted

in ac-

Chart.

Coolant (drain) Brake Pedal and Spring

I W A R N IN G

Right Footpeg Left Handguard

O To avoid a serious burn, nevar touch tha angina or ex-

Clutch Cable Upper and Lower Ends

haust pipa during clutch adjustm ant.

O il Filter W ater Purnp Cover (turn up) Im peller eTurn

the clutch release lever toward the rear and free the

release shaft from the clutch spring plate pusher.

Ad ju s tm e n t

C heck

e Rem ove the handguard. e Pull the clutch lever just enough to take up the free play. e M easure

the

gap

between

the

lever and

the

lever

without

the

bracket.

o Do

not rem ove the clutch

rem oval.

release shaft for clutch cover

C over release shaft rem oval dam ages the oil

seal in the clutch

cover necessitating

oil seal replace-

m ento

e Rem ove the cover bolts, and take off the cover.

A. Clutch Lever Free Play: 2 ,.., 3 m m

eW hen

checking

handguard

the

rem oval,

clutch

lever

play

check the lever play at the lever

end.

A. Cover Bolts

In s ta lla tio n

N o te s

e Before installation, the rear. eAfter

installation,

turn the clutch

release lever toward

adjust the clutch.

A. Clutch Lever Play (at lever end): 10 ,.., 15 m m

If the gap is too wide, the clutch If the gap is too

narrow,

m ay not release fully.

the clutch

fully. In either case, adjust the clutch.

m ay not engage

5-6 WVUTSRQPONMLKJIHGFEDCBA E N G IN E R IG H T S ID E / L E F T S ID E KJIHGFEDCBA A d ju s tm e n t

.Slip

.Slide

.Turn

.Loosen

back the dust cover at the clutch cable low er end. both adjusting nuts at the right engine cover as

the rubber dust cover back into place. the adjuster at the clutch lever until the free play is

correct. .Tighten

far as they w il! go.

the knurled locknut at the clutch lever.

N O T E MLKJIHGFEDCBA O Be

s u r e th a t th e

o u te r

c a b le e n d

a t th e

c lu tc h

le ve r is

fu l l y s e a t e d i n t h e a d j u s t e r a t t h e c l u t c h l e v e r , o r i t c o u l d s lip in to

th e p la c e

le te r . c r e a tin g

p r e ve n t c lu tc h d is e n g a g e m e n t

enough

c a b le p la y to

• After the adjustm ent, start the engine and check that the clutch does not slip and that it releases properly.

A. D ust C over

8. Adjusting

N uts R e le a s e S h a ft

R em oval

• Loosen the knurled locknut at the clutch lever. • Turn the adjuster so that 5 ,.., 6 m m of threads are visible.

o D o not rem ove the clutch release shaft unless it is absolutely necessary. If rem oved, you m ust replace the oil seal w ith a new one .

• Slide the dust cover at the clutch cable low er end out of place. • Loosen the nuts, and slide the low er end of the clutch cable to give the cable plenty of play. • R em ove the left handguard. • Loosen the knurled

locknut

at the clutch

lever, and

screw in the adjuster. • Line up the slots in the clutch

lever, knurled locknut,

and adjuster, and then free the cable from the lever. A. Knurled Locknut

C .5 ,.., 6 m m

B. Adjuster A • Pul! the clutch cable tight and tighten the adjusting nuts against the bracket.

A. Knurled Locknut

C . Slot

B. Adjuster

• Free the clutch inner cable tip from the clutch release lever. A. C lutch C able B. Pul! Tight

C . Adjusting

N uts

.Turn

the release lever tow ard the rear as show n in the

figure.

E N G IN E

A. Release Lever

C. Positioning

A.1

Bolt

R IG H T

S ID E

/ lE F T

S ID E

5 -7

,.., 3 m m

B. Rear

e Rem ove the positioning e Pull the

bolt.

lever and shaft

assem bly

out

of the

clutch

cover. KJIHGFEDCBA

R e le a s e S h a ft

o Install

In s ta lla tĂo n

a new oil seal alw ays w hen rem oving the clutch

release shaft.

R em o val

eApply

high tem perature

grease to the oil seallips

on the

eApply

oil to the bearing in the hole of the clutch cover.

eApply

the release lever toward

lease shafts straight

e Rem ove the

clutch

spring

plate with

the thrust

ball

bearing and pusher.

oil to the release shaft.

eTurning

e Rem ove the right engine cover. e Rem ove the clutch spring bolts, washers and springs.

upper ridge of the clutch cover.

the rear, insert the re-

e Rem ove the friction

plates and steel plates.

into the upper hole of the clutch

cover.

O W hen inserting

the release shaft, be careful not to re-

m ove the spring of the oil sea!.

WVUTSRQPONMLKJIHGFEDCBA

e l nstall the position ing bolt.

eTurn

the release lever clockwise

until it becom es hard

to turno O The release lever should

have proper clearance and an-

gle as shown. A. Clutch $pring

Bolt

D. Thrust Ball Bearing E. Plate Pusher

B. W asher C. Clutch $pring eUsing

Plate

the clutch

clutch hub nut.

holder

(special

tool),

rem ove

the

5-8 WVUTSRQPONMLKJIHGFEDCBA E N G IN E R IG H T S ID E / L E F T S ID E o Before using the special tool, rem ove the fram e pipe cap and insta" the right footpeg

w ith

turning

it up side

dow n as a stopper for the special tool.

o If

new dry steel plates and friction

plates are installed,

apply engine oil to the surfaces of each plate to avoid clutch plate seizure .

• Apply engine oil to the thrust ball bearing . • Apply

m olybdenum

disulfide

grease to

the

rubbing

portion of clutch spring plate pusher. .Tighten

the clutch spring bolts to the specified torque

(see Exploded View ).

F r ic tío n P la te

.Visua"y

B. Footpeg

C ap

W ea r, D a m a ge

inspect the friction

In s p e c tío n

plates to see if they show

any signs of seizure, overheating, or uneven w ear. If any plates show signs of dam age, replace the friction plates and steel plates as a set. A

A C lutch H older: 57001 -1243 B. H ub N ut A Friction Plate

• R em ove the follow inq

out of the drive shaft.

W asher Friction P late Thickness

C lutch H ub Thrust W asher

S tandard:

2.9 ~ 3.1 m m

C lutch H ousing and Bushing

S ervice lim it:

2.8 m m

Spacer MLKJIHGFEDCBA

F r íc tío n a n d In s ta lla tio n

N o te s

• D iscard the used clutch hub nut, and insta" a new nut. .Insta"

the clutch hub nut w ith the projected side facing

outw ard. .Insta"

the clutch holder (special tool:

S te e l

P la te

W a r p In s p e c tío n

• Place each friction plate or steel plate on a surface plate,

57001-1243)

keep the clutch hub from turning and tighten the clutch

and m easure the gap betw een the surface plate and each friction plate or steel plate. The cap is the am ount of friction or steel plate w arp.

* If any plate

is w arped over the service lirnit, replace it

w ith a new onq,

hub nut to the specified torque (see Exploded View ) . • After torquing, caulk the nut. .Insta"

the friction plates and steel plates, starting w ith a

friction plate and alternating them .

Friction and S teel P late W arp S tandard:

N ot m ore than 0.2 m m

S ervice lim it:

0.3 m m

E N G IN E

B. Friction Plate KJIHGFEDCBA

A. Steel Plate

R IG H T

A. C lutch H ousing Finger

C lu tc h S p r in g F r e e L e n g th M e a s u r e m e n t WVUTSRQPONMLKJIHGFEDCBA

C lu tc h

S p r'in g F re e L e n g th

S ta n d a rd : A

3 4 .2 m m

S e rv ic e

3 3 .1 m m

L im it:

A. C lutch Spring

C lu tc h H o u s in g F in g e r In s p e c tio n eVisually

inspect the fingers of the clutch housing w here

the tangs of the friction plates hit them .

* If they are badly w orn

or if there are grooves cut w here

the tangs hit, replace the housing.

Also, replace the

friction plates if their tangs are dam aged.

S ID E

/ L E F T S ID E

B. Friction Plate Tang

5 -9

5 -1 0

E N G IN E

R IG H T

S ID E

/ L E F T S ID E kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Externa I S h ift M e c h a n is m MLKJIHGFEDCBA

In s p e c tio n e Exam ine the shift shaft for any dam age. O Check the shift

shaft for bending

or dam age

to the

splines.

R e m o va l

* If the shaft is bent, straighten or replace it. If the splines

e Rem ove :

are dam aged, replace the shaft.

Shift Pedal

O Check the return spring

Right Engine Cover

and arm spring

for cracks or

distortion.

Clutch Housing e Pull out the shift shaft with

the shift m echanism

arm ,

arm spring and shaft return spring. e Rem ove the gear positioning

lever m ounting

bolt, and

* If the springs are dam aged in any way, replace them . O Check the shift m echanism arm for distortion. *If

the shift m echanism

arm is dam aged in any way, re-

place the arm o A

take off the lever and spring. e Rem ove the Allen bolt in the shift drum cam , and take off the drum cam . epull

off the dowel pino

A. Shift Shaft

C. G ear Positioning

B. Shift M echanism

Arm

A. Shift Shaft

C. Arm Spring

B. Return Spring

D. Shift M echanism

Arm

Lever

D. Shift Drum Cam

eCheck

that the return spring pin is not loose.

* If it is loose, unscrew agent to the threads,

it. apply a non-perm anent and tighten

locking

it to the specified

torque (see Exploded View). eCheck

eSet

the dowel

into

the largest hole of the three

*If

the lever or spring

eVisually *If

A. Dowel Pin Hole

non-perm anent

locking agent to the threads of

the shift drum cam Allen bolt. e Before installing

gear positioning

lever, and

its spring

for

the shift shaft. apply high tem perature

grease to the oil seal lips.

is dam aged

in any way, replace

them .

which is the nearest hole from the center.

eApplya

the

cracks or distortion.

In s ta lla tio n N o te s

inspect the shift drum cam .

it is badly worn or if it shows any dam age, replace it.

E N G IN E

P rim a ry

R IG H T

In s ta lla tio n

G e a r MLKJIHGFEDCBA

S ID E

/ lE F T

S ID E

5 -1 1

N o te s

Fit the claw of the washer into the key groove of the oil pum p drive gear.

eTighten

R e m o va lA

e kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Rem ove : Right Engine Cover

Shift Pedal Engine Sprocket Cover Cover (place on one side)

e Flatten out the bend claw washer, and rem ove the prim ary gear nut with using the rotor holder (special tool) flywheel

to keep the crankshaft

from

turning.

A. Rotar Holder: 57001 -1184

e A. Prim ary G ear Nut B. Claw W asher

Rem ove the claw washer, oil pum p drive gear, prim ary gear, key and spacer.

gear nut, using

57001 -1184)

the rotor

holder

to keep the crankshaft from

to the specified torque (see Exploded View). the

washer over the nut.

G il Pum p

on the m agneto

tum ing,

e After torquing

Clutch Housing

M agneto

the prim ary

(special tool:

nut,

bend

the

one

side

of claw

5 -1 2

E N G IN E

R IG H T

S ID E

/ L E F T S ID E N o t e kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

In s ta lla tía n

C o v e r MLKJIHGFEDCBA

M a g n e to

e Run the m agneto Routing

leads in accordance

in the G eneral Inform ation

with

the W ire

chapter.

R e m o va l

eRem ove: Engine O il (drain) FuelTank M agneto

Lead Connectors

(disconnect)

Cylinder Head Bracket D ís a s s e m b ly

See the chapter.

A. Connectors

B. Cylinder Head Bracket

Shift Pedal Engine Sprocket Cover Neutral Switch M agneto

A. Neutral Switch B. M agneto

Lead Connector

Lead Clam ps

Lead Connector

C. Cover Bolts

Lead Clam p

e Hem ove the

bolts,

and

take off

the

cover

pickup coil, the stator and lead grom m ets.

with

the

/ As s e m b ly

Flywheel

M agneto

in the

Electrical

System

E N G IN E /n s ta //a tio n

F ly w h e e l MLKJIHGFEDCBA

M a g n e to

R IG H T

S ID E

/ L E F T S ID E

5 -1 3

N o te s

e Replace the m agneto

flywheel

bolt with

a new

one.

This bolt is required to replace if it has been tightened one to the specified torque.

R e m o v a / kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

e Using a high flashpoint

eRem ove:

that

Engine O il (drain)

m ay be on the

portions

Shift Pedal

solvent, clean off any oil or dirt new

of the crankshaft

flywheel

bolt,

and the flywheel.

the tapered Dry them

with a clean cloth.

Engine Sprocket Cover M agneto

Lead Clam p

M agneto

Cover (place on one side)

Starter Clutch Id le G ear e Hold the flywheel

steady with the rotor holder (special

tool), and rem ove the flywheel

bolt.

A. Clean off.

e Rem ove the washer and the starter clutch gear. eAssem ble A. Rotor Holder:

the washer and the starter clutch gear into the

flywheel with turning the gear to the unlocked direction.

57001 -1184

e Fit

B. Footpeg

the

woodruff

key

securely

crankshaft befare installing e Hold the flywheel e Using

the

flywheel

rotor

steady,

starter clutch

holder

(special

rem ove

the

assem bly

with

tool)

m agneto the rotor

hold

flywheel puller

tool:

the

slot

the

assem bly.

steady with the rotor holder (special

57001 -1184),

and tighten the flywheel bolt to the

specified torque (see Exploded View).

and

(special

the flywheel

eTightening

tool).

procedure

of the flywheel

bolt is the fol-

bolt to 120 N-m

(12.0 kg-m , 87

lowing. O Tighten ft-Ib)

the flywheel

of torque.

Do not overtighten

O Loosen the bolt and then tighten

it now. it again to the sam e

torque (above). O Finafly, tighten the bolt to the specified tarque (see Ex-

ploded View). If any oil is deposited tighten

on the threads of the bolt, finally

it to 175 N-m (18.0 kg-m , 130 ft-Ib)

of tarque.

O U se a 6-point socket instead of 12-point one to tighten the flyw heel bolt to the specified torque.

A. Rotar Holder: B. Rotor Puller:

o If

57001 -1184 57001 -1216

the flyw heel

w hile

tapping

is difficult

rem ove, turn

the head of the puller w ith

D o not strike the flyw heel

itself.

the puller a ham m er.

S triking the flyw heel

can cause the m agnets to lose their m agnetism o

5 -1 4

E N G IN E

R IG H T

S ID E

/ LEFT

S ID E

S ta rte r M e c h a n is m MLKJIHGFEDCBA

S ta r te r

M o to r

In s ta lla tio n

e Clean the starter m otor

N o te s

lugs and crankcase where the

starter m otor is grounded. S ta r te r M o to r

e Rem ove :

eApplya

little engine oil to the O -ring on the starter m oR e m o v a l kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA tor.

Fairings Exhaust Pipe e Disconnect the starter m otor term inallead. e Rem ove the starter m otor m ounting

bolts.

A. Clean here.

B.O -ring

e M ount the battery ground rear m ounting O M ount

A. Term inal

B. M ounting

the tip so that its face is as shown. A

Bolts

e Prying the starter m otor loose from the left engine cover with

a screwdriver,

lead tip with the starter m otor

bolt on the m otor leg.

slide the starter m otor off towards

Tip

the right side of the engine.

M otO C L ,gn o Do

not tap on the starter m otor body.

G round

Lead

T apping on the

body could dam age the m otor.

O M ount

the tip

w ith

turning

the

rear, as inside as

possible, to m ake a gap betw een the ground lead and the hot exhaust pipe.

Starter M otor A. Pry

Tip

G round

Lead

E N G IN E eTighten

the starter m otor m ounting

R IG H T

S ID E

/ L E F .T S ID E

5 -1 5

bolts to the speci-

fied torque (see Exploded View). MLKJIHGFEDCBA

S ta r te r M o to r

D is a s s e m b /y/As s e m b /y//n s p e c tio n

eSee Electrical System chapter.

A. Starter Clutch G ear S ta r te r

C /u tc h

e Rem ove the m agneto

C. Locked.

B. Turns freely.

R e m o va /

flywheel

and starter clutch

as-

flywheel

in a vise, rem ove the

sem bly. e Holding

the m agneto

Allen bolts and separate the starter clutch.

NOTE O S ta r te r

c /u tc h

in s p e c tio n

ca n be done

b y r e m o vin g

th e

and starter clutch

as-

s ta r te r m o to r , to a .

A. M agneto

Flywheel

B. Starter Clutch Allen Bolts

A. Starter Id le G ear

C. Locked.

B. Turns freely.

S ta r te r

C /u tc h

eApplya

/n s ta //a tio n

non-perm anent

N o te

locking agent to the threads of

the Allen bolts and tighten them to the specified torque (see Exploded View).

S ta r te r

C /u tc h

G e a r R e m o va /

e Rem ove the m agneto

flywheel

sem bly. O In this tim e, the starter clutch gear m ay be rem oved with the flywheel.

If so, separate the starter clutch gear from

the flywheel. e Rem ove the washer, and pull off the starter clutch gear.

S ta r te r

C /u tc h

eRem ove

/n s p e c tio n

the m agneto

cover and starter idle gear, and

turn the starter clutch gear by hand. gear should

turn clockwise

The starter clutch

freely, but should

not turn

counterclockwise.

S ta r te r

C /u tc h

does not operate as it shou Id or if it m akes

eApply

engine oil to the inside bushing of the gear.

noise, disassem ble the starter clutch, exam ine each part

elnstall

the starter clutch gear after assem bling

* If the clutch

G e a r /n s ta //a tio n

flywheel. visually, and replace any worn or dam aged parts. WVUTSRQPONMLKJIHGFEDCBA

N o te s

it into the

5 -1 6

E N G IN E

R IG H T

S ID E

/ lE F T

S ID E MLKJIHGFEDCBA

S t a r t e r T o r q u e L i m i t e r R e m o v a l kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

le ft

e Rem ove : M agneto

E n g in e C o v e r

Cover (place on one side)

Starter Clutch Idle G ear

R e m o va l

e Rem ove the starter tor.que lim iter.

e Rem ove : M agneto

Cover (place on one side)

Starter Clutch Idle G ear M agneto

Flywheel

Starter Clutch G ear and Shaft Starter Torque Lim iter Balancer Chain Tensioner Lock Bolt Balancer Chain Tensioner Adjusting

A. Starter Clutch G ear

Lever

C. Starter Torque Lim iter

B. Starter Clutch Idle G ear

S ta r te r T o r q u e L im ite r In s ta lla tio n eApply shaft.

m olybdenum

N o te

disulfide grease to the torque lim iter

A. Balancer Chain Tensioner Lock Bolt B. Balancer Chain Tensioner Adjusting

Lever

C. Circlip

e Rem ove the cover bolts, and take off the cover.

N O T E KJIHGFEDCBA O P r y in g

th e c o v e r u p p e r e n d lo o s e fr o m th e s ta r te r m o to r

w ith a s c r e w d r iv e r , ta k e o ff th e c o v e r .

A. Left Engine Cover A

B . P ry

E N G IN E In s ta //a tio n

R IG H T

S ID E

/ LEFT

S ID E

5 -1 7 MLKJIHGFED

N o t e s kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

e Before installing the cover, apply a little engine oil to the

B a la n c e r

M e c h a n is m

0- ring on the starter m otor. eTurning clockwise bolt.

the

balancer

chain

tensioner

adjusting

lever

to tighten the balancer chain, tighten the lock

B a la n c e r

C h a in

T e n s io n

Ad ju s tm e n t

Balancer chain wear and chain guide wear cause the chain to develop

slack, which

will

m ake noise and m ay

result in engine dam age. To prevent this, tension adjustm ent cordance with the Periodic M aintenance

is necessary in acChart.

e Rem ove the tensioner cap and loosen the tensioner lock bolt a few turns. eTighten

the bolt securely and install the cap.

A. Cap

B. Tensioner Lock Bolt

R e m o va l

e Rem ove: M agneto

Cover (palce on one side)

M agneto

Flywheel

Starter M echanism Left Engine Cover e Rem ove the tensioner spring. e Rem ove the circlip, and take off the tensioner lever and washer' (Circlip is m ounted

A. Tensioner Spring

only on the 89 m odel).

B. Tensioner Lever

e Pull out the idler shaft with a pliers, and take out the idle sprocket, bearing and spacer.

5 -1 8

E N G IN E

R IG H T

S ID E

/ LEFT

S ID E

NOTEA

KJIHGFEDCBA p u llin g o u t

MLKJIHGFEDCBA th e c h a in w ith kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

O B e fo r e

th e id le r s h e t t . lo o s e n

tu r n in g

th e s h a ft to th e c o u n te r c /o c k w is e .

A. Shaft Punch M ark

A. Idler Shaft

~e e

Punch M ark

B. Pliers

Rem ove the inside and outside chain guides. Pull

the

slack

chain

forward,

sprocket ano left weight coupling

B. Coupling

rem ove

the

front

assem bly.

Rem ove the rear sprocket and coupling

assem bly with

the chain.

A. Left W eight

Punch M ark

B. Shaft Punch M ark (Ieft side)

Position

the crankshaft

at T D C whĂŠre the punch m ark

on the crankshaft sprocket is at the topo

Engage the balancer chain with as shown

in the following

the balancer sprockets

figure.

O The plated links of the chain m ust face outwards.

Fit tooth

of the crankshaft

sprocket

into the single

plated link. O The tooth A engaged with a single plated link is on opposite side to the sprocket punch m ark. A. Inside Chain G uide

eThe

B. Front Sprocket and Left W eight Coupling C. Rear Sprocket and Coupling

Assem bly

other two sprocket teeth with the punch m ark m ust

fit between the plated links.

Assem bly

D. O utside Chain G uide

In s ta lla tio n eThe

N o te s

balancer shafts, weights,

couplings

and sprockets

have punch rnarks. Assem bly them , aligning their m arks with each other as shown

in the figure.

A. Plated Links.

\ kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

'~IN E

R IG H T SID E / LEFT SID E WVUTSRQPONM 5 -1 9 Two Plated Links

R e a r B a la n c e r

\ T

C y lin d e r C e n te r L in e

Top

C ra n k p in

Balallcer Punch M ark Sprocket

M ark

A Single Plated Link

F ro n t B a la n c e r

B a la n c e r T e n s io n e r KJIHGFEDCBA

eApplya .J

non-perm anent

.the inside chain guide

locking agent to the threads of bolts. and tighten

them to the

specified torque (see Exploded View). eTap

the idler shaft and sprocket into the hole in the left

crankcase.

A. Idler Shaft and Sprocket

e T u rn the tensioner

lever clockwise

to tighten the chain.

5 -2 0

E N G IN E

R IG H T

S ID E

/ L E F T S ID E kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA R ig h t W e ig h t R e m o va l .R em ove: R ight Engine C over M agneto C over (place on one side) • Flatten out the bent claw w asher, and rem ove the front right w eight

nut w ith

using the rotor holder (special

tool: 57001 -1184) to keep the crankshaft and balancer shafts from turning.

A. Tensioner Spring

B. Tensioner Lever MLKJIHGFEDCBA

S p r o c ke t a n d C o u p lin g As s e m b ly N o te s .Align

the punch m ark on the coupling

w ith the punch

m ark on the sprocket.

A. W ater Pum p Shaft

C. N ut

B. R ight W eight

D . C law W asher

• R em ove the claw w asher, w eight and spacer.

R ig h t W e ig h t In s ta lía tio n N o te s .Align

the punch m ark on the w eight

w ith the punch

m ark on the shaft.

A. Sprocket M ark

B. C oupling Punch M ark

,1\.1

A. R ight W eight Punch M ark B. Shaft Punch M ark (right side)

• Fit the claw of the w asher into the hole of the w eight. .Tighten A. Left W eight Punch M ark

B. Sprocket M ark

holder

the front (special

right w eight tool:

crankshaft from turning,

nut.

using

the

keep

the

to the specified torque

(see

57001 -1184)

rotor

Exploded View ) . • After torquing

the

w asher over the nut.

nut,

bend the

one side of claw

E N G IN E Rear

W e ig h t

a n d B a la n c e r

R IG H T

S h a ft

R e m o v a l /1n s ta lla tio n kjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

o For the rem ovaljlnstallation

the

rear weight

and

balancer shafts, operate after crankcase spritting.

B a la n c e r

C h a in

W ear

e Hold the chain taut with a force of about 5 kg in som e m anner, and m easure a 20-link m ay

wear

unevenly,

take

length.

Since the chain

m easurem ents

several

places. *If

any m easurem ent

exceeds the service lim it, replace

the chain. B a la n c e C h a in 2 0 -lin k

le n g th

S ta n d a rd :

1 9 0 .5 ,...,1 9 0 .9 m m

S e rv ic e lim it:

1 9 3 .4 m m

20-Link

Length A

O C a m s h a ft

eVisually

C h a in ,

B a la n c e r

C h a in

G u id e

W ear

inspect the rubber on the guides.

* If the rubber is dam aged, cut, or is m issing

pieces, re-

place the guides.

.â&#x20AC;˘.

1. Cam shaft Chain Tension G uide 2. Inside Balancer Chain G uide 3. O utside Balancer Chain G uide

S ID E

/ lE F T

S ID E

5 -2 1 KJIHGFEDC

E N G IN E

L U B R IC A T IO N

SYSTEM

6-1

E ngine Lubrication S ystem Table 01 C ontents ihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View

6-2

Enqine O il Flow C hart

6-4

Specifications

6-5

Special Tools

6-5

Engine O il and O il Filter

6-6

O il Level Inspection

6-6

O il and/or Filter C hange

6-6

O il Filter R em oval

6-6

O il Filter Installation

N otes

6-7

O il Pum p and R elief Valve

6- 7

R elief Valve R em oval

6-7

R elief Valve Installation

N otes

O il Pum p R em oval O il Pum p Installation

6-7 6- 7

N otes

6-8

O il Pum p D isassem bly

6-8

O il Pum p Assem bly N otes

6-8

O il Pum p D rive G ear R em oval

6-8

O il Pum p D rive G ear Installation

6-8

O il Pressure M easurem ent

6-8

O il Pum p Inspection

6-9

R elief Valve Inspection

6-9

O il Screen

6-10

R em oval Installation

6-10 N ote

6-10

C leaning and Inspection

6-10

O il Pipe

6-10

M ain O il Pipe R em oval M ain O il Pipe Installation

6-10 N otes

6-10

C ylinder H ead O il Pipe R em oval

6-10

C ylinder H ead O il Pipe Installation N otes

6-10

6-2

E N G IN E

E xploded V iew

LU B R IC A TIO N

S Y S TE M

E N G IN E

1 . O il P re s s u re

S Y S TE M ihgfedcbaZYXWVU 6-3 VUTSRQPON

LU B R IC A TIO N

R e lie f V a lv e

2 . O il P a s s a g e P lu g 3 . O il P u m p 4 . O il S c re e n 5.

E n g in e O il D ra in P lu g

: A p p ly a n o n -p e rm a n e n t

: A p p ly e n g in e o il.

L G : A p p ly

liq u id

92104路1003) le ft c ra n k c a s e S

: F o llo w

gasket to

th e

lo c k in g a g e n t to th e th re a d s .

b la c k

m a tin g

T 2 : 2 0 N - m ( 2 .0 k g - m , 1 4 .5 f t- lb ) T 3 : 2 3 N - m ( 2 .3 k g - m , 1 6 .5 f t- lb ] 1 5 N - m ( 1 .5 k g - m , 1 1 .0 f t- lb )

B ond:

o f th e rig h t a n d

h a lv e s .

th e s p e c ific tig h te n in g

T 1 : 1 2 N - m ( 1 .2 k g - m , 8 .5 f t- lb )

T4:

(K a w a sa k i

su rfa c e

sequence.

6-4

E N G IN E

LU B R IC A TIO N

S Y S TE M

E ngine O il Flow C hart ihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

I I

M ain O il Pipe

" IHGFEDCBA f

N eedle Bearing

O il Pum p

O il Screen

O utput

Shaft

D rive Shaft

E N G IN E

LU B R IC A TIO N

S Y S TE M

S pecifications

Item Engíne

Standard

O il and O il Fílter:

Engine O il:

G rade

SE of SF class

Viscosity

SAE10VV40, 10VV50, 20VV40, or 20VV50

C apacity

2.5L (w hen engine is com pletely dry) 2.2L (w hen filter is not rem oved) 2.5L (w hen filter is rem oved)

Level O íl Pum p

and R elíef

Betw een upper and low er levels

Valve:

R elief valve opening pressure

430 '" 590 kPa (4.4 '" 6.0 kq/crn",

O il pressure @ 4,000 r/rnin (rprn), oil tem p.

78 '" 147 kPa (0.8 '" 1.5 kq/crn-,

63 '" 85 psi) 90°C (194°F)

11 '" 21 psi)

S pecial Tools D il Pressure G auge:

57001-164

D il Pressure G auge Adapter:

57001-1182

6-5

6-6

E N G IN E

LU B R IC A TIO N

S Y S TE M

Oil and/or Filter Change

E ngine O il and O il Filter

eW arm

up the engine so that the oil w ill

pick up any

sedim ent and drain easily. Then stop the engine. ePlace

an oil pan beneath the engine.

eR em ove

I WARNING' o M otorcycle

operation

or contam inated

w ith

insufficient.

engine oil w ill

the engine

drain

plug,

and

let the oil drain

com pletely.

deteriorated.

N O TE VUTSRQPONMLKJIHGFEDCBA

cause accelerated w ear

and m ay result in engine or transm ission

seizure. acci-

dent. and injury.

O H o ld

t h e m o t o r c y c le

u p r ig h t

s o th a t th e

o i! m a y

d r a in

c o m p le t e ly .

Oil Levellnspection elf the oil has just been changed. start the engine and run it for several m inutes at idle speed. This fills the oil filter w ith

oil.

Stop the engine. then w ait

severa I m inutes

until the oil settles.

o R acing

the engine before the oil reaches every part can

cause engine seizure.

elf

the m otorcycle

has just been used. w ait several m in-

A. D rain Plug

utes for all the oil to drain dow n. eSituate

the m otorcycle

so that it is perpendicular

qround, and check the engine oil level through level gauge.

to the the oil

The oil level should com e up betw een the

the oil level is too high. rem ove the excess oil, using the oillevel through

is too low , add the correct am ount of oil

the oil filler opening.

U se the sam e type and

a new

plug

the gasket w ith a new one if it is dam aged.

the oil has com pletely w ith

drained out, install the drain

the gasket. and tighten

it to the specified

torque (see Exploded View ). e Fill the engine w ith

m ake of oil that is already in the engine.

replace it w ith

the gasket at the drain plug for dam age.

*R eplace eAfter

a syringe or so m e other suitable device. *If

the oil filter is to be changed,

one. eC heck

upper and low er levellines. *If

elf

a good

quality

m otor oil specified

in the table. eC heck

the oillevel.

N O TE IHGFEDCBA O f f t h e e n g in e o i! t y p e a n d m a k e 'a r e u n k n o w n , b r a n d o f t h e s p e c if ie d e n c e t o r u n n in g

o i! t o t o p

t h e e n g in e . .w it h

use any

u p t h e le v e l in p r e f e r t h e o ille v e llo w .

Then

a t y o u r e a r lie s t c o n v e n ie n c e , c h a n g e t h e o i! c o m p le t e ly .

E ngine

G rade: V iscosity:

S E or S F class S A E 10W 40,10W 50, 20W 40, 2O W 50

C apacity:

2.5L (w hen

engine

is com pletely

dry)

level:

2.2L (w hen

filter

is not rem oved)

2.5l (w hen

filter

is rem oved)

B etw een

upper and low e levels

Oil Filter Removal e R em ove the oil filter cap w ith prying the pry point. eTake out the oil filter. A. U pper Level

B. Low er Level

E N G IN E

LU B R IC A TIO N

S Y S TE M

6-7

Oi/ Fi/ter /nsta//ation NotesihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA eApply

oil to the m ounting

the m ounting

pin, turn the filter elem ent or

pin to w ork the elem ent into place.

careful that the elem ent grom m ets

O il P um p and R elief V alve

do not slip out of

place.

Re/iet Va/ve Remova/ e R em ove the right engine cover. e R em ove the relief valve from the oil passaqe on the right engine cover.

A. Turn the elem ent

eW hen

installing

B. G rom m et

the oil filter, put the m ounting

pin into

the filter so that the sm aller diam eter end is inw ard.

A. R elief Valve

e Fit the O -ring of the oil filter in place, being careful not to tw ist the O -ring.

Re/iet Va/ve /nsta//ation Notes eApplya

non-perm anent

locking agent to the threads of

the relief valve, and tighten

it to the specified

torque

(see Exploded View )

o Do

not over-apply

the threads.

a non-perm anent

locking

agent to

T his m ay block the oil passage.

A. O -ring eSee the next section for R elief Valve Inspection. elnstall

the oil filter cap so that the arrow points upw ards.

Oi/ Pump Remova/ e R em ove the right engine cover. eTurn

the crankshaft so that the engine oil pum p screw s

(3) can be rem oved

through

the oil pum p

and rem ove the screw s (3) and oil pum p.

A. O il Filter C ap B. Arrow

C . Pry Point (for rem oval) LKJIHGFEDCBA

gear hole,

6-8 LKJIHGFEDCBA E N G IN E LU B R IC A TIO N

S Y S TE M O í! P u m p

eApplya

A s s e m b ly

N o te s

non-perm anent

locking

agent to the threads of

the oil pum p cover screw . e Before installing

the oil pum p,

be sure the shaft and

rotors tu rn freely.

O í! P u m p

eThe

D rív e

G ear R em oval

oil pum p drive gear is rem oved during

rem oval (see Engine R ight Side/Left

prim ary gear

Side chapter).

A. O il Pum p G ear O í l P u m p D r í v e G e a r I n s t a lla t í o n B. O il Pum p Screw s C . O il Pum p C over Screw : rem oval is not required IHGFEDCBA eThe oil pum p drive gear is installed during prim ary gear installation (see Engine R ight Side/Left Side chapter).

O í! P re s s u re O íl P u m p

eC lean

tnsteltstion

M easuring N o te s

M e a s u re m e n t

the oil pressure w hen

(about room tem perature)

any m etal particles and dirt off the oil screen.

operation.

the engine

is cold

is a w ay to inspect relief valve

First inspect the relief valve operation

w ith the

eFill the oil pum p w ith engine oil for initiallubrication.

engine to m easure the oil pressure at the norm al operating

eC heck

tem perature.

to see that the knock

pins (2),

plugs

(2), the

screen and new gasket are in place.

W hen the engine is cold: e R em ove the low er fairing. e R em ove the oil passage plug. elnstall

oil

pressure gauge

(special

tool)

and adapter

(special tool).

A. Knock Pin

C . G asket

B. Plug

D . O il Screen

A. O il Pressure G auge: 57001 -164 O íl P u m p

B. Adapter: 57001 -1182

D í s a s s e m b ly

e R em ove the oil pum p. e R em ove the oil pum p pum p cover.

cover screw ,

and take off the

the engine, and read the oil pressure gauge w hile

running valve

eTake out the inner and outer rotor. eTake

eStart

out the pin, and pull off the oil pum p

gear and

the engine at various speeds.

keeps the

m axim um

oil

A norm al relief

pressure

betw een

the

specified values.

shaft. R elief Valve O pening 430 (4.4 -

•

Pressure

590 kPa 2 6.0 kg/cm VUTSRQPONMLKJIHGFEDCBA , 63 - 85 psi)

EN G IN E .Stop

the engine.

LU BR IC ATIO N

SYSTEM

6-9

R e / ie f V a / v e / n s p e c t io n

• R em ove the oil pressure gauge and adapter.

• R em ove the relief valve .

• Install the oil passage plug.

• C heck to see if the steel ball inside the valve slides

* If the reading exceeds the standard

by very m uch, the

sm oothly

relief valve is stuck at its closed position.

w hen

pushing

it in w ith

a w ooden

or other

soft rod, and see if it com es back to its seat by valve spring pressure.

* If the reading is m uch low er than the standard, the relief valve m ay be stuck open, or there m ay be other dam age in the lubrication

system .

Stop the engine im m ediately

and find the cause.

N O TE O /n s p e c t

th e

v a / v e in

it s a s s e m b / e d s t a t e .

D is a s s e m b / y

a n d a s s e m b /y m a y c h a n g e th e v a /v e p e rfo rm a n c e .

*If W hen the engine is w arm ed

any rough spots are found w ash

up:

.W arm

up the engine, and then stop the engine.

.Install

the oil pressure gauge

and adapter

blow

the valve clean a high out any foreign

during

above inspection,

flash-point

solvent

and

particles that m ay be in the valve

w ith com pressed air.

as show n

above.

I W ARNING LKJIHGFEDCBA I o If

the oil passage plug is rem oved w hile

w arm , hot engine oi] w ill drain through

the engine is

the oil passage;

take care aqainst burns.

the engine at the specified speed, and read the oil

pressure gauge.

C lean the parts in a w ell-ventilated that

there

w orking flam m able

is no spark

area.

• Stop the engine .

valve as an assem bly.

it to the speci-

fied torque (see Exploded View ) . • Install the low er fairing. * If the oil pressure is significantly

below

the specifica-

tion, inspect the oil pum p and relief valve.

O il Pressure , 1.5 kg/cm 2VUTSRQPONMLKJIHGFEDCBA

78 -

147 kPa (0.8 -

11 -

21 psi) @ 4.000 r/m in

(rpm ).

90°C

(194°F) of oil tem p.

* If the oil pum p and relief valve are not at fault, inspect system . IHGFEDCBA

O i/ P u m p / n s p e c t io n • D isassem ble the oil pum p . inspect

the oil pum p

body,

outer

and

inner

rotors, and covers. *If

there

is any dam age

B ecause

the

area. and take care anyw here danger

near the of

highly

* If cleaning does not solve the problem , replace the relief

• R em ove the oil pressure gauge and adapter . • Install the oil passage plug and tighten

• Visually

or flam e

liquids, do not use gasoline or low flashpoint

w ith no allow ance

the rest of the lubrication

solvents .

• Start the engine again. .R un

I W ARNING

or uneven

rotors or the oil pum p assem bly.

w ear,

replace the

The relief valve is precision m ade

for replacem ent of individual

parts .

6-10

E N G IN E

LU B R IC A TIO N

S Y S TE M

O il P ipe

O il S creen

Main Oil Pipe Removal Remo valihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA e R em ove the right engine eover.

e R em ove :

e Pull out the oil sereen.

Exhaust Pipe Starter M otor Engine Sproeket C over M agneto Lead C lam p e R em ove the banjo bolts and m ounting

bolt. take off the

pipe.

A. G il Sereen

Installation Note

A. Banjo Bolts

eC lean the oil sereen thoroughly

w henever it is rem oved

B. M ounting

C . M ain G il Pipe

Bolt

for any reason.

Main Oil Pipe Installlation Notes e Before

Cleaning and Inspection eC lean the oil sereen w ith rem ove

high flash-point

solvent and

any particles stuek to it.

W ARNING

installation,

flash-point

flush

out

the

a high

e Fill the pipe w ith engine oil to shorten air bleeding tim e and prevent engine dam age.

eaeh side of the pipe fittings. e Lightly tighten the banjo bolts and m ounting

area. and take care that hat there is no spark or flam e anyw here near the w orking area. Because of the danger of highly flam m able liquids. do not use gasoline or low flash-point solvents.

snug fit, and tighten

bolt to a

the banjo bolts to the speeified

torque (see Exploded View ).

Cylinder Head Oil Pipe Removal eSee C am shaft R em oval in the Engine N O T E VUTSRQPONMLKJIHGFEDCBA t h a t m ig h t

w ith

e D iseard the used gaskets and install new gaskets on

o C lean the screen in a w ell-ventilated

o IHGFEDCBA W h ile c / e a n in g

pipe

solvent.

Top End ehapter.

t h e s c r e e n . c h e c k f o r a n y m e t a l p a r t ic / e s

in d ic a t e

in t e r n a !

e n g in e

dam age.

Cylinder Head Oil Pipe Installation Notes eC heck

the screen earefully for any dam age: holes and

broken w ires. If the sereen is dam aged, replaee it.

eSee C am shaft Installation N otes in the Engine Top End ehapter.

E N G IN E

REMOVAL

/ IN S T A L L A T IO N

E n g in e ZYXWVUTSRQPONMLKJIHGFEDCBA R e m o v a l I In s ta lla tio n T a b le 0 1 C o n te n ts

E x p lo d e d V ie w

7 -2

S p e c ia l T o o l

7 -3

E n g in e R e m o v a l/ln s ta lla tio n

7 -3

R em oval In s ta lla tio n

7 -3 N o te s

7 -4

7 -1

7 -2

E N G IN E

E x p lo d e d

REMO VAL

/ IN S T A L L A T IO N

V ie w

. (2 5 T 1 : 2 5 N -m .

k g - m , 1 8 . O ft- lb ) 3 3 ft- Ib )

T 2 : 4 4 N - m ( 4 .5 k g - m , 7 2 ft- Ib ) T 3 : 9 8 N - m ( 1 0 .0 k g - m ,

E N G IN E

REMOVAL

/ IN S T A L L A T IO N

7 -3

S p e c ia l T 0 0 1

E n g in e

Jack Stand:

Remo va/ZYXWVUTSRQPONMLKJIHGFEDCBA

57DCn-1238

R e m o v a l/ln s ta lla tio n

• R e m o v e ( s e e a p p r o p r ia te

c h a p te r )

E n g in e O il ( d r a in ) F a ir in g s C o o la n t

( d r a in )

E x h a u s t P ip e S id e C o v e r s Seat F u e lT a n k C a r b u r e to r W a te r H o s e R a d ia to r

Fan

R a d ia to r Ig n itio n

C o il

C y lin d e r

H e a d B ra c k e t

S id e S ta n d S w itc h

C over

L e ft F o o tp e g S h ift

Pedal

E n g in e S p r o c k e t

C over

E n g in e S p r o c k e t R ig h t F o o tp e g B r a k e P e d a l a n d S p r in g C lu tc h

C a b le L o w e r

End

E n g in e B r e a th e r H o s e L o w e r • D is c o n n e c t

F a n M o to r

L e a d C o n n e c to r

F a n S w itc h Ig n itio n

L e a d C o n n e c to r

C o il L e a d C o n n e c to r s

W a te r T e m p e r a tu r e M a g n e to

End

L e a d C o n n e c to r s

B a tte r y G r o u n d S ta r te r M o to r

B . S ta r te r M o to r

Lead

T e r m in a l

A . B a tte r y G r o u n d

a n d P lu g C a p

S e n s o r L e a d C o n n e c to r

Lead

T e r m in a l

Lead

7 -4

E N G IN E

REMOVAL

/ IN S T A L L A T IO N

/nstallation Notes

NOTE

e T ig h te n

th e n u ts to th e s p e c ifie d

to r q u e

( s e e E x p lo d e d

Off the crankcase is to split after engine removet. you may V ie w ) in th e fo llo w in g o r d e r : s w in g a r m p iv o t remove the following parts in the following order for e n g in e m o u n tin g b o lts , a n d th e n b r a c k e t b o lts . easy engine removal and crankcase splitting (see epe T o r o u te th e le a d s , c a b le s a n d h o s e s , r e fe r to th e propriate chapter).ZYXWVUTSRQPONMLKJIHGFEDCBA e r a l In fo r m a tio n

C y lin d e r

eTo

H ead C over

M a g n e to

C over

in s ta ll p a r ts r e m o v e d ,

e F ill th e e n g in e w ith C o o lin g

C lu tc h

T h r o ttle

S ta r te r M e c h a n is m

C lu tc h

C a m s h a ft C h a in T e n s io n e r

C h o k e C a b le

C a m s h a fts

D r iv e C h a in

L e ft E n g in e C o v e r G il P ip e

In s id e B a la n c e r C h a in G u id e C a m s h a ft C h a in G u id e

B a la n c e r M e c h a n is m C y lin d e r

Head .

C y lin d e r ,

P is to n

e P la c e th e ja c k

s ta n d

( s p e c ia l

to o l)

u n d e r th e fr a m e to

s te a d y th e m o to r c y c le . e U s in g

a s u ita b le

u p s lig h tly

s h a ft a n d e n g in e

A ..J a c k B . S w in g

ja c k

u n d e r th e e n g in e , ja c k th e e n g in e

to ta k e th e w e ig h t

S ta n d : A rm

m o u n tin g

o ff th e s w in g

a r m p iv o t

b o lts a n d b r a c k e t b o lts .

5 7 0 0 1 -1 2 3 8 P iv o t S h a ft

C . E n g in e M o u n tin g

B o lts

D . E n g in e B r a c k e t B o lts e P u ll o u t a v o id

th e

s w in g

a rm

p iv o t

fa llin g

s h a ft

down

th r e e but

q u a r te r s

a d is e n g a g e

fr o m th e e n g in e . e R e m o v e th e e n g in e

m o u n tin g

C a b le C a b le

R e a r B ra k e P e d a l

F ly w h e e l a n d S ta r te r C lu tc h

C a m s h a ft C h a in T e n s io n

w ith

e A d ju s t:

M e c h a n is m

B a la n c e r R ig h t W e ig h t

M a in

c o o la n t

e n g in e

in th e E n g in e L u b r ic a tio n

D r iv e G e a r a n d P r im a r y G e a r

M a g n e to

r e fe r to th e a p p r o p r ia te

chap-

b o lts a n d b r a c k e t b o lts .

e U s in g th e ja c k . ta k e o u t th e e n g in e to th e le ft.

to it

( s e e C o o la n t

Change

in th e

S y s te m c h a p te r ) .

e F ill th e e n g in e

G il P u m p a n d G il S c r e e n

E x te r n a l S h ift

G en-

c h a p te r .

te r s o

R ig h t E n g in e C o v e r

G il P u m p

s h a ft,

o il ( s e e E n g in e

S y s te m c h a p te r ) .

G il C h a n g e

CRANKSHAFT

C ra n k s h a ft

/ T R A N S M IS S IO N

8 -1

T ra n s m is s io n

T a b le 0 1 C o n te n ts jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View

8-2

Specifications

8-4

Special Tools

8-5

Sealant

8-5

Crankcase

8-6

Splitting

8-6

Assembly

8-6

Crankshaft, Connecting

Rod

8-8

Crankshaft Disassembly Note

8-8

Crankshaft Assembly Notes

8-8

Connecting

Rod Big End Radial Clearance

8-8

Connecting

Rod Big End Seizure

8-8

Connecting

Rod Side Clearance

8-8

Crankshaft Runout

8-8

Crankshaft Alignment

8-9

Roller Bearing Wear, Damage Balancer

8-10 8-10

Rear Balancer Installation Notes Transmission

8-10 8-11

Transmission Shaft Removal

8-11

Transmission Shaft Installation Notes

8-12

Transmission Shaft Disassembly Note

8-12

Transmission Shaft Assembly Notes

8-12

Shift Drum and Fork Installation Notes

8-12

Shift Fork Bending

8-13

Shift Fork/Gear Groove Wear

8-13

Shift Fork Guide Pin/Shift

Drum Groove Wear

8-13

Gear Dog/Gear Dog Hole Damage

8-14

Ball and Needle Bearing Wear

8-14

8-2 XWVUTSRQPONMLKJIHGFEDCBA e R A N K S H A F T / T R A N S M IS ::::-;--:--_ _

S IO N

E x p lo d e d YXWVUTSRQPONMLKJIHGFEDCBA V 路i ew

CRANKSHAFT

1 . C ra n k c a se

B o lts (6 m m D ia . 5 0 m m

L e n g th )

2 . C ra n k c a se

B o lts (6 m m D ia . 3 0 m m

L e n g th )

3 . C ra n k c a se

B o lts (8 m m D ia . 8 0 m m

L e n g th )

4 . S e a le d S id e L G : A p p ly

liq u id

9 2 1 0 4 -1 0 0 3 )

gasket to

a n d le ft c ra n k c a s e

th e

b la c k m a tin g

(K a w a sa k i

su rfa c e

th e

B ond: rig h t

h a lv e s .

: A p p ly a n o n -p e rm a n e n t

: A p p ly e n g in e o il to th e s u rfa c e .

lo c k in g a g e n t to th e th re a d s .

: A p p ly h ig h te m p e ra tu re

g re a se .

/ T R A N S M IS S IO N jihgfedcbaZYXWV 8-3 YXWVUTS

8 -4

CRANKSHAFT

/ T R A N S M IS S IO N

S p e c ific a tio n s

Ite m C r a n k s h a ft, C o n n e c tin g

S e r v ic e lim it

S ta n d a r d R o d : jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Connecting rod: Big end radial clearance

0.008 - 0.020 mm 0.25 - 0.35 mm

Big end side clearance Crankshaft runout: Left half Right half

Not more than 0.03 mm TIR Not more than 0.04 mm TIR

Cold-fitting tolerance between crankpin and flywheel

0.093 -

0.07 mm 0.6 mm 0.10TIR 0.10TIR

- - 0.122mm YXWVUTSRQPONMLKJIH

T r a n s m is s io n :

Gear Shift Gear Shift Shift

backlash fork ear thickness shift fork groove width fork guide pin diameter drum groove width

0.06 4.4 4.55 5.9 6.05

0.23 mm 4.5 mm 4.65 mm 6.0 mm 6.20 mm

0.30 mm 4.3 mm 4.8mm 5.80 mm 6.30 rnrn

CRANKSHAFT

/ T R A N S M IS S IO N jihgfedcbaZYXWVU 8-5

0015 Special T YXWVUTSRQPONMLKJIHGFEDCBA Sealant

Outside Circlip

Crankshaft Jig:

Pliers:

57001-144

57001-1174

Bearing Driver Set:

57001-1129

Kawasaki Bond (liquid

Gasket - Black):

92104-1003

8-6 XWVUTSRQPONMLKJIHGFEDCBA CRANKSHAFT / T R A N S M IS S IO N Crankcase

SplĂttĂng eRemove

the engine

(see Engine Removal/lnstallation

chapter). eSet the engine on a clean surface while parts are being removed. e Remove : Cylinder Head Cover Magneto Cover Right Engine Cover Clutch Gil Pump and Gil Screen

A. Pry Point

Gil Pump Drive Gear and Primary Gear External Shift Mechanism Balancer Right Weight Starter Mechanism Camshaft Chain Tensioner

Assembly

Camshafts

e Before fitting

Magneto

Flywheel and Starter Clutch

the left case on the right case, note the

following.

Left Engine Cover

O Chip off the old gasket from the mating surfaces of the

Main Gil Pipe

crankcase

Inside Balancer Chain Guide Camshaft Chain

miss ion and crankshaft with a high flash point solvent.

Camshaft Chain Tension Guide

gears, shift drum, shift forks, crankshaft and so on.

After

Balancer Mechanism

halves, and clean off the crankcase, trans-

cleaning,

apply

engine

oil to the transmission

O Be sure to replace any oil seal removed with a new one.

Cylinder Head

Press in the new oil seal using a press and suitable tools

Cylinder, Piston

so that the seal surface is flush with the surface of the

e Remove the crankcase bolts.

crankcase. OApply high temperature grease to the oil seallips. O Press in the ball bearings

and the collars

bearing driver set (special tool:

using the

57001 -1129)

until the

bearing and the collars are bottomed.

O Do not remove the bearings unless it is necessary.

Re-

moval may damage them.

O Install

the

bearing

for

the

output

shaft

in the

left

crankcase so that its sealed side face toward the engine sprocket cover. O Install the bearing for the rear balancer shaft in the left crankcase so that stepped side face toward the magneto cover. OApplya

A. Crankcase Bolts

non-permanent

locking agent to the threads of

the bearing holding plate mounting screws for the crankshaft bearings in the both crankcase halves and e Pry the points in the figure with

a screwdriver

to split

the crankcase halves apart evenly. There are two knock pins on the crankcase mating surface. crankcase half.

Pull off the left

the drive shaft bearing and the shift drum bearing in the right crankcase half. O Replace the G-ring on the output shaft with a new one, install it securely on the shaft groove, and apply grease to the su rface of it. OAfter

installing

the output

shaft in the right crankcase

half, install the kick starter idle gear to prevent the needie bearing from falling off the output shaft during case assembly. eTurn

the crankshaft to BDC, and install the crankshaft

jig (special tool) connecting as shown.

between

the flywheels

opposite

rod big end to protect flywheel

the

alignment

CRANKSHAFT

/ T R A N S M IS S IO N

o If the crankshaft has been removed from the crankcase, install

the jig

(special

tool)

between

flywheels before pressing the crankshaft crankcase half.DCBA

the crankshaft into the right

I Right Crankcase A. Crankshaft Jig: 57001-1174

.Check to see that the crankcase knock pins are in place on the right crankcase half. If any of them has been removed, replace it with a new one . • Apply

liquid

92104-1003) half . • Constantly

gasket

black

(Kawasaki

Bond:

to the mating surface of the left crankcase check the alignment

halves, and the position

of the two

of the transmission

crankcase shafts, and

shift drum. The front and rear of the crankcase must be pushed together evenly . • Applygrease to the inside of output shaft collar, and install it by hand on the output shaft so that the oil groove goes first and collar does not pinch the O-ring.

A. Collar

C.O-ring

B. Oil Groove

.Check

to see that the crankshaft, drive shaft, and output

shaft all turn freely (in the neutral position) . • Spinning

the

output

shaft,

shift

the

transmission

through all the gears to make certain there is no binding and that all the gears shift properly.XWVUTSRQPONMLKJIHGFEDCBA

8 -7

8-8

CRANKSHAFT

/ TRANSMISSION Rod DCBA

Crankshaft, Connecting

C r a n k s h a ft D is a s s e m b ly N o te

Since assembly of the crankshaft demands exacting tolerances,

the

disassembly

and

reassembly

the

crankshaft can only be done by a shop having the necessary tools and equipment. -The crankshaft left main bearing, chain sprockets, and left crankshaft

are available separately as spare parts,

however, it is recommended that the crankshaft assembly be replaced rather than anempting to replace the components.

C o n n e c tin g C r a n k s h a ft A s s e m b ly N o te s

Since assembly of the crankshaft demands exacting tolerances,

the

disassembly

R od

B ig

E n d S e iz u r e

*In case of serious seizure with damaged flywheels, the crankshaft must be replaced. and

reassembly

the

crankshaft can only be done by a shop having the necessary tools and equipment.

*In

case

less serious

damage,

disassemble

crankshaft and replace the crankpin,

the

needle bearing,

side washers, and connecting rod.

e Reassemble the crankshaft according to the standard tolerances in Specifications. O Connecting rod big end radial clearance. O Cold-fitting

tolerance

between

crankpin

and

O Side clearance between the connecting rod and one of the flywheels. O Crankshaft runout.

R od

S id e C le a r a n c e

rod with

a thickness gauge. * If the clearance exceeds the service limit, replace the crankshaft.

e Make sure oil passages of crank and crank pin are lined up during assembly. eApply

C o n n e c tin g

e Measure the side clearance of the connecting

flywheels.

a locking agent to the oil plugs and push them

until they stop at the bottom of the hole.

Connecting Rod Side Clearance Standard:

0.25 ,.., 0.35 mm

Service limit:

0.6 mm

e Press the camshaft chain sprocket onto the crankshaft as shown.

T YXWVUTSRQPONMLKJIHGFEDCBA S id e C le a ra n c e

C o n n e c tin g

R od

B ig

E n d R a d ia l C le a r a n c e

eSet the crankshaft in flywheel alignment jig or on V blocks, and place a dial gauge against the big end of the connecting rod. e Push the connecting

rod first towards the gauge and

then in the opposite direction.

The difference between

the two gauge readings is the radial clearance. *If

the radial clearance exceeds the service limit, the crankshaft should

be either replaced or disassembled

and the crankpin, needle bearing, and connecting big end examined for wear.

rod

C ra n k s h a ft R u n o u t

eSet the crankshaft in a flywheel alignment jig, and place a dial gauge at the ball bearing (B) and at the sprocket (A).

Connecting Rod Big End Radial Clearance Standard:

0.008 ,.., 0.020 rnm

Service limit:

0.07 mm

eTurn the crankshaft slowly.

The maximum difference in

gauge readings is the crankshaft runout. * If the runout at either point exceeds the service limit, align the flywheels so that the runout falls within the service limit.

CRANKSHAFT

/ T R A N S M IS S IO N

8-9

Crank Pin

Pin Center Direction Sprocket

Mark

:must be aligned YXWVUTSRQPONMLKJIHGFEDCBA 0° ±30' ./'

Oil Plug

Left Hand Main Bearing

Oil Plug DCBA View A

Crankshaft left

Camshaft Chain Sprocket

Runout

C r a n k s h a ft A líg n m e n t

Half (A)

.In

the case of horizontal

misalignment,

which

is the

Standard:

Not more than 0.03 mm TIR

most common, strike the projecting

Service limit:

0.10 mm TIR

with a plastic, soft lead, or brass hammer as indicated in

Right Half (B) Standard:

Not more than 0.04 mm TIR

Service limit:

0.10 mm TIR

the figure. • Recheck the runout

a diai gauge, repeating the

process until the runout falls within the service limit. O

Vertical wedge flywheel

with

rim of the flywheel

misalignment in between

is corrected

either by driving

the flywheels

or by squeezing the

rims in a vise, depending

on the nature of the

B XWVUTSRQPONMLKJIHGFEDCBA misalignment. In both cases of horizontal and vertical misalignment,

* If flywheel

correct the horizontal misalignment

first.

misalignment cannot be corrected by the above method, replace the crankpin or the crankshaft itself.

8 -1 0

CRANKSHAFT

/ T R A N S M IS S IO N jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

B a la n c e r

o Don't

ham m er the flywheel at point "A".

Rear Balancer InstallatĂon Notes elnstall the rear balancer weight on the balancer shaft. aligning the weight punch mark with the shaft punch mark.

Ăź A. Weight Punch Mark

Prior

putting

the

B. Shaft Punch Mark

rear

balancer

shaft

into

the

crankcase, be sure to install the washer and circlip (see Exploded View).

Roller Bearing Wear, Damage The rollers of the bearing wear so little that the wear is difficult to measure. elnspect

the bearing for abrasion. color change, or other

damage. *If

there is any doubt as to the condition of the rollers, replace the left crankshaft or the crankshaft assembly.

elnspect

the bearing outer race in the left crankcase half.

* If there is any damage on the outer race, replace the crankcases as a unit.

CRANKSHAFT

/ T R A N S M IS S IO N

8 -1 1

T ra n s m is s io n DCBA

T r a n s m is s io n

eSplit

S h a ft

R em oval

jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

the crankcase (see Crankcase Splitting).

e Pull off the shift rods. and disengage the shift fork guide pins from the shift drum grooves. eTake off the shift drum. e Remove the shift forks from the transmission

gears.

eTake out the drive shaft and output shaft together, with their gears meshed.

A. Shift Rods

C. Drive Shaft

B. Shift Forks

D. Output Shaft

45°YXWVUTSRQPONMLKJIHGFEDCBA C h a m fe re d S id e D riv e S h a ft

N e e d le B e a rin g ~

2 3 .5 O -rin g

@ ~205

~30

3 4 th

(2 1 T )

~~226

~29

n ~ 2 9 .5

253 C V ~ 2 0 .5

~ 2 5 .5

8 -1 2

CRANKSHAFT

T r a n s m is s io n

S h a ft

/ T R A N S M IS S IO N DCBA

In s ta lla tio n

N o te s

• Be sure that all parts are put back jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

• Hold the drive shaft and output shaft together, with their gears meshed, and fit them into the right crankcase half.

quence, facing the proper direction,

in the correct seand that all circlips

and the washer are properly in place. .Check that each gear spins or slides freely on the transmission shaft without

S h ift

.Apply

D ru m

and

F o rk

binding after assembly.

In s ta lla tio n

N o te s

a little engine oil to the shift fork ears. and fit the

shift forks into the gear grooves.

® YXWVUTSRQPONMLKJIHGFEDC {} A. Drive Shaft

T r a n s m is s io n

B. Output Shaft

S h a ft

D is a s s e m b ly

N o te

• Using the outside circlip pliers (special tool: 57001 -144) to remove the circlips, disassemble the transmission shaft.

A. Output Shaft 4th Gear Shift Fork B. Drive Shaft 3rd Gear Shift Fork C. Output Shaft 5th Gear Shift Fork D. Right Crankcase Half Side T r a n s m is s io n

.Apply

S h a ft

A s s e m b ly

engine oilliberally

N o te s

E. Left Crankcase Half Side

to the transmission shaft, gears

and bearings. • Replace any circlips that were removed with new ones. OAlways install circlips so that the opening is aligned with a spline groove, and install toothed washers so that the teeth are not aligned with the circlip opening. To install a circlip without onto the shaft expanding

S h ift

F o rk Id e n tific a tio n

Output shaft 4th gear shift fork

pin is on fork rib

damage, first fit the circlip it just enough to install it, and

Drive shaft 3rd gear shift fork

then use a suitable gear to push the circlip into place.

ears are shorter than those of the other two shift forks

Output shaft 5th gear shift fork

pin is on fork line

• Fit the shift fork guide pins into the corresponding

shift

drum grooves . • Applya little engine oil to the shift rods, and slide them into the shift forks.

1. Teeth of Toothed Washer 4. Opening of Circlip 2. Toothed Washer 3. Groove of Shaft

5. Circlip 6. Shaft

CRANKSHAFT S h ift F o r k B e n d in g

jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA S h ift F o r k G u id e

.Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting,or allow the transmission power.

to jump out of gear when under

/ T R A N S M IS S IO N P in /S h ift

D ru m

G ro o v e

8 -1 3 W ear

• Measure the diameter of each shift fork guide pin, and measure the width of each shift drum groove.

* If the guide

pin on any shift fork is less than the service limit, the fork must be replaced.

S h ift F o r k G u id e P in D ia m e te r S ta n d a r d :

5 .9 -

S e r v ic e L im it:

5 .8 0 m m

6 .0 m m

A. 90°

S h ift F o r k /G e a r

G ro o v e

A. Shift Fork Guide Pin

W ear

B. Shift Fork Ears

• Measure the thickness of the shift fork ears, and measure the width

of the shift fork grooves

in the trans-

mission gears.

If any shift drum groove is worn over the service limit, the drum must be replaced.

If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.XWVUTSRQPONMLKJIHGFEDCBA

S h ift D r u m G r o o v e W id th S h ift F o r k E a r T h ic k n e s s

S ta n d a r d :

4 .4 -

4 .5 m m

S e r v ic e L im it:

4 .3 m m

If a gear shift fork groove is worn over the service limit, the gear must be replaced.

G e a r S h ift

S ta n d a r d :

6 .0 5 -

S e r v ic e L im it:

6 .3 0 m m YXWVUTSRQPONMLKJIHGFEDCBA

F o r k G r o o v e W id th

S ta n d a r d :

4 .5 5 -

S e r v ic e L im it:

4 .8 m m

4 .6 5 m m

A. Shift Drum Grooves

A. Gear Shift Fork Groove

6 .2 0 m m

8 -1 4

CRANKSHAFT

/ T R A N S M IS S IO N

Gear Dog / Gear Dog Hole DamagejihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA .Visually

inspect the gear dogs and gear dog holes.

Replace any damaged gears or gears with excessively worn dogs or dog holes.

A. Dog

B. Dog Hole

Ball and Needle Bearing Wear .Check the ball bearings and the needle bearings on both sides of the shift drum, drive shaft and output shaft.

o Since

the ball bearings and the needle bearings are

made to extremely close tolerances, the wear must be judged by feel rather than measurement.

Clean each

bearing in a high flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. OSpin the bearings by hand to check its condition.

If the bearings are noisy, do not spin smoothly, or have any rough spots, replace them.

W HEELS

/ T IR E S

9 -1

W h e e ls I T ire s T a b le o f C o n te n ts ihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View

9-2

Specifications

9-3

Special Tools

9-4

W heels

9-5

Front W heel Rem oval

9-5

Front W heel Installation Notes

9-5

Rear W heel Rem oval

9-5

Rear W heel Installation Notes

9-5

Alignm ent

Inspection

9-5

Alignm ent

Adjustm ent

9-5

Inspection

9-6

Spoke Inspection

9-6

Rim Inspection

9-6

Axle Inspection

9-6

Front W heel Balance

9-6

Tires

9-8

Rem oval

9-8

Installation Notes

9-8

Air Pressure Inspection/ Adjustm ent

9-9

Inspection

9-9

Hub Bearings

9-10

Rem oval Note

9-10

Installation Notes Inspection and Lubrication Speedom eter Gear Housing Disassem bly

9-10 :

9-11 9-11 9-11

Assem bly Notes

9-11

Lubrication

9-12

9-2

W H EELS / TIRES

Exploded V·rew MLKJIHGFEDCBA

21 . B a l a n c e 3.

B a la n c e . B a la n c e

4 . S e a le d

W e · Ig h t . 1 0 W e ig h t

20 9

W e ig h t'

30 9

S i1 d e

•'

G ·A . p p ly

g re a se .

W G:

G e e rm a n

W est

T1: 2 O ~

d o

T2... 78 N-m3.9(8 N· Om (O.2 ~ 0.4 kq-rn 17 T3, 93 N-m 195 ~g-m . 58 ft-lb) • .

q -m ,

6 9 ft-lb ]

35 in-lb]

W HEELS

/ T IR E S

9 -3

S p e c ific a tio n s

Ite m

S ta n d a rd

S e rv ic e lim it

W h e e ls : ihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Rim runout (with tire installed): Axial

- --

2m m

Radial

- --

2m m 0.2 m m

Axle runout/1 00 m m

Under 0.05 m m

(0.7 m m :RL) T ire s :

Air pressure (when cold): Front

150 kPa (1.5 kq/crn", 21 psi)

Rear

Up to 97.5 kg (215 lb) load: 150 kPa (1 .5 kq/crn-, 21 psi)

- - -

97.5 - 182 kg (215 - 401 lb) load: 200 kPa (2.0 kq/crn-, 28 psi)

- -

Front

6.4m m

2m m

Rear

8.8m m

2m m

MLKJIHGFEDCBA -

T read Depth:

Standard Tire: Front:

Rear

Size IHGFEDCBA

9 0 /9 0 - 2 1

M ake

DUNLOP

Type

K750, TRAIL M AX

Size

1 3 0 /8 0 - 1 7

54S

- - - - -

65S

- -

- - -

M ake

DUNLOP

- - -

Type

K750, TRAIL M AX

RL: Repair Lim it

9-4

W HEELS

/ TIRES Bearing Driver Set:

57001-1129

Inside Circlip

57001-143

Special Tools

Jack Stand:

57001-1238

Bead Breaker Assem bly:

Rim Protector:

57001-1063

Bearing

Tire Iron:

Pliers:

57001-1072

Rem over

Set:

57001-1264

57001-1073 IHGFEDCBA

W HEELS

/ T IR E S

9 -5

R e a r W h e e / R e m o va /

W h e e ls GFEDCBA

• Rem ove : Disc Cover Caliper (with the brake hose connected)

F r o n t W h e e / R e m o v a / ihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Cotter Pin, Axle Nut • Rem ove : Chain Adjuster Lock Nut, Adjusting Nut (turn out Disc Cover fully) Speedom eter Cable Lower End Chain Cover Cotter Pin, Axle Nut, W asher Chain (disengage) Lower Fairing Lower Fairing • Using the jack stand (special tool: 57001 -1238), raise • Using the jack stand (special tool: 57001 -1238), raise the front wheel off the ground. the rear wheel off the ground. • Pull out the axle, and rem ove the wheel. .Pull out the axle, and rem ove the wheel.

o Do

not lay the wheel on the ground with the disc facing down. This can dam age or warp the disco Place blocks under the wheel so that the disc does not touch the ground.

Do not lay the wheel on the ground with the disc facing down. This can dam age or warp the disco Place blocks under the wheel so that the disc does not touch the ground.

F r o n t W h e e / /n s ta //a tío n N o te s .Install

the collar on the left side of the hubo

.Install

the speedom eter gear housing so that it fits in the

R e a r W h e e / /n s ta //a tío n N o te s .Adjust

speedom eter gear drive notches. • Fit the speedom eter gear housing stop to the fork leg stop. MLKJIHGFEDCBA

the drive chain slack (see Drive Chain Slack In-

spection in the Final Drive chapter). .Tighten

the axle nut to the specified torque (see Ex-

ploded View) . • Install a new cotter pino .Tighten

the caliper m ounting

bolts to the specified

torque (see Exploded View in the Brakes chapter) . • Check the rear brake.

W A R N IN G

o Do

not attem pt to drive the m otorcycle until a full brake pedal is obtained by pum ping the brake pedal until the pads are against the disco The brake will not function on the first application of the pedal if this is not done.

,.1 \ A. Collar

C. Housing Stop

B. Speedom eter G ear Housing

D. Fork Leg Stop

.Tighten

the axle nut to the specified torque (see Ex-

• Refer to W heel Alignm ent Inspection in the Final Drive chapter.

ploded View). .Install

A /íg n m e n t /n s p e c tío n

a new cotter pino

• Check the front brake.

W A R N IN G

o Do

not attem pt to drive the m otorcycle until a full brake lever is obtained by pum ping the brake lever until the pads are against the disco The brake will not function on the first application of the lever if this is not done.

A /íg n m e n t A d ju s tm e n t • Refer to W heel Alignm ent Adjustm ent in the Final Drive chapter.

9-6 LKJIHGFEDCBA W H E E L S / T IR E S GFEDCBA In s p e c tio n

e Rem ove the lower fairing. e Using the jack stand (special tool: 57001 -1238),

raise

the rear wheel off the ground. eSpin

the wheel

lightly,

and check for roughness

binding. * If roughness or binding is found, replace or lubricate the hub bearings. eVisually inspect the front and rear axles for dam ages. * Ifaxle is dam aged or bent, replace it.

Sp o ke

In s p e c tio n

eCheck that all the spokes are tightened evenly.

A. Rim

C. Axial Rim Runout

B. Dial G auge

D. Radial Rim Runout

* If spoke tightness is uneven or loose, tighten the spoke nipples to the specified torque

evenly (see Exploded

View). eCheck the rim runout.

A xle

In s p e c tio n

e Place the axle in V blocks that are 100 m m apart, and

I WARNING I

set a dial gauge on the axle at a point halfway between the blocks.

Turn the axle to m easure the runout.

The

difference between the highest and lowest dial readings O lf any spoke breaks, it should be replaced im m ediately. A m issing spoke places an additional spokes, w hich

w ill

eventually

load on the other

cause other

spokes to

is the am ount of runout. * If runout exceeds the repair lirnit, replace it. * If runout only exceeds the service lim it, straighten the

break.

axle. * If the axle cannot be straightened to within service lirnit, replace the axle. R im

In s p e c tio n

AxJe R unout/100 m m

e Rem ove the lower fairing. e Using the jack stand (special tool: 57001 -1238).

raise

the front/rear wheel off the ground. elnspect

the rim for sm all cracks, dents, bending,

Standard:

U nder 0.05 m m

Service Lim it:

0.2 m m

R epair Lim it:

0.7 m m MLKJIHGFEDCBA

warping. * If there is any dam age to the rim , it m ust be replaced. eSet a dial gauge against the side of the rim , and rotate the rim to m easure the axial runout. tween

the

highest

and

lowest

The difference be-

dial

readings

is the

am ount of runout. eSet a dial gauge against the outer circum ference of the rim , and rotate the rim to m easure radial runout.

The

difference between the highest and lowest dial readings is the am ount of runout. *If

rim runout exceeds the service Iirnit, check the wheel bearings first. Replace them if they are dam aged.

1 0 0 rnrn

If the

problem is not due to the bearings, correct the rim warp (runout).

A certain am ount of rim warp can be cor-

rected by recentering the rim . Loosen som e spokes and tighten others within the standard torque to change the position of different parts of the rim . bent, however, it m ust be replaced.

If the rim is badly

F ront

W heel

B a la n c e

To im prove stability

and decrease vibration

at high

speed, the front wheel m ust be kept balanced. Check and balance the front wheel when required, or

R im R unout (w ith tire installed)

when a tire and/or rim is replaced with a new one. eCheck that all the spokes are tightened evenly and

Service Lim it

e Rem ove the lower fairing. eUsing

Axial

2m m

Radial

2m m

the jack stand (special tool: 57001-1238),

raise

the front wheel off the ground. eCheck that all spokes are tightened evenly and the rim runout is within the service lim it.

W HEELS eSpin

/ T IR E S

9 -7

the wheel lightly, and m ark the wheel at the top

when the wheel stops.

A. X turno

* If

A. M ark at the topo

* If e Repeat this procedure several tim es. LKJIHGFEDCBA e the wheel stops of its own accord in various positions, it is well balanced. e If the wheel always stops in one position, balance the wheel. e

* If

eTem porarily

the wheel rotates and the weight goes up, replace the

weight with the next heavier size. the wheel rotates and the weight goes down, replace

the weight with the next lighter size. Repeat these step until the wheel rem ains at rest after being rotated X turno Rotate the wheel another X turn and then another X turn to see if the wheel is correctly balanced.

Repeat the entire procedure as m any tim es as necessary attach a balance weight on the wheel. MLKJIHGFEDCBA to achieve correct wheel balance.

a Attach a balance weight loosely to the spoke under the m arking.

elnstall

the balance weight firm ly on the wheel.

a Clam p on the balance weight firm ly using pliers.

N O T E IHGFEDCBA a B a la n c e

w e ig h ts

a r e a v a ila b le

1 0 , 2 0 , a n d 3 0 g ra m

s iz e s .

1 0 g r a m s w ill n o t u s u a lly aDo g ) .If

th e

wheel

r e q u ir e s

e Rotate the wheel X turn, and see whether or not the

wheel stays in this position. If it does, the correct balance weight is being used.

K a w a s a k i D e a le r s in

im b a la n c e

a fte r r u n n in g

n o t u s e fo u r o r m o r e b a la n c e

m o v e a n d d is a s s e m b le

A. Balance W eight

fr o m An

o f le s s th a n

s ta b ility .

w e ig h t

(m o re

a n e x c e s s b a la n c e

th a n 9 0

w e iq h t,

th e w h e e l to fin d th e c a u s e .

re -

9-8

W H EElS

/ TIR ES

Tires GFEDCBA

R e m o va /

o Do

not lay the w heel on the ground w ith the disc facing

dow n.

This can dam age or w arp the disco P lace blocks

under the w heel so that

the disc does not touch

the

ground.

e Rem ove the wheel from the m otorcycle eTo tion

(see W heels).

A. Bead Breaker Assem bly: 57001 -1072

m aintain wheel balance, m ark the valve stem posion the tire with

chalk

so that

the tire can be

reinstalled in the sam e position.

e Pry the tire off the rim with tire iron (special tool) tecting the rim with rim protector

eTake out the valve core to let out the air .

pro-

(special tool).

.-"*"

A. Rim Protector: 57001 -1063 B. M ark valve stem position. MLKJIHGFEDCBA B. Tire Iron: 57001 -1073

A. Unscrew valve coreo

o W hen handling the rim s, be careful not to dam age the alum inum

rim flanges.

e Lubricate the tire beads and rim flanges on both sides with a soap and water solution

or rubber lubricant.

This

helps the tire beads slip off the rim flanges.

/n s ta //a tio n

N o te s

e Check the tire rotation

m ark on the front/rear

tire and

install it on the rim accordingly.

o N ever

lubricate w ith

m ineral oil (engine oil) or gasoline

because they w ill cause deterioration

NO TE

of the tire.

T h e d ir e c tio n

o f th e tir e r o ta tio n

o n th e tir e s id e w a ll.

e Break the beads away from both sides of the rim with the bead breaker assem bly (special tool).

is s h o w n

by an arrow

W HEELS

/ T IR E S

9-9

A. Arrow

M ark (Rotation

B. Rotating

M ark)

C. Front Tire

A. Air Pressure Gauge

Direction GFEDCBA D. Rear Tire

• Position the tire on the rim so that the valve is at the tire balance m ark (the chalk m ark m ade during

rem oval or

In s p e c tio n

the yellow paint m ark on a new tire).

As the tire tread wears down, susceptible

the puncture

the tire becom es m ore

and failure.

An accepted esti-

m ate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).

So it is false econom y and

unsafe to use the tires until they are bald .

• Rem ove any im bedded stones or other foreign particles from the tread . • Visually

inspect the tire for cracks and cuts, replacing

the tire in case of bad dam age

Swelling

or high spots

indicate internal dam age, requiring tire replacem ent. • M easure the tread depth at the center of the tread with a depth gauge.

Since the tire m ay wear unevenly, take

m easurem ents at several places. *If

any m easurem ent is less than the service lim it, replace the tire.

A. Balance M ark

.Check

and adjust the air pressure after installing.

A ír P r e s s u r e In s p e c tio n /A d ju s tm e n t • Using an air pressure gauge, m easure the tire air pressure when the tires are cold. * Adjust the tire air pressure according specifications, if necessary.

to the following

A. Tire Depth Gauge Air Pressure (w hen cold) Front:

150 kPa (1.5 kg/cm MLKJIHGFEDCBA 21 psi)

R ear:

U p to 97.5 kg (215 lb) load:

150 kPa (1.5 kg/cm

Tread D epth Front:

21 psi)

97.5 ~ 182 kg (215 ~ 401 lb) load: 200 kPa (2.0 kg/cm .

Standard:

6.4m m

Service lim it:

2m m

R ear:

2 ,

28 psi) LKJIHGFEDCBA

Standard:

8.8m m

Service lim it:

2m m

W HEELS

9-10

/ TIRES

WARNING LKJIHGFEDCBA

O To ensure safe handling and stability.

H ub Bearings

use only the re-

com m ended standard tires for replacem ent. inflated to the standard pressure.

NOTE MLKJIHGFEDCBA

GFEDCBA a n d b a la n c e

O C heck

w ith a n e w

O D o not lay the w heel on the ground w ith the disc facing th e

wheel

when

tir e is r e p la c e d

dow n.

This can dam age or w arp the disco P lace blocks

under the w heel so that the disc does not touch the

one.

ground.

Standard

Tire

Front: Size:

90/90-21

M ake:

DUNLOP

54S

Type:

K750. TRAIL

M AX

Rear: Size:

130/80-17

65S

M ake:

DUNLOP

Type:

K750. TRAIL

R e m o va l N o te -Use the bearing rem over ( s p e c i a l

tool]

to rem ove the

hub bearings.

M AX Hub Bearing

A. Bearing Rem over Set: 5 7 0 0 1 - 1 2 6 4

In s ta lla tio n

N o te s

e Before installing the wheel bearings. blow any dirt or foreign particles out of the hub with com pressed air to prevent contam ination of the bearings. elnspect

the bearings and replace them

if necessary.

Lubricate them and install them using the bearing driver set (special tool) so that the m arked or shielded sides face out.

W HEELS

S p e e d o m e te r

/ T IR E S

9 -1 1

G e a r H o u s in g

D is a s s e m b ly e Pull the speedom eter front whee!.

gear housing

and collar off the

e Pull out the grease seal using a hook.

A. Bearing Driver Set: 57001 -1129

elnspect

the grease seal and replace if necessary.

Press

it in until it stops at the circlip in the hole using the sam e special tools used for bearing installation. GFEDCBA

1 . Speedom eter Gear Housing

3. Grease Seal

2. Pin

In s p e c tio n a n d L u b r ic a tio n Since the wheel bearings are m ade to extrem ely close

tolerances, the clearance cannot norm ally be m easured. LKJIHGFEDCBA e Pu 1 1 out the speedom eter gear. e T u rn each bearing back and forth while checking for roughness or binding. MLKJIHGFEDCBA

If roughness or binding

eW ash

is found, replace the bearing.

the bearing with a high flash point solvent. dry it

or has any rough

the bearing

cable

bushing

be rem oved,

first

or drill

speedom eter the

housing

the pin using a 1.0 to 1.5 m m drill bit.

Drill the

housing from the under side using a 3.0 to 3.5 m m drill Using a suitable tool. tap out the pin, and then pull

out the speedom eter

cable bushinq, pinion, and wash-

ers.

spots, it m ust be replaced.

* If

needs to

through bit.

to check its condition. it is noisy, does not spin sm oothly,

speedom eter

pinion

(do not spin it while it is dry), and oil it. Spin it by hand

* If

the

e lf

is to be used again, rewash

it with

quality flash point solvent, dry it and pack it with good

NOTE

bearing by hand a few tim es to m ake sure the grease is distributed

uniform ly

inside the bearing, and wipe the

oil grease out of the hub before

bearing

Clean and grease the wheel

bearings

with the Periodic M aintenance

Chart.

installation.

o It

is r e c o m m e n d e d

th a n a tte m p tin g

th a t th e a s s e m b ly

b e r e p la c e d r a th e r

to r e p a ir th e c o m p o n e n ts .

in accordance

A s s e m b ly

N o te s

eAssem bly

is the reverse of disassem bly.

eAfter

inserting a new pin, stake the housing hole to se-

cure the pin in place. e Replace the grease seal with a new one. grease to the seal.

Apply a little

Install it using a press or suitable

driver so that the face of the seal is level with the surface of the housing. e Regrease the speedom eter gear. elnstall

the speedom eter gear housing so that it fits in the

speedom eter gear drive notches. 1. Grease

e Exam ine the bearing seal for tears or leakage.

* If the seal is torn

or is leaking, replace the bearing.

HEELS

/ T IR E S

9 -1 2 . ihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA W . P in R e m o v a l S p e e d o m e te r

G e ar Housm g

ear housing L u b r i c e t i o.n e the speedom .et er gance Chart. eClean an d greas . h the Periodic. M am ten cor dance wrt

S p e e d o m e te r

1 . Speedom eter 2 . Grease.

1 .1

1 . 5 m m Bit

2 . Housing

43-

5 : 3m m

3 . Pin

Gear Housing A Speedom eter drive notches. B. Fit in the gear

3 .5 m m Bit

Rod

in ac- GFEDCBA

G e a r H ousi in 9 lu b r ic a tio n

Gear Housing MLKJIHGFEDCBA

F IN A L

D R IV E

1 0 -1

F in a l D r iv e T a b l e o f C o n t e n t s fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View

10-2

Specifications

10-3

Special Tools

10-3

D rive C hain

10-4

Slack Inspection

1 0-4

Slack Adjustm ent

1 0-4

W heel Alignm ent

Inspection

W heel Alignm ent

Adjustm ent

10-4 10-5

W ear Inspection

10-5

Lubrication

1 0-5

R em oval Installation

10-6 N otes

10-6

Sprockets, C oupling

10-6

Engine Sprocket R em oval Engine Sprocket Installation

1 0-6 N otes

R ear Sprocket, C oupling

R em oval

R ear Sprocket, C oupling

Installation

10-6 10-6 N otes

10-7

Sprocket W ear Inspection

10-7

Sprocket W arp Inspection

1 0-7

C oupling

Bearing R em oval

C oupling

Bearing Installation

C oupling

Bearing Inspection and Lubrication

D am per Inspection

10-8 N otes

1 0-8 10-8 10-8

10-2

F IN A L

D R IV E

E xploded V iew

@ @ ~~

~ (WGl

~ \ ~

,~.

(WGI (@~¿

.~.~

() ~ ---I-G )

1. S ealed S ide G : A pply O

grease.

: A pply oil.

WG:

W est G erm an M odel

T1: 9.8 N -m (1.0 kg-m , 7.0 ft-Ib) T2: 32 N -m (3.3 kg-m , 24 ft-Ib) T3: 93 N -m (9.5 kg-m , 69 ft-lb] T4: 98 N -m (10.0 kg-m , 72 ft-Ib)

FIN A L

D R IV E

S pecifications

Item D rive

Service

Standard

lim it

C hain:

C hain slack

50 ~ 55 m m

Less than 50 m m , or

317.5 ~ 318.4 m m

323 m m

m ore than 60 m m C hain 20-link

length

Standard chain M ake

D AID O

- - -

Type

D ID 520V2

- - -

KL650-B1

106 Link

- - -

KL500-B1

108 Link

- - -

65.58 ~ 65.78 m m /15T

64.9 m m

KL650-B1

207.23

~ 207.73 m m /43T

206.93 m m

KL500-B1

227.43 ~ 227.93 m m /47T

227.13 m m

U nder 0.4 m m

0.5m m

Link:

Sprockets,

C oupling:

Engine sprocket diam eter R ear sprocket diam eter:

R ear sprocket w arp

Jack S tand:

S pecial Tools

Inside C irclip

P liers:

57Q (n -143 /

B earing D river S et:

57Q (n -1129

57Q (n-1238

10-3

10-4FEDCBA F IN A L

D R I V E fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA elf

D rive C hain BA

the chain istoo

loose, turn both chain adjusting nuts

e v e n ly

until the

slack.

To keep the chain and w heel properly aligned,

chain has the correct am ount of

d r iv e

the notch on the left chain adjuster should align w ith S /a c k

/n s p e c tio n

the sam e sw ing

eS et the m otorcycle on its side stand. eC heck the w heel alignm ent

(see W heel A lignm ent

In-

eTighten

spection), and adjust it if necessary (see W heel A lign-

th e

c h a in

nuts slightly.

the left and

Take care not to change

the adjustm ent during the adjusting nut tightening.

N O TE le a n

the axle nut loosely, and tighten

right adjusting

m ent A djustm ent).

arm m ark as the right chain adjuster

notch.

if it is

d ir ty , a n d

lu b r ic a te

eTighten

the both chain adjuster locknuts securely.

eTighten

the axle nut to the specified torque

(see E x-

ploded V iew ).

it if it a p p e a r s

e R otate the w heel, m easure the chain slack again at the

d r y.

tightest position, and readjust if necessary. e R otate the rear w heel to find the position chain is tightest. m ovem eM easure the vertical BA sprockets.

m idw ay

ent

w here the

elnsert

a new cotter pin through the axle nut and axle,

and spread its ends.

betw een the

r W ARNING

If the chain slack exceeds the standard, adjust it.

o If

th e a xle n u t is n o t se cu re ly tig h te n e d

a n d th e co tte r

p in is n o t in sta lle d , a n u n sa fe rid in g co n d itio n

m a y re -

su lt.

e C heck the rear brake effectiveness.

C hain S lack S tandard:

50,..,

S ervice Lim it:

Less than

55 m m

W h e e / A /ig n m e n t

5O m m ,

or m ore than

eC heck

OOmm

w ith

/n s p e c tio n

that the notch on the left chain adjuster alignes the sam e sw ing

arm m ark as the

right

chain

adjuster.

S /a c k A d ju s tm e n t

e P ull out the cotter pin, and loosen the axle nut. e Loosen the Jeft and right chain adjuster locknuts.

i..

A . M ark

B . N otch

N O TE

o A . A xle N ut

D . Locknut

B . C otter P in

W h e e l

a lig n m e n t

s tr a ig h te d g e

a ls o

b e

c h e c ke d

u s in g

th e

m e th o d .

E . N otch

C . C hain A djusting

N ut

F. M arks

eJf the chain is too tiqht, back out the left and right chain adjusting nuts

c a n

o r s tr in g

e v e n ly ,

the chain is too loose.

and push the w heel forw ard until

o M isa lig n m e n t

W A R N IN G '

th e

wheel

w ill

re su lt

a b n o rm a l

w e a r. a n d m a y re su lt in a n u n sa fe rid in g co n d itio n .

F IN A L W h e e / A /ig n m e n t

This procedure

A d ju s tm e n t

10-5

D R IV E

S tandard C hain fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

is the sam e as Slack Adjustm ent. KL650-B1

W e a r /n s p e c tio n

KL500-B1

M ake

D AID O

Type

010520 V2

Link

106 Link

108 Link

e R em ove the chain cover and guardo e R otate the

rear w heel

inspect

the drive

chain

for

dam aged rollers, and loose pins and links.

* If there

is any irregularity, replace the drive chain.

eStretch

the chain taut by hanging

*Lubricate

the drive chain if it appears dry. a 98N (10 kg, 20 lb)

The chain should

w eight on the chain. e M easure the length

of 20 links on the straight

part of

the chain from the pin center of the 1st pin to the pin center of the 21 st pino Since the chain m ay w ear uneany m easurem ents the chain.

exceed the service lim it, replace

Also, replace the front

and rear sprockets

w hen the drive chain is replaced.

be lubricated

w ith

a lubricant w hich

w ill both prevent the exterior from rusting and also absorb shock and reduce friction effective, chains

venly, take m easurem ents at severa] places. *If

L u b r ic e tio n

good

quality

in the interior of the chain.

lubricant

is best for regular chain

lubricant

specially

form ulated

lubrication.

An for

If a special

is not available, a heavy oil such as SAE 90 is

preferred to a lighter oil beca use it w ill stay on the chain longer and provide better lubrication. elf the chain appears especially dirty, it should be cleaned before lubrication.

O T he

O -rings

lubricant

betw een

the

side

plates

seal

betw een the pin and the bushing.

dam aging the

O -rings

observe the follow ing

and resultant

the

T o avoid

loss of lubricant,

rules.

O U se only kerosene or diesel oil for cleaning an O -ring drive chain.

A ny other cleaning solution such as gaso-

line or trichloroethylene

w ill

cause deterioration

and

sw elling of the O -rings. O Im m ediately

blow

the chain dry w ith

com pressed air

after cleaning. O C om plete cleaning and drying the chain w ithin

10 m in-

utes.

A. W eight

B. M easure eApply

C hain lO -link

Length

oil to the sides of the rollers so that oil w ill pene-

trate to the rollers and bushings.

S tandard:

317.5 -

S ervice Lim it:

323 m m

eW ipe

the drive

chain w ear

sult.

A chain that

..L

-L

exceeds the service lim it,

place the chain or an unsafe riding

condition

re-

could sag on the engine sprocket or lock the rear w heel.

2nd

It is an endless

type and should not be cut for installation.

1st

and causing it to go

O F or safety. use only the standard chain.

3rd

FEDCBA

•• ••

m ay re-

breaks or jum ps off the sprockets

severely dam aging the m otorcycle out of control.

the oil to the

off any excess oil.

I WARNING' o If

Apply

O -rings so that the O -rings w ill be coated w ith oil.

318.4 m m

Apply

M easure th is length.

oil.

21 st

¡ 1.::F"

•• ••

10-6, FEDCBA F I N A L D R I V E BA R e m o

va l

S p ro c k e ts ,

e R em ove :

C o u p lin g

Engine Sprocket C hain C over and G uard E n g in e

Low er Fairing e U sing the jack stand (special tool: 57001 -1238),

raise

the rear w heel off the qround.

S p r o c ke t

R e m o va l

eR em ove

the engine sprocket cover.

eR em ove

the engine sprocket bolts and holding

e D isengage the chain from the rear sprocket.

e Pull off the engine sprocket from the output

e R em ove the tie-rod

upper m ounting

e R em ove the sw ing

arm pivot shaft, and pull back the

* If

plate,

shaft, and

disengage the sprocket from the chain.

bolt.

the

chain

has not

slack

enough

pull

off

the

sprocket, get the chain slack w ith the chain adjuster.

sw ing arm , e R em ove the chain.

A. Engine Sprocket Bolts A. Tie- R od U pper M ounting

B. H olding

Plate

Bolt

B. Sw ing Arm Pivot Shaft

E n g in e

S p r o c ke t

eTighten

the

In s ta lla tĂo n

engine

sprocket

N o te s

bolts

the

specified

torque (see Exploded View ). In s ta lla tĂo n

eTighten

eAdjust

N o te s

the follow ing

to the specified

torque

the chain slack.

(see Ex-

ploded view ). Sw ing Arm Pivot N ut Tie-R od

U pper M ounting

N ut

Engine Sprocket Bolts R ear Axle N ut eAdjust

the chain slack after installation.

R e a r

BA S p ro c k e t.

e R em ove

the

W heels/Tires

o Do

C o u p lin g

rear w heel

R e m o va l

(see rear w heel

rem oval

chapter).

not lay the w heel on the ground w ith the disc facing

dow n.

T his can dam age or w arp the disco P lace blocks

under the w heel so that

the disc does not touch

the

ground.

e R em ove the coupling

from the w heel.

epull

collar from the left, and the cou-

out the coupling

pling sleeve from the right. elnstall

the rubber dam per and w heel coupling

tem po-

rarily on the rear hub to aid in rear sprocket rem oval. e R em ove the rear sprocket

nuts (8) to separate the rear

sprocket from the w heel coupling. e R em ove the coupling

from the rear w heel.

F IN A L R e a r S p r o c k e t,

elnstall out.

C o u p lin g

the rear sprocket the rear sprocket

10-7

NOTE fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

In s ta lla tio n N o te s

so that the m arked side faces

o BA If a s p ro c k e t w o rn

eTighten

D R IV E

nuts to the specified

torque

r e q u ir e s

a ls o .

W h e n

r e p la c e m e n t, r e p la c in g

th e

c h a in

s p ro c k e t,

is p r o b a b ly in s p e c t

th e

c h a in .

(see Exploded View ).

A. R ear Sprocket

S p r o c ke t

eVisually

A. R ear Sprocket

B. M ark

W e a r In s p e c tio n

inspect the engine and rear sprocket

teeth for S p r o c ke t

w ear and dam age. If they are w orn sprocket.

as illustrated

or dam aged, replace the

W a r p In s p e c tio n

e R em ove the low er fairing. eU sing

the jack stand (special tool: 57001-1238),

raise

the rear w heel off the ground. eSet a dial gauge against the rear sprocket near the teeth W orn Tooth

W orn Tooth

as show n,

(Engine Sprocket)

(R ear Sprocket)

sprocket

and rotate the rear w heel

runout

(w arp).

highest and low est

D irection

If the runout sprocket.

exceeds the service lim it, replace the rear

teeth. to less than the service

E ngine S procket D iam eter S tandard:

65.58 -

S ervice lim it:

64.9 m m

65.78 m m /15T 1 . D ial G auge

R ear S procket D iam eter

3. R otate

2. R ear Sprocket

K l650-B 1 S tandard:

207.23 -

S ervice lim it:

206.93 m m

207.73 m m /43T

K l500-B 1 S tandard:

227.43 -

227.93 m m /47T

S ervice lim it:

227.13 m m FEDCBA

the

of runout (w arp).

of rotation

If the sprocket is w orn dow n lim it, replace the sprocket.

betw een

dial gauge readings is the am ount

e M easure the diam eter of the sprocket at the base of the

to m easure the

The difference

R ear S procket W arp S tandard:

U nder 0.4 m m

S ervice lim it:

0.5 m m

1 0 -8 .

D R I V E BA

F IN A L

C o u p lín g

B e a rín g

R em oval

e Pull out the coupling

fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA D a m p e r In s p e c tío n

collar from the left.

e R em ove the rear w heel coupling,

e R em ove the circlip. e U sing

the

bearing

driver

set (special

tools)

or som e

other suitable tool, rem ove the bearing by tapping

from

e R eplace the dam per orated.

the w heel side.

A. Bearing D river Set 57001 -1129

C o u p lín g

elnspect

B e a rín g

A. R ubber D am per

In s ta lla tío n

N o te s

the bearing, and replace it if necessary.

e Lubricate

the bearing, and install it using the bearing

driver set (special tool: 57001-1129).

C o u p lín g

B e a rín g

Since the coupling

In s p e c tío n

and

L u b ríc a tío n

bearing is m ade to extrem ely close

tolerances, the clearance cannot norm ally be m easured. eW ash

the bearing w ith a high flash-point

solvent, dry it

(do not spin it w hile it is dry), and oil it. Spin it by hand

to check its condition. If it is noisy, does not spin sm oothly,

or has any rough

spots, it m ust be replaced. e l f the bearing

is to be used again, rew ash it w ith a high

flash- point solvent, dry it, and pack it w ith good quality bearing grease before installation.

Turn the bearing by

hand a few tim es to m ake sure the grease is distributed uniform ly

inside the bearing, and w ipe the old grease

out of the coupling

before bearing

and grease the coupling Periodic M aintenance

1. G rease.

and inspect the rubber

dam per.

installation.

C lean

bearing in accordance w ith the

C hart.

if it appears dam aged

or deteri-

BRAKES

1 1 -1

B ra k e s T a b le 0 1 C o n t e n t s jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Exploded View Specifications Special Tools Brake Adjustment Front Brake:

11-2 11-4 11-4 11-5 11-5

Rear Brake: Pedal Position Inspection Pedal Position Adjustment Caliper Front/Rear Caliper Removal FrontjRear Caliper Installation Notes Disassembly

11-5 11-5 11-5 11 -6 11-6 11-6 11-6

Assembly Fluid Seal Damage Dust Seal, Cover and Shaft Rubber Friction Boot Damage Piston Cylinder Damage Holder Shaft Wear Brake Pads

11-7 11-8 11-8 11-8 11-8 11 -8

Removal Installation Inspection Master Cylinder Front Master Cylinder Front Master Cylinder Rear Master Cylinder Rear Master Cylinder Front Master Cylinder

Removal Installation Notes Removal Installation Notes Disassembly

11 -8 11-8 11-8 11-9 11-9 11-1 O 11-1 O 11 -10 11 -10

Rear Master Cylinder Disassembly Assembly Notes Inspection (Visuallnspection) Brake Disc Inspection

11 -11 11 -11 11-11 11-12 11 -12

Brake Fluid Level Inspection Change Bleeding the Brake Line Brake Hose

11 -13 11 -1 3 11 -1 3 11 -14 11-16

Removal/lnstallation Inspection

Notes

11-16 11-16

11-2

BRAKES

Exploded View ZYXWVUTSRQPONMLKJIHGFEDCBA

1. F r o n t

L i h t S w itc h B ra k e gA t tio n ( B a la n c e d c ua

BAC

: A p p ly

g~ ease.

e r a tu r e

C a lip e r )

g re a se .

H : A p p ly h lg h te m ~ . . h te n in g S . F o IIo w th e s p e c if ic d tlgI ·

sequence.

Mo e

18 O ft-lb) 1'3 in lb ) T1 . 25 N - m (2.5 k q - m , 1T2 ' · 1.5 N - m (O . 15 k q -m , . lb ) 52 .m - lb ) T3 ' · 5.9 N - m (0.6 k g - m , T 4' · 8 8 N - m (0.9 k g - ,m 78 m.- b] W G:

W e st G e rm a n

· . k m 11 in-l T5: 1.3 N - m (0.1~ ~ 25 ft-lb] T6 ' 33 N - m (3.3 s- , 9' lb ) · 8 k m 6 mT7: 7.8 N - m (O. g - '16.5 ft-lb] 152 in - lb ) T8: 23 N - m (2.3 kq-rn, T9: 17.2 N - m (1.75 k q - m ,

BRAKES

u ZYXWVUTSRQPONMLKJIHGFEDCBA o

8 8 8 8 8 '- .J

~ LKJIHGFEDCBA

速 SRQPONMLKJIHGFEDCBA

1 1 -3

1 1 -4

BRAKES

S p e c if ic a t io n s

It e m

S e r v ic e

S ta n d a rd

L im it

B r a k e A d ju s t m e n t : jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Level with footpeg top

- ZYXWVUTSRQPONMLKJIHGFEDCBA --

4.35 4.5mm

1 mm 1 mm

4.8 - 5.1 mm Not more than 0.2 mm

4.5mm

Type

D.0.T.3

- --

Brand

Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty Castrol Girling-Universal Castrol GT (LMA) Castrol Disc Brake Fluid

Brake pedal position B ra k e P a d s :

Pad lining thickness:

Front Rear

B r a k e D is c :

Disc thickness Disc runout

0.3mm

B r a k e F lu id :

Recommended disc brake fluid:

S p e c ia l T o o ls

In s id e C ir c lip

P lie r s :

5 7 0 0 1 -1 4 3

/ /

J a c k S ta n d :

5 7 0 0 1 -1 2 3 8

- -- --

- -- -- --

- --

BRAKES P eda l

Brake Adjustment

P o s itio n

1 1 -5

A d ju s tm e n t

• Loosen the adjuster locknut. • Pull out the cotter pin, and remove the joint pino

Front Brake: Disc and disc pad wear is automatically

compensated

for and has no effect on brake lever action.

so there are

front

parts that

require

adjustment

the

However if the brake lever has a soft, or "spongy

brake.

feeling",

check the brake fluid level in the master cylinder and bleed the air from the brake line (see Bleeding the Brake Line).

• Unscrew cylinder.

the mounting

bolts, and remove the master

• Move the bracket up or down by turning nut to adjust the brake pedal position. .After

adjustment,

footpeg

the adjusting

install the master cylinder on the rear

bracket, and tighten the mounting

bolts to the

specified torque (see Exploded View). .Install the joint pin from the out side, and insert a new cotter pin and spread its ends.

NOTE ZYXWVUTSRQPONMLKJIHGFEDCBA .Tighten the adjuster locknut against the adjusting

o LKJIHGFEDCBA C h e c k th e b ra k e flu id o d ie M a in te n a n c e

le v e l in a c c o rd a n c e

w ith

th e P e ri-

nut

to the specified torque (see Exploded View).

C h a rt.

Rear Brake: Disc and disc pad wear is automatically for and has no effect on brake pedal action. brake pedal position

may occasionally

compensated However the

require adjustment

due to wear of the pedal pivot. or in case of disassembly. If the brake pedal has a soft, or "spongy feeling", check the brake fluid level in the reservoir and bleed the air from the brake line (see Bleeding the Brake Line).

NOTE

o C heck

th e b ra k e flu id

o d ie M a in te n a n c e

le v e l in a c c o rd a n c e

C h a rt.

w ith

th e P e ri-

GFEDCBA

A. Master Cylinder B. Locknut C. Adjusting Nut D. Brake Pedal Shaft Arm E. Master Cylinder Mounting F. Bracket

Bolts

G. Joint Pin P eda l

P o s itio n

H. Cotter Pin

In s p e c tio n

.When the brake pedal is released, it should return to the position specified. • Recheck the necessary.

Brake Pedal Position Standard:

Level with

footpeg top

.Adjust

the brake light switch

Light Timing ter).

A. Footpeg

brake pedal position,

B. Brake Pedal Position

If it does not, adjust the brake pedal position.SRQPONMLKJIHGFEDCBA

Inspection

and readjust it if

if necessary (see Brake

in the Electrical System chap-

1 1 -6

BRAKES F r o n t/R e a r

C a lip e r GFEDCBA

.Tighten

C a lip e r In s ta lla tio n

the

caliper

mounting

N o te s

bolts

to the

specified

torque (see Exploded View). F r o n t/R e a r

• Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt to the specified torque

C a l i p e r R e m o v a l jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

• Remove the disc cover. • Loosen the banjo bolt at the brake hose lower end, and tighten it loosely. .Unscrew

(see Exploded View) . .Change

the brake fluid (see Brake Fluid Change).

.Check

the mounting

bolts. and remove the caliper

the brake for wear braking

power,

brake drag,

and fluid leakage by operating the brake lever/pedal.

from the disco

N O T E LKJIHGFEDCBA O /f th e c a lip e r is to b e d is a s s e m b le d

a fte r r e m o v a l a n d

c o m p r e s s e d a ir is n o t a v a ila b le , d is a s s e m b le th e c a lip e r b e fo r e b r a k e h o s e r e m o v a T ( s e e D is a s s e m b ly ) .

D is a s s e m b ly

• Remove the front/rear caliper . • Remove the pads and spring (see Pad Removal). • Unscrew the banjo bolt and remove the brake hose from the caliper (see Brake Hose Removal/lnstallation). OThere is a flat washer on each side of the hose fitting.

• Remove the caliper holder, shaft rubber friction and dust cover. .Using

boot

compressed air, remove the piston(s).

O Cover the caliper opening with a clean, heavy cloth. O Remove the piston (s) by lightly

applying

compressed

air to where the brake line fits into the caliper.

W A R N IN G

OTo avoid serious injury, never place your fingers or palm inside the caliper opening.

you apply compressed air

into the caliper. the piston(s)

may crush your hand or

fingers.

A. Apply compressed air.

B. Cloth

NOTE O /f

A. Front Caliper

D. Brake Disc E. Brake Hose

B. Rear Caliper C. Caliper Mounting

Bolts

F. Banjo Bolt

th e c a lip e r is to b e d is a s s e m b le d

c o m p re s s e d u s in g

th e

a ir is n o t

fo llo w in g

a fte r r e m o v a l a n d

a v a ila b le , r e m o v e

th r e e s te p s b e fo r e

th e p is to n ( s ) d is c o n n e c tin g

th e b r a k e h o s e fr a m th e c a lip e r .

O P r e p a r e a s u ita b le c o n ta in e r fo r b r a k e flu id , a n d p e r fo r m th e w o r k a b o v e it. O R e m o v e th e p a d s a n d s p r in g ( s e e P a d R e m o v a l) . O Pum p

th e b r a k e le v e r o r p e d a l

p is to n ( s ) .

to r e m o v e

th e

c a lip e r

BRAKES

{Eu:Dill

@ :u !!:~ ~

ZYXWVUTSRQPONMLKJIHGFEDCBA

o Do Im m ediately wipe up any brake fluid that spills. It m ay o jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

not

injure

1 1 -7

the

cylinder.

piston

and dust seal by

forcing it in place.

painted or painted surfaces.

e Remove the dust seal(s) and fluid seal(s). e Remove the bleed valve and rubber cap.GFEDCBA

o Properly fit the dust sealupper the piston. e Replace the shaft rubber friction

end into the groove in boot and dust cover if

they are damaged. eApplya thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts and holder holes (PBC is a A s s e m b ly

special high temperature, water-resistant

grease).

eClean the caliper parts except for the pads.

o For

cleaning the parts. use only isopropyl alcohol. or ethyl alcohol.

eTighten

disc

brake

fluid.

the bleed valve to the specified torque (see Ex-

ploded View).SRQPONMLKJIHGFEDCBA e lt

is recommended

that the fluid seal, which

is removed,

be replaced with a new one, eApply

brake

fluid

the

fluid

seal(s),

and

install

it(them) into the cylinder(s) hand. e Replace the dust seal if it is damaged. e For the front caliper, do the following.

o Apply brake fluid to the dust seals, and install them into the cylinders by hand.

A. Shaft Rubber Friction Boot

o Apply brake fluid to the outside of the pistons, and push them into the each cylinder by hand. o Install the pisto n pads into the each piston. e For the rear caliper, do the following.

B. Dust Cover C. Caliper Holder Shafts D. Holder Holes

OApply brake fluid to the outside of the pist贸n. and install the dust seal around

the piston from the pad side of

elnstall

the anti-rattle

spring in the caliper as shown.

piston and slide down it.

o Extend the dust seal lower end, and properly fit it into the groove in the cylinder by hand.

搂 !l: m o

Do not use a thin screwdriver

or any other sharp in-

strum ent to fit the dust seal. or it m ay be dam aged.

A. Anti-Rattle

elnstall

A. Dust Seal

B. Groove

o Push the piston into the cylinder by hand.

Spring

the pads (see Pad Installation).

11-8 SRQPONMLKJIHGFEDCBA B R A K E S LKJIHGFEDCBA F lu íd

Seal Dam age The fluid seal around the piston maintains the proper

pad/disc clearance. If this seal is not in good condition, pad wear will in crease, and constant pad drag on the disc will raise brake and brake fluid temperature.

Brake Pads

R em o val

• Remove the disc cover. • Remove the caliper form the disc, and take out the piston side pad from the caliper holder. • Push the caliper holder toward the piston, and then remove the pad from the caliper holder shafts.

1. Caliper

3. Fluid Seal

2. Piston

4. Dust Seal A. Pad

Replace the fluid seal under any of the following conditions: (a) fluid leakage around the pad; (b) brakes

C. Holder Shafts

B. Caliper Holder

overheat; (e) there is a large difference in left and right pad wear; (d) the seal is stuck to the piston.

If the fluid seal

is replaced, replace the dust seal as well.

Also, replace all In s ta lla tío n

seals every other time the pads are changed.

• Push the caliper piston in by hand as far as it will go . • Install the anti-rattle spring . • Install the piston side pad first, and then install the reD u s t S e a /, C o v e r a n d S h a ft Boot

.Check boot

Rubber

F ric tío n

Dam age

I WARNING I

that the dust seal, cover and shaft rubber friction are not cracked, worn,

swollen,

or otherwise

o Do

damaged. *If

maining pad.

not attem pt

drive the

m otorcycle

until

a full

brake lever or pedal is obtained by pum ping the brake

they show any damage, replace them.

lever or pedal until the pads are against the disco The brake will

not function

on the first application

of the

lever or pedal if this is not done. GFEDCBA

P is to n

C y lín d e r

Dam age

.Visually

inspect the piston and cylinder surfaces.

*Replace

the cylinder and piston if they are badly scored

or rusty.

ln s p e c tio n

.Check

the lining thickness and condition of the pads in

each caliper.

* If

either pad is damaged, replace both

pads in the

caliper as a set. H o ld e r

S h a ft

W ear

The caliper body must slide srnoothlv.on

the caliper

holder shafts. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature. .Check

to see if the caliper holder shafts are not badly

worn or stepped, or rubber friction boot are not damaged.

* If the

ru bber friction boot are damaged, replace the rubber friction boot, and the caliper holder.

* If the lining thickness of either pad is less than the service limit, replace both pads in the caliper as a set. Pad Lining Thickness Front Standard:

4,35mm

Service Limit:

1mm

Rear Standard:

4,5mm

Service Limit:

1mm

BRAKES

M a s te r

C y lin d e r ZYXWVUTSRQPONMLKJIHGFEDCBA

Brake fluid quickly ruins painted or plated surfaces; any spilled

速 jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA diately. fluid

A. Lining Thickness

1 1 -9

should

be completely

wiped

up imme-

B. Service LimitGFEDCBA F r o n t M a s te r

C ylin d e r

R em o va l

e Remove the right handguard. e Pull back the dust cover, and remove the banjo bolt to disconnect the upper brake hose from the master cylinder (see Brake Hose Removal/lnstallation). There is a flat washer on each side of the hose fitting.

A. Dust Cover

C. Master Cylinder

B. Banjo Bolt

D. Reservoir

e Disconnect the front brake switch connectors. e Unscrew the clamp bolts, and take off the master cylinder as an assembly with the reservoir, brake lever, and brake switch attached.

A. Brake Switch B. Connectors

C. Clamp Bolts

1 1 -1 0

B R A K E S GFEDCBA

F r o n t M a s te r

C ylin d e r

In s ta lla tio n

• Unscrew the master cylinder mounting N o t e s jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

• The master cylinder clamp must be installed with the arrow mark pointing upward. • Tighten

the upper clamp

bolt

first to the specified

torque (see Exploded View), and then tighten the lower clamp bolt to the same torque.

There will be a gap at

bolts. and remove the master cylinder with the reservoir.

• Unscrew the reservoir cap and pour the brake fluid into a container . • Remove the reservoir and its hose from the master cylinder.

the lower part of the clamp after tightening.

Rea r

M a s te r

.Tighten

C ylin d e r

In s ta lla tio n

the master cylinder

N o te s

mounting

bolts

the

specified torque (see Exploded View). • Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolts to the specified torque (see Exploded View) . • Tighten

the reservoir mounting

bolt to the specified

torque (see Exploded View). • Change the brake fluid after master cylinder installation (see Brake Fluid Change) . • Check the brake for weak braking power, brake drag, and fluid leakage. • Check the brake pedal position, and the rear brake light A. Arrow Mark

switch operation (see Brake Pedal Position Inspection,

B. Clamp Bolt (Tiqhten upper clamp bolt first.)

and

Brake Light Timing

Inspection

in the

Electrical

System chapter). • Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt to the specified torque (see Exploded View) . • Change the brake fluid after master cylinder installation F r o n t M a s te r

(see Brake Fluid Change). • Check the brake for weak braking power, brake drag, and fluid leakage.

R e a r M a s te r

C ylin d e r

D is a s s e m b ly

• Remove the front master cylinder Cylinder Removal).

(see Front Master

R em o va l

• Remove the reservoir cover.

5. Primary Cup

1. Dust Cover 2. Circlip

6. Return Spring

3. Piston

7. Reservoir

4. Secondary Cup A. Joint Pin B. Reservoir Mounting

D. Master Cylinder Bolt

E. Mounting

Bolts

C. Banjo Bolt

• Remove the reservo ir cap and diaphragm, and pour the brake fluid into a container.

• Remove the reservoir mounting bolt.

• Unscrew the locknut and pivot bolt, and remove the brake lever.

• Pull out the cotter pin. and remove the joint pino • Unscrew the banjo bolt to disconnect the brake hose from the master cylinder (see Brake Hose Removal/ Installation). There is a flat washer on each side of the hose fitting.

• Push the dust cover out of place, and using the inside circlip pliers (special tool: 57001-143), remove the circlip. • Pull out the pistón, secondary cup, primary cup. and return spring.

BRAKES

1 1 -1 1

off com pletely, and will eventually deteriorate the rubber used in the disc brake.

o Do not

rem ove the secondary cup from the piston since

rem oval will dam age it. GFEDCBA

eTake care not to damage the inner surface of the cylinder. or the piston. eTighten

the brake lever pivot bolt locknut to the speci-

fied torque (see Exploded View). R e a r M a s te r C ylin d e r D is a s s e m b ly

e Remove the rear master cylinder (see Rear Master Cvlinder Removal). eSlide the dust cover on the push rod out of place, and using the inside circlip pliers (special tool: 57001 -143), remove the circlip. e Pull out the push rod with the piston stop. eTake off the piston, secondary return spring.

cup, primary cup. and

In s p e c tio n

(V is u a lln s p e c tio n )

e Disassemble the front and rear master cylinders. e Check that there are no scratches, rust or pitting on the inside of each master cylinder each piston. *If

o Do not

rem ove the secondary cup from the piston since

rem oval will dam age it.

a master cylinder place them.

elnspect *If

and on the outside

or piston shows any damage, re-

the primary cups and secondary cups.

a cup is worn, damaged, softened

(rotted),

or swol-

len, the piston assembly should be replace to renew the cups. *If

fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew tlle cupo eCheck the dust covers for datnage.

* If they are damaged, replace t hem. e Check that the relief and supply ports are not plugged. * If the small relief port becomes plugged, the brake pads will drag on the disco Blow the ports clean with cornpressed air. e Check the piston return springs for any damage. * If a spring is damaged, replace it.

1. Push Rod

5. Secondary Cup

2. Dust Cover

6. Primary Cup

3. Circlip

7. Return Spring

4. Piston

A s s e m b ly

eClean

N o te s

all parts with

brake fluid

or alcohol,

and apply

brake fluid to the inner surface of the cylinder assembly.

o Except fluid,

for the disc pads and disc, use only disc brake

isopropyl alcohol. or ethyl alochol. for cleaning

brake pards. these parts. leum distillate parts.

before

Do not use any other fluid

for cleaning

Gasoline, engine oil, or any other perrowill

cause deterioration

of the rubber

Oil spilled on any part will be difficult

to wash SRQPONMLKJIHGFEDCBA

11-12

BRAKES

Brake Disc GFEDCBA

/n s p e c tio n

.Visually *If

inspect the disco

disc is scratched or damaged replace the disco

• Measure the thickness of each disc at the point where it has worn the most. * Replace the disc if it has worn past the service limit.

1. Disc

2. Measuring Area

Disc Thickness Standard:

4.8 -

Service Limit:

4.5mm

5.1 mm

• Remove the lower fairing. • Using the jack stand (special tool: 57001 -1238), the front/rear wheel off the ground .

raise

• Set up a dial gauge against the disco O For the front disc, turn the handlebar fully to one side. • Rotate the wheel to measure ® ZYXWVUTSRQPONMLKJIHGFEDCBA

disc runout. The difference between the highest and lowest dial readings is the amount of runout.

® *If

1. Reservoir

8. Piston

2. Diaphragm

9. Secondary Cup

3. Relief Port 4. Supply Port

10. Washer 11. Circlip

5. Cylinder

12. Dust Cover

6. Return Spring 7. Primary Cup

13. Brake Lever

disc runout exceeds the service limit, replace the disco

14. Push Rod

1. Disc

2. Measuring Area

Disc Runout Standard:

Not more than 0 .2 mm

Service Limit:

0.3mm

BRAKES

11-13

Brake Fluid LKJIHGFEDCBA

L e v e lln s p e c tĂo n In accordance

with

Maintenance

the Periodic

Chart,

inspect the brake fluid level in the front and rear brake fluid reservoirs. eCheck

the brake fluid level in the reservoir.

NOTE

o H o ld

th e re s e rv o ir h o riz o n ta l

when

c h e c k in g

b ra k e flu id

le v e l.

A. Reservoir(Rear)

C. lower

B. Upper level Line

D. Reservoir Cover

level line

*The fluid level must be kept above the lower level lines. If the fluid level is lower than the lower levelline, fill the reservo ir to the upper level line of the reservo ir.

Change

I WARN.lNG

In accordance changed

o Change the

brake fluid in the brake system com pletely

if the brake fluid

m ust be refilled

with

the Periodic

change the brake fluid.

but the type and

brand of the brake fluid that already is in the reservoir are unidentified. After changing the fluid, use only the sam e type and brand of fluid thereafter.

M ixing

Maintenance

The brake fluid should

if it becomes contaminated

with

Further more, the brake fluid should

Chart, also be

dirt or water.

be changed when-

ever the brake line parts are removed to bleed the air fast and completely.

dif-

ferent types and brands of brake fluid lowers the brake fluid boiling point and could cause the brake to be ineffective.

It m ay also cause the rubber brake parts to

Brake Fluid Requirement: Recommended fluids are given in table below,

deteriorate.

of the recommended heavy-duty D.0.T.3

brake fluid

Recommended

If none

brake fluids are available, use extra only

from

a container

marked

Disc Brake Fluid

Type:

D.O.T.3

Brand:

Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty VVagner Lockheed Heavy Duty Castrol Girling-Universal Castrol GT(LMA) Castrol Disc Brake Fluid

Changing Brake Fluid: A. Reservoir(front) B. lower

C. Upper level Line

NOTE

level Line

T h e p ro c e d u re lo w s .

to c h a n g e

C h a n g in g

th e fro n t

b ra k e flu id

th e re a r b ra k e flu id

is a s fo l-

is th e s a m e a s fo r

th e fro n t b ra k e .

elevel

the brake fluid reservoir.

e Removal the reservoir cap. e Remove the rubber cap on the bleed valve. eAttach

a clear plastic hose to the bleed valve on the

caliper, and run the other end of the hose into a container.

1 1 -1 4

B R A K E S jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

eChange

the brake fluid as follows.

e Remove the reservoir cap, and fill the reservo ir to the upper level line of the reservoir.

NOTE

T h e flu id in g

le v e l m u s t b e c h e c k e d

o p e ra tio n

n e c e s s a ry .

a n d re p le n is h e d

If th e flu id

a n y tim e d u rin g

o fte n w ith

d u rin g

th e b le e d -

fre s h b ra k e flu id

in th e re s e rv o ir ru n s a lm o s t

b le e d in g

o p e re tio n .

a tio n m u s t b e d o n e o v e r a g a in fro m

as out

th e b le e d in g

o p e r-

th e b e g in n in g

s in c e

a ir w ill h a v e e n te re d th e lin e .

eWith

the reservoir cap off, slowly

pump the brake lever

several times until no air bubbles can be seen rising up through

the fluid from the holes at the bottom

reservoir.

of the

Bleed the air completely from the master cyl-

inder by this operation.

NOTE

1 . Open the bleed valve.

3. Close the bleed valve.

2. Apply the brake and hold it,

T a p th e b ra k e h o s e lig h tly

4. Release the brake.

o Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes.

elnstall eAttach

c h a n g in g flu id . in g

o p e ra tio n

If th e flu id

th e c h a n g in g

and

checked

o fte n

re p le n is h e d

w ith

d u rin g fre s h

th e b ra k e

in th e re s e rv o ir ru n s o u t a n y tim e d u ro p e re tio n ,

th e c a lip e r to th e re s e r-

the reservoir cap. a clear plastic hose to the bleed valve on the

caliper, and run the other end of the hose into a container.

NOTE

o LKJIHGFEDCBA T h e flu id le v e l m u s t

fro m

v o ir fo r e a s ie r b le e d in g .

th e b ra k e s w ill n e e d to b e

epump

the brake lever until it becomes hard and then,

holding

the brake applied, quickly open (turn counter-

clockwise) and close the bleed valve. e Release the brake. e Repeat this operation

b le d s in c e a ir w ill h a v e e n te re d th e b ra k e lin e .

until

no more air can be seen

coming out into the plastic hose. e Remove the plastic hose from the bleed valve. eTighten the bleed valve to the specified torque (see Exploded View), and install the rubber cap. eAfter

changing

the fluid,

check

the brakes for weak

braking power, brake drag, and fluid leakage.

* If necessary, bleed the air from B le e d Ăn g

the line.GFEDCBA

e Detach the clear plastic hose from the bleed valve on the caliper. eTighten the bleed valve to the specified torque (see Exploded View), and install the rubber cap. eCheck the fluid leve!. eAfter bleeding is done, check the brake for weak braking power, brake drag, and fluid leakage.

th e B r a ke U n e

The brake fluid has a very low compression

coefficient

so that almost all the movement of the brake lever is transmitted directly to the caliper for braking action. Air, however, is easily compressed.

When air enters the brake

line, brake lever movement will be partially used in compressing the air. This will make the lever feel spongy, and there will be a loss in braking power. Bleed the air from the brake whenever brake lever action feels soft or spongy, after the brake fluid is changed, or whenever ened for any reason:

a brake line fitting

has been loos-

N O T E ZYXWVUTSRQPONMLKJIHGFEDCBA

T h e p ro c e d u re B le e d in g b ra k e .

to b le e d th e fro n t b ra k e lin e is a s io llo w s ,

th e re a r b ra k e lin e is th e s a m e a s fo r th e fro n t

BRAKES

WARNING

1 1 -1 5

OWhen working with the disc brake, observe the precautions listed below.

1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake.

This lowers the brake fluid

boiling

could cause the brake to be ineffective.

point and It may also

cause the rubber brake parts to deteriorate. 4. Don't leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. 5. Don't change the fluid in the rain or when a strong wind 1. Pump the brake lever until it becomes hard, and apply the brake and hold it.

is blowing. 6. Except for the disc pads and disc. use only disc brake fluid,

2. Ouickly open and clase the bleed valve while holding

isopropyl alcohol, or ethyl alcohol for cleaning

brake parts.

the brake applied.

Do not use any other fluid for cleaning

these parts. Gasoline, engine oil, or any other petroleum

3. Release the brake.SRQPONMLKJIHGFEDCBA

distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off cornpletely and will eventually deteriorate the rubber used in the disc brake. 7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them.

Clean off any

fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent. Do not use one which will leave an oily residue.

Replace the pads with new

ones if they cannot be cleaned satisfactorily. 8. Brake fluid quickly

ruins painted surfaces; any spilled

fluid should be completely wiped up immediately. 9. If any of the brake line fittings

or the bleed valve is

opened at any time, the ZYXWVUTSRQPONMLKJIHGFEDCBA A IR M U S T B E B lE D FROM THE BRAKE.

1 1 -1 6

BRAKES

B r a k e H o s e GFEDCBA

R e m o va lj

In s ta lla tio n

N o te s

jihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

removing the brake hose, take care not to spill the

eWhen

brake fluid on the frame or other painted parts. eWhen

removing the brake hose, temporarily

secure the

end of the brake hose to some high place to keep fluid loss to a minimum.

o Brake fluid spilled

quickly ruins painted or plated surfaces; any

fluid

should

be completely

wiped

imme-

diately.

e There is a flat washer on each side of the brake hose fining. Replace them with new ones when installing it. eWhen

installing

kinking, flanening

the

hoses,

or twisting,

avoid

sharp

bending,

and route the hoses ac-

cording to the Hose Routing section in the General Information chapter. eTighten

the banjo bolts at the hose finings to the spec-

ified torque (see Exploded View). eChange the brake fluid after installing (see Brake Fluid Change).

the brake hose

In s p e c tio n

eThe

high pressure inside the brake line can cause fluid

to leak or the hose to burst if the line is not properly maintained. amining it.

Bend and twist the rubber hose while ex-

* Replace it if any cracks or bulges are noticed.

S U S P E N S IO N

S u s p e n s io n T a b le

E x p lo d e d

o f C o n te n ts

V ie w fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

12 -2

S p e c ific a tio n s

1 2 -4

S p e c ia l

1 2 -4

T o o ls

12-5

F ro n t F o rk A ir P r e s s u r e A d ju s tm e n t

12-5

O il C h a n g e

12-5 12-6

Rem oval In s ta lla tio n

12-6

N o te s

12-6

D is a s s e m b ly A s s e m b ly

Bush

In s p e c tio n

12-8

D u s t S e a l In s p e c tio n

12-8

O il S e a l a n d S p r in g

12-8

Inspection

In n e r T u b e G u id e

12-7

N o te s

T ension

R e a r S u s p e n s io n Rear Shock S p r in g

12-8 12-9

(U n i- T r a k )

12-9

A b s o rb e r: P r e lo a d

D a m p in g

A djustm ent

F o rc e

A djustm ent

R em oval

12-9

In s ta lla tio n S w in g

12-1 O

N o te

12-10

A rm

R em oval

12-10

In s ta lla tio n T ie -R o d ,

12-9 12-9

12-10

N o te s

Rocker

A rm :

T ie -R o d

R em oval

T ie - R o d

In s ta lla tio n

12-10 1 2 -1 0 N o te s

R o c k e r A rm

Rem oval

R o c k e r A rm

In s ta lla tio n

12-1 O 12-11

N o te s

12-11

1 2 -1

1 2 -2

S U S P E N S IO N

E xp lo d e d V ie w

WVUTSRQPONMLKJIHGFEDCBA

L G : A p p ly

liq u id g a s k e t

a n o n -p e rm a n e n t

: A p p ly

th e

th re a d s .

lo c k in g

agent

th e

th re a d s .

T 1 : 1 2 N -m

( 1 .2 k q -m ,

8 .5 ft-lb ]

T 2 : 2 9 N -m

( 3 .0 k g -m ,

2 2 ft-Ib )

T 3 : 2 5 N -m

( 2 .5 k g -m ,

1 8 .0 ft-Ib )

T 4 : 1 .5 N -m T 5 : 3 9 N -m

( 0 .1 5 k g , 1 3 in -lb ) ( 4 .0 k g -m ,

2 9 ft-lb ]

S U S P E N S IO N

, JJ

~ ,~ ~

~~@ ~

flf

隆~

\ @

. ~

~ ~

: A p p ly m o ly b d e n u m

d is u lfid e

T 6 : 5 9 N 路 m ( 6 .0 k q - r n , 4 3 f t- lb ] T I:

9 8 N - m ( 1 0 .0 k q - m , 7 2 f t- lb )

g re a se .

1 2 -3 WVUTSRQ

1 2 -4

S U S P E N S IO N

S p e c ific a tio n s

It e m

S e r v ic e L im it

S ta n d a rd

F r o n t F o r k : fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

A ir pressure

O (atom ospheric

- - pressure) WVUTSRQPONMLKJIHGFEDCBA

F ork oil: V iscosity A m ount

S A E 10W 20

- - -

(per side):

W hen changing oil A fter disassem bly and com pletely O il level (fully com pressed, w ithout

approx. 320 m L

- - -

dry

377 ± 4 m L

- - -

spring)

159 ± 2 m m

- - -

F ork spring free length

(from the top of the inner tube)

464.4 m m

455m m

F ro n t

F o r k C y lin d e r

H o ld e r

F ro n t

F o r k O il S e a l D r iv e r :

H a n d le :

- -

5 7 0 0 1 -1 8 3

S p e c ia l T o o ls

J a c k S ta n d :

O il S y r in g e :

5 7 0 0 1 -1 2 3 8

5 7 0 0 1 -1 2 9 0

B e a r in g

F ro n t

5 7 0 0 1 -1 2 1 9

F o r k C y lin d e r

H o ld e r

A d a p te r :

5 7 0 0 1 -1 0 5 7

D r iv e r

S e t:

5 7 0 0 1 -1 1 2 9

S U S P E N S IO N

1 2 -5

F o rk O il

F ro n t F o rk EDCBA

V is c o s ity :

SAE 10W 20

A m o u n t (p e r s id e ): A ir P r e s s u r e

W h e n c h a n g in g o il:

A d ju s tm e n t

a p p ro x . 3 2 0 m l

A fte r d is a s s e m b ly a n d

e R em ove the low er fairing. e U sing the jack stand (special tool: 57001 -1238),

c o m p le te ly d ry :

raise

377 Âą 4 m l

the frong w heel off the ground. e R em ove the air valve cap and push the air vlave to open. elnstall

the air valve cap.

eA djust O

the oillevel

w ith the oil syringe (special tool).

S et the oil syringe stopper so that its low er side show s the oil level distance specified.

A ir P re s s u re WVUTSRQPONMLKJIHGFEDCBA O (a tm o s p h e ric p re s s u re )

NOTE O The gauge

tu b e

O T h e s yr in g e c /u d in g

is g r a d u a te d

body

is g r a d u a te d

th e g a u g e

tu b e

of about

1 cm in

d ivis io n .

10 mL

d ivis io n .

ex-

5 m L c a p a c ity.

O il le v e l (fu lly c o m p re s s e d , w ith o u t

s p rin g )

1 9 0 Âą2 m m (fro m th e to p o f th e in n e r tu b e )

W ith

the fork fully com pressed,

insert the gauge tube

into

the inner tube and position

the stopper across the

inner tube top end.

NOTE O P o s itio n

A . A ir V alve

th e s to p p e r

o f in n e r tu b e

s o th a t th e g a u g e

tu b e is th e c e n te r

d i a m e t e r , o r t h e s p e c i fi e d

o ille ve l

ca n not

g e t c o r r e c tly.

NOTE O A d d itio n

o f a ir p r e s s u r e

m o s p h e r ic

pressure

is n o t th e

m ost

recom m ended s u ita b le

s in c e

s e ttin g

a t-

fo r

a ll

r a n g e s o f r id in g .

P ull the handle slow ly the

to pum p out the excess oil until

oil com es out no longer.

If no oil is pum ped inner tube.

out, there is insufficient

P our in enough

cess oil as show n above. I W ARNING YXWVUTSRQPONMLKJIHGFEDCBA I

D o n o t re m o v e th e s p rin g s a n d re ly o n a ir o n ly .

C o rre c t

s p rin g s m u s t b e u s e d in th is s u s p e n s io n s y s te m . w ith o u t

s p rin g s c a n le a d to a c o n d itio n

oil in the

oil, then pum p out the ex-

U se

c a u s in g a c c i-

d e n t a n d in ju ry . O D o n o t in c in e ra te th e fro n t

fo rk w ith o u t

firs t re m o v in g

th e a ir v la v e o r it m a y e x p lo d e .

O il C h a n g e

e R elease the air in both fork legs through

the air valve at

the top of the fork leg. e U nscrew the drain screw and top plug, and pull out the spacer, spring seat and fork spring. eA llow

the oil to drain into a suitable container.

If you

pum p the fork legs to force out the oil, be sure to catch the oil in a container as it squirts out. eW ash

t h e : drain

screw

threads

a liquid gasket to the threads of the drain screw

and install the screw and a new gasket. eT ighten

the drain screw s

C . S topper

B . H andle

clean of oil, and blow

them dry. eA pply

A . O il S yringe: 57001 -1 290

to the specified

elnstall

the parts rem oved.

eC heck

the O -ring

at the top plug, and replace it w ith a

new one if dam aged. torque

E xploded V iew ). e P our in the type and am ount of fork oil specified.

(see

eT ighten

the top

plug to the specified

ploded V iew ). eA djust

the air pressure.

torque

(see E x-

S U S P E N S IO N EDCBA

1 2 -6 Rem o

v a / fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

e R em ove : F airings S peedom eter C able C lam p (for right fork) B rake H ose C lam p (for left fork) S peedom eter C able Low er E nd C aliper (w ith

hose connected)

F ront W heel F ront F ender M ounting

B olts

e Loosen the clam p bolts.

A . A ir V alve C ap

D . S pacer

B . T op P lug

E . S pring S eat

C .O -ring

F . S pring

e P our the fork oil into a container. eS top

the cylinder

cylinder

holder

from turning handle

and

by using the front adapter

(special

fork

tools).

U nscrew the A llen bolt, and take the bolt and gasket out of the bottom

of the outer tube . WVUTSRQPONMLKJIHGFEDCBA ..,..1

, A . U pper C lam p B olts

B . Low er C lam p B olts ""'1

eW ith out.

a tw isting

m otion,

w ork

the fork

leg dow n

and

t速

1 . A llen W rench 2. A llen B olt 3. C ylinder U nit 4. A dapter: 57001 -1057 5. F ront F ork C ylinder H older H andle: 57001 -183

In s ta lla tio n

N o te s

e R em ove the cylinder

elf the fork leg w as disassem bled, adjust the fork oillevel. e R oute the cables and hose according H ose R outing

unit and the spring from the top

of the front fork tube.

to the C able and

section in the G eneral Inform ation

chap-

ter. eT ighten

the low er clam p nuts and upper clam p bolts to

the specified torque

(see E xploded V iew ).

D is a s s e m b /y e R elease the air. e Loosen the top plug. e R em ove the fork leg. e R em ove the rubber boot. e R em ove the top plug

and O -ring,

A . C ylinder U nit

B . S pring

pull out the spacer,

spring seat and sprinq. e R em ove

the

retaining

ring from

the top

of the outer

tube. eS eparate

the

inner tube

w ith

the

dust

seal, oil seal,

w asher and guide buhes from the outer tube.

H olding

the inner tube

stroke the outer tube

by hand in a vertical position,

up and dow n

several tim es and

S U S P E N S IO N p u ll it d o w n .

1 2 -7

T h is sh o ck to th e fo rk le g se p a ra te s th e

o u te r tu b e fro m th e in n e r tu b e .

A . In n e r T u b e

C . C ylin d e r B a se

B . C ylin d e r U n it

A . D u st S e a l

C . W a sh e r

B . O il S e a l

D . G u id e B u sh e s

e ln se rt

th e in n e r tu b e a n d cylin d e r u n it a s a se t in to th e

o u te r tu b e . e A p p ly

a liq u id g a ske t to b o th sid e s o f th e g a ske t, a n d

a p p lya e R e m o ve th e d u st se a l, o il se a l, w a sh e r a n d o u te r tu b e g u id e b u sh fro m th e to p o f th e in e n r tu b e . e R e m o ve tire cylin d e r b a se fro m th e b o tto m o f th e o u te r tu b e .

n o n -p e rm a n e n t

lo ckin g a g e n t to th e th re a d s o f

th e A lle n b o lt a t th e b o tto m o f th e o u te r tu b e . e S to p

th e cylin d e r fro m tu rn in g

b y u sin g th e fro n t fo rk

cylin d e r h o ld e r h a n d ie (sp e cia l to o l: 5 7 0 0 1 -1 8 3 ) a d a p te r (sp e cia l to o l:

5 7 0 0 1 -1 0 5 7 ),

and

tig h te n th e A lle n

b o lt to th e sp e cifie d to rq u e (se e E xp lo d e d V ie w ). eW hen

re p la cin g th e o u te r tu b e g u id e b u sh w ith a n e w

o n e , h o ld th e u se d g u id e b u sh a g a in st th e n e w o n e , a n d ta p th e u se d g u id e d rive r (sp e cia l to o l)

b u sh w ith

th e fro n t fo rk o il se a l

u n til it sto p s.

速 WVUTSRQPONMLKJIHGFEDCBA A . O u te r T u b e

A s s e m b /y

B . C ylin d e r B a se EDCBA

N o te s

e C h e ck th e O -rin g a t th e to p p lu g .

R e p la ce it w ith a n e w

速

o n e if d a m a g e d . e R e p la ce th e o il se a l re m o ve d w ith a n e w o n e . e R e p la ce th e g u id e b u sh e s w ith n e w o n e s. e ln se rt th e cylin d e r u n it a n d sp rin g in th e in n e r tu b e .

1 . F ro n t F o rk O il S e a l D rive r: 5 7 0 0 1 -1 2 1 9 e ln se rt th e cylin d e r b a se in th e cylin d e r u n it. YXWVUTSRQPONMLKJIHGFEDCBA 2 . U se d G u id e B u sh 3 . S lit 4 . N e w G u id e B u sh 5 . O u te r T u b e 6. Tap

1 2 -8 YXWVUTSRQPONMLKJIHGFEDCBA S U S P E N S IO N eA fter

installing

seal by

the w asher, install the oil seal and dust

using

the

fork

oil

seal driver

(special

tool:

of fork oil specified

(see

57001-1219). e P our in the type and am ount S pecifications),

and

adjust

the

oil

level

(see

O il

C hange).

/nner Tube /nspection eV isually eN icks

速

inspect the inner tube, and repair any dam age. or rust dam age can som etim es

WVUTSRQPONMLKJIHGFEDCBA

be repaired by us-

ing a w et- stone to rem ove sharp edges or raised areas

w hich

A . D ust S eal

cause seal dam age.

B . O il S eal

If the dam age is not repairable, replace the inner tube. S ince dam age to the inner tube dam ages the oil seal, replace the oil seal w henever

the inner tube is repaired

or replaced. eT em porarily pum p

them

assem ble the back

and

inner and outer

forth

m anually

tubes,

and

check

for

Spring Tension

sm ooth operation.

eS ince

* o If

a spring becom es shorter as it w eakens, check its

free length to determ ine lim it, it m ust be replaced.

th e

in n e r tu b e

is b a d ly b e n t o r c re a s e d , re p la c e it.

E x c e s s iv e b e n d in g , fo llo w e d

b y s u b s e q u e n t s tra ig h te n -

in g , c a n w e a k e n th e in n e r tu b e .

its condition.

If the spring of either fork leg is shorter than the service It the length of a replacem ent

spring and that of the rem aining spring vary greatly, the rem aining

spring

should

also be replaced

keep the fork legs balanced tor m otorcycle

F o rk S p rin g F re e L e n g th

Guide Bush /nspection eV isually

inspect the guide

bushes, and replace them

S ta n d a rd :

4 6 4 .4 m m

S e rv ic e L im it:

455 m m

necessary.

A . F ree Length A . G uide B ushes

DiI Seal and Dust Sea/ lnspectiorr elnspect

the dust seal for any signs of deterioration

dam age. R eplace them if necessary.

e R eplace the oil seal w ith been rem oved.

a new

one w henever

it has

in order to stability.

.. S U S P E N S IO N

R e a r S u s p e n s io n

R iding

(U n i- T r a k )

A n average-

C ondition A djuster

R e a r S h o c k A b s o rb e r:

1 2 -9

A rider and

build rider

A rider and

a passenger

or a rider

a passenger

w ith load

D am p,ing F orce

Spring Pre/oad AdjustmentfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

'1 or 11

'11 or 111

'111or 1111

T he spring preload adjuster on the rear shock absorber has 5 positions so that the spring tension

can be adjusted â&#x20AC;˘ : S tandard S etting

for different road and loading conditions. e U sing a socket w rench,

turn the adjuster to adjust the

spring tension. S p r in g

P r e lo a d

A d ju s tm e n t

A djuster P osition WVUTSRQPONMLKJIHGFEDCBA 1 2 3 4 5

S pring T ension

----------+

R iding

S tronger

A n average-

C ondition

A rider and

build rider

A rider and

a passenger

or a rider

a passenger

w ith load

'2 or 3

'3,4, or 5

A djuster

w ith load

S pring P reload

'1 or 2

, : S tandard S etting

A . A djusting

D ial

Remo va/ e R em ove the low er fairing. e U sing the jack stand

(special tool: 57001 -1238),

raise

the rear w heel off the ground. e U nscrew

the tie-rod

the m ounting e U nscrew

low er m ounting

nut, and pull out

bolt.

the rear shock absorber low er m ounting

and pul! out the m ounting

nut,

bolt.

A . S pring P reload A djuster

Damping

Force Adjustment

T he dam ping has 4 positions

force adjuster on the rear shock absorber so that the dam ping

force can be adjusted

for different road and loading conditions. eT ake

off the cover, and turn the adjusting

the dam ping D a m p in g

dial to adjust

force.

F o r c e A d ju s tm e n t

A djuster

D am ping

P osition

F orce

S etting

Load

R oad

S peed

W eak

S oft

Light

G ood

Low

A . T ie-R od

Low er M ounting

B . R ear S hock A bsorber

B olt

Low er M ounting

B olt

11 111

e P ul! off the engine breather upper end. S trong

H ard

H eavy

B ad

H igh

e R em ove the rear shock absorber upper m ounting and pull the rear shock absorber dow n

and out.

bolt,

•

S U S P E N S IO N fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

1 2 -1 0

In s ta lla tio n

eA pply

N o te s

plenty of m olybdenum

disulfide

grease to the in-

side of the needle bearings, and oil seals. eT ighten

the follow ing

to the specified

torque

(see E x-

ploded V iew ). S w ing A rm P ivot N ut T ie-R od e R oute

U pper M ounting

the

R outing

follow ing

N ut

through

the

in the G eneral Inform ation

clam p

(see

H ose

chapter).

C arburetor A ir V ent T ube C arburetor

D rain T ube

A ir C leaner D rain T ube F uel T ank B reather H ose B attery V ent H ose A . R ear S hock A bsorber

B . U pper M ounting

B olt EDCBA

e R efer to

the

W heels/T ires,

F inal

D rive,

and

B rakes

chapters for w heel installation.

In s ta lla tio n

eT ighten

N o te

the follow ing

to the specified

torque

(see E x-

ploded V iew ).

T ie -R o d ,

R o c k e r A rm :

T ie -R o d

R em o va l

R ear S hock A bsorber

U pper M ounting

B olt

e R em ove the low er fairing.

R ear S hock A bsorber

Low er M ounting

N ut

e U sing the jack stand (special tool: 57001 -1238),

T ie-R od

Low er M ounting

raise

the rear w heel off the ground.

N ut

e R em ove the tie-rod

low er m ounting

bolt.

e R em ove the tie-rod

upper m ounting

bolt, and then take

out the tie-rods.

S w in g Rem o

A rm :

va l

e R em ove the rear w heel (see R ear W heel R em ova in the w heels/T ires

chapter).

e R em ove the air cleaner oil reservoir. e R em ove the tie-rod e P ull out the siw ng

upper m ounting arm

pivot

bolt.

shaft,

and

rem ove

the

sw ing arm o

••

A . Low er M ounting

B olt

B . U pper M ounting

B olt

T ie -R o d

eA pply

In s ta lla tio n

C . T ie-R ods

N o te s

plenty of m olybdenum

disulfide

grease to the In-

side of the needle bearings, and oil seals. A . T ie-R od

B . S w ing A rm P ivot S haft

eT ighten

follow ing

to the specified torque

V iew ). T ie-R od

U pper M ounting

N ut

T ie-R od

Low er M ounting

N ut

(see E xploded

S U S P E N S IO N

Rocker Arm Remova/fedcbaZYXWVUTSRQPONMLKJIHGFEDCBA e R e m o ve th e lo w e r fa irin g . e U sin g th e ja ck sta n d (sp e cia l to o l: 5 7 0 0 1 -1 2 3 8 ),

ra ise

th e re a r w h e e l o ff th e g ro u n d .

A . T ie -R o d L o w e r M o u n tin g

B o lt

B . R e a r S h o ck A b so rb e r L o w e r M o u n tin g C . E n g in e M o u n tin g

B o lt

D . S w in g A rm P ivo t S h a ft E . R o cke r A rm P ivo t S h a ft F . R o cke r A rm e R e m o ve th e tie -ro d lo w e r m o u n tin g

b o lt.

e R e m o ve th e re a r sh o ck a b so rb e r m o u n tin g e L o o se n th e e n g in e m o u n tin g

b o lt.

e L o o se n th e sw in g a rm p ivo t sh a ft. e P u ll o u t th e ro cke r a rm p ivo t sh a ft, a n d re m o ve th e ro cke r a rm o

Rocker Arm /nsrta//ation e A p p ly

Notes

p le n ty o f m o lyb d e n u m

d isu lfid e g re a se to th e in -

sid e o f th e n e e d le b e a rin g s, a n d o il se a l, a n d b e tw e e n th e m . e T ig h te n

th e fo llo w in g

p a rts to th e sp e cifie d to rq u e

o rd e r (se e E xp lo d e d V ie w ).

in .

1 . S w in g A rm P ivo t N u t 2 . R o cke r A rm P ivo t N u t 3 . E n g in e M o u n tin g e T ig h te n

Nut

th e re a r sh o ck a b so rb e r lo w e r m o u n tin g

a n d th e tie -ro d

lo w e r m o u n tin g

to rq u e (se e E xp lo d e d V ie w ).

nut

n u t to th e sp e cifie d

1 2 -1 1

S T E E R IN G

S te e r in g T a b le 0 1 C o n te n ts

E x p lo d e d V ie w

1 3 -2

S p e c ia l T o o ls

1 3 -3

S te e rin g A d ju s tm e n t

1 3 -4

In s p e c tio n

1 3 -4

A d ju s tm e n t.

1 3 -4

S te e rin g R e m o v a l/ln s ta lla tio n

1 3 -5

R em oval

1 3 -5

In s ta lla tio n

1 3 -5

S te e rin g M a in te n a n c e

1 3 -7

B e a rin g L u b ric a tio n

1 3 -7

B e a rin g W e a r, D a m a g e G re a s e S e a l D e te rio ra tio n , S te m W a rp

, EDCBA

1 3 -7 Dam age

1 3 -7 1 3 -7

1 3 -1

13-2EDCBA S T E E R I N G cbaZYXWVUTSRQPONMLKJIHGFEDCBA E x p lo d e d

V ie w

A D :A p p ly

a d h e s iv e c e m e n to

: A p p ly

q re a s e,

: F o llo w th e s p e c ific tig h te n in g

sequence.

T 1 : 2 4 N -m (2 .4 k g -m , 1 7 .5 ft-lb ] T 2 : 3 9 N -m (4 .0 k g -m , 2 9 ft-Ib ) T 3 : 2 5 N -m (2 .5 k g -m , 1 8 .0 ft-lb ) T 4 : H a n d -tig h te n

(a b o u t 4 .9 N -m , 0 .5 k g -m , 4 3 in -lb )

S T E E R IN G H e a d P ip e O u te r

R a c e P re s s S h a ft:

H e a d P ip e O u te r

R a c e D riv e r:

5 7 0 0 1 -1 1 0 6

H e a d P ip e O u te r

R a c e D riv e r:

5 7 0 0 1 -1 0 7 6

13-3

5 7 0 0 1 -1 0 7 5

S p e c ia l T o o ls EDCBA

J a c k S ta n d :

S te e rin g

5 7 0 0 1 -1 2 3 8

S te m

N u t W re n c h :

5 7 0 0 1 -1 1 0 0

S te m

H e a d P ip e O u te r

R a c e R e m o v e r:

B e a rin g

P u lle r:

B e a rin g

P u lle r A d a p te r:

B e a rin g

D riv e r:

5 7 0 0 1 -1 3 7

5 7 0 0 1 -1 1 0 7

5 7 0 0 1 -1 5 8

5 7 0 0 1 -3 1 7

S te e rin g

S te m

B e a rin g

D riv e r A d a p te r:

5 7 0 0 1 -1 0 7 4

1 3 -4

S T E E R IN G

S te e r in g

A d ju s tm e n t

InspectioncbaZYXWVUTSRQPONMLKJIHGFEDCBA e R e m o v e th e lo w e r fa irin g . e U s in g th e ja c k s ta n d

(s p e c ia l to o l: 5 7 0 0 1 -1 2 3 8 ),

ra is e

th e fro n t w h e e l o ff th e g ro u n d . e W ith

th e fro n t w h e e l p o in tin g

nudge

e a c h e n d o f th e

s tra ig h t a h e a d , a lte rn a te ly

h a n d le b a r.

T h e fro n t

wheel

s h o u ld s w in g fu lly le ft a n d rig h t fro m th e fo rc e o f g ra v ity u n til th e fo rk h its th e s to p . * If th e s te e rin g th e ro u tin g

b in d s o r c a tc h e s

b e fo re th e s to p , c h e c k

o f th e c a b le s , h o s e s , a n d h a rn e s s e s .

* If th e s te e rin g fe e ls tig h t, a d ju s t o r lu b ric a te th e s te e rin g . e F e e l fo r s te e rin g

lo o s e n e s s b y p u s h in g

a n d p u llin g

th e

fo rk s .

A . S te e rin g S te m H e a d N u t B . S te e rin g S te m L o c k n u t C . S te e rin g S te m N u t W re n c h : 5 7 0 0 1 -1 1 0 0

* If y o u fe e l lo o s e n e s s , a d ju s t th e s te e rin g .

e C h e c k th e s te e rin g a g a in . * If th e s te e rin g

is s till to tig h t

c o rre c t a d ju s tm e n t,

A . P u s h a n d p u ll.

Adjustment e R em ove : U p p e r F a irin g S id e C o v e rs Seat F u e lT a n k H a n d le b a r C la m p s H a n d le b a r (p la c e o n o n e s id e ) e L o o s e n th e fo rk lo w e r c la m p n u ts . e L o o s e n th e s te m h e a d n u t. e R e m o v e th e lo w e r fa irin g . e U s in g th e ja c k s ta n d

(s p e c ia l to o l: 5 7 0 0 1 -1 2 3 8 ),

ra is e

th e fro n t w h e e l o ff th e g ro u n d . e U s in g

th e s te e rin g s te m n u t w re n c h

(s p e c ia l to o l),

ad-

ju s t th e s te e rin g . *If

th e s te e rin g

is to a

tig h t,

lo o s e n

th e s te m

lo c k n u t

fra c tio n

o f a tu rn ; if th e s te e rin g is to a lo o s e , tig h te n

lo c k n u t

a fra c tio n

o f a tu rn o

T u rn th e lo c k n u t

th e

1 /8 tu rn

a t a tim e m a x im u m . e T ig h te n

th e fo llo w in g

to th e s p e c ifie d

p lo d e d V ie w ). S te e rin g S te m H e a d N u t F ro n t F o rk L o w e r C la m p N u ts H a n d le b a r C la m p B o lts

to rq u e

(s e e E x -

o r to a

lo o s e

in s p ite

in s p e c t th e s te e rin g s te m p a rts .

4i-

S T E E R IN G

S te e r in g

1 3 -5

R e m o v a ljln s ta lla tio n

Remo valcbaZYXWVUTSRQPONMLKJIHGFEDCBA e R em ove : F a irin g s S id e C o v e rs Seat F u e lT a n k F ro n t W h e e l F ro n t F e n d e r H a n d le b a r(p la c e

o n o n e s id e )

F ro n t F o rk e R e m o v e th e s te e rin g s te m h e a d n u t a n d w a s h e r. 1 . H e a d P ip e O u te r R a c e R e m o v e r:

e R e m o v e th e s te e rin g s te m h e a d . eTake

e P u s h u p o n th e s te m

base, and

re m o v e

th e s te e rin g

s te m lo c k n u t w ith th e s te e rin g s te m n u t w re n c h to o l),

5 7 0 0 1 -1 1 0 7

o ff th e lo c k w a s h e r.

th e n

re m o v e

th e

s te e rin g

s te m

and

(s p e c ia l

s te m

base

e R em ove w h ic h

th e

lo w e r

in n e r

ra c e

(w ith

its g re a s e s e a l)

is p re s s e d o n to th e s te e rin g s te m , w ith

th e b e a r-

in g p u lle r a n d a d a p te r (s p e c ia l to o ls ).

(s in g le u n it).

o R e m o v e th e p lu g fro m th e to p o f th e s te m b e fo re s e ttin g th e b e a rin g p u 1 le r a d a p te r.

e A . S te m B a s e B . S te e rin g S te m N u t W re n c h : 5 7 0 0 1 -1 1 0 0 C . S te e rin g S te m L o c k n u t

A . B e a rin g P u lle r: 5 7 0 0 1 -1 5 8

C . B e a rin g In n e r R a c e

D . S te e rin g S te m

B . A d a p te r: 5 7 0 0 1 -3 1 7

D . S te m B a s e

e R e m o v e th e s te e rin q s te m c a p a n d u p p e r ta p e re d ro lle r b e a rin g in n e r ra c e . eTo

re m o v e th e

u te r ra c e s p re s s e d in to th e h e a d p ip e ,

in s ta ll th e h e a d p ip e o u te r ra c e re m o v e r as show n

(s p e c ia l to o l)

b e lo w , a n d h a m m e r th e s te m b e a rin g re m o v e r

to d riv e it o u t.

Installation e A p p ly

g re a s e to th e o u te r

ra c e s , a n d th e n d riv e th e m

in to th e h e a d p ip e u s in g th e h e a d p ip e o u te r ra c e p re s s s h a ft a n d d riv e rs (s p e c ia l to o ls ). NOTE

o If eíther steeríng stem bearíng is damaged, ít is recommended that both the upper and lower bearíngs (including outer races) should be replaced with new ones.

1 3 -6

S T E E R IN G

A . N o tc h S id e

1.cbaZYXWVUTSRQPONMLKJIHGFEDCBA H e a d P ip e O u te r R a c e r P re s s S h a ft: 57001 -1075 2. H e a d P ip e O u te r R a c e D riv e r: 57001 -1106 3. H e a d P ip e O u te r R a c e D riv e r: 57001 -1076

T h e fo llo w in g s te e rin g

b e a rin g th e

tig h te n g re a s e to th e ta p e re d

fo u r

s te p s

s h o u ld

in s ta lla tio n .

T h is

b e p e rfo rm e d p ro c e d u re

a fte r

s e ttle s th e

b e a rin g s in p la c e . O U s in g

e A p p ly

B. Cap

ro lle r b e a rin g , a n d d riv e it

o f to rq u e .

o n to th e s te e rin g s te m u s in g th e s te m b e a rin g d riv e r a n d

s p e c ifie d

a d a p te r (s p e c ia l to o ls ).

s te e rin g

s te m

th e s te m lo c k n u t to (T o tig h te n

w re n c h

(s p e ic a l

(4.0

N -m

k g -m ,

to o l).

th e s te e rin g s te m lo c k n u t

to rq u e , h o o k th e w re n c h

a n d p u ll th e w re n c h d ire c tio n

nut

ft-Ib ) to th e

o n th e s te m lo c k n u t,

22.2

a t th e h o le b y

k g fo rc e in th e

s h o w n .)

180

1â&#x20AC;˘â&#x20AC;˘â&#x20AC;˘< : : : - - - - - - -

m m --------:~

22.2

1. A . S te m B e a rin g D riv e r: B . A d a p te r:

57001-1074

e L u b ric a te th e s te e rin g s te m b e a rin g s w ith

O C h e c k th a t th e re is n o p la y a n d th e s te e rin g s te m tu rn s

th e s te m lo c k n u t

s m o o th ly g re a s e .

s o th a t th e n o tc h e d

s id e fa c e s

w ith o u t

ra ttle s .

If n o t,

th e

s te e rin g

s te m

b e a rin g s m a y b e d a m a g e d . O A g a in

b a c k o u t th e s te m

lo c k n u t

a fra c tio n

o f a tu rn

u n til it tu rn s lig h tly .

down. e ln s ta ll n u t.

57001 -1100

S te e rin g S te m N u t W re n c h :

57001 -137

, e ln s ta ll

th e lo c k w a s h e r,

s te e rin g s te m h e a d , w a s h e r, a n d

O L o o s e ly in s ta ll th e n u t a t th is tim e .

O T u rn th e s te m lo c k n u t c o m e s h a rd to tu rn o

lig h tly

c lo c k w is e

D o n o t o v e rtig h te n ,

u n til it ju s t b e o r th e s te e rin g

w ill b e to o tig h t. e ln s ta ll

th e re m o v e d p a rts (s e e a p p ro p ria te

c h a p te rs ).

O R o u te th e c a b le s , w ire s a n d h o s e s c o rre c tly W ire ,

and

H ose

R o u tin g

in th e

G e n e ra l

(s e e C a b le , In fo rm a tio n

c h a p te r). e A d ju s t

th e s te e rin g (s e e S te e rin g A d ju s tm e n t).

S T E E R IN G

1 3 -7

Stem Warp S te e r in g

M a in te n a n c e

eW henever in g c a n n o t

w ith

th e

P e rio d ic

M a in te n a n c e

C h a rt,

lu b ric a te th e s te e rin g s te m b e a rin g s . e R e m o v e th e s te e rin g s te m . e U s in g

a h ig h fla s h -p o in t

s o lv e n t,

w ash

th e u p p e r a n d

lo w e r ta p e re d ro lle r b e a rin g s in th e c a g e s , a n d w ip e th e u p p e r a n d lo w e r o u te r ra c e s , w h ic h

a re p re s s -fitte d

in to

th e fra m e h e a d p ip e , c le a n o f g re a s e a n d d irt. e V is u a lly

c h e c k th e o u te r ra c e s a n d th e ro lle rs .

*R e p la c e

th e

b e a rin g

a s s e m b lie s

if th e y s h o w

wear or

dam age. e P a c k th e u p p e r a n d lo w e r ta p e re d ro lle r b e a rin g s in th e c a g e s w ith

g re a s e , a n d a p p ly a lig h t c o a t o f g re a s e to

th e u p p e r a n d lo w e r o u te r ra c e s . e ln s ta ll

th e s te e rin g s te m , a n d a d ju s t th e s te e rin g .

A . S te e rin g S te m B e a rin g s

Bearíng Wear, Damage e U s in g

a h ig h fla s h -p o in t

lo w e r ta p e re d a n d lo w e r

s o lv e n t,

w ash

th e u p p e r a n d

ro lle rs in th e c a g e s , a n d w ip e

o u te r

ra c e s , w h ic h

th e u p p e r

a re p re s s -fitte d

in to th e

fra m e h e a d p ip e , c le a n o f g re a s e a n d irt. e V is u a lly

c h e c k th e o u te r ra c e s a n d th e ro lle rs .

R e p la c e th e b e a rin g a s s e m b lie s if th e y s h o w

dam age.

Grease Seal Deteríoration, Damage e ln s p e c t

th e

g re a s e

seal on

th e

upper

b e a rin g fo r a n y s ig n s o f d e e rio ra tio n R e p la c e th e g re a s e s e a l if n e c e s s a ry .

ta p e re d

or dam age.

ro lle r

b e a d ju s te d

fo r s m o o th

a c tio n ,

c h e c k th e

s te e rin g s te m fo r s tra ig h tn e s s .

Bearíng LubrícationcbaZYXWVUTSRQPONMLKJIHGFEDCBA In a c c o rd a n c e

th e s te e rin g s te m is re m o v e d , o r if th e s te e r-

If th e s te e rin g

stern.

s te m s h a ft is b e n t, re p la c e th e s te e rin g

FRAME

Frame Table of Contents

Exploded View ZYXWVUTSRQPONMLKJIHGFEDCBA

1 4 -2

Rear Frame

1 4 -4

Removal/lnstallation Footpeg

1 4 -4

Brackets

1 4 -4

Right Footpeg

Bracket R e m o v a l

Right Footpeg

Bracket Installation

1 4 -4 N o te s

Fenders

1 4 -4 1 4 -5

Rear Fender Rear Section

R em oval

Rear Fender Rear Section

Installation

Rear Fender Front Section

Removal

Rear Fender Front Section

Installation

Fairings

1 4 -5 N o te

1 4 -5 14- 5

N o te s

1 4 -6 1 4 -6

Lower Fairing Removal

1 4 -6

Upper Fairing R e m o v a l

1 4 -6

Upper Fairing Installation Inner Fairing Removal

Note

1 4 -7 14- 7

14-1

1 4 -2

FRAMEZYXWVUTSRQPONMLKJIHGFEDCBA

E x p lo d e d V ie w

: A p p ly

AD'

g re a se

.A p p ly

a d h e s iv e

: A u s tria n I

: Ita lia n

M odel

: N o rw e g ia n

: S w is s

M odel

S W : S w e d is h

W G '.

cem ent

M odel

W est

T 1 : 25 N -m

M odel

G e rm a n

M odel

(2 .5 k g - m ,

1 8 .0 ft-Ib )

FRAME

\ ZYXWVUTSRQPONMLKJIHGFEDCBA 速

~ \

(1 )

,,~

(A ) @

14-3 HGFEDC

14-4

FRAME

Rear Frame

Footpeg Brackets

RemovaljlnstallatíonZYXWVUTSRQPONMLKJIHGFEDCBA Ríght Footpeg Bracket Removal e R e fe r

A ir

C le a n e r

H o u s in g

R e m o v a l/ ln s t a lla t io n

e R em ove

N o t e s in t h e F u e l S y s t e m c h a p t e r .

th e

fo o t

g u a rd ,

and

u n f it

th e

b ra k e

hose

g ro m m e t fro m th e g u a rd o e Unhook

th e

r e a r b r a k e lig h t

s w it c h

s p r in g

lo w e r

end,

a n d r e m o v e t h e b r a k e p e d a l. e P u ll o u t t h e c o t t e r p in , a n d r e m o v e t h e jo in t

p in o

A . F o o t G u a rd B . B ra k e H o s e G ro m m e t C . B r a k e L ig h t S w it c h D . J o in t

S p r in g

P in

E . M a s t e r C y lin d e r M o u n t in g F . F o o tp e g

e U n s c re w fo o tp e g

B r a c k e t M o u n t in g

th e

B o lt s B o lt s

r e a r m a s t e r c y lin d e r

b ra c k e t

m o u n t in g

b o lt s ,

and

ta k e

o ff

r ig h t th e

b ra c k e t. e R e m o v e th e

b ra k e s h a ft a n d

r e t u r n , s p r in g

out

o f th e

b ra c k e t.

, Ríght Footpeg Bracket Installatíon Notes e A fte r

t ig h t e n in g

th e

r ig h t

fo o tp e g

b o lt s , h o o k t h e r e a r b r a k e s w it c h

in s t a ll t h e m a s t e r c y lin d e r m o u n t in g down e T ig h t e n

s w it c h

m o u n t in g

lo w e r e n d a n d

b o lt s w h ile

p u s h in g

t h e b r a k e p e d a l. t h e r e a r m a s t e r c y lin d e r

s p e c if ie d t o r q u e eC heck

b ra c k e t

s p r in g

m o u n t in g

b o lt s t o t h e

(s e e th e B ra k e s c h a p te r).

t h e b r a k e p e d a l p o s it io n , a n d t h e r e a r b r a k e lig h t o p e r a t io n

S y s te m c h a p te r).

(s e e th e

B ra k e s , a n d

th e

E le c t r ic a l

•

FRAME

14-5

Rear Fender Rear Section /nsta//ation Note

Fenders

• R o u te c la m p

th e

c o o la n t

r e s e r v o ir

vent

o n th e r e a r fe n d e r r e a r s e c tio n

in th e G e n e r a l In fo r m a tio n

hose

th r o u g h

th e

( s e e H o s e R o u tin g

c h a p te r ) .

Rear Fender Rear Section Remova/ZYXWVUTSRQPONMLKJIHGFEDCBA • R em ove : S id e C o v e r s Seat • D is c o n n e c t T u rn

S ig n a l

M a in

L ig h t

C o n n e c to r s

H a r n e s s C o n n e c to r

Rear Fender Front Section Remova/ .R e m o v e : S id e C o v e r s Seat • U n s c re w

th e r e g u la to r /r e c tifie r

• U n s c re w

th e fe n d e r c o n n e c tin g

m o u n tin g

b o lts .

s c re w s .

• R e m o v e th e h a r n e s s c la m p .

A . T u r n S ig n a l B . M a in

L ig h t

L e a d C o n n e c to r s

H a r n e s s C o n n e c to r

• R e m o v e th e c a r r ie r w ith

th e g r ip s , tu r n s ig n a l

lig h ts

and

h e lm e t lo c k . A . R e g u la to r /R e c tifie r

M o u n tin g

B . F e n d e r C o n n e c tin g

S c re w s

B o lts

C . H a r n e s s C la m p

• P u l! th e b a tte r y v e n t h o s e o u t o f th e c la m p .

A . C a r r ie r M o u n tin g

B o lts

B . F e n d e r C o n n e c tin g C . C o o la n t

• U n s c re w • P u l! o ff

S c re w s

R e s e r v o ir V e n t H o s e

th e fe n d e r c o n n e c tin g th e

c o o la n t

r e s e r v o ir

s c re w s . vent

hose

fr o m

th e

• T a k e o ff th e r e a r fe n d e r r e a r s e c tio n

re a r A . B a tte r y V e n t H o s e

fe n d e r r e a r . s e c tio n . w ith

B . C la m p

th e fla p . • U n fit th e fr a p s fr o m

th e s lit in th e fr a m e , a n d ta k e o ff th e

r e a r fe n d e r fr o n t s e c tio n .

14-6

FRAME

Rear Fender Front Section Installation NotesZYXWVUTSRQPONMLKJIHGFEDCBA .W h e n

in s t a llin g t h e r e a r f e n d e r f r o n t s e c t io n , f it t h e f la p s

Fairings

in t o t h e s lit in t h e r e a r f r a m e .

Lower Fairing Removal •

A . S lit

U n s c r e w t h e m o u n t in g

B . F la p s A . M o u n t in g

• R o u te th e b a tte ry v e n t h o s e th ro u g h fro n t

b o lt s , t a k e o f f t h e lo w e r f a ir in g .

o f th e te n d e r

I n f o r m a t io n

B o lt s

t h e c la m p o n t h e

( s e e H o s e R o u t in g

in t h e

G e n e ra l

c h a p te r).

Upper Fairing Removal • U n s c r e w t h e m o u n t in g

s c r e w s a n d b o lt .

, A . M o u n t in g

B o lt s

A . M o u n t in g

S c re w s

• P u ll t h e b o s s e s o f f t h e f u e l t a n k , a n d p u ll o f f t h e f a ir in g to th e fro n tw a rd .

•J FRAME • D is c o n n e c t

th e

tu r n

ta k e o ff th e fa ir in g

s ig n a l

lig h t

le a d c o n n e c to r s ,

and

to th e fr o n tw a r d .

Upper Fairing Insta//ation Note • F it th e

c e n te r

boss

th e

fa ir in g

in to

th e

h o le

in th e

s ta y .

A . C e n te r B o s s B . H o le C . T u rn

S ig n a l L ig h t

L e a d C o n n e c to r s

Inner Fairing Removal • R e m o v e th e u p p e r fa ir in g . • D is c o n n e c t

M e te r L e a d C o n n e c to r S p e e d o m e te r

C a b le U p p e r E n d

• R e m o v e th e m e te r b r a c k e t

m o u n tin g

\ b o lt, a n d ta k e o ff

th e m e te r u n it. • U n s c re w

th e m o u n tin g

s c r e w s , a n d ta k e o ff th e fa ir in g .

A . M e te r L e a d C o n n e c to r B . S p e e d o m e te r

C a b le U p p e r

C . M e te r B r a c k e t M o u n tin g D . F a ir in g

M o u n tin g

S c re w s

End

B o lts

14-7 ZYXWVUTS

ELECTRICAL

SYSTEM

15-1

Electrical System

Table 01 Contents zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONML

Parts Location Exploded View Specifications Special Tools Sealant Precautions Wiring Diagram(KL650-B1 /KL500-B1 ) Electrical Wiring Inspection Battery Precautions: Electrolyte: Level Inspection Charging: Battery Condition Initial Charging Ordinary Charging Test Charging Flywheel Magneto Flywheel Removal/lnstallation Notes Stator Removal Stator Installation Notes Inspection Charging System Magneto Output Voltage Inspection Charging Coillnspection Charging Voltage (Regulator/Rectifier Output Voltage) Inspection Regulator/Rectifier Inspection Ignition System Safety Instruction: Ignition Coil Removal Ignition Coil Installation Note Ignition Coillnspection Spark Plug Cleaning and Inspection Spark Plug Gap Inspection CDI Unit Inspection Pickup Coil Removal Pickup Coil Installation Notes Pickup Coil Inspection Exciter Coil Inspection Diode Inspection Electric Starter System Starter Motor Removal/lnstallation Note Starter Motor Disassembly Starter Motor Assembly Notes

15-2 15-3 15-6 15-7 15-7 15-8 15-9 15-11 15-11 15-11 15-11 15-11 15-11 15-12 15-12 15-12 1 5-13 15-14 15-14 15-14 15-14 15-14 15-15 15-15 15-15 15-15

15-16 15-17 1 5-19 15-19 15-19 15-19 15-19 15-20 15-20 15-20 15-22 15-22 15-22 15-22 15-23 15-25 15-25 15-25 15-25

Starter Motor Brush Length Brush Spring Inspection Commutator Cleaning and Inspection Armature Inspection Brush Plate Inspection Positive Brush Assembly Inspection Starter Relay Inspection Starter Circuit Relay Inspection Lighting System Headlight Beam Horizontal Adjustment Headlight Beam Vertical Adjustment.. Headlight Bulb Replacement Notes Headlight Unit Removal/ Installation Note Tail/Brake Light Bulb Replacement Note Tail/Brake Light Lens Removal/lnstallation Note Turn Signal Light Bulb Replacement Note Turn Signal Relay Inspection Radiator Fan System Circuit Inspection Fan Inspection Fan Relay Inspection Meter and Gauge Removal/lnstallation Note Meter Mounting Inspection Bulb Replacement Note Tachometer Inspection Water Temperature Gauge Operation Inspection Switch and Sensor Brake Light Timing Inspection Brake Light Timing Adjustment Switch Inspection Fan Switch Inspection Water Temperature Sensor Inspection Fuse Main/Headlight Fuse Removal Main/Headlight Fuse Installation Note Fan Fuse Removal Fan Fuse Instรกllation Notes Inspection

15-25 15-26 15-26 15-26 15-26 15-26 15-27 15-27 15-29 15-29 15-29 15-29 15-30 15-30 15-30 15-30 15-30 15-31 15-31 15-32 15-32 15-32 15-32 15-32 15-32 15-32 15-33 15-34 15-34 15-34 15-35 15-36 15-36 15-37 15-37 15-37 15-37 15-37 15-37

15-2

ELECTRICAL

SYSTEM

Parts Location zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

1. Ignition Switch 2. Starter Lockout Switch 3. Radiator Fan 4. Starter Relay 5. Fuses (Main 20A, Headlight 10A) 6. Battery 7. Regulator/Rectifier 8. Thermostatic Fan Switch 9. Pickup Coil

10. 11. 12. 13. 14. 15. 16. 17. 18.

Flywheel Magneto Neutral Switch Starter Circuit Relay Side Stand Switch Front Brake Light Switch Tachometer Water Temperature Gauge Fan Relay Turn Signal Relay

19.0iode 20. COI Unit 21. Rear Brake Light Switch 22. Starter Motor 23. Water Temoerature Sensor 24. Spark Plug 25. Ignition Coil 26. Fuse (Fan 10A) 27. Horn

•zy ELECTRICAL

SYSTEM

15-3

Exploded View

T~3

(2).

CD $

1~llt jL/

~SRQPONMLKJIHGFEDCBA

~'~JV

~ ~l ~ ~/~'~ ~.~

@"0Y

L~~l~ffA

6\."

~/, ~~

()~

,,~

/"-

,P~

~®

0@ ~

1. Headlight 2. Water Temperature Gauge 3. Tachometer 4. Starter Lockout Switch 5. Ignition Switch 6. Front Brake light Switch 7. Thermostatic Fan Switch 8. Radiator Fan G : Apply grease. O : Apply oil. T1: 1.3 N-m (0.13 kg-m, 11 in-lb) T2: 7.4 N-m (0.75 kq-m, 65 in-lb)

• 15-4 ELECTRICAL

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

9. 10 11.. 12.

@(I)

COI Unit Oiode Turn Signal Relay Fan Relay

13. Horn (Fan 10A) 14. Fuses . 15. Ignition Col! 16. 17. 18. 19 20:

f' ~

Spark Plug ature Sensor Water Tempe; Starter Mo.to Pickup COII Magneto Stator

tf v@ f ~@ 8

@®

SRQPONMLKJIHGFEDCBA

21. 2 2 23 . 24·

Magneto FIy wheel Starter Relay Starter Circuit . Relay h Side Stand SWltC

25: Neutral S~itChA) Fuse (MalO 20 ) 26. Fuses (H ea dlight 10A 27. Regulator /Rectifier 28.

29. Battery Li ht Switch 30. Rear Brake 9 20 19

•zy ElECTRICAl

15-5

SYSTEM

-~--/1 ~®#'"" // 1#'

l~ZYXWVUTSRQPONMLKJIHGFEDCBA J ®/ ® ~-~

iZYXWVUTSRQPONMLKJIHGFEDCBA (jjP

() ~

ss: Apply

silicone sealant (Kawasaki Bond: 56019-120)

to the threads. I

: Italian Model

T3: 14 N-m (1_4 kg-m,10.0ft-lb) T4: 15 N-m (1_5 kg-m,11_0ft-lb) T5: 9.8 N-m (1.0 kq-m, 7.0 ft-lb] T6: 195 N-m (20 kg-m, 145 ft-lb)

15-6

ELECTRICAL

SYSTEM

Specifications

Battery: Type Electrolyte level Electrolyte amount

Service Limit

Standard

Item

- -12 V 14 Ah - -Between upper and lower levels - -870 mL;145 mL per one cellzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Specific gravity of electrolyte Charging System: Type Magneto output voltage Charging coil resistance Charging voltage (regulator/rectifier output voltage)

1.280 @20°C (68°F)

- --

Three-phase AC Not less than 34 V @4 000 r/rnin (rpm) 0.3 - 1.0 O (Y - Y) Battery - 15 V (with headlight switch ON if applicable)

- --

From 10° BTDC @1 300 r/min (rpm) to

- --

- -- -- --

Ignition System: Ignition timing

30° BTDC @3 300 r/rnin (rpm) Ignition coil: 3 needle arcing distance Winding resistance: Primary windings Secondary windings Spark plug: Type Spark plug gap CDI unit internal resistance Pickup coil resistance Exciter coil resistance Electric Starter System: Starter motor: Brush length Commutator diameter Switch and Sensor: Brake light timing Fan switch connections:

- --

7 mm or more 0.15-0.210

- --

3.8 -

- --

5.8 kO

NGK DPR8EA-9 or ND X24EPR-U9 (I)(SA)NGK DP8EA-9 or ND X24EP-U9 0.8 - 0.9 mm Refer to page 21 100 - 150 O (B K - B K/Y) 100 - 200 O (R - W)

- -- -- --

12.0 28mm

6mm 27mm

12.5 mm

--- --

On after about 15 mm pedal travel

- --

Rising temperature

From OFF to ON at 94 -

- --

Falling temperature

From ON to OFF above 91°C (196°F) ON: Less than 0.5 O OFF: More than 1 MO

- --

47 -

- --

(201 -

Water temperature sensor internal resistance

100°C

212°F)

57 O @80° (176°F)

26 - 30 O @100°C(212°F)

(1): Italian Model

- --

(SA): South African Model

ELECTRICAL

SYSTEM

15-7

Special Tools

Sealant zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONM

Coil Tester:

Kawasaki Bond (Silicone Sealant):

Hand Tester:

57001-1242

57001-983

56019-120

15-8

ELECTRICAL

SYSTEM

Precautions zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA O Color Cedes:SRQPONMLKJIHGFEDCBA BK Black BL Blue Brown BR CH Chocolate DG Dark green G Green Gray GY LB Light blue Light green LG Oranqe O Pink P PU Purple R Red White W y Yellow

There are numbers of important precautions that are musts when servicing electrical system. Learn and observe all the rules below. O Do not reverse the battery lead connections. Th'is will burn out the diodes in the electrical parts. OAlways check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. l OThe electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. OTo prevent damage to electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or the engine is running. O Do not use a meter illumination bulb rated for other than the voltage or wattage specified in the wiring diagram, as the meter or gauge panel could be warped by excessive heat radiated from the bulb. OTake care not to short the leads that are directly connected to the battery positivezyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA (+) terminal to the chassis ground. . OTroubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail again. O Make sure all connectors in the circuij are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation. . a.Measure coil and winding resistance when the part is cold (at room temperature). O Electrical Connectors Female Gonnectors

Male Gonnectors

•g ELECTRICAL

Rear

Srqnal

Tum -

15-9

zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA EDCBA

ught

Relay r--

SYSTEM

Brake

SWitch

IgmtlOnCO'I~

:TI I

I Spark

I I

Plug

iSRQPONMLKJIHGFEDCBA Rear

Rlght

Turn

Slgnal

l..Jght

12V21W

.1: 0: ...•

"''''

--Tali/Brake

ught

12V5/21W

Ucense

Ptate

LJght

12V5W

.•.. R ear

le ft

12V21W

" '"

l.ltehan W:\Nest

re;-

Magneto

1:'

{J-

BKr-=--~

Starter Relay

il---=-,r<1r

+ 12V14Ah

Bl/Y

R/W

R/Bl

Color

BK/Y

BK/W

Starter Button Color

B K/R B K/R

OFF

RUN

0-1-0

ONIPushl

198051-1148A,

Blue

Brown

Green

Gray light light

Blue Green

Orange

Pink

Eng'ine Stop Switch

Headlight Switch Color

CONNECTIONS

Black

Model

Color Code BK

Motor

SWITH

ZYXWVUTSRQPONMLKJIHGFEDCBA

Banery

Starter

RIGHT HANDlEBAR

BK,

Model German

o-~

1149A, 1150AI

White

Yellow

T urn

519nal

llg h t

Rlght

Handlebar

Swuches

Wiring Diagram {KL650-B1/KL500-B1) Fan

Dtode

Relav

Front

Rlght

Tum

Slgnal

~GY-rrrGY {!.J-- BK/Y \lrBK/YzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

ught

12V21W

Oa:~ "'><

~> a: a: ::.::::.::a:::.::::.:: Igmtlon SWitch

"''''

Fan ~ SWitch

Wat.,

Temperatur Sensor

r- Meter 12VJ

ught 4W

Meter 12VJ

ught 4W

Meter

ught

_ .....•al .....• ~>><a:a: ~~ CD>

--- - --.,

"''''>

I I

I I I

12VJW

I Neutral

Inchcator

Loghl 12VJ

Turo

Inchcator

I I

Lrqht

T emperature

I I I

a:><

=======--W

55W

-.c

lIght

12V4W

Front

...JI

(~~~::~~::::::::::A/BK-----~ "'''' BK/Y A/Y fF .;:::; • ...• - + - BA/W--tlPICCI:J---BA/W----++_' BK/Y----4 ...• J " '" " ,..L _ _ BKlY

Headllght

Clty

Left

Turn

Slgnal

\Lr ~GY-{i1-

lJght

12V21W

-4+-1- •..•

I I I I

Tachometer

BK/Y BK

Gauge

12V60

Water

A/BK

BK/W ZYXW

GY G Y/W r:1= •.. --f:=titt~BK/Y BK 1

Slgnal

12VJ

Hlgh Beam lndrcator llght 12VJ

SRQPONMLKJIHGFEDCBA

G BK/Y-iY- BKlY L

L Hom 12V25A

left

Handlebar

Dunrner 2 T urn

Swnches

SWitch

Slgnal

SWitch

3 Horn Button 4 Passmq Button

LEFT HANDLEBAR Color HI

R BK BL Y

C- ¡.o

SWITCH

R/Y

Color R

C-

e- ~

L-

Passmq Burton

Color

BK Y BK/W

Color

ONIPush)

e- ¡.o

ONIPush)

R/BKI

-..o

NIOFF,Pushl LO

CONNECTIONS Horn Bunon

Turn Signal SWitch

Dimmer SWItch

e- i-o

O;;; ¡;o

_ Sice Stand SWItch

Neutral SWitch

15-10

ElECTRICAl

SYSTEM

Il-gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Rlght

Wiring Diagram (KL650-B2) (US and Canada)

Handlebar

Swrtches

Front Brake LJght

Engme Stop

Starter

SWitch

Button

Fan Aelay

Badrater Fan

Front Right

Tum

Signal

12V23W

lig h t

O:~~:fw=t:Ell BR R

SWitch

r -

- - - - - - -

BR R

-.,

I I

ltg h t

12V3.4W

Meter

Ltght 12V3.4W

Meter

EDCBA zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA ~BK/Y~BK/Y

Ignlllon

M e te r

-fFl-

I I

ught

12V3W

R/BK O

I ugh1

lndrcator

Neutral

12V3

HIgh Beam tndrcator ught

12V34W

Tum

519nal

fndrcatcr 12V3.4W

BK/W

'Ai= •. _-t=Htt:!:BK/Y

Y/W

y BK/Y BK

ught

SRQPONMLKJIHGFEDCBA

I I

I I I I

W a t e r T emperature

Gauge

Tachometer

left

••••

\.~ift:::tll~======~~

12V60/55W

12V23W

"'><

l"i~~~~I----------R/BK-------~

Headhght

Front

.•••

Tum

Signal

Light

BK/Y R/Y

~GY-iii-

~BK/Y~BK/Y

o Horn

Left

12V25A

Handlebar

3 Hom

'lEFT Color

R/BK .BLlY

Hti

O- -O

"'~, .-

SWITCH

H A N D lE B A R

-c:.

R/Y

Color R

'- o

NIOFF,Pushl l

IGNITION Horn Button

Color

BK/Y

Color BK

ONIPushl

()III

-O

SWITCH

BK/Y BK/W

ON OFF

O- -O

.c-~

Srde

S ta n d

SWitch

Bunon

CONNECTIONS

Turn Signal Switch

Dimmer Switch

Swrtches

I Dnnmer SWitch 2 T um 51gnal SWitch

lOCK p

CONNECTIONS W

C- -O O- ~ O- -O O-

'- o

C-

R R/W

.. I

Turn Slgnal

EDCBA

A e la y

._.

o::;

SWitch

a:»>~~ a> Spark

Brake

L ig h t

Regu~to,

Rear

:i~

Plug

6 <,

~==:t:i===== ~~~==tt======~~W

SRQPONMLKJIHGFEDCBA

RIW Bl BKlY G

I I¡

~~=ill

Light

zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPON

> ~

12V8/27W

:,:,í:t:=J;nl

..J~CD

m ¡

c r a :a :

l1 I i I i i fJ

-,-,-,--r

~::;

I~~O~ ~~

PIckup

Col!

TI ~

¿G'"1' ¡Ü

~~~~ a:~~~m):

Relay

"~~ ~

~ ~

r?,

Magneto

¡, ~

'--

> ;;¡

, a>

"a>

Color'Code

Starter Motor

IGHT HAN OLE BAR

SWITH

- Enginll Stop Switch Color IBK/YI

IBK/WI

CONNECTIONS

Starter Color

Bunon

IBK/RIBK/R

O¡:FAUN-I~

--j~

(98051-1172A)

":-_--~

,-, . . f, ~ ~ ~ ¡

liI

Blue

Brown

Relav

License

Plate

Light

12V8W

~ ~ a>

~ ,,~ a : ~ ~ " ~ ~ ~»>a: a> a> " ma::CDCC >a>ZYXWVUTSRQPONMLKJIHGFEDCBA a> a:;:

a: O'"

••••• ¿

TaiVBrake

RIW""OO" R Bl ""00" BKlY Bl ~ BKIY""OO" G -Qct- GY BKlY-oQ- BK/Y

S~gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 11 ~

~B~W

Ught

GY ~B~~Y~B~~Y_

RIW Bl BKIY G BK Y

Signal

.-----

~~~~~~~~

Right Turn

t2V23W

a:-J a> a>

"---

YIBK

Bear

Black

Green

Gray

Light Blue

I I

Light Green

Orange

Pink

Red

White

Yellow

Bear

le ft

12V23W

T urn

Signal

L ig h t

• ELECTRICAL

SYSTEM

15-11

Electrical Wiring ZYXWVUTSRQPONMLKJIHGFEDCBABattery / n s p e c t i o n zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Precautions: .Visually inspect the wiring for signs of burning, fraying, Following a few simple rules will greatly extend the life of the batterv, etc. a When the level of the electrolyte in the battery is low, * If any wiring is poor, replace the damaged wiring.

add only distilled water to each cell, until the level is at the upper levelline marked on the outside of the battery. Ordinary tap water is not a substitute for distilled water *If the connector is corroded or dirty, clean it carefully. and will shorten the life of the battery. If it is damaged, replace it. a Never add sulphuric acid solution to the battery -, This .Check the wiring for continuity.zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA will make the electrolyte solution too strong and will o Use the wiring diagram to find the ends of the lead ruin the battery within a very short time. which is suspected of being a problem. aAvoid guick-charging the battery. A quick-charge will a Connect an ohmmeter between the ends of the leads. damage the battery plates. range, and read the meter. a Set the meter to the x 1 a Never let a good battery stand for more than 30 days * If the meter does not read O n, the lead is defective. without giving it a supplemental charge, and never let a Replace the lead or the wirinq harness if necessary. discharged battery stand without charging it. If a battery stand <tor any length of time, it slowly selfdischarges. Once it is discharged, the plates sulphate (turn white), and the battery will no longer take a charge. a Keep the battery well-charged during cold weather so crack open the that the electrolyte does not freeze andZYXWVUTSR battery. The more discharged the battery becomes, the more easily it freezes. aAlways keep the battery vent hose free of obstruction, and make sure it does not get pinched, crimped, or melted shut by contact with the hot muffler. If battery gases cannot escape through this hose, they will explode the battery. aDON'T INSTALL THE BATIERY BACKWARDS. The negative side is groun·aed. • Pull each connector dirt, and damage.

apart and insect it for corrosion,

Electrolyte: L e ve / /n s p e c tio n .Visually check the electrolyte level in the battery .

•. 'I...a.

ti (j0

A. Upper t.evet

' ' ' ' ·. ,. ..·,._ .. . . . - - 0 , , - , ; ; . '

. .,.,._ ;

SRQPONMLKJIHGFEDCBA

. ®

B. Lower Level

If the level line of electrolyte in any cell is below the lower level line on the battery case, add distilled water only to that cell

15-12

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

ElECTRICAl

Charging:ZYXWVUTSRQPONMLKJIHGFEDCBA 8 a tte r y

C o n d itio n

O C e ls í u s : above

• Before charging, check battery condition by testing the specific gravity of the electrolyte in each cell. O Draw a little fluid from the cell with a hydrometer. O Read the level of the electolyte on the floating scale. This is the specific gravity of the electrolyte.

lo w

Add

2 0 °C

p o ín ts

0 .0 0 7

re a d ín g p o ín ts

fo r

each

fo r e a c h

1 0 °C

1 0 °C b e -

2 0 °C .

O F a h re n h e ít: above 101#

0 .0 0 7

o r s u b tra c t

6 8 °F

Add

0 .0 0 4

p o ín ts

to re a d ín g

o r s u b tra c t

0 .0 0 4

p o ín ts

fo r

fo r e a c h

each

1 0 °F ,

1 0 °F b e - '

6 8 °F .

* If the specific gravity of any of the cells is more than

0.050 away from any other reading, the battery will probably not accept a charge. If it generally best to replace a battery in this condition.

* If the specific gravity of all the cells is 1.280 or more the battery is fully charged.

Read ~ here

\ /n itia / C h a r g in g

Before being placed in service, a new battery must be given an initial charging . • Cut off the sealed end of the battery vent hose and remove the filler caps. • Fill each cell to the upper level line on the battery case with fresh electrolyte at a temperature of 30°C (86°F) or less. Let the battery stand for about 30 minutes before charging.

NOTE O If • Look for sediment and white sulfation inside the cells on the bottom of the plates.

~ T

!IlI!o

%1..

•

•••••.•

...

t h e e le c t r o ly t e

le v e l I in e b e f o r e

le v e l d r o p s . a d d e le c t r o ly t e

to th e u p p e r

c h a rg ín g .

• Leaving the caps off the cells, connect the battery to a charger, set the charging rate at 1/10 the battery eapacity, and charge it for 10 hours. For example, if the battery is rated at 14Ah, the charging rate would be 1.4A.

~~~--~. O If the battery is not given a full initial charging, it will discharge in a few weeks and will not recover fully even with supplemental charqfnq.

I WARNINGgfedcbaZYXWVUTSRQPONML I A. Sulfation here

B. Sediment here

.See the Battery Troubleshooting Guide in Test Charging.

* If the specific gravity is below 1.200 the battery needs

O Keep the battery away fr.oRl sparks and open flames during charging, since the b"'atterygives off an explosive gas mixture of hvdroqen and oxygen, When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.

to be charged.

NOTE OZYXWVUTSRQPONMLKJIHGFEDCBA T h e s p e c if í c g ra v íty of th e e le c t r o ly t e v a ríe s changes

te m p e ra tu re ,

m u s t b e c o rre c te d

s o t h e s p e c it ic

fo r th e te m p e ra tu re

g ra v íty

w íth

re a d ín g

o f t h e e le c t r o ly t e .

O Do not use a high rate batterv: charger, as is typically employed at auto motive service stations, unless the charger rate can be reduced to the level required. Charging the battery at arate highe.r than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause

ELECTRICAL Battery Charging

SYSTEM

15-13

Rate/Time Table (12V 14Ah)gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 1.280 Fully Charged

1.28 1.24

1.20zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 1.140

l.16

Sample

1.12 1.08 1.04 1.00

at 1A charge rate

.~~~~:45 i ! ! i~t~Fo;"h"g'd) 15

at 2A charge rate

at 3A charge rate

5 4

at 4A charge rate

10.5

7 5.3

Hours of Charging Time at Rates Shown

internal shorting. Higher-than-ríormal charging rates also causé the plates to shed active material. Oeposits will accumulate, and can cause internal shorting. O If the ternperature

of the electrolyte

eConnect a charger to the battery BEFORE plugging it in or turning it on.

rises above 45°C

(115°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.

eTurn the charger off, then disconnect eCheck battery voltage. 13 V.

it from the battery.

Battery voltage should be 12 -

e Check the specific gravity of each hydrometer (see Battery Cond ition).

cell

with

WARNING

O Keep the battery away from sparks and open flames during charging, since the battery gives off anexplosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. "

If the voltmeter or hydrometer readings are below those eSet the charge rate and time according to the battery specified, additional charging.is necessary before the condition previously determined (see Battery Condibattery can be installed. 'ZYXWVUTSRQPONMLKJIHGFEDCBA tion), using the table.

O r d in a r y C h a r g in g

e Remove the battery from the motorcycle.

O Always remove the batrerv from the motorcycle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the motorcycle.

O Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charger rate can be reduced to the level required. Charging the battery at arate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than-normal charging rates also cause theplates to shed active material. Oeposits will accumulate, and can cause internal shorting. Olf the temperature of the electrolyte

eClean off the battery using a baking soda-and-water solution. O Mix one heaping tablespoon of baking soda in one cup of water. O Be careful notto get anv of the cleaning solution in the battery. OThe terminals must be especially clean. elf any of the cells are low, fill them to the LOWER level line with distilled water only. The electrolyte will expand during charging, and the level will rise.

rises above 45°C

(115°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.

eTurn the charger off or unplug it, then disconnect' it from the battery. eCheck battery condition (see Battery Condition).

If the battery condition indicates that it is not fully charged, additional charging time is necessary.

â&#x20AC;˘

15-14

ElECTRICAl

SYSTEM ZYXWVUTSRQPONMLKJIHGFEDCBA

T e s t C h a r g in g

Flywheel Magneto elf zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA the battery is suspected of being defective, su Ifated, or unable to take a charge, consult the table. eTo test charge a battery, perform the ordinary charging

procedure and monitor the battery voltage signs as mentioned below. * If the battery voltage suddenly jumps to after the start of charging, the plates sulfated. A good battery will rise to 12 and then gradually go up to 12.5 or 13 V to and hour after the start of charging.

and other

over 13 V just are probably V immediately i about 30 min

F /yw h e e /

R e m o ve ltln s te tle tio n

eSee the Magneto Flywheel Right Side/Left Side chapter.

N o te s

Removal

in the

Engine

*If

one cell produces no gas bubbles or has a very low specific gravity, it is probably shorted.

S ta to r

*If

there does not appear to be enough sediment in a cell to short the plates, but that cell has a very low specific gravity after the battery is fully charged, the trouble may be that there is not enough acid in that one cell. In this case only, sulfuric acid solution may be added to correct the specific gravity.

eRemove the magneto cover (see the Magneto Cover Removal in the Engine Right Side/Left Side chapter). e Remove the holding plate. eUnfit the pickup coillead and stator coillead grommets out of the notch of cover. e Unscrew the mounting bolt, and take off the stator.

R e m o va /

* If a fully charged battery not in use loses its charge after 2 to 7 days; or if the specific gravity drops markedly, the battery is defective. The self-discharge rate of a good battery is only about 1zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA % per day.

A. Holding Plate

C. Mounting D. Stator

B. Grommets

S ta to r

/n s ta //a tio n

Bolts

N o te s

e Fit the stator coil lead grommet first, and the pickup coil lead grommet into the notch of cover securely. e Route the magneto leads in accordance with the Wire Routing in the General Information chapter.

Battery Troubleshooting

Guide

Good Battery Plates

Action

Suspect Battery

( +) chocolate color

white (sulphated); + plates

(-)

broken or corroded

gray

Replace

Sediment

none, or small amount

sediment up to plates, causing short

Replace

Voltage

above 12 V

below 12 V

Test charge

Electrolyte Level

above plates

below top of plates

Fill and test charge

above 1 .200 in all cells; no two

below 1.100, or difference of more

Test charge

cells more than 0.020 different

than 0.020 between two cells

Specific Gravity

ELECTRICAL

SYSTEM

15-15

I n s p e c t i o n zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Charging System There are three types of magneto problems: short. open (wire burned out), or loss in flywheel magnetismo A short or open in one of the coil wires wil! result in either a low M a g n e to O u tp u t V o lta g e In s p e c tio n output. or no output at all, A loss in flywheel magnetism, eTurn off the ignition switch. which may be caused by dropping or hitting the flywheel, eRem~ve : or just by aging, wil! result in low output. Therefore, in Side Covers inspecting the flywheel magneto, first measure the output, Seat next, inspect the coils and the flywheel (see Charging e Disconnect the regulator/rectifier connector. System, Ignition System).gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA eConnect the multimeter as shown in table 1. Table 1 Magneto Output Voltage Meter Range

Connections

Reading @4,OOO

MeterzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONM (+) to Meter (-) to rpm

250 V AC

One yellow lead (6 pin connector)

Another yellow lead (6 pin connector)

Not less than 34 V

eStart the engine. e Run it at the rpm given in table 1 . eNote the voltage readings (total 3 measurements).

* If the

output voltage shows the value in table 1, the magneto is working properly. A much lower reading than that given in the table indicates that the magneto is defective. Check the charging coil,

C h a r g in g C o illn s p e c tio n

eTurn off the ignition switch. e Remove : Side Covers Seat FuelTank e Disconenct the magneto lead connector

A. Magneto

(6 pin).

Lead Connector

eZero the ohmmeter, and connect it as shown in table 2 .:

15-16

Table 2 Charging Meter Range x 1O

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

ELECTRICAL

Coil Resistance

C h a r g i n g V o l t a g e ( R e g u l a t o r / R e c t i fi e r

Connections

Reading

O u tp u t V o lta g e ) In s p e c tio n • Remove : (+) to Meter (-) to MeterzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Side Covers Seat 0.3 ...., One yellow Another yellow .Check the battery condition (see Battery). lead (6 pin lead (6 pin 1.0 O connector) connector)

NOTE

oZYXWVUTSRQPONMLKJIHGFEDCBA T h e b a t t e r y m u s t b e f u l/ y c h a r g e d . • Note the resistance reading. * If there is more resistance than shown in table 2, the stator may have an open lead, the lead between the stator and the connector may be open, or the connections may be bad. Check the stator and the leads, and fix or replace any damaged parts.

.Warm up the engine to obtain actual magneto and regulator/rectifier operating conditions. .Stop the engine, and connect the multimeter as shown in table 3.

*If

there is much less resistance than shown in table 2, the stator may have an internal short, or the lead between the stator and the connector may be grounded. Check the stator and the lead, and fix or replace any damaged parts. • Using the highest resistance range of the ohrnrneter, measure the resistance between each of the yellow leads and chassis ground.

* Any meter readinq less than infinity (00) short, necessitating stator replacement. *If

Table 3 Charging

Voltage

Range

Meter (+) to

Meter (-) to

25 V

Battery (+)

Battery (-) -

Lead connector (White)

Lead connector ( Black/Yellow)

indicates a

the charging coils have normal resistance, but the output voltage check showed the magneto to be defective, then the flywheel magnets have probably weakened, and the flywheel must be replaced.

Reading

Connections

Meter

Battery ....,15 V

.Start the engine, and note the voltage readings at various engine speeds with the headlight turned on and then turned off. The readings should show nearly battery voltage when the engine speed is low, and, as engine speed rises, the readings should also rise. But they must stay under the specified maximum voltage . • Turn off the ignition switch to stop the engine, and disconnect the multimeter.

BR/W W

:R12]

BK/Y

@ >-

c:o

+ oSRQPONMLKJIHGFEDCBA O

1. Charging Coils (Magneto) 2. Regulator/Rectifier 3. Ignition Switch

4. 20A Main Fuse 5. Battery 6. LoadsZYXWVUTSRQPONMLKJIHGFEDCBA

•• ELECTRICAL * If the charging voltage stays between the values given in table 3, the charging system is considered to be working normally.

Rectifier Circuit Check

* If the charging voltage is much higher than the values specified in the table 3, the regulator/rectifier is defective. Check the regulator/rectifier.

Meter (+) to

* If the charging voltage does not rise as the engine speed increases, then the regulator/rectifier is defective of the magneto output is insufficient. Check the magneto and the regu lator / rectifier.ZYXWVUTSRQPONMLKJIHGFEDCBA

No.

Connections

Reading

Meter (-)

x 10 Q

G 0M1

f--

t--

scale

x 100 Q

connector. B (Battery)

Terminal

M (Monitor)

Terminal

G (Ground)

MI (Magneto)

A. Regulator/Rectifier

Meter Range

Rectifier Circuit Check: .Turn off the ignition switch. • Remove : Side Covers Seat • Disconnect the regulator/rectifier

15-17

f---

R e g u la t o r / R e c t if í e r I n s p e c t í o n

SYSTEM

B. Connector

.Zero the ohmmeter, and connect it to the regulator/rectifier terminals. .Check the resistance between the terminals following the table.

M2 (Magneto)

Terminal

M3 (Magneto)

Regulator Circuit Check: • Before checking, prepare the test circuit shown. will need: OTest light: Bulb rated 12 V and 3 O Battery: 6 V and 1 2 V battery OLead: 5 leads

You

6 W

*The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and must be replaced.gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

OThe test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of a test light.

NOTE

o The

a c t u a l m e t e r r e a d in g

t h e in d iv id u a l r e a d in g

s h o u ld

v a r ie s w it h

th e m e te r u s e d a n d

.Turn

off the ignition switch.

• Remove : ZYXWVUTSRQPONMLKJIHGFEDCBA s p e a k in g t h e lo w e r Side Covers 1/2. o f t h e s e a le . f r o m z e r o t o t h e f ir s t zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

r e c t if ie r , b u t , g e n e r a lly be

Seat • Disconnect the regulator/rectifier connector. • Unscrew the mounting bolt, and remove the regulator/rectifier from the frame . • Check to be sure the rectifier circuit is normal before continuing.

15-18

ELECTRICAL

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Regulator Circuit Test-1 st Step: .Connect the test light and the 12 V battery to the regulator/rectifier as shown. .Check M1, M2, and M3 terminal respectively.

Regulator Circuit Test-3rd Step: .Connect the test light and the 12 V battery in the same manner as specitied in the "Regulator Circuit Test-1 stzyxwvutsrqponmlk Step." • Momentarily apply 18 V to the voltage monitoring terminal by adding a 6 V battery . • Check M1, M2, and M3 terminals respectively.

Regulatorl Rectifier

o Do

not apply more than 18 V to the regulator/rectifier and do not leave the 18 V applied for more than a few seconds, or the unit will be damaged.

Test Light * If the test light did not light when the 18 V was applied momentarily to the voltage monitoring terminal, the regulator/rectitier is detective. Replace it. * If the regulator/rectifier passes all of the tests described, it may still be detective. It the charging system still does not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.

12 V Battery

6 V Battery OThe test light limits the current flow through the regulator/rectifier. Do not use an ammeter or multimeter in its place.

*It

the test light turns on. the regulator/rectifier tive. Replace it.

is detecRegulatorl Rectifier

* It the test light does not turn on, continue the test. Regulator Circuit Test-2nd Step: .Connect the test light and the 12 V battery in the manner specified in the "Regulator Circuit Test-1 st step" . • Apply 12 V to the voltage detection terminal. .Check M1, M2, and M3 terminal respectively.

RegulatorZYXWVUTSRQPONMLKJIHGFEDCBA I Rectifier 12 V Battery

Test Light

+ 12 V Battery

*It *It

the test light turns on, the regulator/rectifier tive. Replace it.

is defec-

the test light does not turn on, continue the test.

• ELECTRICAL

SYSTEM

15-19

Ignition System Safety Instruction:

I WARNINGgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA I OThe ignition system produces extremely high voltage. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you could receive asevere electrical shock.ZYXWVUTSRQPONMLKJIHGFEDCBA

1. (+) Terminal +- BK

Ig n ítío n C o í! R e m o va l e Remove :

Terminal +- BK/Y

2. (-)

Ig n ítío n C o ílln s p e c tío n Measuring arcing distance:

Side Covers Seat FuelTank e Disconnect the ignition coil primary lead connectors. e Pull the plug cap off the spark plug. eUnscrew the mounting bolt, and remove the ignition coil.

The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance with the Coil Tester (special tool) for the 3-needle method.

NOTE

o S in c e

a te s te r o th e r

d if f e r e n t m ended

e Remove eConnect installed measure

a r c in g

f o r r e lia b le

the the on the

th a n

t h e C o ll

d is t a n c e ,

th e

T e s te r m a y p ro d u c e

C o il

T e s te r

re c o m -

r e s u lt s .

ignition coil, ignition coil (with the spark plug cap left the spark plug lead) to the tester, and arcing distance,

A. Primary Lead Connectors C. Mounting Bolt B. Plug CapZYXWVUTSRQPONMLKJIHGFEDCBA D. Ignition Coil

1. Coil Tester: 57001 -1242

Ig n ítío n C o ílln s ta lla tío n N o te

2. Ignition Coil

WARNING eConnect the primary leads to the ignition coil terminals as shown in the figure.zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA OTo avoid extremely high voltage shocks, do not touch the coil or lead.

* If the distance

reading is less than the specified value, the ignition coil or spark plug cap is defective.

3 Needle Arcing Distance 7mm or more

â&#x20AC;˘ZY 15-20

ELECTRICAL

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

eTo determine which part is defective, measure the arcS p a r k P lu g C le a n in g a n d I n s p e c t io n ing distance again with the spark plug cap removed e Remove the spark plug, and visually inspect. form the ignition coil lead.zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA e Clean the spark plug, preferably in a sandblasting deIf the arcing distance is subnormal as before, the trouble vice, and then clean off any abrasive particles, The plug is with the ignition coil itself. If the arcing distance is may also be cleaned using a high flashpoint solvent and now normal, the trouble is with the spark plug cap. a wire brush or other suitable tool.

Measuring coil resistance: If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. e Disconnect the primary leads from the coil terminals. eMeasure the primary winding resistance. o Connect an ohmmeter between the coil terminals.

o Set

the meter to the x 1 O range, and read the meter. e Measure the secondary winding resistance. o Pull the spark plug cap off the lead. O Connect an ohmmeter between the spark plug lead and the black/yellow lead terminal.

O Set the meter to the x 1 kO range, and read the meter. * If the meter does not read as specified, replace the coil,

Winding

* If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

S p a r k P lu g G s p I n s p e c t io n

e Measure the gap with a wire-type

thickness gauge.

* If the gap is incorrect, carefully bend the side electrode with a suitable tool to obtain the correct gap.

Spark Plug Gap 0.8 -

0.9 mm

Resistance

Primary windings: Secondary windings:

0.15 - 0.21 O 3.8 - 5.8 kO

.--O

I\-

~ Q)

1 . Measure primary winding resistance. 2. Measure secondary winding resistance. 3. Ignition Coil

* If the meter reads as specified, the ignition coil windings are probably good. However, Ăf the ignition system still does not perform as it should after all other components have been checked, test replace the coil with one known to be good. eCheck the spark plug lead for visible damage. *If

the spark plug lead is damaged, replace the coil.

1. Insulator 2. Center Electrode

3. Plug Gap 4. Side Electrode

C D I U n it I n s p e c t io n

e Remove : Side Covers Seat FuelTank Coolant Reservoir Tank Cover e Disconnect the CDI unit lead connectors. eTake out the CDI unit.

ELECTRICAL CDI Unit Internal Resistance

SYSTEM

15-21

Unit: kO Meter PositivezyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA (+) Lead Connection

(-r

Lead

BL/R

R/G

BK/W

Y/BK

10 -

BL/R

4 -

R/G

2 -

BK/W

5 -

-6

2 -

Y/BK

15 -

10 -

A. Connectors

5 -

-6

• : Meter Negative (-)

20 -

00 1SRQPONMLKJIHGFEDCBA 1 -6 10 - 55 -6

5 -

10 -

10 50

Lead Connection

B. CDI·Unit

o Use only

Kawasaki Hand Test (special tool: 57001-983) for this test. A tester other than the Kawasaki Hand Tester may show different readings. O Do not use a megger or a meter with a large-capacity battery. or the COI unit will be damaged.

1. 2. 3. 4. 5. 6. 7.

White Lead Terminal Red Lead Terminal Blue/Red Lead Terminal Red/Green Lead Terminal Brack/White Lead Terminal Black Lead Terminal Yellow/Black Lead Terminal

eSet

the

Kawasaki

Hand

Tester

(special

tool:

57001-983) to the x 1 kO range. connect the Tester to the terminals in the CDI unit lead connectors. and check the internal resistance following the table.

*If the

readings do not correspond the CDlunit.

to the table, replace

15-22gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA EtECTRICAL SYSTEM ZYXWVUTSRQPONMLKJIHGFEDCBA eZero the ohmmeter, and connect it to the pickup coil P i c k u p C o i l R e m o v a l zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA leads. eRemove the magneto cover (see the Magneto Cover If there is more resistance than the specified value, the Removal in the Engine Right Side/Left Side chapter). coil has a broken wire and must be replaced. Much less e Remove the holding plates for the pickup coil lead. than this resistance means the coil is shorted, and must eUnfit the pickup coillead grommets out of the notch of be replaced. cover.

eUnscrew coil.

the mounting

screw, and take off the pickup Pickup

Coil Resistance

100 -

150 O (BK - BK/Y)

e Using the highest resistance range of the ohmmeter, measure the resistance between the pickup coil leads and chassis ground.

* Any

meter reading less than infinity (00) indicates a short, necessitating replacement of the pickup coil assembly.

E xc ite r C o il In s p e c tio n

A. Holding Plates B. Grommets

C. Mounting Screw O. Pickup Coil

P ic ku p C o illn s ta //a tio n N o te s eRoute the pickup coil lead with fitting into the groove between the rib and wall of cover. eAfter fitting the stator coil lead grommet fit the pickup coil lead grommet into the notch of cover securely. e Route the magneto leads in accordance with the Wire Routing in the General Information chapter.

e Remove : Side Covers Seat FuelTank e Oisconnect the magneto lead connector (6 pin). eZero the ohmmeter, and connect it as shown in the table. Exciter

Coil Resistance

Range x 10 O

Reading

Connections

Meter Meter (+) to

Meter (-)

Red lead

White lead

(6 pin connector)

100 2000

P ic ku p C o illn s p e c tio n e Remove : Side Covers

Seat FuelTank eOisconnect (3 pin).

the magneto

(pickup

coil) lead connector

A. Magneto Lead Connector (6 pin)

'* If there

* A. Magneto Lead Connector

(3 pin)

is more resistance than shown in the table, the stator has a broken wire, the leads between the stator and the connector are open, or the connections are bad. Check the stator. and the leads, and fix or replace the damaged parts.

If there is much less resistance than shown in the table, the stator is shorted, or the leads between the stator and the connector is grounded. Check the stator and the leads, and fix or replace the damaged parts.

ELECTRICAL • Using the highest resistance range of the ohmmeter, measure the resistance between each of the red or white leads and chassis ground.

SYSTEM

Anode

* Any meter reading less than infinityzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA (00) indicates a short to ground. Replace the stator.ZYXWVUTSRQPONMLKJIHGFEDCBA

D ío d e In s p e c tío n

• Remove : Side Covers Seat FuelTank Coolant Reservoir Tank Cover • Remove the bracket mounting bolts and the reservoir tank upper-Ieft mounting bolt. .While pulling the bracket to the right side, disconnect the diode assembly.

A. Bracket Mounting Bolts B. Reservoir Tank Upper- Left Mounting C. Diode Assembly

Bolt

.Zero the ohmmeter, and connect it to each diode's terminals to check the resistance in both directions. *The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high resistance in both directions, the diode is defective and the diode assernblv must be replaced.gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

NOTE

o The

a c t u a l m e t e r r e a d in g

t h e in d iv id u a l r e a d in g

s h o u ld

v a r ie s w it h

d io d e , b u t . g e n e r a lly b e fro m

th e m e te r u s e d a n d s p e a k in g ,

z e r o t o t h e f ir s t

t h e lo w e r

1/2 o t . t h e

s c a le .

Cathode

15-23

:I>'~!'-l:-"

...,¡

~B:~~ rf:~:;ID::§e

zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

;:¡ CQ. ;::+. CD CD :J _. CJ) ...•CD Q.

~~cn Qi"O~ -c u ;::+. cnO

.ti><J

-o m

g, g,

;::+.

R/BK BK/W

Y/BK -{>CJ- Y/BK I

~BK/Y

~ ~

-Jt.-Jt.--JoC,O

(J)

~ m

:=ij=-.:/w

I·--------BK I

BK/Y3}K/R

•

QlQ.Ql

Acng¡~ :::QSrcn

~;~~~B~Y.

,ºltrB~~ft~~R'

c: :J o ~ Q. o ;::+.

O cnA ~ E tr ~. ~

BK~

~ LG LG---....---IIf----1If------i1 •..•gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

...

ucncncnCD _ .•..• c: -rC'D;¡-

BL/R~BK/R

(J)

N-"O·

R/BK W

..L. I

Ql (Q

o -t

R/G~BK

~ f2. - ;:¡: c: Cii e u ...• :J:J

o o

BK/Y

BK/W

(")<5 o :J

_. x

m rm

:~~~~B~;Y

~ ~ ~.ZYXWVUTSRQPONMLKJIHGFEDCBA

OO~cnC1 ....

(J'1

~(d ~

BR-fÍl--BK/Y

G/w---L¿J-G/w

•

ELECTRICAL

SYSTEM

15-25

Electric Starter System ZYXWVUTSRQPONMLKJIHGFEDCBA S t a r t e r M o t o r R e m o v a l / l n s t a l l a t i o n N o t e zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA .See the Starter Mechanism in the Engine Right Side/Left Side chapter.

S ta r te r M o to r D is a s s e m b ly

• Unscrew the retaining screws, and pull off both end covers. • Take the armature out of the yoke housing. • Remove the brush plate assembly from the housing.

A. Long Tab

B. Key Slot

.As a further check, these marks should align on the outside of the starter.

• Remove the nut and remove the terminal bolt, and then remove the positive brush assembly with the plastic holder.

A. Align marks.

S ta r te r M o to r B r u s h L e n q th • Measure the length of each brush. S te r te r M o to r A s s e m b ly

N o te s

• Push the brush plate into place with its tab fitting in the yoke housing notch.

* If any is worn

down to the service limit, replace all brushes.zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIH

A. Tab

B. Notch

.Install the brush end cover so that the long vertical tab on the brush plate aligns with the key slot in the cover.

A. Measure brush length.

Brush length Standard: Service limit:

B. Brush Spring

12.0 - 12.5EDCBA m m 6m m

• 15-26

SYSTEM ZYXWVUTSRQPONMLKJIHGFEDCBA

ElECTRICAl

• Using the highest ohmmeter range, measure the resistB r u s h S p r i n g I n s p e c t i o n zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA ance between the commutator and the shaft . • Check that the brush springs are in place and snap the brushes firmly into place. *If

not, reinstall or replace the spring.

C o m m u ta to r C le a n in g a n d In s p e c tio n

.Smooth the commutator surface if necessary with fine emery cloth. and clean out the grooves.

* If there is any reading at all, the armature has a short and the starter motor must be replaced. Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with an ohmmeter. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.

B r u s h P la te In s p e c tio n

.Using the x 1 ohmmeter range, measure the resistance between the negative brushes and the plate. * If there is not close to zero ohms, the brush plate must be replaced.

A. Commutator • Measure the diameter of the commutator. * Replace the starter motor with a new one if the commutator diameter is less than the service limit.

Commutator Diameter Standard:

28 mm

Service limit:

27 mm

A r m a tu r e In s p e c tio n

ohmmeter range, measure the resist.Using the x 1 ance between any two commutator segments. * If there is a high resistance or no reading (ao) between any two segments, a winding is open and the starter motor must be replaced.

• Using the highest ohmmeter range, measure the resistance between the metal plate and the positive brush holders. * If there is any reading at all, the brush holder has a short and the brush plate must be replaced.

P o s itive B r u s h A s s e m b ly

In s p e c tio n

.Using the x 1 ohmmeter range, measure the resistance between the positive brush and the te:rminal bolt. * If there is a high resistance or no reading (00), a lead is open and the brush assembly must be replaced.

A. Segment

B. ShaftzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

ELECTRICAL

A. Starter Relay

SYSTEM

15-27

B. Starter Circuit Relay

• Using the highest ohmmeter range, measure the resistance between the terminal bolt and the pole housing.

* If there is any reading

at all, the insulation is faulty and S ta r te r C ir c u it R e /a y ln s p e c tio n the positive brush assembly must be replaced.ZYXWVUTSRQPONMLKJIHGFEDCBA • Remove the side stand switch cover. • Remove the relay. • Connect the ohmmeter and one 12-volt relay as shown.

S ta r te r R e /a y /n s p e c tio n

* If the relay does not work

battery to the

as specified, the relay is de-

fective.

• Remove the side stand switch cover. • Disconnect the starter motor lead and battery positivezyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Testing Relay ( +) lead from the starter relay. Meter range : x 1 O range Connection 1 +-Meter-+2 OThe battery positive (+) lead with the rubber cap is connected directly to the battery positive (+) terminal even when the ignition switch is off. so take care not to short the removed lead to chassis ground.

3+-Meter-+4

65 - 850 O O with battery connected

3+-Meter-+4

O with battery disconnectedSRQPONMLKJ

@®

• Using the x 1 O ohmmeter range, measure the resistance across the relay terminals.

* If the relay clicks

but the meter does not read zero, the relay is defective and must be replaced. If the relay does not click at all, the relay is defective and must be replaced.

* If the relay makes a single clicking

sound and the meter reads zero the relay is good. The trouble is in the starter motor or the motor power supply wires.

Switch Position: Ignition switch ON Engine stop switch RUN Starter button ON Neutral switch ON (transmission is in neutral) Meter Connection: location

Starter relay terminals (Ieads disconnected)

Meter range

x10

Meter Reading:

O O and relay clicks when starter button is pushed.

@CD Ohmmeter

Relay

12 V Battery 1 and 2 : Relay Coil Terminals 3 and 4 : Relay Switch Terminal

15-28

ELECTRICAL

SYSTEM

~+-+---Y/BK---+---4-~~zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQP IR +- __--1 yZYXWVUTSRQPONMLKJIHGFEDCBA B R --+--....J SRQPONMLKJIHGFEDCBA

w---+------zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA W .--------< •....-------BK/Y-EDCBA -+ --+ ---+ -+ BK/Y~ BK/Y ~------~---,,--'----,LG

-m-

BL/R LG

--I--..J

il5 ~

1. 2. 3. 4.

Ignition Switch Engine Stop Switch Starter Bunon Starter Circuit Relay

5. 6. 7. 8.

20A Main Fuse Starter Lockout Switch Neutral Switch Starter Motor

9. Starter Relay 10. Banery

ELECTRICAL

SYSTEM

15-29

Lighting System zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA The headlight beam is adjustable both horizontally and vertically. Headlight aiming must be correctly adjusted both for your safety as well as that of oncoming drivers. In most areas it is illegal to ride with an improperly adjusted headlight.ZYXWVUTSRQPONMLKJIHGFEDCBA

H e a d lig h t B e a m H o r izo n ta l A d ju s tm e n t

eTurn the adjusting screw on the headlight rim in or out until the beam points straight ahead. Turning the adjusting screw clockwise makes the headlight beam point to the left.

A. Adjusting Knob

H e a d lig h t B u lb R e p la c e m e n t

N o te s

A. Adjusting Screw

OWhen handling the quartz-halogen bulbs. never touch the glass portaion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.

H e a d lig h t B e a m V e r tic a lA d ju s tm e n t The headlight beam is adjustable vertically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the .high beam will fail to illuminate the road close ahead, and the low beam will blind oncoming drivers. eTurn the adjusting knob on the headlight rim to the right or left until the beam points straight ahead. Turn-

elnstall the dust cover so that the "TOP" mark point up and the cover fits onto the bulb firmly as shown.

ing the adjusting knob clockwise makes the headlight beam point to the lower.EDCBA

NOTE

oOn

h ig h

b e lo w

beem ,

th e

b r ig h te s t

p o in t

h o r izo n ta l w ith th e m o to r c yc le

th e r id e r s e a te d . g le a c c o r d in g

A d ju s t

th e h e a d lig h t

s h o u ld

s lig h tly

o n its w h e e ls

and

to th e p r o p e r e n -

to lo c a l r e g u la tio n s .

A. Top Mark

B.Up

15-30

ELECTRICAL

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

GoodzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA T a i//B r a ke L ig h t L e n s R e m o va ///n s ta lla tio n

N o te

• Be careful not to overtighten the lens mounting

T u r n S ig n a / L ig h t B u /b R e p /a c e m e n t

N o te

• Be careful not to overtighten the lens mounting

1. Dust Cover .Check

2. Headlight Bulb

screws.

T u r n S ig n a / R e /a y /n s p e c tio n

• Remove : Side Covers the headlight aim after installation.ZYXWVUTSRQPONMLKJIHGFEDCBA Seat FuelTank .Take the fan relay and the turn signal relay out of the bracket.

H e a d lig h t U n it R e m o va ///n s ta lla tio n

N o te .Install the headlight unit so that the "TOP" mark on the lens points up.

A. Fan Relay

A. Top Mark

• Check the condition bles.

B. Turn Signal Relay or the relay for the following

trou-

B. Up (1) Neither right nor left turn signals come on at all:

T a i//B r a ke L ig h t B u /b R e p /a c e m e n t

N o te .Insert the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base is to the upper right.

• Check that banery voltage is normal. • Remove the fuel tank. • Unplug the relay leads and use an ohmmeter to check that there is continuity (close to zero ohms) between the relay terminals. *If

there is no ohmmeter reading, or if there is several ohms resistance, replace the relay with a new one . • Turn the meter to the 25 V DC range, connect the (+) meter lead to the brown lead that was disconnected from the relay, and connect the (-) meter lead to the orange lead . • With the ignition switch on, first switch the turn signal switch to the R and then to the L position. The meter should register banery voltage at either position.

* If it does not, the fuse, ignition fault.

switch, or wiring

is at

(2) Both right or both left turn signals come on and stay on or flash too slowly: .Check that battery voltage is normal.

A. Pin Closest to Base.

• Check that all wiring connections are good . • Check that the turn signal bulbs and indicator bulbs are of the correct wattage.

â&#x20AC;˘g ELECTRICAL

SYSTEM

15-31

* If all of theZYXWVUTSRQPONMLKJIHGFEDCBA a b o v e check good, replace the relay.

Radiator

Fan System

(3) A single light on one side comes on and stays on: * Either the light that does not come one is burned out of the incorrect wattage, or the wiring is broken or irnproperly connected.

(4) Neither light on one side comes: *Unless both lights for that side are burned out, the trouble is with the turn signal switch.

(5) Flashing rate is too fast: *If

this occurs on both the right and left sides, check that the battery is not being overcharged.

* If the magneto and the battery place the turn signal relay.

v o lt a g e

are normal, re-

C ir c u it I n s p e c t io n

e R em ove Side

C o v e rs

Seat FuelTank e Disconnect female 4-pin connetor from the fan relay. eConnect the blue wire to any white wire in with a suitable wire. * If the fan turns, inspect the following. Wires and Connectors Fan Relay Fan Switch * If the fan does not turn, inspect the following. Wires and Connectors Fuse Fan

* If this occurs on only one side, one or both of the turn signal bulbs are of too high a wattage.zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

BL -----' W

>-:::,Âż co

R/W

1 . Radiator Fan 2. Fan Relay 3. Fan Lead Connector 4. 4- Pin Connector

5. 6. 7. 8.

10A Fan Fuse Battery Fan Switch Radiator

• 15-32

ELECTRICAL

SYSTEM ZYXWVUTSRQPONMLKJIHGFEDCBA

F a n /n s p e c tio n

Meter and Gauge

• Remove : Side Covers Seat FuelTank

R e m o vs llln s ts lte tio n

N o te

• Disconnect the tan lead connector. • Using two auxiliary wires, supply battery power to the tan.

o Place the

meter or gauge so that the face is up. If a meter or gauge is left upside down or sideways for any length of time. it will malfunction.

Wire Connections

BatteryzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA (+)

Blue Lead Black/yellow

Lead

+-+

Battery (-)

* lf the tan does not turn at this time, the tan is detective and must be replaced.

M e te r M o u n tin g

/n s p e c tio n .Check to see that the rubber dampers are installed at the meter mounting bracket.

*Install a new damper where it is absent. • Check to see that the rubber dampers mounting bracket are -in good condition. not be hard or cracked.

in the meter They should

* Replace any damaged rubber dampers with new ones . • Check to see that all meter mounting nuts are tightened securely. *Tighten

~ A. Fan Lead Connector (2-Pin)

F a n R e /a y /n s p e c tio n • Remove :

Side Covers Seat FuelTank

any loose tasteners.

B u /b R e p /a c e m e n t N o te .To remove the wedge-base type bulbs (indicator and illumination), pull out the bulb sockets and pull the bulbs off the sockets.

o Do

not use bulbs rated for greater watlage than the specified value. as the meter or gauge panel could become warped by excessive heat radiated from the bulbs.

• Remove the tan relay. T a c h o m e te r /n s p e c tio n

NOTE

o T a c h o m e te r

in s p e c tio n

th a t th e ig n itio n s ys te m

is e xp la in e d

th e a s s u m p tio n

o p e r a te s n o r m a l/y .

• Check to see that the rubber dampers are installed in those positions. *Install new dampers it any are missing . • Check to see that the rubber dampers are' in good condition. They should not be hard or cracked. * Replace any damaged rubber dampers with new ones . • Check to see that all meter mounting screws and nuts are tightened securely. A. Fan Relay

*Tighten any loose tasteners. .Check the tachometer circuit wiring.

• Fan relay inspection is same as starter circuit relay inspection. Reter to the starter circuit relay inspection section.

* It all wiring and components other than the tachometer unit check out good, the unit is suspect. Check the unit as shown. .Turn the ignition switch ON.

•g ELECTRICAL

IP+- -15lBR

W ~

-+-------

15-33

SYSTEM

20A Main Fuse

-=i.hl- w --fb?"'§l-

Ignition Switch

;

BRiBR/W BK/YzyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA BK/Y Ignition BK BK __ Coil

--~en

---J

Tachometer

-->::,¿

SparkPI';¡" .With the BR lead connected, open or connect the BK lead to the BR lead repeatedly. Then, the meter hand should flick.

See IgnitionSYstel¡

Battery

W a te r T e m p e r a tu r e G a u g e O p e r a tio n In s p e c tio n • Prepare an auxiliary lead, and check the operation of the gauge.

* If the hand does not flick, replace the meter unit.ZYXWVUTSRQPONMLKJIHGFEDCBA Gauge Operation Test Ignition Switch Position: ON lead location: Female, Sensor Connector (disconnected) Results: Gauge should read C when sensor lead is opened. Gauge should read H when sensor lead is grounded briefly to engine.

Tachometer

o Do

not ground the wiring longer than necessary. After the needle swings to the H position, stop the test, Otherwise the gauge could be damaged.

BR BK/Y

* If the gauge readings are correct, the water temperature sensor is bad. If these readings are not obtained, the trouble is with the gauge and/or wiring . • Check the water temperature gauge circuit wiring (see Wiring Inspection). *If

all wiring and components other than the water temperature gauge unit check out good, the gauge is defective.

• 15-34

ELECTRICAL

SYSTEM zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Switch

and Sensor ZYXWVUTSRQPONMLKJIHGFEDCBA T im in g I n s p e c t io n EDCBA

B r a k e L ig h t

on the ignition switch . • Check the operation of the rear brake light switch depressing

.T u r n

Brake light

Timing

On after about at mm pedal travel

>-zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA A. Brake Pedal

B r a k e L ig h t

1. 2. 3. 4. 5.

Water Temperature Gauge Ignition Switch Water Temperature Sensor 20A Main Fuse Battery

B. About 1 5 mm

T im in g A d ju s t m e n t

Brake light timing is adjusted by changing the position of the rear brake light switch. .Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the adjusting nut.

OTo avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

A. Rear Brake Light Switch B. Adjusting Nut

C. Light sooner. D. Light later.

ELECTRICAL

SYSTEM

I n s p e c t i o n zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA IGNITION SWITCH CONNECTIONS eUsing an ohmmeter, check to see that only the conR W BR BK/W nections shown in the table have continuity (about zero Color BK/Y ohms).zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA ON

15-35

S w itc h

* If the

switch has an open or short, repair it or replace it OFF with a new one.gfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA LOCK

-C

R/W

LEFT HANDLEBAR

R/BK

BL/Y

Color

R/Y

N(OFF,

Push)

RIGHT

HANDLEBAR

Headlight Switch BL

Color

BK/Y

Color

BK/W

Color

Passing Button

Horn Button

Turn Signal Switch

Dimmer Switch Color

SWITCH CONNECTIONS

BL/Y

OFF

O ON

Color

BK/Y

OFF RUN

Color

BK/R

Color

When brake lever is pulled in

When brake pedal is pushed down

When brake lever is released

When brake pedal is released

Switch Connections

Color

BK/Y

BL/R

When clutch lever is pulled in When clutch lever is released

Neutral Switch Connections LG

Color

(SW. Terminal)

When transmission

is in neutral

When transmission

is not in neutral

Side Stand Switch Connections Color When side stand is up When side stand is down

G/W

Rear Brake Light Switch Connections

Starter Lockout

Starter Button BK/W

ON(Push)

Front Brake Light Switch Connections Color

SWITCH CONNECTIONS

Engine Stop Switch R/BL

R/W

ON(Push)

R/BK

r lr

• 15-36

ELECTRICAL

SYSTEM ZYXWVUTSRQPONMLKJIHGFEDCBA

l n s p e c t i o n zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA W a te r T e m p e r a tu r e S e n s o r ln s p e c tio n e Remove the fan switch. e Removethe water temperature sensor. eSuspend the switch in a container of water so that the eSuspend the sensor in a container of water so that the temperature sensing projection and threaded portion are temperature-sensing projection and threaded portion are submerged. submerged. eSuspend an accurate thermometer in the water. eSuspend an accurate thermometer in the water. e Place the container over a source of heat and gradually e Place the container over a source of heat and gradually raise the temperature of the water while stirring the raise the temperature of the water while stirring the water gently. water gently.

F a n S w itc h

NOTE

o The

s w itc h

and

th e r m o m e te r

NOTE m ust

not

to u c h

th e c o n -

o The

ta in e r s id e s o r b o tto m .

Fan Switch Connections Rising temperature: From OFF to On at 94 Falling temperature:

s w itc h

and

th e r m o m e te r

m ust

not

to u c h

th e

100°C

(201 - 212°F) From EDCBA O N to OFF

eUsing an ohmmeter, measure the internal resistance of the sensor across the terminal and the body at the ternperatures shown in the table. *If

the ohmmeter does not show the specified values, replace the sensor.

above 91°C (196°F) ON:

con-

ta in e r s id e s o r b o tto m .

t.ess than 0.5 O

Water Temperature

Sensor Internal Resistance

OFF:zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA More than 1· MO 47 - 57 O @ 80°C (176°F) 26 -

30 O

@ 100°C (212°F)

ELECTRICAL Fuse ZYXWVUTSRQPONMLKJIHGFEDCBA

M a ín /H e a d líg h t

F use

F a n F use

elnstall

In s ta lla tío n

SYSTEM

15-37

N o te s

the fuse case so that it is parallel to the stay pipe.

R e m o v a l zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

eRemove: Side Covers Seat eSlide the rubber damper off the bracket. e Pull the fuse case out of the rubber damper. eOpen the case, and pull out the fuse carefully.

A. Fuse Case

B. Stay Pipe

eClamp the case with a tie band at the bracket portion.

A. Rubber Damper

B. Fuse Case

In s p e c tío n M a ín /H e a d líg h t

elnstall

F use

In s ta lla tío n

N o te

the specified fuse in its place of the case.

e Remove the fuse. el nspect the fuse element.

* If it is blown

out, replace the fuse. Before replacing a blown fuse. always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.

OWhen replacing a fuse, be sure the new fuse match es the specified fuse rating for that circuito Installation of a fuse with a higher rating may cause damage to wiring and components.

A. 1DA Headlight Fuse B. Brown Lead C. Blue/White Lead

F a n F use

D.ZYXWVUTSRQPONMLKJIHGFEDCBA 2 D A Main Fuse E. White Lead

R e m o va l

e Remove : Side Covers Seat FuelTank e Pull the fuse case out of the clamp. eOpen the case, and pull out the fuse carefully.

A P P E N D IX

1 6 -1

A p p e n d ix

T a b le 0 1 C o n te n ts ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFED

Aditional Conciderations for Racing

16-2

Carburetor:

16-2

Spark Plug:

16-2

Inspection

16 - 3

Troubleshooting

Guide

16-4

General Lubrication

16-8

Lubrication

16-8

Unit Conversion Table

16-9

•

1 6 -2

A P P E N D IX whether or not a spark plug of a correct heat range is used

A d d itio n a l

fo r R a c in g ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA should be determined by removing and inspecting

C o n s id e ra tio n s

the

plug.

This motorcycle

has been manufactured

reasonable and prudent

for use in a

manner and as a vehicle

only.

However, some may wish to subject this motorcycle abnormal operation, such as would racing conditions.

KAWASAKI

~ f-------< T

be experienced under STRONGLY

RECOM-

MENOS THAT ALL RIOERS RIOE SAFELY ANO OBEY ALL LAWS ANO REGULATIONS

CONCERNING

MOTORCYCLE ANO ITS OPERATION. Racing should be done under supervised and recognized

sanctioning

for further details.

bodies should

l-----'C í·

conditions,

be contacted

Far those who desire to participate

competitive

racing or related use, the following

information

may prove useful.

following

THEIR

technical

However, please note the

important points.

eyou are entirely responsible for the use of your motorcycle under abnormal conditions such as racing, and . Kawasaki shall not be liable for any damages

which

might arise from such use. e US model only:

Kawasaki's

ranty and Limited specifically

exclude

competitive carefully.

or related uses.

e Motorcycle

Limited

Emission Control motorcycles

Motorcycle

which

are used

Reach

Please read the warranty

racing is a very sophisticated

to many variables.

War-

Systems Warranty

The following

---''---::j~~~=~

sport, subject

information

is the-

0 .8 -

0 .9

oretical only, and Kawasaki shall not be liable for any damages which this information. eWhen

might

arise from

alterations

utilizing

is operated

on public

roads, it

1. Terminal

the motorcycle

must be in its original state in arder to ensure safety and compliance with applicable regulations.

4. Gasket 5. Center Electrode

2. Insulator 3. Cement

6. Side Electrode

When a plug of the correct heat range is being used, the electrodes will stay hot enough to keep all the carbon

C a rb u re to r:

burned off, but cool enough

Sometimes an alteration may be desirable for improved performance under special conditions when proper mix-

engine and the plug itself. This temperature is about 400

to keep from damaging

the

ture is not obtained after the carburetor has been properly

'" 800°C (750 '" 1 A50°F) and can be judged by noting the condition and color of the ceramic insulator around

adjusted, and all parts cleaned and found to be function-

the center electrode.

ing properly.

brown color, the plug is operating at the right temperature.

If the engine

still exhibits

symptoms

of overly

lean

carburetion after all maintenance and adjustments are correctly performed, the main jet can be replaced with a smaller or larger one.

A smaller numbered

jet gives a

leaner mixture and a larger numbered jet a richer mixture.

If the ceramic is clean and of a light

A spark plug for higher operating for racing.

temperatures is used

Such a plug is designed for better cooling ef-

ficiency so that it will not overheat and thus is often called a "colder" plug. If a spark plug with toa high a heat range is used - that is, a "cold"

plug that cools itself too well -

the plug will stay too cool to burn off the carbon, and the carbon

will

correct

on the electrodes

and the ceramic

insulator. The carbon on the electrodes conducts

Spark P lu g : The spark plug ignites the fuel/air bustion chamber.

mixture in the com-

To do this effectively and at the proper

time, the correct spark plug must be used, and the spark plug must be kept clean and adjusted. Test have shown the plug listed in the "Specifications" section in the "Generallnformation"

chapter to be the best

electricity, and

can short the center electrode to ground by either coating the ceramic insulator or bridging

across the gap.

short will prevent an effective spark.

the plug can also cause otber troubles. red-hot

and cause preignition

Since spark plug requirements change witt. the ignition and carburetion adjustments and with riding conditions,LKJIHGFEDCBA

It can heat up

and knocking,

eventually burn a hole in the top of the piston.

plug for general use.

Such a

Carbon build-up which

may

•K

16-3

A P P E N D IX Spark Plug Condition

Oil Fouling

Carbon Fouling

Overheating

Standard Spark Plug Threads

Inspection eRemove the insulator. *W hether

Normal Operation

spark

plug

and

inspect

the

ceramic

or not the right temperature plug is being used

Diam eter

12 m m

Pitch

1.25 m m

Reach

19.0 m m

can be ascertained by noting the condition of the ceramic insulator around the electrode.

A light brown

color indicates the correct plug is being used.

If the

ceramic is black, it indicates that the plug is firing at too low a temperature, so the next hotter type should be used instead.

If the ceramic is white, the plug is oper-

ating at too high a temperature and it should be replaced with the next colder type.

NOTE

a EDCBA T h e h e a t ra n g e m o s ta t p lu g g in e

o f th e s p a r k p lu g

fo r th e e n g in e .

U s in g

c a n m a k e th e e n g in e r u n dam age)

m is fir in g , s e le c te d

and

s ta llin g ) .

to m a tc h

is c o m b in e d c o n d itio n s

to o

c o ld

w ro n g

to o

hot

( w ith

the spark plug is replaced with a type other than the

standard

plug

listed

in the

"Specifications"

section

m ake certain the replacem ent plug has the sam e thread pitch and reach (Iength of threaded portion)

and the

sam e insulator type (regular type or projected type) as the standard plug.

a If

the plug reach is too short, carbon will

the

plug hole threads

in the cylinder

overheating and m aking it very difficult correct spark plug later.

a If

build up on

head, causing to insert the

the reach is too long, carbon will build up on the ex-

posed spark plug threads causing overheating,

preig-

nition, and possibly burning a hole in the piston topo In addition, without

m ay be im possible

rem ove the

plug

dam aging the cylinder head.

Too short

~ /l

Correct reach LKJIHGFEDCBA

Carbon builds up here

( r e s u ltin g

poor

T h e s ta n d a rd

lik e a th e r -

ty p e o f s p a rk in

en-

p e rfo rm a n c e ,

p lu g

has

been

th e n o r m a l u s a g e o f th is m o to r c y c le

s tr e e t a n d h ig h w a y

r id in g .

U n u s u a l r íd in g

m a y r e q u ir e a d iffe r e n t s p a r k p lu g

F o r r a c ín g , in s ta ll th e c o ld e r p lu g .

a If

fu n c tio n s

th e

h e a t ra n g e .

â&#x20AC;˘

16-4

APPENDIX Flywheel magneto damaged

Troubleshooting

Guide

Ignition or engine stop switch shorted Neutral, clutch, or side stand switch trouble Wiring shorted or open Fuse blown Fuel/air m ixture incorrect:

NOTE LKJIHGFEDCBA T h is is n o t o EDCBA

Pilot screw and/or id le adjusting screw maladjusted an

e x h a u s tiv e

c a u s e fo r e a c h p r o b le m ro u g h

g u id e

Iis t.

lis te d .

g lv m g

e v e ry

It is m e a n t s im p ly

a s s is t th e tr o u b le s h o o tin g

th e m o re c o m m o n

p o s s ib le as a

fo r s o m e

d iffic u ltie s .

Pilot jet or air passage clogged Air cleaner clogged, poorly sealed, or missing Starter jet clogged Com pression low:

Engine Doesn't Start, Starting Difficulty: Starter m otor not rotating:

Spark plug loose Cylinder head not sufficiently

down

Cylinder, piston worn

Starter lockout or neutral switch trouble

Piston rings bad (worn, weak, broken, or sticking)

Starter motor trouble

Piston ring/land

Battery voltage low Relays not contacting

clearance excessive

Cylinder head gasket damaged

or operating

Cylinder head warped Valve spring broken or weak Valve not seating properly (valve

Starter button not contacting Wiring open or shorted Ignition switch trouble

carbon accumulation

Engine stop switch trouble

Compression

Fuse blown Starter m otor rotating

tightened

No valve clearance

but engine doesn't turn over:

bent, worn,

on the seating surface)

release cam

(KAC.R.)

sticks

open

(Engine stalls when moving off).

Starter motor clutch trouble Engine won't

turn over:

Poor Running at Low Speed:

Valve seizure Valve lifter seizure

Spark weak:

Cylinder, piston seizure

Battery voltage low

Crankshaft seizure

Spark plug dirty, damaged, or maladjusted

Connecting

rod small end seizure

Spark plug cap or high tension wiring trouble

Connecting

rod big end seizure

Spark plug cap shorted or not in good contact Spark plug incorrect

Transmission gear or bearing seizure Camshaft seizure Compression Compression

release cam spring broken (KAC.R.) release cam sticks close (K.A.C.R.)

Exciter coil shorted or open Ignition

No fuel flow:

Fuel/air

Fuel tap turned off

m ixture incorrect:

Pilot screw maladjusted Pilot jet, or air passage clogged Air bleed pipe bleed holes clogged

Fuel tap vacuum hose clogged Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged

Air cleaner clogged, poorly sealed, or missing Air cleaner/carburetor

Float valve clogged

poorly sealed

Starter plunger stuck open

Engine flooded:

Fuel level too high or too low

Fuellevel too high

Fuel tank air vent obstructed

Float valve worn or stuck open Starting technique with

coil trouble

Flywheel magneto damaged

No fuel in tank

engine

CDI unit trouble Pickup coil trouble

faulty (When flooded,

the throttle

fully

opened

crank the to allow

more air to reach the engine.) No spark; spark weak:

Carburetor holder loose Com pression low:

Spark plug loose Cylinder head not sufficiently

tightened down

Battery voltage low

No valve clearance

Ignition switch not on

Cylinder, piston worn Piston rings bad (worn, weak, broken or sticking)

Engine stop switch turned off Clutch lever not pulled in or gear not in neutral

Piston ring/land

Spark plug dirty, damaged, or maladjusted Spark plug cap or high tension wiring trouble

Cylinder head gasket damaged Cylinder head warped

Spark plug cap shorted or not in good contact

Valve spring broken or weak

Spark plug incorrect

Valve

CDI unit trouble Pickup coil trouble Exciter coil shorted or open Ignition coil trouble Ignition coil resistor open

clearance excessive

not seating

properly

carbon accumulation Compression

(valve

bent. worn,

on the seating surface)

release cam

(KAC.R.)

(Engine stalls when moving off)

stick

open

APPEN Other:

D IX

Crankshaft bearing worn or damaged

COI unit trouble Carburetor vacuum piston does not slide smoothly Engine oil viscosity too high Orive train trouble

O v e rh e a tin g : Firing incorrect:

Brakes dragging

Spark plug dirty, broken, or maladjusted

Over heating

Spark plug incorrect

Clutch slipping

COI unit trouble

Throttle valve does not open fully KJIHGFEDCBA

Fuel/air m ixture incorrect:

Main jet clogged or wrong size Fuel level too low

P o o r R u n n in g o r N o P o w e r a t H ig h S p e e d :

Carburetor holder loose

Firing incorrect:

Spark plug dirty, damaged, or maladjusted

Air cleaner poorly sealed, or missing

Spark plug cap or high tension wiring damaged

Air cleaner duct poorly sealed Air cleaner clogged

Spark plug cap shorted or not in good contact

Com pression high:

Spark plug incorrect

Carbon built up in combustion

COI unit trouble Exciter coil shorted or open Ignition coil trouble

Clutch slipping Engine oil level too high

Flywheel magneto damaged

Engine oil viscosity too high

Fuel/air m ixture

Brakes dragging

incorrect:

Lubrication

Main jet clogged or wrong size

Engine oil poor quality or incorrect

too high or too low

Gauge incorrect:

Air bleed pipe bleed holes clogged

Water temperature gauge broken

Air cleaner clogged, poorly sealed, or missing Air cleaner/carburetor poorly sealed

Water temperature sensor broken Coolant incorrect:

Starter plunger stuck open

Coolant level too low

Fuel to carburetor insufficient

Coolant deteriorated

Water or foreign matter in fuel

Cooling system com ponent

Carburetor holder loose

Thermostat trouble Radiator cap trouble

Fuel tap clogged Fuel line clogged

Thermostatic

Com pression low:

Cylinder head not sufficiently No valve clearance

tightened

Fan motor broken

down

Fan blade damaged Water pump not rotating

Cylinder, piston worn

Water pump impeller damaged

Piston rings bad (worn, weak, broken, or sticking) Piston ring/land clearance excessive Cylinder head gasket damaged

O v e r C o o lin g :

Cylinder head warped

Gauge incorrect:

Valve spring broken or weak properly

carbon accumulation

(valve

bent, worn,

on the seating surface.)

Compression release cam (KAC.R) (Engine stalls when moving off)

sticks

open

Knocking:

Carbon built up in combustion

chamber

Fuel poor quality or incorrect Spark plug incorrect COI unit trouble M iscellaneous:

Carburetor vacuum piston does not slide smoothly Timing not advancing Brakes dragging Clutch slipping Overheating too high

Engine oil viscosity too high Balancer mechanism Orive train trouble

fan switch trouble

Fan relay trouble

Spark plug loose

Engine oillevel

incorrect:

Radiator clogged

Fuel tank air vent obstructed

Valve not seating

inadequate

Engine oil level too low

Jet needle or needle jet worn Fuellevel

chamber

Engine load faulty:

Pickup coil trouble

malfunctioning

Water temperature gauge broken Water temperature senser broken Cooling system com ponent

incorrect:

Thermostatic fan switch trouble Thermostat trouble

1 6 -5

1 6 - 6 KJIHGFEDCBA A P P E N D IX ponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Clutch Operation

Piston ring worn, broken or stuck

Faulty:

Piston seizure or damaged

Clutch slipping:

Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection

No clutch lever play Clutch cable maladjusted Clutch inner cable catching

Crankshaft runout excessive

Friction plate worn or warped

Engine mounts loose

Steel plate worn or warped

Crankshaft bearing worn

Clutch spring broken or weak

Primary gear worn or chipped

Clutch release mechanism trouble

Magneto flywheel

Clutch hub or housing unevenly worn

Camshaft chain tensioner trouble

Clutch not disengaging

properly:

loose

Clutch lever play excessive.

Camshaft chain, sprockets, guides worn Balancer chain, sprockets, chain tensioner worn

Clutch plate warped or too rough

Balancer mechanism springs weak or broken

Clutch spring tension uneven

Balancer bearings worn

Engine oil deteriorated Engine oil viscosity too high Engine oillevel

Abnormal

too high

Drive Train Noise:

Clutch noise:

Clutch housing frozen on drive shaft

Clutch rubber damper deteriorated

Clutch release mechanism trouble

Clutch housing/friction plate clearance excessive Clutch housing gear/primary gear backlash exces-

Clutch hub nut loose

sive

Gear Shifting

Faulty:

Doesn't go into gear; shift

Metal chip jammed in clutch housing gear teeth pedal doesn't

return:

Transmission

noise:

Clutch not disengaging

Bearings worn

Shift fork bent or seized

Transmission

Gear stuck on the shaft

Metal chips jammed in gear teeth Engine oil insufficient

Gear positioning lever binding Shift return spring weak or broken

gears worn or chipped

Drive chain noise:

Shift return spring pin loose

Orive chain adjusted improperly

Shift mechanism arm spring broken

Chain worn

Shift mechanism arm broken

Rear and/or engine sprocket(s)

Shift drum broken

Chain lubrication

Jumps out of gear:

worn

insufficient

Rear Wheel misaligned

Shift fork worn Gear groove worn Gear dogs and/or dog holes worn Gear positioning

lever spring weak or broken

Frame Noise:

Oil insufficient

or too thin

Spring weak or broken

Shift fork guide pin worn Orive shaft, output shaft, and/or gear splines worn Overshifts:

Gear positioning

Abnormal

Front fork noise:

Shift drum groove worn

lever spring weak or broken

Shift mechanism arrn spring broken

Rear shock absorber noise:

Shock absorber damaged Disc brake noise:

Pad installed incorrectly Pad surface glazed Oisc warped

Abnormal Engine Noise:

Caliper trouble Cylinder damaged

Knocking:

COI unit trouble

Other noise:

Carbon built up in combustion Fuel poor quality or incorrect

chamber

Brackets, nuts, bolts, etc. not properly tightened

Spark plug incorrect Overheating

Exhaust Smokes Excessively:

Piston slap:

Cylinder/piston

clearance excessive

W hite smoke:

Cylinder, piston worn

Piston oil ring worn

Connecting

Cylinder worn

rod bent

Piston pin, piston holes worn Valve noise:

Valve clearance incorrect Valve spring broken or weak Camshaft bearings worn Valve lifter worn

Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level too high Black smoke:

Air cleaner clogged Main jet too large or fallen off

Other noise:

Connecting

rod small end clearance excessive

Starter plunger stuck open

Connecting

rod big end clearance excessive

Fuellevel too high

mounted

A P P E N D IX LKJIHGFEDCBA 1 6 -7 Brown sm oke:

Load excessive (e.g., bulb of excessive wattage)

Main jet too small

Ignition switch trouble

Fuel level in carburetor float bowl too low

Flywheel magneto damaged

Air cleaner duct loose Air cleaner poorly sealed or missing

Wiring faulty

Handling and/or Stability

Regulator/rectifier

Unsatisfactory:

Handlebar hard to turn:

Battery Overcharged:

Cable routing incorrect

Regulator/rectifier

Hose routing incorrect

Battery trouble

Wiring routing incorrect Steering stem locknut too tight Bearing damaged Bearing race dented or worn Steering stem lubrication

inadequate

Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates:

Tire worn Swing arm bushing or needle bearing damaged Rim warped, or not balanced Front, rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem head nut loose Handlebar pulls to one side:

Frame bent Wheel misalignment Swing arm bent or twisted Swing arm pivot shaft runout excessive Steering maladjusted Steering stembent Front fork leg bent Right/left

front fork oil level uneven

Shock absorption

unsatisfactory:

(Too hard) Front fork oil excessive Front fork oil viscosity too high Front fork air pressure too high Front fork leg bent Tire air pressure too high Rear shock absorber maladjusted (Too soft) Front fork oil insufficient

and/or leaking

Front fork oil viscosity too low Front fork, rear shock absorber spring weak Rear shock absorber oilleaking Rear shock absorber maladjusted

Brakes Don't Hold: Air in the brake line Pad or disc worn Brake fluid leak Disc warped Contaminated pads Brake fluid deteriorated Primary or secondary cup damaged Master cylinder scratched inside

Battery Discharged: Battery

faulty

(e.g.,

trouble

plates

through sedimentation,

sulphated,

shorted

electrolyte level too low)

Battery leads making poor contactKJIHGFEDCBA

trouble

.1 6 -8

A P P E N D IX

G e n e ra l L u b ric a tio n

LubricetionponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA • Before lubricating

each part. clean off any rusty spots

with rust remover and wipe off any grease, oil, dirt, or grime . • Lubricate lubricant.

the

points

listed

below

with

indicated

NOTE

o EDCBA W henever r a in y

th e

v e h ic le h a s b e e n

c o n d itio n s .

h ig h - p r e s s u r e

s p ra y

o p e ra te d

e s p e c ia lly

w a te r, p e rfo rm

under

a fte r th e

g e n e ra l

c a tio n .

Pivots: Lubricate with

M otor

Oil.

Side Stand Clutch Lever Brake Lever Brake Pedal Rear Brake Rod Joint Points: Lubricate with

Grease.

Throttle Inner Cable Lower Ends Clutch Inner Cable Upper End Side Stand Switch Inner Cable Lower End Speedometer Inner Cable" * Grease

the lower part of the 'inner cable sparingly.

Cables: Lubricate with

Rust Inhibitor.

Choke Cable Throttle Cables Clutch Cable Side Stand Switch

Cable LKJIHGFEDCBA

@ 1

1. Cable 2. Pressure Cable Luber: K56019-021

wet

u s in g

or a

lu b r i-

APPENDIX Units of Length:

Unit Conversion Table

Prefixes for Units: Prefix

16-9

Symbol

0.6214

3.281

mile ft

0.03937

Power

M LKJIHGFEDCBA x 1,000,000

mega kilo

x 1,000

centi

x 0.01

milli

x 0.001

N-m

0.1020

kg-m

micra EDCBA

¡..L

x 0.000001

N-m

x x

0.7376 8.851

ft-Ib

N-m kg-m

9.807

N-m

kg-m

7.233

ft-lb

kg-m

86.80

in-lb

kq/crn?

Units of Torque:

Un its of Mass: kg

2.205

0.03527

in-lb

Units of Pressure: Units of Volume:

kPa

0.01020

kPa

0.1450

psi

gal (US)

kPa

0.7501

cm Hg

0.2200

gal (imp)

kq/crn?

98.07

kPa

1.057

qt (US)

kg/cm 2

14.22

psi

0.8799

qt (imp)

cm Hg

1.333

kPa

2.113

0.6214

mph

0.2642

pint (US) pint (imp)

1.816

0.03381

oz (US)

0.02816

oz (imp)

0.06102

Units of Speed:

cu in

km/h

Units of Force:

Units of Power:

0.1020

1.360

0.2248

1.341

9.807

0.7355

2.205

0.9863

Units of Temperature:

°F -40

-40

°e

-20

-4 :0

, ,

-20: -17_8

32 : , 40

I ,,

4.4

68 , 60 , 80

,, ,, , ,

26_7

104 100: 120 l'

40 48_9

140

160

I 60

, " 71.1

212 176 :180 200 :220

,' I ,

,I,

, I I

, 100 93_3

248 240 ; 260 I

, I

: 120 116

284 280: 300 I

;140 " 138

°F 320

, I

160

°e

SUPPLEM ENT

- 1990

MODEL

1 7 -1

S u p p le m e n t - 1 9 9 0 M o d e l tsrqponmlkjihgfedcbaZYXWVU This "Supplement - 1990 Model" chapter is designed to be used in conjunction with the front part of this manual (up to the end of the "Appendix" chapter). The maintenance and repair procedures described in this chapter are only those that are unique to the 1990 KL650-B2 and 1990 KL650-B2 and 1990 KL550-B2 motorcycles. Most service operations for these models remain identical to those described in front of this chapter. Complete and proper servicing of the 1990 KL650- B2 and 1990 KL500- B2 motorcycles, therefore requires mechanics to read both this chapter and the text in front of this chapter.

T a b le 01 C o n te n ts

Generallnformation General Specifications Periodic Maintenance Chart Fuel System Exploded View (US California Vehicle only) Specifications Evaporative Emission Control System (US California Vehicle only) Carburetor Coolant Filter Cleaning (UK model) High Altitude Performance Adjustment (US model) Wheels/Tires Specifications Wiring Diagram (US and Canada)

17-2 17-2 17-5 17-6 17-6 17 -7 17-8 17-9 17-9 17-9 17 -1 O 17 -10 15-10RQPONMLKJIHGFEDCBA

â&#x20AC;˘ 1 7 -2

S U P P lE M E N T

- 1990 M O DEl

G e n e ra l In fo rm a lio n G e n e ra l S p e c ific a tio n s

K L 6 5 0 -B 2 tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA K L 5 0 0 -B 2

Ite m s D im e n s io n s :

Overalllength Overall width Overall height

2220 mrn. (US)(Ca)(C)(SA) 920mm 1 300m m

Wheelbase Road clearance Seat height Ory weight Curb weight:

1 480 mm 210 mm 870 mm 159 kg (Ca) 159.5 kg 87 kg

Front Rear

Fuel tank capacity

2175 mm

2220 mm +---+---+-- -+-- -+-- --

159 kg +--- -

97 kg (Ca) 97.5 kg 23 L

97 kg

12.5 m from 50 krn/h 2.4RQPONMLKJIHGFEDCBA m

+----

4-stroke, OOHC, 4-valve, 1 -cylinder

+--- -

+----

P e rfo rm a n c e :

Braking distance Minimum turning radius

+-- --

E n g in e :

Type Cooling system Bore and stroke Oisplacement Compression ratio Maximum horsepower

Maximum torque

Carburetion system Starting system Ignition system Timing advance

Liquid-cooled 100.0 x 83.0 mm 651 mL 9.5: 1 35.3 kW (48 PS) @6 500 r/min (rpm) (A)(E)(I) 30.2 kW (41 PS) @7 000 r/rnin (rpm) (F) 29.3 kW (39.8 PS) @7 000 r/min (rpm): UTAC's norms (G) 19.9 kW (27 PS) @5 500 r/rnin (rpm): OIN 54.9 N-m (5.6 kg-m, 40.5 ft-lb) @5 500 r/rnin (rpm) (A)(E) 48.1 N-m (4.9 kg-m, 35.4 ft-lb) @5 000 r/rnin (rpm) (G) 45.1 N-m, (4.6 kg-m, 33.3 ft-Ib) @2 800 r/rnin (rpm): OIN Carburetor, Keihin CVK40 Electric Starter COI Electronicallyadvanced

+----

89.0 x 80.0 mm 497 mL +----

29.4 kW (40 PS) @7 500 r/rnin (rpm)

38.2 N-m (3.9 kg-m, 28.2 ft-Ib) @6 000 r/rnin (rpm)

+--- +-- -+---+----

Ignition timing

From 10 BTOC @1 300 r/rnin (rpm) to

Spark plug

30 BTOC @3 300 r/rnin (rpm) NGK OPR8EA-9 or NO X24EPR-U9 (US)(C)(I)(SA) NGK OP8EA-9, or o

NO X24EP-U9

+---+----

SUPPLEM ENT

- 1990

M O D E L 1 7 -3

K L 6 5 0 -B 2

K L 5 0 0 -B 2 tsrqponmlkjihgfedcbaZY

Open

19° (BTDC)

~---

69° (ABDC)

~---

Duration

268°

~---

Open

57° (BBDC)

~---

31 ° (ATDC)

~---

Duration

268°

~---

Forced lubrication (wet sump)

~---

SE or SF class SAE10VV40, 10VV50, 20VV40,or20VV50 2.5 L

~---

Gear

~---

2.272 (75/33) VVet multi disc

~---

5-speed, constant mesh, return shift 2.266 (34/1 5) 1 .529 (26/17)

~---

1.181 (26/22) 0.954 (21/22) 0.791 (19/24)

~---

Chain drive 2.866 (43/15) 5.157 @Top gear

~---

3.133 (47/15) 5.637 @Top gear

Type

Tubular, semi-double cradle

~---

Caster (rake angle) Trail

28°

~---

113 mm

~---

Tube type

~---

Ite m s

Valve timing: Inlet

Exhaust

Lubrication system Engine oil: Grade Viscosity Capacity

~---

D riv e T ra in :

Primary reduction system: Type Reduction ratio Clutch type Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Final drive system: Type Reduction ratio Overall drive ratio

~---

~--~---

F ra m e :

Front tire: Type Size Rear tire: Type Size Front suspension: Type VVheel travel Rear suspension: Type VVheel travel Brake type: Front Rear

90/90-21

54S

Tube type 130/80-17

~---

~--65S

~---

Telescopic air fork (pneumatic)

~---

220 mm

~---

Swing arm (uni-trak) 200mm

~---

Single disc

~---

Single disc

~---

1 7 -4

SUPPLEM ENT

- 1990 M O DEL K L 5 0 0 -B 2

K L 6 5 0 -B 2

Ite m s

E le c tric a l E q u ip m e n t: tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

Battery Headlight: Type Bulb Tail/brake light Alternator: Type Rated output

12 V 14 Ah

+----

Semi-sealed beam 12 V 60/55 W (quartz-halogen)

+-- --

12 V 5/21 W, (US)(Ca)(C)(SA)

+--- -

12 V 8/27 W

Three-phase AC 14 A @8 000 r/min (rprn), 14 V

Specifications subject to change withoutRQPONMLKJIHGFEDCBA n o t i c e . and may not apply to every country.

A b b re v ia tio n

(A)

Australian Model

(G)

Canadian Model California Vehicle European Model French Model

(1 )

West German Model Italian Model

(S) (SA) (US)

Swiss Model South African Model US Model

+----

+---+-- --

SUPPLEMENT

- 1990 MODEL

17-5

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.

Whichever.. FREQUENCY OPERATION

comeSfi~~

tODOMETER

READING

~~~~~~~~~~~RQPONMLKJIHGFEDCBA

~ ~ e~

~C)

C O C ) C<) r ; , ~ \ j , C ) ~

~C)

BA,< r ; ,~

~C)

" 'C ) ~

~C)

See Page

~ C )~

Every Spark plug - clean Spark plug - check* Valve clearance - check* Air cleaner element - clean Air cleaner element - replace Throttle grip play - check* Idle speed - check* Fuel system - check* Spark arrestor ( C, US) - clean Evaporative emission control system (Cal) - change* Engine oil - change Oil filter - replace Radiator hoses, connections - check" Coolant - change Fuel hose - replace Balancer chain tensión - adjust Clutch - adiust Drive chain wear - check* Drive chain - lubricate Drive chain slack - check* Brake lining or pad wear - check* Brake fluid level - check* Brake fluid - change Brake hose - replace Brake master eylinder cup and dust seal - replace Caliper piston seal and dust seal - replace Brake light switch - check* Steering - check* Steering stem bearing - lubricate Front fork oil - change Tire wear - check* Spoke tightness and rim runout - check * Swing arm pivot, uni-trak linkage - lubricate Battery electrolyte level - check * General lubrication - perform Nut, bolt, and fastener tightness - check" Coolant filter (UK) - clean

• • 5 cleanings • • • year year 2 years 4 years

month 2 years 4 years

•

• •

• • •

• •

•

• •

• • •

• •

• • • •

• •

300 km 800 km

•

• •

• • •

• • • • • • • • • • • • •

• • • • • • • • • • • •

•

• •

•

• • •

•

• • • • • • • • •

15-21 15-21 4-16 2-15 2-15 2-6 2-9 2-11 -

6-6 6-6 3-13 3-5 -

5-17 5-6 10-5 10-5 10-4 11-8 11-13 11-13 11-16

2 years

11-11

2 years

11-8 15-34 13-4 13-7 12-5 9-9 9-6

2 years

month

year

• •

•

• •

• • •

• •

•

• • • • •

• • • •

• •

• • • • • • • • •

12-3 15-11 16-8 1-15 17-9

: For higher odometer readings, repeat at the frequency interval established here.

: Replace, add, adjust, clean, or torque if necessary. (C) : Canadian Model (Cal) : California Vehicle

(US) : US Model

(UK) : UK Model

1 7 -6

S U P P lE M E N T

- 1990

MODEl

F u e l S y s te m E x p lo d e d V ie w

U S C a lifo rn ia V e h ic le O n ly RQPONMLKJIHGFEDCBA

G re e n tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLK

"< ,

C(b

río

') - R e d

n~.

B lu e

1t---BI~~

(s h o~rte r)

-:o

).~

~~.

.--ti' 6-

o --W h ite

( O

1, Liquid/Vapor 2. Canister

Separator

~ ~~,

W h ite

Red

C (o

LKJIHGFEDCBA

~ ¿ .(

( l) C O ~

t5 ~ .'

G re e n

.-----.-/

" B lu e

SUPPLEM ENT

- 1990 M O DEL

1 7 -7

S p e c ific a tio n s

Ite m T h ro ttle

K L 6 5 0 -B 2

G rip F re e P la y tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 2 - 3mm

K L 5 0 0 -B 2 +----

C h o k e C a b le F re e P la y

2 - 3mm

+----

Id le S p e e d

1 300 ±50 r/rnin (rpm)

+----

Make/type Main jet

Keihin/CVK40 #148, (UK)(G) #145

+----

#148

Main air jet Needle jet Jet needle

#50

+----

#6 N31 R, (G) N74D, (UK) N74C, (S) N60N

+--- -

#40 #70 1%, (S) 1*, (UK) 1~ (turns out)

+----

C a rb u re to r

S p e c ific a tio n s :

Pilot jet Pilot air jet Pilot screw Starter jet Service fuel level (above the bottom edge of the carburetor body) Float height

N54G +--- -

1~ (turns out)

#52

+----

0.5 ±1 mm 17.5 mm

+----

SE class

+----

SAE 30

+----

A ir C le a n e r:

Air cleaner element oil:

Grade Viscosity

(UK) : UK Model

(G) : West German Model

(S) : Swiss Model

17-8

SUPPLEMENT

- 1990 MODEL

Evaporative Emission Control System (US California Vehicle only) The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or sto res the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.BA

S e p a r a to r

O p e r a tio n

Test

WARNING

I RQPONMLKJIHGFEDCBA

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

• Connect the hoses to the separator, and install the separator on the motorcycle . • Disconnect the breather hose from the separator, and inject about 20 mL of gasoline into the separator through the hose fitting. P a r ts R e m o va ljln s ta lla tio n N o te s • Disconnect the fuel return hose from the fuel tank. • Run the open end of the return hose into the container level with the tank topo WARNINGZYXWVUTSRQPONMLKJIHGFEDCBA .Start the engine, and let it idle.

o Gasoline

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

If the gasoline in the separator comes out of hose, the separator works well. If it does not, replace the separator with a new one.

C a n is te r In s p e c tio n

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

NOTE

o If

gasoline, solvent, water, or any other liquid enters the canister, the canister's vapor absorbing capacity is greatly reduced. If the canister does become contaminated. replace it with a new one.

oLKJIHGFEDCBA T h e c a n is te r is d e s ig n e d m o to rc y c te 's lífe w ith o u t

w e ll

System

VACUUM HOSE ROUTING DIAGRAM

A IR

H ose

In s p e c tio n

(P e r io d ic

th ro u g h

u n d e r n o rm a l c o n d itio n s .

Evaporative Emission Control .To prevent the gasoline from flowing into the canister or from flowing out of the canister, hold the separator perpendicular to the ground. • Connect the hoses according to the diagram of the system. Make sure they do not get pinched or kinked.

w o rk

In s p e c tio n )

CLEANER

RED

• Check that the hoses are securely connected. • Replace any kinked, deteriorated or damaged hoses.

S e p a r a to r

In s p e c tio n

(P e r io d ic

In s p e c tio n )

• Remove the seats and the right side cover. • Visually inspect the separator for cracks and other damage.

If the separator has any cracks or is bad Iy damaged, replace it with a new one.

SEPARATOR W H IT E

th e

a n y m a in te n a n c e if i t is u s e d

SUPPLEM ENT (Water

Pump

Right

- 1990 M O DEL

1 7 -9

Side View)

C a rb u re to r LKJIHGFEDCBA

C o o la n t F ilte r C le a n in g (K L 6 5 0 -B 2 U K M o d e l) tsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA Before winter season start, clean the filter of carburetor system. • Remove the lower fairing. • Drain the coolant (see Cooling System chapter). • Remove the filter from the cooling hoses of carburetor system . • Blow off dirt and sediment on the filter with cornpressed air.

Hose Routing (Engine Left Side View)

(Valve)

.,.

Water Flow

Carburetor Side

1. 2. 3. 4. 5. 6.

(Engine

Right

Water Pump SideBA

Filter Valve Joint Pipe Lower Radiator Hose Water Pump Hose Upper Radiator Hose

7. 8. 9. 10. 11.

Water Pump Thermostat Housing Cap Damper Band Clamp

Side View)

H ig h A ltitu d e

P e rfo rm a n c e A d ju s trn e n t

(U S M o d e l) OTo improve the EMISSION CONTROL PERFORMANCE of the vehicles operated above 4 000 feet, . Kawasaki recommends the following Emission Protection Agency (EPA) approved modification . • Change the main jet and pilot jet for high altitude use.

High Altitude

Carburetor

Specifications

Main Jet #145 Pilot JetRQPONMLKJIHGFEDCBA #38

1 7 -1 0

SUPPLEM ENT

- 1990

MODEL

W h e e ls /T ire s S p e c ific a tio n s

K L 6 5 0 -B 2 A u s tra lia n

m o d e l a n d E u ro p e a n

m odel

S ta n d a rd tsrqponmlkjihgfedcbaZYXWVUTS

Ite m

Tires: Standard Tire:

Front:

Size Make Type

90/90-21 54S DUNLOP TRAIL MAX

Rear:

Size Make Type

130/80-17 65S DUNLOP TRAIL MAX

MODEL APPLlCATION Year

B e g in n in g

M odel

F ra m e

No.

K L 6 5 0 B -0 0 0 0 0 1

K L650·B 1 1989

K L500B ·000001

K L500·B 1

J K A K L E B 1 D L A 0 0 4 0 0 1 ,o r

K L650·B 2 1990

K L650B ·00400 K L500·B 2

K L500B ·000501

KAWASAKI HEAVV

INDUSTRIES, LTD. & COM PONENTS GROUP

CONSUM ER PRODUCTS

Part No. 99924-1113-02JIHGFEDCBA

P r in t e d

in J a p a n