Parts Catalog Kawasaki Ninja RR 250 Karburator 2007 — Isi Lengkap 428 Halaman
toc
Halaman 1
Kawasaki
Ninja 250R
Kawasaki
Ninja
Motorcycle
Service Manual
toc
Halaman 3
Quick Reference Guide
General Information
1
j
Periodic Maintenance
2
j
Fuel System
3
j
Cooling System
4
j
Engine Top End
5
j
Clutch
6
j
Engine Lubrication System
7
j
Engine Removal/Installation
8
j
Crankshaft/Transmission
9
j
Wheels/Tires
10
j
Final Drive
11
j
Brakes
12
j
Suspension
13
j
Steering
14
j
Frame
15
j
Electrical System
16
j
Appendix
17
j
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
toc
Halaman 5
Motorcycle
Service Manual
All rights reserved.
No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2007 Kawasaki Heavy Industries, Ltd.
First Edition (1): Nov. 15, 2007 (M)
Ninja 250R
toc
Halaman 6
LIST OF ABBREVIATIONS
A
ampere(s)
lb
pound(s)
ABDC
after bottom dead center
m
meter(s)
AC
alternating current
min
minute(s)
ATDC
after top dead center
N
newton(s)
BBDC
before bottom dead center
Pa
pascal(s)
BDC
bottom dead center
PS
horsepower
BTDC
before top dead center
psi
pound(s) per square inch
°C
degree(s) Celsius
r
revolution
DC
direct current
rpm
revolution(s) per minute
F
farad(s)
TDC
top dead center
°F
degree(s) Fahrenheit
TIR
total indicator reading
ft
foot, feet
V
volt(s)
g
gram(s)
W
watt(s)
h
hour(s)
Ω
ohm(s)
L
liter(s)
COUNTRY AND AREA CODES
AT
Austria
GB
United Kingdom
AU
Australia
MY
Malaysia
CA
Canada
US
United States
CAL
California
ID
Indonesia
CH
Switzerland
PH
Philippines
DE
Germany
WVTA
Whole Vehicle Type Approval
FR
France
3.
Halaman 7
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Addi-
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly 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 follow-
ing its sale and delivery to the ultimate purchaser...”
NOTE
○The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10
PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Halaman 8
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
• Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
• Removal of the muffler(s) or any internal portion of the muffler(s).
• Removal of the air box or air box cover.
• Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
Halaman 9
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily.
When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully 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 ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
• Follow the Periodic Maintenance Chart in the
Service Manual.
• Be alert for problems and non-scheduled
maintenance.
• Use proper tools and genuine Kawasaki Mo-
torcycle parts.
Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
• Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into its
major systems and these systems make up the
manual’s chapters.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tion.
NOTE
○This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
• Indicates a procedural step or work to be
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
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 spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
General Information
Halaman 11
GENERAL INFORMATION 1-1
___
# General Information
### Table of Contents
Before Servicing ................................................................................ 1-2
Model Identification............................................................................ 1-7
General Specifications....................................................................... 1-8
Unit Conversion Table ........................................................................ 1-11
1
Cleaning vehicle before disassembly
Halaman 12
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) ca-
ble to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Assembly Order
Halaman 13
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse.
Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
GENERAL INFORMATION 1-3
Liquid Gasket, Non-permanent Locking Agent
Halaman 14
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age.
When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove the old gaskets and clean the sealing surfaces
thoroughly so that no gasket material or other material re-
mains. Install the new gaskets and replace the used O-rings
when re-assembling
Liquid Gasket, Non-permanent Locking Agent
For
applications
that
require
Liquid
Gasket
or
a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively.
Excessive application can clog oil passages and
cause serious damage.
Circlips, Cotter Pins
Halaman 15
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
GENERAL INFORMATION 1-5
Instrument
Halaman 16
1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
Engine Number
Halaman 17
Model Identification
EX250J8F Left Side View (United States and Canada)
EX250J8F Right Side View (United States and Canada)
Frame Number
GENERAL INFORMATION 1-7
Engine Number
Engine Number
Halaman 18
1-8 GENERAL INFORMATION
General Specifications
Items
EX250J8F
Dimensions
Overall Length
2 085 mm (82.1 in.)
Overall Width
715 mm (28.1 in.)
Overall Height
1 110 mm (43.7 in.)
Wheelbase
1 400 mm (55.1 in.)
Road Clearance
130 mm (5.1 in.)
Seat Height
775 mm (30.5 in.)
Dry Mass
152 kg, (335 lb)
Curb Mass:
Front
82 kg (181 lb)
Rear
87 kg (192 lb)
Fuel Tank Capacity
18.0 L (4.8 US gal)
Performance
Minimum Turning Radius
2.7 m (8.9 ft)
Engine
Type
4-stroke, DOHC, 2-cylinder
Cooling System
Liquid-cooled
Bore And Stroke
62.0× 41.2 mm (2.5 × 1.6 in.)
Displacement
249 cm³ (15.2 cu in.)
Compression Ratio
11.6
Maximum Horsepower
23.4 kW (31.8 PS) @11 000 r/min (rpm),
Maximum Torque
22.0 N·m (2.24 kg·m, 16.2 ft·lb) @9 500 r/min (rpm),
Carburetion System
Carburetor, Keihin CVK 30× 2
Starting System
Electric starter
Ignition System
Battery and coil (transistorized)
Timing Advance
Electronically advanced
Ignition Timing
From 10° BTDC @1 300 r/min (rpm)
35° BTDC @4 000 r/min (rpm)
Spark Plug
NGK CR8E or ND U24ESR-N
Cylinder Numbering Method
Left to Right, 1-2
Firing Order
1-2
Valve Timing:
Inlet
Open
36° BTDC
Close
56° ABDC
Duration
272°
Exhaust
Open
61° BBDC
Close
31° ATDC
Duration
272°
Engine Number
Halaman 19
General Specifications
Items
EX250J8F
Lubrication System
Forced ubrication (wet sump)
Engine Oil:
Grade
API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity
SAE10W-40
Capacity
1.7 L (1.80 US qt)
Drive Train
Primary Reduction System:
Type
Gear
Reduction Tatio
3.087 (71/23)
Clutch Type
Wet multi disc
Transmission:
Type
6-speed, constant mesh, return shift
Gear Ratios:
1st
2.600 (39/15)
2nd
1.789 (34/19)
3rd
1.409 (31/22)
4th
1.160 (29/25)
5th
1.000 (27/27)
6th
0.893 (25/28)
Final Drive System:
Type
Chain drive
Reduction Ratio
3.214 (45/14) (AU) 3.071 (43/14)
Overall Drive Ratio
8.859 @Top gear (AU) 8.466 @Top gear
Frame
Type
Tubular, diamond
Caster (Rake Angle)
26°
Trail
82 mm (3.2 in.)
Front Wheel:
Tire Type
Tubeless
Tire Size
100/70-17M/C 54H
Rim Size
17 × 2.75
Rear Wheel:
Tire Type
Tubeless
Tire Size
130/70-17M/C 62H
Rim Size
17 × 3.50
Front suspension:
Type
Telescopic fork
Wheel Travel
120 mm (4.7 in.)
Rear Suspension:
Type
Swingarm (uni-trak)
Wheel Travel
130 mm (5.1 in.)
GENERAL INFORMATION 1-9
Engine Number
Halaman 20
1-10 GENERAL INFORMATION
General Specifications
Items
EX250J8F
Brake Type:
Front
Single disc
Rear
Single disc
Electrical Equipment
Battery
12 V 6 Ah
Headlight:
Type
Semi-sealed beam
Bulb:
High
12 V 55 W + 55 W (quartz-halogen)
Low
12 V 55 W (quartz-halogen)
Tail/brake Light
12 V 5/21 W
Alternator:
Type
Three-phase AC
Rated Output
19 A @5 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
AU: Australia Model
Units of Temperature:
Halaman 21
Unit Conversion Table
Prefixes for Units:
Prefix
Symbol
Power
mega
M
× 1 000 000
kilo
k
× 1 000
centi
c
× 0.01
milli
m
× 0.001
micro
µ
× 0.000001
Units of Mass:
kg
×
2.205
=
lb
g
×
0.03527
=
oz
Units of Volume:
L
×
0.2642
=
gal (US)
L
×
0.2200
=
gal (imp)
L
×
1.057
=
qt (US)
L
×
0.8799
=
qt (imp)
L
×
2.113
=
pint (US)
L
×
1.816
=
pint (imp)
mL
×
0.03381
=
oz (US)
mL
×
0.02816
=
oz (imp)
mL
×
0.06102
=
cu in
Units of Force:
N
×
0.1020
=
kg
N
×
0.2248
=
lb
kg
×
9.807
=
N
kg
×
2.205
=
lb
Units of Temperature:
GENERAL INFORMATION 1-11
Units of Length:
km
×
0.6214
=
mile
m
×
3.281
=
ft
mm
×
0.03937
=
in
Units of Torque:
N·m
×
0.1020
=
kgf·m
N·m
×
0.7376
=
ft·lb
N·m
×
8.851
=
in·lb
kgf·m
×
9.807
=
N·m
kgf·m
×
7.233
=
ft·lb
kgf·m
×
86.80
=
in·lb
Units of Pressure:
kPa
×
0.01020
=
kgf/cm²
kPa
×
0.1450
=
psi
kPa
×
0.7501
=
cm Hg
kgf/cm²
×
98.07
=
kPa
kgf/cm²
×
14.22
=
psi
cm Hg
×
1.333
=
kPa
Units of Speed:
km/h
×
0.6214
=
mph
Units of Power:
kW
×
1.360
=
PS
kW
×
1.341
=
HP
PS
×
0.7355
=
kW
PS
×
0.9863
=
HP
Periodic Maintenance
Halaman 23
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
2-3
Torque and Locking Agent......................................................................................................
2-6
Specifications .........................................................................................................................
2-11
Special Tools ..........................................................................................................................
2-13
Periodic Maintenance Procedures..........................................................................................
2-14
Fuel System.........................................................................................................................
2-14
Air Cleaner Element Cleaning...........................................................................................
2-14
Air Cleaner Element Installation........................................................................................
2-15
Throttle Control System Inspection...................................................................................
2-15
Choke Operation Inspection .............................................................................................
2-17
Engine Vacuum Synchronization Inspection.....................................................................
2-17
Idle Speed Inspection .......................................................................................................
2-18
Idle Speed Adjustment......................................................................................................
2-18
Fuel Hose Inspection (fuel leak, damage, installation condition)......................................
2-19
Evaporative Emission Control System (California Model) ...................................................
2-19
Evaporative Emission Control System Inspection ............................................................
2-19
Cooling System....................................................................................................................
2-20
Coolant Level Inspection...................................................................................................
2-20
Radiator Hose Damage and Installation Condition Inspection..........................................
2-21
Coolant Filter Cleaning (Australia Model) .........................................................................
2-21
Air Suction System ..............................................................................................................
2-21
Air Suction System Damage Inspection............................................................................
2-21
Engine Top End ...................................................................................................................
2-22
Valve Clearance Inspection ..............................................................................................
2-22
Valve Clearance Adjustment.............................................................................................
2-23
Clutch...................................................................................................................................
2-26
Clutch Operation Inspection..............................................................................................
2-26
Wheels/Tires........................................................................................................................
2-27
Air Pressure Inspection.....................................................................................................
2-27
Wheel/Tire Damage Inspection.........................................................................................
2-27
Tire Tread Wear, Abnormal Wear Inspection....................................................................
2-27
Wheel Bearing Damage Inspection ..................................................................................
2-28
Drive Train ...........................................................................................................................
2-29
Drive Chain Lubrication Condition Inspection...................................................................
2-29
Drive Chain Slack Inspection............................................................................................
2-29
Drive Chain Slack Adjustment ..........................................................................................
2-30
Wheel Alignment Inspection .............................................................................................
2-31
Drive Chain Wear Inspection ............................................................................................
2-31
Chain Guide Inspection.....................................................................................................
2-32
Brake System ......................................................................................................................
2-32
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
2-32
Brake Hose and Pipe Damage and Installation Condition Inspection...............................
2-32
Brake Operation Inspection ..............................................................................................
2-32
Brake Fluid Level Inspection.............................................................................................
2-33
Brake Pad Wear Inspection ..............................................................................................
2-33
Brake Light Switch Operation Inspection..........................................................................
2-34
Suspensions ........................................................................................................................
2-34
Front Forks/Rear Shock Absorber Operation Inspection..................................................
2-34
Front Fork Oil Leak Inspection..........................................................................................
2-35
Rear Shock Absorber Oil Leak Inspection........................................................................
2-35
PERIODIC MAINTENANCE 2-1
2
Periodic Maintenance
Halaman 24
2-2 PERIODIC MAINTENANCE
Rocker Arm Operation Inspection.....................................................................................
2-35
Tie-Rod Operation Inspection ...........................................................................................
2-35
Swingarm Pivot Lubrication ..............................................................................................
2-36
Steering System ..................................................................................................................
2-36
Steering Play Inspection ...................................................................................................
2-36
Steering Play Adjustment..................................................................................................
2-36
Steering Stem Bearing Lubrication ...................................................................................
2-37
Electrical System .................................................................................................................
2-37
Lights and Switches Operation Inspection........................................................................
2-37
Headlight Aiming Inspection .............................................................................................
2-39
Sidestand Switch Operation Inspection ............................................................................
2-40
Engine Stop Switch Operation Inspection.........................................................................
2-41
Others..................................................................................................................................
2-42
Chassis Parts Lubrication .................................................................................................
2-42
Bolts, Nuts and Fasteners Tightness Inspection...............................................................
2-43
Replacement Parts ..............................................................................................................
2-44
Air Cleaner Element Replacement....................................................................................
2-44
Fuel Hose Replacement ...................................................................................................
2-44
Coolant Change................................................................................................................
2-44
Radiator Hose and O-ring Replacement...........................................................................
2-46
Engine Oil Change............................................................................................................
2-47
Oil Filter Replacement ......................................................................................................
2-47
Brake Hose and Pipe Replacement..................................................................................
2-48
Brake Fluid Change ..........................................................................................................
2-48
Master Cylinder Rubber Parts Replacement ....................................................................
2-50
Caliper Rubber Parts Replacement ..................................................................................
2-51
Spark Plug Replacement ..................................................................................................
2-52
The scheduled maintenance must be done in accordance with this c
Halaman 25
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY Whichever
comes
first
INSPECTION
Every
(0.6) (4)
(7.5) (12) (15) (20) (24)
Fuel System
Air cleaner element - clean
•
•
•
2-14
Throttle control system (play, smooth
return, no drag) - inspect
year
•
•
•
•
2-15
Choke operation - inspect
year
•
•
•
•
2-17
Engine vacuum synchronization - inspect
•
•
•
2-17
Idle speed - inspect
•
•
•
•
2-18
Fuel leak (fuel hose and pipe) - inspect
year
•
•
•
•
2-19
Fuel hose and pipe damage - inspect
year
•
•
•
•
2-19
Fuel hose and pipe installation condition -
inspect
year
•
•
•
•
2-19
Evaporative Emission Control System
(CAL)
Evaporative emission control system
function - inspect
•
•
•
•
•
•
•
2-19
Cooling System
Coolant level - inspect
•
•
•
•
2-20
Coolant leak (radiator hose and pipe) -
inspect
year
•
•
•
•
2-21
Radiator hose damage - inspect
year
•
•
•
•
2-21
Radiator hose installation condition -
inspect
year
•
•
•
•
2-21
Coolant filter - clean
year
Air Suction System
Air suction system damage - inspect
•
•
•
2-21
Engine Top End
Valve clearance - inspect
•
•
•
2-22
Clutch
Clutch operation (play, disengagement,
engagement) - inspect
•
•
•
•
2-26
Wheels and Tires
Tire air pressure - inspect
year
•
•
•
2-27
Wheel/tire damage - inspect
•
•
•
2-27
Tire tread wear, abnormal wear - inspect
•
•
•
2-27
Wheel bearing damage - inspect
year
•
•
•
2-28
Drive Train
Drive chain lubrication condition - inspect #
Every km (400 mile)
2-29
PERIODIC MAINTENANCE 2-3
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
See
Page
1
6
12
18
24
30
36
The scheduled maintenance must be done in accordance with this c
Halaman 26
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
INSPECTION
Every
(0.6) (4)
(7.5) (12) (15) (20) (24)
Drive chain slack - inspect #
Every 1 000 km (600 mile)
2-29
Drive chain wear - inspect #
•
•
•
2-31
Drive chain guide wear - inspect
•
•
•
2-32
Brake System
Brake fluid leak (brake hose and pipe) -
inspect
year
•
•
•
•
•
•
•
2-32
Brake hose and pipe damage - inspect
year
•
•
•
•
•
•
•
2-32
Brake hose and pipe installation condition
- inspect
year
•
•
•
•
•
•
•
2-32
Brake operation (effectiveness, play, no
drag) - inspect
year
•
•
•
•
•
•
•
2-32
Brake fluid level - inspect
6 months •
•
•
•
•
•
•
2-33
Brake pad wear - inspect #
•
•
•
•
•
•
2-33
Brake light switch operation - inspect
•
•
•
•
•
•
•
2-34
Suspensions
Front forks/rear shock absorber operation
(damping and smooth stroke) - inspect
•
•
•
2-34
Front forks/rear shock absorber oil leak -
inspect
year
•
•
•
2-35
Rocker arm operation - inspect
•
•
•
2-35
Tie-rods operation - inspect
•
•
•
2-35
Swingarm pivot - lubricate
•
2-36
Steering System
Steering play - inspect
year
•
•
•
•
2-36
Steering stem bearings - lubricate
2 years
•
2-37
Electrical System
Lights and switches operation - inspect
year
•
•
•
2-37
Headlight aiming - inspect
year
•
•
•
2-39
Sidestand switch operation - inspect
year
•
•
•
2-40
Engine stop switch operation - inspect
year
•
•
•
2-41
Others
Chassis parts - lubricate
year
•
•
•
2-42
Bolts and nuts tightness - inspect
•
•
•
•
2-43
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
See
Page
1
6
12
18
24
30
36
The scheduled maintenance must be done in accordance with this c
Halaman 27
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
comes
first
CHANGE/REPLACE ITEM
Every
(0.6)
(7.5)
(15)
(24)
(30)
Air cleaner element #
2 years
2-44
Fuel hose
4 years
•
2-44
Coolant
3 years
•
2-44
Radiator hose and O-ring
3 years
•
2-46
Engine oil #
year
•
•
•
•
•
2-47
Oil filter
year
•
•
•
•
•
2-47
Brake hose and pipe
4 years
•
2-48
Brake fluid
2 years
•
•
2-48
Rubber parts of master cylinder and caliper
4 years
•
2-50
Spark plug
•
•
•
•
2-52
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
PERIODIC MAINTENANCE 2-5
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
See
Page
1
12
24
36
48
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 28
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is
applied, the bolts and nuts could loosen and fall out. If too much torque is applied, the threads could
be sheared off.
To tighten a bolt or a nut, or to check their torque, loosen the bolt or nut one-half turn before tight-
ening it to the specified torque.
Letters used in the “Remarks” column mean:
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent to the threads.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
R: Replacement Parts
S: Tighten the fasteners following the specified sequence.
Si: Apply silicone grease.
SS: Apply silicone sealant.
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Fuel System
Fuel Tap Mounting Bolts
2.5
0.25
22 in·lb
Fuel Gauge Mounting Bolts
6.9
0.7
61 in·lb
Air Cleaner Housing Cap Bolts
2.5
0.25
22 in·lb
Air Cleaner Housing Screws
1.15
0.12
10 in·lb
Air Cleaner Housing Mounting Bolts
9.8
1.0
87 in·lb
Air Cleaner Housing Clamp Screws
2.0
0.2
18 in·lb
Separate Bracket Bolt
9.8
1.0
87 in·lb
Cooling System
Water Temperature Switch
7.5
0.76
66 in·lb
SS
Thermostat Cover Bolts
9.8
1.0
87 in·lb
Thermostat Housing Mounting Bolts
9.8
1.0
87 in·lb
Radiator Fan Switch
23.5
2.4
17
Radiator Bolts
9.8
1.0
87 in·lb
Radiator Cap Bracket Bolt
9.8
1.0
87 in·lb
Water Pipe Bolts
9.8
1.0
87 in·lb
Water Hose Clamp Screws
1.5
0.15
13 in·lb
Drain Bolt
9.8
1.0
87 in·lb
Water Pump Cover Bolts
9.8
1.0
87 in·lb
Water Pump Bolts
9.8
1.0
87 in·lb
Reserve Tank Cap
–
–
–
Hand-Tighten
Reserve Tank Bolts
9.8
1.0
87 in·lb
Reserve Tank Bracket Bolt
9.8
1.0
87 in·lb
Engine Top End
Cylinder Head Cover Bolts
9.8
1.0
87 in·lb
Camshaft Sprocket Bolts
15
1.5
11
L
Chain Tensioner Cap Bolt
5.0
0.5
44 in·lb
Air Suction Cover Bolts
9.8
1.0
87 in·lb
Vacuum Switch Valve Bracket Bolts
9.8
1.0
in·lb
Rear Camshaft Chain Guide Bolt-Lower
1.7
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 29
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Chain Tensioner Mounting Bolts
9.8
1.0
87 in·lb
Camshaft Cap Bolts
12
1.2
106 in·lb
S
Camshaft Cap Bolts
12
1.2
106 in·lb
S
Cylinder Head Bolt (M6)
12
1.2
106 in·lb
MO, S
Cylinder Head Bolts (M8)
24.5
2.5
18
MO, S
Water Passage Plugs
20
2.0
15
L
Carburetor Holder Clamp Screws
2.0
0.2
18 in·lb
Water Drain Bolt
5.9
0.6
52 in·lb
Muffler Body Rear Cover Bolts
9.8
1.0
87 in·lb
L
Muffler Body Mounting Bolt
30
3.1
22
Muffler Body Clamp Bolt
17
1.7
13
Muffler Cover Bolts
9.8
1.0
87 in·lb
Muffler Cover Clamp Screw
6.9
0.70
61 in·lb
Exhaust Pipe Mounting Bolt
9.8
1.0
87 in·lb
Exhaust Pipe Holder Nuts
12
1.2
104 in·lb
Clutch
Clutch Lever Holder Clamp Bolts
8.8
0.9
78 in·lb
Clutch Spring Bolts
8.8
0.9
78 in·lb
Clutch Hub Nut
132
13.5
97.4
Oil Filler Plug
–
–
–
Hand-Tighten
Clutch Cover Bolts
9.8
1.0
87 in·lb
Engine Lubrication System
Oil Hose Banjo Bolts
19.6
2.0
14.5
Oil Pressure Relief Valve
15
1.5
11
L
Crankcase Oil Passage Plug
15
1.5
11
Oil Passage Plugs for Oil Pump
20
2.0
15
L
Oil Pipe Banjo Bolts
12
1.2
104 in·lb
Oil Drain Bolt
19.6
2.0
14.5
Oil Pressure Switch
15
1.5
11
SS
Oil Pressure Switch Terminal Bolt
1.5
0.15
13 in·lb
Oil Filter Mounting Bolts
19.6
2.0
14.5
Oil Breather Mounting Bolts
9.8
1.0
87 in·lb
L
Oil Pump Mounting Bolts
9.8
1.0
87 in·lb
L
Oil Screen Cover Bolts
9.8
1.0
87 in·lb
Plug
19.6
2.0
14.5
Breather Bolt
9.8
1.0
87 in·lb
Engine Removal/Installation
Engine Mounting Bracket Bolts and Nuts
64
6.5
47
Engine Mounting Nuts
64
6.5
47
Crankshaft/Transmission
Oil Breather Mounting Bolts
9.8
1.0
87 in·lb
L
Crankcase Bolts
6
12
1.2
104 in·lb
Crankcase Bolts
(L = 90)
2.4
MO, S
PERIODIC MAINTENANCE 2-7
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 30
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Crankcase Bolts
8 (L = 73)
19
1.9
14
MO, S
Starter Motor Clutch Bolts
34.3
3.5
25
L
Connecting Rod Big End Cap Nuts
27.5
2.8
20
MO
Shift Drum Bearing Holder Bolt
12
1.2
104 in·lb
L
Shift Drum Pin Plate Bolt
9.0
0.9
80 in·lb
L
Neutral Switch
15
1.5
11
External Shift Mechanism Return Spring Pin
19.6
2.0
14.5
L
Shift Drum Positioning Bolt
24.5
2.5
18
Shift Lever Link Bolt
12
1.2
104 in·lb
Front Tie-Rod Locknut (Left-Hand Threads)
7.0
0.7
62 in·lb
Rear Tie-Rod Locknut (Right-Hand Threads)
7.0
0.7
62 in·lb
Shift Pedal Mounting Bolt
25
2.5
18
Wheels/Tires
Front Axle Nut
88
9.0
65
Rear Axle Nut
98
10.0
72
Final Drive
Engine Sprocket Cover Bolts
9.8
1.0
87 in·lb
Engine Sprocket Nut
127
13
94
MO
Rear Sprocket Nuts
59
6.0
44
Rear Sprocket Studs
–
–
–
L
Brakes
Brake Lever Pivot Bolt Locknut
5.9
0.6
52 in·lb
Bleed Valve
5.5
0.55
49 in·lb
Front Master Cylinder Clamp Bolts
8.8
0.9
78 in·lb
S
Brake Disc Mounting Bolts
27
2.8
20
L
Brake Hose Banjo Bolts
25
2.5
18
Front Caliper Mounting Bolts
25
2.5
18
Front Brake Light Switch Screw
1.0
0.1
9 in·lb
Brake Lever Pivot Bolt
1.0
0.1
9 in·lb
Front Reservoir Cap Screws
1.5
0.15
13 in·lb
Reservoir Mounting Bolt
6.9
0.7
61 in·lb
Bleed Valve
5.5
0.55
49 in·lb
Brake Pedal Pivot Bolt
8.8
0.9
78 in·lb
L
Push Rod Locknut
18
1.8
13
Brake Disc Mounting Bolts
27
2.8
20
L
Brake Hose Banjo Bolts
25
2.5
18
Rear Master Cylinder Mounting Bolts
25
2.5
18
Rear Caliper Mounting Bolts
25
2.5
18
Suspension
Front Fork Clamp Bolts (Upper)
21
2.1
15
Front Fork Top Plugs
23
2.3
16.5
Front Fork Clamp Bolts (Lower)
30
3.1
22
Front Fork Bottom Allen Bolts
2.0
L
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 31
Torque and Locking Agent
Torque
Fastener
N·m
kgf·m
ft·lb
Remarks
Rocker Arm Pivot Nut
59
6.0
44
Tie-Rod Nuts
59
6.0
44
Rear Shock Absorber Mounting Nuts
59
6.0
44
Swingarm Pivot Nut
98
10.0
72
Steering
Steering Stem Nut
4.9
0.5
43 in·lb
Handlebar Holder Mounting Bolts
25
2.5
18
Steering Stem Head Bolt
44
4.5
32
Front Fork Clamp Bolts (Upper)
20
2.0
15
Front Fork Clamp Bolts (Lower)
30
3.1
22
Frame
Sidestand Nut
44
4.5
32
Front Footpeg Bracket Mounting Bolts
25
2.5
18
Rear Footpeg Bracket Mounting Bolts
25
2.5
18
Sidestand Switch Bolt
8.8
0.90
78 in·lb
L
Windshield Mounting Screws
0.42
0.043
3.7 in·lb
Electrical System
Tail/Brake Light Mounting Bolts
5.9
0.6
52 in·lb
Plugs on Alternator Cover
–
–
–
Hand-Tighten
Alternator Cover Bolts
9.8
1.0
87 in·lb
Alternator Rotor Bolt
68.6
7.0
51
Alternator Stator Bolts
12
1.2
104 in·lb
Regulator/Rectifier Bolts
9.8
1.0
87 in·lb
Starter Motor Clutch Bolts
34.3
3.5
25
L
Crankshaft Sensor Screws
3.0
0.30
27 in·lb
Ignition Coil Bolts
–
–
–
see text
Spark Plugs
13
1.3
115 in·lb
Starter Motor Terminal Locknut
9.8
1.0
87 in·lb
Starter Motor Assembly Bolts
3.5
0.36
31 in·lb
Starter Motor Mounting Bolts
9.8
1.0
87 in·lb
Starter Relay Terminal Nut
5.0
0.5
44 in·lb
Oil Pressure Switch
15
1.5
11
SS
Neutral Switch
15
1.5
11
PERIODIC MAINTENANCE 2-9
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 32
2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads
Torque
dia. (mm)
N·m
kgf·m
ft·lb
5
3.4 ∼4.9
0.35 ∼0.50
30 ∼43 in·lb
6
5.9 ∼7.8
0.60 ∼0.80
52 ∼69 in·lb
8
14 ∼19
1.4 ∼1.9
10.0 ∼13.5
10
25 ∼34
2.6 ∼3.5
19.0 ∼25
12
44 ∼61
4.5 ∼6.2
33 ∼45
14
73 ∼98
7.4 ∼10.0
54 ∼72
16
115 ∼155
11.5 ∼16.0
83 ∼115
18
165 ∼225
17.0 ∼23.0
125 ∼165
20
225 ∼325
23 ∼33
165 ∼240
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 33
Specifications
Item
Standard
Service Limit
Fuel System
Throttle Grip Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
– – –
Idle Speed
1 300 ±50 r/min (rpm)
– – –
Carburetor Synchroniza-
tion Vacuum
Less than 2.7 kpa (2 cmHg) difference
between two carburetors
– – –
Air Cleaner Element
Polyurethane foam
– – –
Cooling System
Coolant:
Type (Recommended)
Permanent type antifreeze
– – –
Color
Green
– – –
Mixed Ratio
Soft water 50%, coolant 50%
– – –
Freezing Point
–35°C (–31°F)
– – –
Capacity
1.5 L (1.59 US qt)
– – –
Engine Top End
Valve Clearance:
Inlet
0.15 ∼0.24 mm (0.0059 ∼0.0094 in.)
– – –
Exhaust
0.22 ∼0.29 mm (0.0087 ∼0.0114 in.)
– – –
Clutch
Clutch Lever Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
– – –
Engine Lubrication System
Engine Oil:
Grade
API SE, SF or SG
API SH, SJ or SL with JASO MA
– – –
Viscosity
SAE 10W-40
– – –
Capacity
1.3 L (1.4 US qt) (when filter is not removed)
1.6 L (1.7 US qt) (when filter is removed)
– – –
Level
Between upper and lower level lines (Wait 2 ∼
3 minutes after idling or running)
Wheels/Tires
Tread Depth:
Front:
BRIDGESTONE
4.6 mm (0.181 in.)
1 mm (0.04 in.)
DUNLOP
4.5 mm (0.177 in.)
Rear:
2 mm (0.08 in.) up to
130 km/h (80 mph)
3 mm (0.12 in.) over
130 km/h (80 mph)
Air pressure: (when Cold)
BRIDGESTONE
7.0 mm (0.276 in.)
DUNLOP
7.4 mm (0.291 in.)
Front
Up to 170 kg (375 lb) load: 200 kPa (2.0
kgf/cm², 28 psi)
Rear
Up to 170 kg (375 lb) load: 225 kPa (2.25
kgf/cm², 32 psi)
Final Drive
Drive Chain Slack
∼ mm (0.8 ∼1.2 in.)
– – –
PERIODIC MAINTENANCE 2-11
– – –
– – –
– – –
Use a torque wrench to tighten bolts and nuts to their specified
Halaman 34
2-12 PERIODIC MAINTENANCE
Specifications
| Item | Standard | Service Limit |
| :----------------------- | :--------------------------------------------- | :------------------ |
| **Brakes** | | |
| Brake Fluid: | | |
| Grade | DOT4 | --- |
| Brake Pad Lining | | |
| Thickness: | 4.5 mm (0.18 in.) | 1 mm (0.04 in.) |
| Brake Light Timing: | | --- |
| Front | Pulled ON | --- |
| Rear | ON after 10 mm (0.39 in.) of pedal travel | |
| **Electrical System** | | |
| Type | CR8E, U24ESR-N | --- |
Steering Stem Nut Wrench:
Halaman 35
PERIODIC MAINTENANCE 2-13
## Special Tools
Steering Stem Nut Wrench:
57001-1100
Filler Cap Driver:
57001-1454
Vacuum Gauge KEK-55-5:
57001-1369
Air Cleaner Element Cleaning
Halaman 36
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Air Cleaner Element Cleaning
• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Air Cleaner Cap Bolts [A]
Air Cleaner Cap [B]
• Pull out the air cleaner element [A].
• Separate the plastic holders [A].
WARNING
If dirt or dust is allowed to pass through into the car-
buretors, the butterfly valves may become stuck,
possibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
Throttle Control System Inspection
Halaman 37
Periodic Maintenance Procedures
WARNING
Clean the element in a well-ventilated area, and
make sure that there are no sparks or flame any-
where near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or a low-flash point solvent to
clean the element.
• Clean the element [A] in a bath of high-flash point solvent,
and then dry it with compressed air or by shaking it.
• After cleaning, saturate a clean, lint-free towel with SE,
SF, or SG class SAE 30 oil and apply the oil to the element
by tapping the element outside with the towel.
• Visually check the element for tears or breaks.
• If the element has any tears or breaks, replace the ele-
ment.
Air Cleaner Element Installation
• Install the removed parts in reverse of removal.
• Torque the air cleaner cap bolts.
Torque - Air Cleaner Cap Bolts: 2.5 N·m (0.25 kgf·m, 22
in·lb)
Throttle Control System Inspection
• Check that the throttle grip moves smoothly from full open
to close [A], and the throttle closes quickly and completely
by the return spring in all steering positions.
If the throttle grip doesn’t return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
• Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play
Standard:
2 ∼3 mm (0.08 ∼0.12 in.)
PERIODIC MAINTENANCE 2-15
Throttle Control System Inspection
Halaman 38
2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Loosen the locknut [A], and screw accelerator cable ad-
juster [B] in completely so as to give the throttle grip plenty
of play.
• Turn the accelerator cable adjuster until 2 ∼3 mm (0.08 ∼
0.12 in.) of throttle grip play is obtained.
• Tighten the locknut.
If the throttle cables can not be adjusted by using the ca-
ble adjuster at the upper end of the throttle cable, use the
cable adjusters at the lower ends of the throttle cables.
• Remove:
Side Cover (see Side Cover Removal in the Frame chap-
ter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• To make service easy, unscrew the reserver tank bolts
and remove the reserver tank with hoses
• Turn out both upper nuts [A] and turn in both lower nuts [B]
as far as they will go so as to give the throttle grip plenty
of play.
• With the throttle grip completely closed, turn out the lower
nut and turn in the upper nut of the decelerator cable [C]
until the inner cable just becomes tight.
• Turn out the lower nut and turn in the upper nut of the
accelerator cable [D] until the correct free play is obtained.
• Check that the throttle linkage lever [A] stops against the
idle adjusting screw [B] with the throttle grip closed.
Special Tool -
Halaman 39
Periodic Maintenance Procedures
Choke Operation Inspection
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
Side Covers (see Side Cover Removal in the Frame
chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal)
• Push the choke lever [A] back all the way to its released
position.
• Check choke cable free play [B].
○Determine the amount of choke cable play at the choke
lever.
If the free play is incorrect, adjust the choke cable.
Choke Cable Free Play
Standard: 2 ∼3 mm (0.08 ∼0.12 in.)
• Push the choke lever back all the way to its released po-
sition.
• Pull the choke lever until the starter plunger lever [A] at the
carburetor touches the starter plunger [B]; the amount of
choke lever travel is the amount of choke cable play.
• Loosen the locknut [A], and turn the adjuster [B] until the
cable has the proper amount of free play.
• Tighten the locknut securely.
Engine Vacuum Synchronization Inspection
• Situate the motorcycle using the center stand so that it is
perpendicular to the ground.
• Remove the fuel tank, and connect the sub-fuel tank to
supply the fuel.
• Remove the right lower fairing.
• Warm up the engine.
• Check the idle speed and adjust if necessary.
• Pull the vacuum hoses off, and attach vacuum gauge [A]
to the vacuum hose fittings on the carburetors.
Special Tool - Vacuum Gauge KEK-55-5: 57001-1369
PERIODIC MAINTENANCE 2-17
Idle Speed Adjustment
Halaman 40
2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Start the engine and let it idle to measure the carburetor
intake vacuum.
If the intake vacuum difference between the two cylinders
exceeds the limit, adjust the synchronization.
Engine Vacuum Synchronization
Less than 2.7 kPa (2 cmHg) difference between both
cylinders
• Turn the adjusting screw [A] to synchronize the carbure-
tor.
If the carburetor synchronization cannot be obtained by
using the adjusting screw, check for dirt or blockage, and
then check the pilot screw settings.
• Check the Carburetor Synchronization again.
NOTE
○Do not turn the pilot screws carelessly during carburetor
synchronization. You may cause poor running at low
engine speed.
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged.
Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection or Cable, Wire, and Hose Routing section in
the Appendix chapter).
WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding condition.
• Check idle speed.
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:
1 300 ±50 r/min (rpm)
Idle Speed Adjustment
• Start the engine and warm it up thoroughly.
• Turn the adjusting screw [A] until the idle speed is correct.
○Open and close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.
Evaporative Emission Control System Inspection
Halaman 41
Periodic Maintenance Procedures
Fuel Hose Inspection (fuel leak, damage,
installation condition)
○The fuel hose is designed to be used throughout the mo-
torcycle’s life without any maintenance. However, if the
motorcycle is not properly handled, the high pressure in-
side the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel Tank Removal in
the Fuel System chapter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B], bulges [C]
or ozone cracks [D] are noticed.
• Check that the hose [A] are securely connected and
clamps [B] are tightened correctly.
• Check that the hoses are routed according to Cable, Wire,
and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.
Evaporative Emission Control System (California Model)
Evaporative Emission Control System Inspection
• Inspect the canister as follows.
○Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
○Remove the canister [A], and disconnect the hoses from
the canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.
NOTE
○The canister is designed to work well through the motor-
cycle’s life without any maintenance if it is used under
normal conditions.
PERIODIC MAINTENANCE 2-19
Coolant Level Inspection
Halaman 42
2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Check the liquid/vapor separator as follows.
○Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
○Disconnect the hoses from the separator, and remove the
separator [B] from the motorcycle left side.
○Visually inspect the separator for cracks and other dam-
age.
If the separator has any cracks or damage, replace it with
a new one.
○To prevent the gasoline from flowing into or out of the
canister, hold the separator perpendicular to the ground.
• Check the hoses of the evaporative emission control sys-
tem as follows.
○Check that the hoses are securely connected and clips
are in position.
○Replace any kinked, deteriorated or damaged hoses.
○Route the hoses according to Cable, Wire, and Hose
Routing section in the Appendix chapter.
○When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses with a minimum
of bending so that the emission flow will not be obstructed.
Cooling System
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambi-
ent temperature).
• Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L” level line [B], re-
move the right center fairing (see Center Fairing Removal
in the Frame chapter) and unscrew the reserve tank cap,
and add coolant to the “F” level line [C].
“L”: low
“F”: full
CAUTION
For refilling, add the specified mixture of coolant
and soft water.
Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en-
gine parts. In an emergency, soft water alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank
has run completely dry, there is probably leakage in
the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash
away any coolant that spills on the frame, engine,
wheels or other painted parts.
Air Suction System Damage Inspection
Halaman 43
Periodic Maintenance Procedures
Radiator Hose Damage and Installation Condition
Inspection
○The high pressure inside the radiator hose and pipe can
cause coolant to leak [A] or the hose to burst if the line is
not properly maintained.
• Visually inspect the hoses for signs of deterioration.
Squeeze the hoses.
A hose should not be hard and
brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
• Check that the hoses are securely connected and clamps
are tightened correctly.
Torque - Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Coolant Filter Cleaning (Australia Model)
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
• Drain the coolant (see Coolant Change).
• Remove the filter [A] from the water hoses [B] of carbure-
tor system.
• Blow off dirt and sediment on the filter with compressed
air.
Filter Body [C]
Water Pipe [D]
Coolant Valve Assy [E]
Water Pump [F]
Carburetor [G]
Damper [H]
Air Suction System
Air Suction System Damage Inspection
• Pull the vacuum switch valve hose [A] out of the air
cleaner.
PERIODIC MAINTENANCE 2-21
Special Tool -
Halaman 44
2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Start the engine and run it at idle speed.
• Plug [A] the vacuum switch valve hose end with your fin-
ger and feel vacuum pulsing in the hose.
If there is no vacuum pulsation, check the hose line for
leak. If there is no leak, check the vacuum switch valve
or air suction valve (see Engine Top End chapter).
Engine Top End
Valve Clearance Inspection
NOTE
○Valve clearance must be checked and adjusted when
the engine is cold (room temperature).
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Unscrew the two plugs [A], [B] on the alternator cover.
Special Tool - Filler Cap Driver: 57001-1454
• Check the valve clearance when the pistons are at TDC.
○The pistons are numbered beginning with the engine left
side.
• Using a wrench on the crankshaft rotation bolt, turn the
crankshaft clockwise until the "2/T" [A] mark on the timing
rotor is aligned with the projection [B] in the inspection
window on the alternator cover.
○Measure the valve clearance of the valves for which the
cam [A] are turned away from each other.
Valve Clearance Adjustment
Halaman 45
Periodic Maintenance Procedures
• Using the thickness gauge [A], measure the valve clear-
ance between cam and valve lifter.
Valve Clearance
Standard:
Exhaust
0.22 ∼0.29 mm (0.0087 ∼0.0114 in.)
Inlet
0.15 ∼0.24 mm (0.0059 ∼0.0094 in.)
○Each piston has two inlet and two exhaust valves. Mea-
sure these two inlet or exhaust valves at the same crank-
shaft position.
Valve Clearance Measuring Position
#1 Piston TDC at End of Compression Stroke →
Inlet valve clearances of #1 piston, and
Exhaust valve clearances of #1 piston
NOTE
○Check the valve clearance using this method only.
Checking the clearance at any other cam position may
result in improper valve clearance.
Valve Clearance Measuring Position
#2 Piston TDC at End of Compression Stroke →
Inlet valve clearances of #2 piston, and
Exhaust valve clearances of #2 piston
If the valve clearance is not with in the specified range,
first record the clearance, and adjust it.
Valve Clearance Adjustment
• To change the valve clearance, remove the camshaft
chain tensioner, camshafts and valve lifters. Replace the
shim with one of a different thickness.
NOTE
○Mark and record the locations of the valve lifters and
shims so that they can be reinstalled in their original
positions.
PERIODIC MAINTENANCE 2-23
Valve Clearance Adjustment
Halaman 46
2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Clean the shim to remove any dust or oil.
• Measure the thickness of the removed shim [A].
• Select a new shim thickness calculation as follows.
a + b – c = d
[a] Present Shim Thickness
[b] Measured Valve Clearance
[c] Specified Valve Clearance (Mean Value = 0.255 mm
(Exhaust), 0.195 mm (Inlet))
[d] Replace Shim Thickness
Example (Inlet):
2.90 + 0.45 – 0.195 = 3.155 mm
○Exchange the shim for the 3.175 size shim.
CAUTION
Don’t use the shims for another models. This could
cause wear of the valve stem end, and valve stem
damage.
Valve Clearance Adjustment
Halaman 47
PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
Adjustment Shims
| Thickness | Part Number | Mark |
| :-------- | :---------- | :--- |
| 2.50 | 92180-1014 | 50 |
| 2.55 | 92180-1016 | 55 |
| 2.60 | 92180-1018 | 60 |
| 2.65 | 92180-1020 | 65 |
| 2.675 | 92180-1174 | 68 |
| 2.70 | 92180-1022 | 70 |
| 2.725 | 92180-1175 | 73 |
| 2.75 | 92180-1024 | 75 |
| 2.775 | 92180-1176 | 78 |
| 2.80 | 92180-1026 | 80 |
| 2.825 | 92180-1177 | 83 |
| 2.85 | 92180-1028 | 85 |
| 2.875 | 92180-1178 | 88 |
| 2.90 | 92180-1030 | 90 |
| 2.925 | 92180-1179 | 93 |
| 2.95 | 92180-1032 | 95 |
| 2.975 | 92180-1180 | 98 |
| 3.00 | 92180-1034 | 00 |
| 3.025 | 92180-1181 | 03 |
| 3.05 | 92180-1036 | 05 |
| 3.075 | 92180-1182 | 08 |
| 3.10 | 92180-1038 | 10 |
| 3.125 | 92180-1183 | 13 |
| 3.15 | 92180-1040 | 15 |
| 3.175 | 92180-1184 | 18 |
| 3.20 | 92180-1042 | 20 |
| 3.25 | 92180-1044 | 25 |
| 3.30 | 92180-1046 | 30 |
| 3.35 | 92180-1048 | 35 |
| 3.40 | 92180-1050 | 40 |
| 3.45 | 92180-1052 | 45 |
| 3.50 | 92180-1054 | 50 |
Clutch Operation Inspection
Halaman 48
2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clutch
Clutch Operation Inspection
• Pull the clutch lever just enough to take up the free play
[A].
• Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust it.
Clutch Lever Free Play
Standard:
2 ∼3 mm (0.08 ∼0.12 in.)
WARNING
To avoid a serious burn, never touch the engine or
exhaust pipe during clutch adjustment.
• Turn the adjuster [B] so that 5 ∼6 mm (0.20 ∼0.24 in.) [A]
of threads are visible.
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Slide the dust cover [A] from the clutch cable lower end
out of place.
• Loosen both adjusting nuts [B] at the clutch cover as far
as they will go.
• Pull the clutch outer cable [C] tight and tighten the adjust-
ing nuts against the bracket [D].
• Slip the rubber dust cover back onto place.
• Turn the adjuster at the clutch lever until the free play is
correct.
WARNING
Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into place later, creating enough cable
play to prevent clutch disengagement.
• After the adjustment, start the engine and check that the
clutch does not slip and that it releases properly.
Tire Tread Wear, Abnormal Wear Inspection
Halaman 49
Periodic Maintenance Procedures
Wheels/Tires
Air Pressure Inspection
• Remove the air valve cap.
• Measure the tire air pressure with an air pressure gauge
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
• Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front:
Up to 170 kg (375 lb)
200 kPa (2.00 kgf/cm², 28 psi)
Rear:
Up to 170 kg (375 lb)
225 kPa (2.25 kgf/cm², 32 psi)
Wheel/Tire Damage Inspection
• Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.
• Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.
• Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.
Tire Tread Wear, Abnormal Wear Inspection
As the tire tread wears down, the tire becomes more sus-
ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
• Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).
PERIODIC MAINTENANCE 2-27
Wheel Bearing Damage Inspection
Halaman 50
2-28 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Tread Depth
Standard:
Front:
BRIDGESTONE
4.6 mm (0.181 in.)
DUNLOP
4.5 mm (0.177 in.)
Rear:
BRIDGESTONE
7.0 mm (0.276 in.)
DUNLOP
7.4 mm (0.291 in.)
Service Limit:
Front
1 mm (0.04 in.)
Rear
2 mm (0.08 in.)
(Up to 130 km/h (80 mph))
3 mm (0.12 in.)
(Over 130 km/h (80 mph))
WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, in-
flated to the standard pressure.
NOTE
○Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them.
○Check and balance the wheel when a tire is replaced
with a new one.
Wheel Bearing Damage Inspection
• Raise the front wheel off the ground with jack (see Front
Wheel Removal in the Wheels/Tires chapter).
• Turn the handlebar all the way to the right or left.
• Inspect the roughness of the front wheel bearing by push-
ing and pulling [A] the wheel.
• Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Front Wheel
Removal, Hub Bearing Inspection in the Wheels/Tires
chapter).
• Raise the rear wheel off the ground with stand (see Rear
Wheel Removal in the Wheels/Tires chapter).
• Inspect the roughness of the rear wheel bearing by push-
ing and pulling [A] the wheel.
• Spin [B] the rear wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Rear Wheel Re-
moval, Hub Bearing Inspection in the Wheels/Tires chap-
ter) and coupling (see Coupling Bearing Inspection in the
Final Drive chapter).
Drive Chain Slack Inspection
Halaman 51
Periodic Maintenance Procedures
Drive Train
Drive Chain Lubrication Condition Inspection
• If a special lubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
• If the chain appears especially dirty, clean it before lubri-
cation.
CAUTION
The O-rings between the side plates seal in the lu-
bricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubri-
cant, observe the following rules.
Use only kerosene or diesel oil for cleaning an O
-ring drive chain. Any other cleaning solution such
as gasoline or trichloroethylene will cause deterio-
ration and swelling of the O-ring. Immediately blow
the chain dry with compressed air after cleaning.
Complete cleaning and drying the chain within 10
minutes.
• Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings. Apply the oil to the O-rings so
that the O-rings will be coated with oil.
• Wipe off any excess oil.
Oil Applied Areas [A]
O-rings [B]
Drive Chain Slack Inspection
NOTE
○Check the slack with the motorcycle setting on its side-
stand.
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
• Check the wheel alignment (see Wheel Alignment Inspec-
tion).
• Rotate the rear wheel to find the position where the chain
is tightest.
• Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
20 ∼30 mm (0.8 ∼1.2 in.)
PERIODIC MAINTENANCE 2-29
Torque -
Halaman 52
2-30 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Chain Slack Adjustment
• Remove the cotter pin [A], and loosen the axle nut [B].
• Loosen the both chain adjuster locknuts [C].
If the chain is too loose, turn in the left and right chain
adjuster nuts [D] evenly.
If the chain is too tight, turn out the left and right chain
adjuster nuts evenly, and kick the wheel forward.
• Turn both chain adjuster nuts evenly until the drive chain
has the correct amount of slack.
To keep the chain
and wheel properly aligned, the notch [E] on the left
wheel alignment indicator [F] should align with the same
swingarm mark or position [G] that the right indicator
notch aligns with.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
• Tighten both chain adjuster locknuts securely.
• Tighten the axle nut.
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
• Turn the wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30°.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut [B].
WARNING
If the rear axle nut is not securely tightened or the
cotter pin is not installed, an unsafe riding condi-
tion may result.
Drive Chain Wear Inspection
Halaman 53
Periodic Maintenance Procedures
Wheel Alignment Inspection
• Check that the notch [A] on the right wheel alignment indi-
cator [B] aligns with the same swingarm mark or position
[C] that the left alignment indicator notch aligns with.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment).
NOTE
○Wheel alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Drive Chain Wear Inspection
• Remove:
Chain Cover (see Swingarm Removal in the Suspension
chapter)
• Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
• Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5 ∼318.1 mm (12.50 ∼12.52 in.)
Service Limit:
323 mm (12.72 in.)
WARNING
If the drive chain wear exceeds the service limit, re-
place the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprock-
ets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safely, use only the standard chain. It is an end-
less type and should not be cut for installation.
Standard Chain
Make:
ENUMA
Type:
EK520SR-O2
Link:
106 links
PERIODIC MAINTENANCE 2-31
Brake Operation Inspection
Halaman 54
2-32 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Chain Guide Inspection
• Remove:
Swingarm (see Swingarm Removal in the Suspension
chapter)
• Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.
Brake System
Brake Fluid Leak (Brake Hose and Pipe) Inspection
• Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A], fittings [B] and pipes [C].
If the brake fluid leaked from any position, inspect or re-
place the problem part.
Brake Hose and Pipe Damage and Installation
Condition Inspection
• Inspect the brake hoses, fittings and pipes for deteriora-
tion, cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace the hose and pipe if any crack [B], bulge [C] or
leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Inspect the brake hose routing.
If any brake hose routing is incorrect, route the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
Brake Operation Inspection
• Inspect the operation of the front and rear brake by run-
ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.
Brake Pad Wear Inspection
Halaman 55
Periodic Maintenance Procedures
Brake Fluid Level Inspection
• Check that the brake fluid level in the front brake reservoir
[A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C] in the reservoir.
• Check that the brake fluid level in the rear brake reservoir
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that is already in the reser-
voir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.
Recommended Disc Brake Fluid
Grade:
DOT4
• Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
Brake Pad Wear Inspection
• Check the lining thickness [A] of the pads in each caliper.
If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
4.5 mm (0.18 in.)
Service Limit:
1 mm (0.04 in.)
PERIODIC MAINTENANCE 2-33
Front Forks/Rear Shock Absorber Operation Inspection
Halaman 56
2-34 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Light Switch Operation Inspection
• Turn on the ignition switch.
• The brake light [A] should go on when the brake lever is
applied or after the brake pedal is depressed about 10
mm (0.39 in.).
If it does not, adjust the brake light switch.
• Disconnect the connector [A].
• Turn the brake light switch to adjust the switch.
• Connect the connector.
If it does not go on, inspect or replace the following items.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Brake Light (see Tail/Brake Light Removal in the Electri-
cal System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-
spection in the Electrical System chapter)
Front Brake Light Switch [A] (see Switch Inspection in
the Electrical System chapter)
Rear Brake Light Switch (see Switch Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Suspensions
Front Forks/Rear Shock Absorber Operation
Inspection
• Pump the forks down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).
Tie-Rod Operation Inspection
Halaman 57
Periodic Maintenance Procedures
• Pump the seat down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection).
Front Fork Oil Leak Inspection
• Visually inspect the front forks [A] for oil leakage.
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
• Visually inspect the shock absorber [A] for oil leakage.
If the oil leakage is found on it, replace the shock absorber
with a new one.
Rocker Arm Operation Inspection
• Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the rocker arm [A] does not smoothly stroke or noise
is found, inspect the fasteners and bushings (see Rocker
Arm/Tie-Rod Bushing, Sleeve Inspection in the Suspen-
sion chapter).
Tie-Rod Operation Inspection
• Pump the seat down and up 4 or 5 times, and inspect the
smooth stroke.
If the tie-rod [A] do not smoothly stroke or noise is found,
inspect the fasteners and tie-rod bushings (see Rocker
Arm/Tie-Rod Bushing, Sleeve Inspection in the Suspen-
sion chapter).
PERIODIC MAINTENANCE 2-35
Torque -
Halaman 58
2-36 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Swingarm Pivot Lubrication
• Remove the swingarm bearing (see Swingarm Bearing
Removal in the Suspension chapter).
• Supply grease to the needle bearings and grease seals
in accordance with the Periodic Maintenance chart.
Steering System
Steering Play Inspection
• Raise the front wheel off the ground with jack (see Front
Wheel Removal in the Wheels/Tires chapter).
• With the front wheel pointing straight ahead, alternately
tap each end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
• Feel for steering looseness by pushing and pulling the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the mo-
tion of the fork which must be taken into account.
○Be sure the wires and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
Steering Play Adjustment
• Loosen:
Front Fork Clamp Bolts (lower) (both sides)
Stem Head Bolt [A]
• Adjust the steering.
If the steering is too loose, tighten the steering stem nut
a fraction of a turn using the special tool [B].
If the steering is too tight, loosen the stem nut a fraction
of a turn.
Special Tool - Steering Stem Nut Wrench: 57001-1100
NOTE
○Turn the stem nut 1/8 turn at a time maximum.
• Tighten:
Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)
Front Fork Clamp Bolts (lower): 30 N·m (3.1 kgf·m,
22 ft·lb)
• Check the steering again.
If the steering is still too tight or too loose, repeat the ad-
justment.
Lights and Switches Operation Inspection
Halaman 59
Periodic Maintenance Procedures
Steering Stem Bearing Lubrication
• Remove the steering stem (see Stem, Stem Bearing Re-
moval in the Steering chapter).
• Using a high-flash point solvent, wash the upper and
lower ball bearings, and wipe the upper and lower outer
races, which are press-fitted into the frame head pipe,
clean off grease and dirt.
• Visually check the outer races and the ball bearings.
Replace them if they show wear or damage.
• Apply a light coat of grease to the upper and lower [A] ball
bearings and outer races.
• Install the steering stem (see Stem, Stem Bearing Instal-
lation in the Steering chapter).
• Adjust the steering (see Steering Play Adjustment).
Electrical System
Lights and Switches Operation Inspection
First Step
• Turn on the ignition switch.
• The following lights should go on according to below table.
Taillight [A]
goes on
License Plate Light [B]
goes on
Meter Panel Lights [C]
goes on
Neutral Indicator Light [D]
goes on
Oil Pressure Warning Indicator Light [E]
goes on
Water Temperature Warning Indicator Light
[F]
goes on
If the light does not go on, inspect or replace the following
item.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Meter Unit for Meter Lights (see Meter Unit Inspection in
the Electrical System chapter)
Meter Unit for Neutral Indicator Light (see Meter Unit
Inspection in the Electrical System chapter)
Meter Unit for Oil Pressure Warning Indicator Light (see
Meter Unit Inspection in the Electrical System chapter)
Meter Unit for Water Temperature Warning Indicator
Light (see Meter Unit Inspection in the Electrical System
chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In-
spection in the Electrical System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
• Turn off the ignition switch.
• The all lights should go off.
If the light does not go off, replace the ignition switch.
PERIODIC MAINTENANCE 2-37
Lights and Switches Operation Inspection
Halaman 60
2-38 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Second Step
• Turn on the turn signal switch [A] (left or right position).
• The left or right turn signal lights [B] (front and rear) ac-
cording to the switch position should flash.
• The turn signal indicator light [C] in the meter unit should
flash.
If the each light does not flash, inspect or replace the
following item.
Turn Signal Light Bulb (see Turn Signal Light Bulb Re-
placement in the Electrical System chapter)
Meter Unit for Turn Signal Light Indicator Light (see Me-
ter Unit Inspection in the Electrical System chapter)
Turn Signal Relay Fuse 10 A (see Fuse Inspection in the
Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
• Push the turn signal switch.
• The turn signal lights and indicator light should go off.
If the light does not go off, inspect or replace the following
item.
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Third Step
• Set the dimmer switch [A] to low beam position.
• Start the engine.
• The low beam headlight should go on.
If the low beam headlight does not go on, inspect or re-
place the following item.
Headlight Low Beam Bulb (see Headlight Bulb Replace-
ment in the Electrical System chapter)
Headlight Fuse 10 A (see Fuse Inspection in the Electri-
cal System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
Headlight Aiming Inspection
Halaman 61
Periodic Maintenance Procedures
• Set the dimmer switch to high beam position.
• The low beam [A] and high beam [B] headlights should
go on.
• The high beam indicator light [C] should go on.
If the high beam headlight and/or high beam indicator light
does not go on, inspect or replace the following item.
Headlight High Beam Bulb (see Headlight Bulb Replace-
ment in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
• Turn off the engine stop switch.
• The low beam and high beam headlights should stay go-
ing on.
If the headlights and high beam indicator light does go off,
inspect or replace the following item.
Headlight Relay (see Relay Circuit Inspection in the
Electrical System chapter)
• Turn off the ignition switch.
• The headlights and high beam indicator light should go
off.
Headlight Aiming Inspection
• Inspect the headlight beam for aiming.
If the headlight beam points to one side rather than
straight ahead, adjust the horizontal beam.
Headlight Beam Horizontal Adjustment
• Turn the horizontal adjuster [A] on the headlight with the
screwdriver in or out until the beam points straight ahead.
If the headlight beam points too low or high, adjust the
vertical beam.
Headlight Beam Vertical Adjustment
• Turn the vertical adjuster [A] on the headlight with the
screwdriver in or out to adjust the headlight vertically.
PERIODIC MAINTENANCE 2-39
Sidestand Switch Operation Inspection
Halaman 62
2-40 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTE
○ON high beam, the brightest points should be slightly
below horizontal with the motorcycle on its wheels and
the rider seated. Adjust the headlight to the proper an-
gle according to local regulations.
○For US model, the proper angle is 0.4 degrees below
horizontal. This is 50 mm (2 in.) drop at 7.6 m (25
ft) measured from the center of the headlight with the
motorcycle on its wheels and the rider seated.
50 mm (2 in.) [A]
Center of Brightest Spot [B]
7.6 m (25 ft) [C]
Low Beam [D]
Height of Headlight Center [E]
High Beam [F]
Sidestand Switch Operation Inspection
• Inspect the sidestand switch [A] operation accordance to
below table.
Sidestand Switch Operation
Sidestand
Gear
Position
Clutch
Lever
Engine
Start
Engine
Run
Up
Neutral
Released
Starts
Continue
running
Up
Neutral
Pulled in
Starts
Continue
running
Up
In Gear
Released
Doesn’t
start
Stops
Up
In Gear
Pulled in
Starts
Continue
running
Down
Neutral
Released
Starts
Continue
running
Down
Neutral
Pulled in
Starts
Continue
running
Down
In Gear
Released
Doesn’t
start
Stops
Down
In Gear
Pulled in
Doesn’t
start
Stops
Engine Stop Switch Operation Inspection
Halaman 63
Periodic Maintenance Procedures
If the sidestand switch operation does not work, inspect
or replace the following item.
Battery (see Charging Condition Inspection in the Elec-
trical System chapter)
Main Fuse 30 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Fuse 10 A (see Fuse Inspection in the Electrical
System chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Sidestand Switch (see Switch Inspection in the Electrical
System chapter)
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Neutral Switch (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Elec-
trical System chapter)
Starter Circuit Relay (see Relay Circuit Inspection in the
Electrical System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
If the all parts are good condition, replace the IC Igniter.
Engine Stop Switch Operation Inspection
First Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to stop position [A].
• Push the starter button.
• The engine does not start.
If the engine starts, inspect or replace the following item.
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
Second Step
• Turn on the ignition switch.
• Set the neutral position.
• Turn the engine stop switch to run position [A].
• Push the starter button and run the engine.
• Turn the engine stop switch to stop position.
• Immediately the engine should be stop.
If the engine does not stop, inspect or replace the follow-
ing item.
Engine Stop Switch (see Switch Inspection in the Elec-
trical System chapter)
If the engine stop switch is good condition, replace the IC
Igniter.
PERIODIC MAINTENANCE 2-41
Chassis Parts Lubrication
Halaman 64
2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Others
Chassis Parts Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Pivots: Lubricate with Grease.
Brake Lever
Brake Pedal
Clutch Lever
Rear Brake Joint Pin
Sidestand
Points: Lubricate with Grease.
Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
Cables: Lubricate with Rust Inhibitor.
Clutch Cable
Throttle Cables
• Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
• With the cable disconnected at both ends, the inner cable
should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Bolts, Nuts and Fasteners Tightness Inspection
Halaman 65
Periodic Maintenance Procedures
Bolts, Nuts and Fasteners Tightness Inspection
• Check the tightness of the bolts and nuts listed here. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retighten them to the spec-
ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Engine:
Clutch Lever Pivot Nut
Engine Mounting Bolts and Nuts
Exhaust Pipe Manifold Holder Nuts
Muffler Body Mounting Bolts
Wheels:
Front Axle
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Caliper Mounting Bolts
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Bolt and Nut
Swingarm Pivot Shaft Nut
Steering:
Steering Stem Head Bolt
Handlebar Holder Bolts
Others:
Footpeg Stay Bolts
Front Fender Bolts
Sidestand Bolt
PERIODIC MAINTENANCE 2-43
Torque -
Halaman 66
2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Replacement Parts
Air Cleaner Element Replacement
• Refer to the Air Cleaner Element Cleaning (see Air
Cleaner Element Cleaning).
Fuel Hose Replacement
• Refer to Fuel Hose Inspection (see Fuel Hose Inspection).
Coolant Change
WARNING
To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down. Coolant on tires will
make them slippery and can cause an accident
and injury. Immediately wipe up or wash away any
coolant that spills on the frame, engine, or other
painted parts.
Since coolant is harmful to the human body, do not
use for drinking.
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Radiator Cap [A]
• Place a container under the drain bolts [A] at the bottom
of the water pump cover and cylinder.
• Drain the coolant from the radiator and engine by remov-
ing the drain bolts.
Torque - Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Torque -
Halaman 67
Periodic Maintenance Procedures
• Remove:
Hoses [A]
Mounting Bolts [B] and Reserve Tank [C]
• Remove the cap [D] and pour the coolant of the reserve
tank into the container.
• Install:
Hoses
Reserve Tank
• Tighten the drain bolt with the specified torque.
Torque - Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Fill the radiator up to the radiator filler neck [A] with
coolant, and install the radiator cap.
NOTE
○Pour in the coolant slowly so that it can expel the air
from the engine and radiator.
• Fill the reserve tank up to the full level line with coolant,
and install the cap.
CAUTION
Soft or distilled water must be used with the an-
tifreeze (see below for antifreeze) in the cooling sys-
tem.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider-
ably reduces the efficiency of the cooling system.
Water and Coolant Mixture Ratio (Recommended)
Soft Water:
50%
Coolant:
50%
Freezing Point: −35°C (−31°F)
Capacity:
1.5 L (1.59 US qt)
NOTE
○Choose a suitable mixture ratio by referring to the
coolant manufacturer’s directions.
PERIODIC MAINTENANCE 2-45
Radiator Hose and O-ring Replacement
Halaman 68
2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Bleed the air from the cooling system as follows.
○Start the engine with the radiator cap removed and run it
until no more air bubbles [A] can be seen in the coolant.
○Tap the radiator hoses to force any air bubbles caught
inside.
○Stop the engine and add coolant up to the radiator filler
neck.
• Install the radiator cap.
• Start the engine, warm it up thoroughly until the radiator
fan turns on and then stop the engine.
• Check the coolant level in the reserve tank after the en-
gine cools down.
If the coolant level is lower than the low level line, add
coolant to the full level line.
CAUTION
Do not add more coolant above the full level line.
Radiator Hose and O-ring Replacement
• Drain the coolant (see Coolant Change).
• Remove:
Thermostat Housing [A] (see Water Pump Removal in
the Cooling System chapter)
Water Pump Cover [B] (see Water Pump Removal in the
Cooling System chapter)
Hoses [C]
Pipe [D]
O-rings [E]
• Apply grease to the new O-rings and install them.
• Install the new hoses and tighten the clamps securely.
• Fill the coolant (see Coolant Change).
• Check the cooling system for leaks.
Oil Filter Replacement
Halaman 69
Periodic Maintenance Procedures
Engine Oil Change
WARNING
To avoid a serious burn, never touch the exhaust
pipe during oil change.
• Warm up the engine sufficiently with the motorcycle
standing on its side stand, and stop the engine.
• Place an oil pan under the engine and remove the drain
bolt [A] to drain the oil.
• Replace the drain bolt gaskets with new ones if they are
damaged.
○The oil in the oil filter can be drained by removing the filter.
• After draining the oil, tighten the drain bolts.
Torque - Oil Drain Bolts: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)
Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5
ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil
Type:
API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity: SAE 10W - 40
Capacity:
1.3 L (1.4 US qt) (When filter is not removed)
1.6 L (1.7 US qt) (When filter is removed)
NOTE
○Although 10W-40 engine oil is the recommended oil
for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.
Oil Filter Replacement
• Drain the engine oil (see Engine Oil change).
• Remove the oil filter mounting bolt [A].
PERIODIC MAINTENANCE 2-47
Brake Fluid Change
Halaman 70
2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
• Replace the oil filter with a new one.
• Apply engine oil to the O-rings [A] before installation after
inspecting its damage.
• Install the oil filter mounting bolt [B] with a specified
torque.
Torque - Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5
ft·lb)
• Pour in the specified type and amount of oil (see Engine
Oil Change).
Brake Hose and Pipe Replacement
CAUTION
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
• Remove the banjo bolts.
• When removing the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
• When removing the brake hoses [A], temporarily secure
the end of the brake hose to some high place to keep fluid
loss to a minimum.
• Immediately wash away any brake fluid that spills.
• There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• When installing the hoses [A], avoid sharp bending, kink-
ing, flatting or twisting, and route the hoses according to
Cable, Wire, and Hose Routing section in the Appendix
chapter.
• Fill the brake line after installing the brake hose (see
Brake Fluid Change).
Brake Fluid Change
NOTE
○The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for
the front brake.
Torque -
Halaman 71
Periodic Maintenance Procedures
• Level the brake fluid reservoir.
• Remove the reservoir cap and diaphragm.
• Remove the rubber cap from the bleed valve [A] on the
caliper.
• Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
• Change the brake fluid.
○Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○Front Brake:
Repeat the above steps for the other
caliper.
• Remove the clear plastic hose.
• Install the diaphragm and reservoir cap.
• Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)
• After changing the fluid, check the brake for good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
PERIODIC MAINTENANCE 2-49
Special Tool -
Halaman 72
2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
• Remove the front master cylinder (see Front Master Cylin-
der Removal in the Brakes chapter).
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Unscrew the locknut and pivot bolt, and remove the brake
lever.
• Pull the dust cover out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the piston [A], secondary cup [B], primary cup [C],
and return spring [D].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
Rear Master Cylinder Disassembly
NOTE
○Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake position ad-
justment.
• Remove the rear master cylinder (see Rear Master Cylin-
der Removal in the Brakes chapter).
• Remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
• Pull out the push rod with the piston stop.
• Take off the piston [A], secondary cup [B], primary cup [C]
and return spring [D].
• Remove the circlip [F] and pull out the brake hose con-
nector [G] and O-ring [H].
Special Tool - Inside Circlip Pliers: 57001-143
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
Master Cylinder Assembly
• Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi-
cult to wash off completely, and will eventually de-
teriorate the rubber used in the disc brake.
Caliper Rubber Parts Replacement
Halaman 73
Periodic Maintenance Procedures
• Apply brake fluid to the removed parts and to the inner
wall of the cylinder.
• Take care not to scratch the piston or the inner wall of the
cylinder.
• Apply silicone grease (ex. PBC grease).
Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Push Rod Contact (Rear)
Dust Cover
• Tighten:
Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9
in·lb)
Brake Lever Pivot Bolt Locknut:
5.9 N·m (0.60
kgf·m, 52 in·lb)
Caliper Rubber Parts Replacement
Caliper Disassembly
• Remove a front Caliper (see Front Caliper Removal in the
Brakes chapter).
• Remove the pads and anti-rattle spring (see Pad Removal
in the Brakes chapter).
If compressed air is available, the piston may be removed
using compressed air as follows.
• Insert the wooden board of 5 mm (0.2 in.) thick inside the
caliper opening or cover the caliper opening with a clean,
heavy cloth [A].
• Lightly apply compressed air [B] to the hose joint opening
until the pistons hit the wooden board or heavy cloth.
WARNING
To avoid serious injury, never place your fingers or
palm in front of the piston. If you apply compressed
air into the caliper, the piston may crush your hand
or fingers.
• Pull out the pistons by hand.
• Immediately wipe up any brake fluid that spills. It may ruin
painted or plated surfaces.
• Remove the dust seals and fluid seals.
• Remove the bleed valve and rubber cap.
NOTE
○If compressed air is not available, do as follows for both
calipers coincidentally, with the brake hose connected
to the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the spring and pads (see Brake Pad Removal).
○Pump the brake lever or pedal until the pistons come
out of the cylinders, and then disassemble the caliper.
PERIODIC MAINTENANCE 2-51
Torque -
Halaman 74
2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Caliper Assembly
• Clean the caliper parts except for the pads.
CAUTION
For cleaning of the parts, use only disc brake fluid,
ispopropyl alcohol, or ethyl alcohol.
• Install the bleed valve and rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)
• Replace the fluid seals [A] and dust seals [B] with new
one.
• Apply brake fluid to the fluid seals and dust seals, and
install them into the cylinder by hand.
• Apply brake fluid [A] to the outside of the pistons and push
them into each cylinder by hand without scratching the
cylinder and piston skirt.
• Apply silicone grease [B] to the caliper holder shaft and
holder holes, and install the caliper holder [C], rubber boot
[D] and dust cover [E].
• Install the anti-rattle spring [F] and pads in the caliper (see
Pad Installation in the Brakes chapter).
Spark Plug Replacement
• Remove:
Spark Plugs (see Spark Plug Removal in the Electrical
System chapter)
• Remove the spark plugs using the 16 mm plug wrench
[A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0044
• Insert the spark plug vertically into the plug hole with the
spark plug installed in the plug wrench [A].
Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-0044
• Tighten:
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)
• Install:
Spark Plugs (see Spark Plug Installation in the Electrical
System chapter)
Fuel System
Halaman 75
Fuel System
Table of Contents
Exploded View........................................................................................................................
3-2
Specifications .........................................................................................................................
3-8
Special Tools ..........................................................................................................................
3-9
Throttle Grip and Cables ........................................................................................................
3-10
Free Play Inspection .........................................................................................................
3-10
Free Play Adjustment........................................................................................................
3-10
Throttle Cable Removal ....................................................................................................
3-10
Throttle Cable Installation .................................................................................................
3-10
Throttle Cable Lubrication.................................................................................................
3-10
Choke Cable...........................................................................................................................
3-11
Free Play Inspection .........................................................................................................
3-11
Free Play Adjustment........................................................................................................
3-11
Choke Cable Removal......................................................................................................
3-11
Choke Cable Installation...................................................................................................
3-11
Choke Cable Lubrication and Inspection ..........................................................................
3-11
Carburetors.............................................................................................................................
3-12
Idle Speed Inspection .......................................................................................................
3-12
Idle Speed Adjustment......................................................................................................
3-12
Engine Vacuum Synchronization Inspection.....................................................................
3-12
Engine Vacuum Synchronization Adjustment ...................................................................
3-12
Pilot Screw Adjustment.....................................................................................................
3-12
Service Fuel Level Inspection...........................................................................................
3-13
Service Fuel Level Adjustment .........................................................................................
3-14
Fuel System Cleanliness Inspection.................................................................................
3-15
Carburetor Removal..........................................................................................................
3-16
Carburetor Installation.......................................................................................................
3-17
Carburetor Separation ......................................................................................................
3-17
Carburetor Joining ............................................................................................................
3-17
Carburetor Disassembly ...................................................................................................
3-19
Carburetor Assembly .......................................................................................................
3-19
Carburetor Cleaning..........................................................................................................
3-20
Carburetor Inspection .......................................................................................................
3-21
Air Cleaner..............................................................................................................................
3-23
Air Cleaner Element Removal...........................................................................................
3-23
Air Cleaner Element Installation........................................................................................
3-23
Air Cleaner Housing Removal...........................................................................................
3-23
Air Cleaner Housing Installation........................................................................................
3-24
Air Cleaner Housing Disassembly ....................................................................................
3-24
Air Cleaner Housing Assembly .........................................................................................
3-24
Oil Draining ......................................................................................................................
3-25
Fuel Tank................................................................................................................................
3-26
Fuel Tank Removal ...........................................................................................................
3-26
Fuel Tank Installation ........................................................................................................
3-26
Fuel Tap Removal.............................................................................................................
3-27
Fuel Tap Installation..........................................................................................................
3-27
Fuel Tank and Tap Cleaning .............................................................................................
3-27
Fuel Tap Inspection...........................................................................................................
3-28
Fuel Tank and Cap Inspection ..........................................................................................
3-28
FUEL SYSTEM 3-1
3
Fuel System
Halaman 76
3-2 FUEL SYSTEM
Exploded View
Fuel System
Halaman 77
Exploded View
1. Throttle Cable (accelerator)
2. Throttle Cable (decelerator)
3. Choke Cable
4. Idle Adjusting Screw
5. Air Cut Valve
6. Jet Needle
7. Vacuum Valve
8. Float Valve
9. Needle Jet
10. Needle Jet Holder
11. Main Jet
12. Pilot Jet
13. Pilot Air Screw
14. Float
15. Plug
CL: Apply cable lubricant.
G: Apply grease.
FUEL SYSTEM 3-3
Fuel System
Halaman 78
3-4 FUEL SYSTEM
Exploded View
(CAL)
Z0332 /B/C
Fuel System
Halaman 79
# FUEL SYSTEM 3-5
## Exploded View
| No. | Fastener | N·m | kgf·m | ft·lb | Remarks |
|:---:|:-----------------------------|-----:|------:|:---------|:--------|
| 1 | Fuel Tap Mounting Bolts | 2.5 | 0.25 | 22 in·lb | |
| 2 | Fuel Gauge Mounting Bolts | 6.9 | 0.7 | 61 in·lb | |
| 3 | Air Cleaner Housing Cap Bolts | 2.5 | 0.25 | 22 in·lb | |
| 4 | Air Cleaner Housing Screws | 1.15 | 0.12 | 10 in·lb | |
| 5 | Air Cleaner Housing Mounting Bolts | 9.8 | 1.0 | 87 in·lb | |
| 6 | Air Cleaner Housing Clamp Screws | 2.0 | 0.2 | 18 in·lb | |
7. Vacuum Switch Valve
AO: Apply motor oil (SE, SF or SG class SAE 10W-30).
Fuel System
Halaman 80
## 3-6 FUEL SYSTEM
### Exploded View
Fuel System
Halaman 81
FUEL SYSTEM 3-7
## Exploded View
| No. | Fastener | Torque | Remarks |
| :-- | :-------------------- | :------------- | :------ |
| | | **N·m** | **kgf·m** | **ft·lb** | |
| 1 | Separate Bracket Bolt | 9.8 | 1.0 | 87 in·lb | |
2. Canister
3. Separator
4. Green Hose
5. Blue Hose
6. White Hose
7. Red Hose
Fuel System
Halaman 82
3-8 FUEL SYSTEM
Specifications
Item
Standard
Throttle Grip and Cable
Throttle Grip Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
Choke Cable Free Play
2 ∼3 mm (0.08 ∼0.12 in.)
Carburetor
Make, Type
Keihin, CVK30
Main Jet
#98
Optional Main Jet
#92, 95, 100, 102
Main Air Jet
#100
Jet Needle
#L: N9VU, #R: N9VW
Needle Jet
#6
Pilot Jet
#38
Pilot Air Jet
#100
Starter Jet
#48
Pilot Screw (turns out)
#L: 2 1/2, #R: 1 3/4
Throttle Valve
11° 00’
Idle Speed
1 300 ±50 r/min (rpm)
Carburetor Synchronization Vacuum Less than 2.7 kPa (2 cmHg) difference between two
carburetors.
Service Fuel Level
0.5 ±1 mm (0.02 ±0.04 in.) above the mating surface of
carburetor float bowl.
Float Height
17 ±2 mm (0.67 ±0.08 in.)
Air Cleaner Element
Type
Polyurethane foam
Fuel Level Gauge:
Halaman 83
Special Tools
Fuel Level Gauge:
57001-1017
FUEL SYSTEM 3-9
Pilot Screw Adjuster, A:
57001-1239
Throttle Cable Lubrication
Halaman 84
3-10 FUEL SYSTEM
Throttle Grip and Cables
Free Play Inspection
• Refer to Throttle Control System Inspection in the Peri-
odic Maintenance chapter (see Throttle Control System
Inspection in the Periodic Maintenance chapter).
Free Play Adjustment
• Refer to Throttle Control System Inspection in the Peri-
odic Maintenance chapter (see Throttle Control System
Inspection in the Periodic Maintenance chapter).
Throttle Cable Removal
• Split the right handlebar switch housing [A] removing the
screws [B], and remove the throttle cable upper ends from
the throttle grip.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Side Cover (see Side Cover Removal in the Frame chap-
ter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Loosen the locknuts [A] and remove the lower end of the
accelerator cable [B] from the pulley.
• Loosen the locknuts [C] and remove the lower end of the
decelerator cable [D] from the pulley.
• Pull out the throttle cables upward
Throttle Cable Installation
• Install the throttle cables in accordance with the Cable,
Wire and Hose Routing in the Appendix chapter.
• Install the accelerator cable first and then decelerator ca-
ble.
• After installation, adjust each cable properly (see Throttle
Cable Inspection in the Periodic Maintenance chapter).
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition.
Throttle Cable Lubrication
• Refer to Chassis Parts Lubrication Perform in the Peri-
odic Maintenance chapter (see Chassis Parts Lubrication
Perform in the Periodic Maintenance chapter).
Choke Cable Lubrication and Inspection
Halaman 85
Choke Cable
Free Play Inspection
• Refer to Choke Operation Inspection in the Periodic Main-
tenance chapter (see Choke Operation in the Periodic
Maintenance chapter).
Free Play Adjustment
• Refer to Choke Operation Inspection in the Periodic Main-
tenance chapter (see Choke Operation in the Periodic
Maintenance chapter).
Choke Cable Removal
• Split the left handlebar switch housing [A], and remove
the choke cable [B] upper end from the choke lever [C].
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
• Remove the choke cable end from the cable bracket of
carburetor.
• Pull out the choke cable upward.
Choke Cable Installation
• Install the choke cable in accordance with the Cable,
Wire, and Hose Routing section in Appendix chapter.
• After installation, adjust the cable properly.
WARNING
Operation with an incorrectly routed or improperly
adjusted cable could result in an unsafe riding con-
dition.
Choke Cable Lubrication and Inspection
• Whenever the cable is removed, or in accordance with
the Periodic Maintenance Chart, lubricate the choke cable
(see General Lubrication in the Appendix chapter).
○Apply a thin coating of grease to the cable lower end.
○Use a commercially available pressure cable lubricator to
lubricate the cable.
○With the cable disconnected at both ends, the cable
should move freely in the cable housing.
FUEL SYSTEM 3-11
Special Tool -
Halaman 86
3-12 FUEL SYSTEM
Carburetors
Idle Speed Inspection
• Refer to Idle Speed Inspection in the Periodic Mainte-
nance chapter (see Idle Speed Inspection in the Periodic
Maintenance chapter).
Idle Speed Adjustment
• Refer to Idle Speed Adjustment in the Periodic Mainte-
nance chapter (see Idle Speed Adjustment in the Periodic
Maintenance chapter).
Engine Vacuum Synchronization Inspection
• Refer to Engine Vacuum Synchronization Inspection in
the Periodic Maintenance chapter (see Engine Vacuum
Synchronization Inspection in the Periodic Maintenance
chapter).
Engine Vacuum Synchronization Adjustment
• Refer to Engine Vacuum Synchronization Inspection in
the Periodic Maintenance chapter (see Engine Vacuum
Synchronization Inspection in the Periodic Maintenance
chapter).
Pilot Screw Adjustment
If the engine idle is still not stable, adjust the pilot screw to
obtain the proper idle speed using the pilot screw adjuster
[A].
Special Tool - Pilot Screw Adjuster: 57001-1239
○Turn in the pilot screw fully but not tightly, and then back
it out the specified turns. To set the screw to its original
position.
Pilot Screw Setting:
#L: 2 1/2
#R: 1 3/4
NOTE
○The standard number of turns the pilot screw must be
backed out varies by carburetor. The values given in the
specifications should be used only when the number of
the original back out turns is unavailable.
Special Tool -
Halaman 87
Carburetors
Service Fuel Level Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Situate the motorcycle so that it is perpendicular to the
ground.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
• Prepare an auxiliary fuel tank and connect the fuel hose
to the carburetor.
• Prepare a fuel hose.
• Connect the fuel level gauge [A] to the carburetor float
bowl with the fuel hose.
Special Tool - Fuel Level Gauge: 57001-1017
• Hold the gauge vertically against the side of the carburetor
body so that the “middle” line [B] is several millimeters
higher than the mating surface [C] of the carburetor float
bowl.
• Feed fuel to the carburetor, then turn the carburetor drain
plug out a few turns.
• Wait until the fuel level in the gauge settles.
FUEL SYSTEM 3-13
Service Fuel Level Adjustment
Halaman 88
3-14 FUEL SYSTEM
Carburetors
• Keeping the gauge vertical, align the “middle” line with the
mating surface.
NOTE
○Do not lower the “middle” line below the mating surface
of the carburetor float bowl.
If the gauge is lowered
and then raised again, the fuel level measured shows
somewhat higher than the actual fuel level. If the gauge
is lowered too far, dump the fuel out of it into a suitable
container and start the procedure over again.
• Read the fuel level [E] in the gauge and compare to the
specification.
• Screw in the carburetor drain plug [D].
• Stop feeding and remove the fuel level gauge.
If the fuel level is incorrect, adjust it (see Service Fuel
Level Adjustment).
Service Fuel Level (above the mating surface of carburetor
float bowl)
Standard: 0.5 mm ±1 mm (0.02 ±0.04 in.)
Service Fuel Level Adjustment
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the carburetor, and drain the fuel into a suitable
container.
• Remove the fittings with water hose.
• Remove the float bowl.
• Slide out the pivot pin [A] with a suitable tool [B], and
remove the float [C] and float valve needle [D].
Fuel System Cleanliness Inspection
Halaman 89
Carburetors
• Bend the tang [A] 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.
Float height
Standard: 17 ±2 mm (0.67 ±0.08 in.)
NOTE
○Do not push the needle rod [A] in during the float height
measurement [B].
• Assemble the carburetor, and recheck the fuel level.
If the fuel level cannot be adjusted by this method, the
float or the float valve [C] is damaged.
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Connect a suitable hose [A] to the fitting at the bottom of
each carburetor float bowl.
• Run the lower end of the carburetor drain hose into a suit-
able container.
• Turn out each drain plug [B] a few turns and drain the float
bowls with a hexagon wrench [C].
• Check to see if water or dirt comes out.
• Tighten the drain plug.
If any water or dirt appears during the above inspection,
clean the fuel system (see Carburetor Cleaning and Fuel
Tank Cleaning).
FUEL SYSTEM 3-15
Carburetor Removal
Halaman 90
3-16 FUEL SYSTEM
Carburetors
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Battery (see Battery Removal in the Electrical System
chapter)
Battery Damper
Battery Case Screws [A]
Battery Case [B]
• Remove the air cleaner housing mounting bolts [A].
• Loosen the carburetor holder clamps [B] off the air cleaner
ducts.
• Pull the air cleaner housing rearward.
• Remove the throttle cable and choke cable (see Throttle
Cable and Choke Cable Removal)
• Remove:
Bolts [C]
Bracket [D]
Carburetor [E]
• Stuff the pieces of lint-free, clean cloths into the carbure-
tor holder and the air cleaner duct to keep dirt out of the
engine and air cleaner.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing an accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
Carburetor Joining
Halaman 91
Carburetors
Carburetor Installation
• Route the cables, harness, and hoses correctly (see Ca-
ble, Wire and Hose Routing section in the Appendix chap-
ter).
• Tighten the clamps for the carburetor holders and slide
back the spring bands for the air cleaner housing securely.
• Check fuel leakage from the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
• Adjust the following items if necessary.
Idle Speed (see Idle Speed Adjustment in the Periodic
Maintenance chapter)
Carburetor Synchronization (see Carburetor Synchro-
nization Adjustment in the Periodic Maintenance chap-
ter)
Throttle Cable (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Choke Cable
Carburetor Separation
• Remove the carburetor (see Carburetor Removal).
• Pull out the air cut valve hoses [A], [B], [C] of the air cut
valve.
• Remove the choke plunger lever [D], spring [E] and car-
buretor mounting plates [F], [G].
• Gently, separately the carburetors each other.
Carburetor Joining
• When installing the carburetor, check to see that the O
-rings [A] are in place.
FUEL SYSTEM 3-17
Carburetor Joining
Halaman 92
3-18 FUEL SYSTEM
Carburetors
• Install the fitting [A] and spring [B] as shown.
• Install the connecting plates [A] [B] and spring [C] as
shown.
• The center lines of the carburetor bores must be parallel
both horizontally and vertically. If they are not, loosen
the mounting screws and align the carburetors on a flat
surface. Retighten the mounting screws.
• After installing the choke mechanism, check to see that
the choke plunger lever slides right to left smoothly with-
out abnormal friction.
CAUTION
Fuel mixture trouble could result if the choke
plunger does not seat properly in its rest position
after the choke lever is returned.
• Visually synchronize the throttle (butterfly) valves.
○Check to see that all throttle valves open and close
smoothly without binding when turning the pulley.
○Visually check the clearance [A] between the throttle
valve and the carburetor bore in each carburetor.
If there is a difference between two carburetors, turn the
balance adjusting screw [B] to obtain the same clearance.
• Install the carburetors (see Carburetor Installation).
• Adjust the synchronization (see Carburetor Synchroniza-
tion Adjustment in the Periodic Maintenance Chapter).
Carburetor Assembly
Halaman 93
Carburetors
Carburetor Disassembly
• Remove the carburetors (see Carburetor Removal).
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• For the Canada model, remove the pilot screw plug as
follows: punch a hole in the plug and pry there with an
awl or other suitable tool.
• Turn in the pilot screw and count the number of turns until
it seats fully but not tightly, and then remove the screw.
This is to set the screw to its original position when as-
sembling.
CAUTION
During carburetor disassembly, be careful not to
damage the diaphragm. Never use a sharp edge to
remove the diaphragm.
• Remove:
Spring [A]
Spring Seat [B]
Jet Needle [C]
Vacuum Piston [D]
Needle Jet [E]
Needle Jet Holder [F] and Main Jet [G]
Pilot Screw [H]
Carburetor Assembly
• Turn in the pilot screw [A] fully but not tightly, and then
back it out the same number of turns counted during dis-
assembly.
• Install the pilot screw plug as follows: install a new plug [B]
in the pilot screw hole of the carburetor body, and apply a
small amount of a bonding agent [C] to the circumference
of the plug to fix the plug.
CAUTION
Do not apply too much bonding agent to the plug or
the pilot screw itself may be fixed.
FUEL SYSTEM 3-19
Carburetor Cleaning
Halaman 94
3-20 FUEL SYSTEM
Carburetors
• To install the needle jet [A], turn the carburetor body up
-side down, and drop the needle jet into place so that the
smaller diameter end [B] of the jet goes in first.
• Carefully screw in the needle jet holder [A]. It will seat
against the needle jet, pushing the end of the jet into the
carburetor bore.
Main Jet [B]
CAUTION
Do not apply force to the jet or overtighten it, as
this could damage the jet or the carburetor body,
requiring replacement.
• Install the float bowl.
• Slip the jet needle [B] through the hole in the center of
the vacuum piston, and put the spring seat [C] on the top
of the needle. Turn the seat so that it does not block the
hole at the bottom of the vacuum piston [A].
Spring [D]
• Install the carburetor top cover.
• Turn in the pilot screw fully but not tightly, and then back it
out the same number of turns counted during disassem-
bly.
• When removing the air cut valve assembly, unscrew the
mounting screws [B] and remove the cover [C], spring [D],
O-ring [E] and diaphragm [F].
• Install:
Left Carburetor [A]
Air Cut Valve Body [G]
Air Cut Valve Mounting Plate [H]
Carburetor Cleaning
WARNING
Clean the carburetor in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low-flash
point solvents to clean the carburetor.
Carburetor Inspection
Halaman 95
Carburetors
CAUTION
Do not use compressed air on an assembled carbu-
retor, or the floats may be crushed by the pressure,
and the vacuum piston diaphragm may be dam-
aged.
Remove as many rubber or plastic parts
from the carburetor as possible before cleaning the
carburetor with a cleaning solution. This will pre-
vent damage to or deterioration of the parts. The
carburetor body has plastic parts that cannot be
removed. Do not use a strong carburetor cleaning
solution which could attack these parts; instead,
use a mild high-flash point cleaning solution safe
for plastic parts. Do not use wire or any other hard
instrument to clean carburetor parts, especially
jets, as they may be damaged.
• Disassemble the carburetor (see Carburetor Disassem-
bly).
• Immerse all the metal parts in a carburetor cleaning solu-
tion.
• Rinse the parts in water.
• When the parts are clean, dry them with compressed air.
• Blow through the air and fuel passages with compressed
air.
• Assemble the carburetor (see Carburetor Assembly).
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the carburetors (see Carburetor Removal).
• Before disassembling the carburetors, check the fuel level
(see Fuel Level Inspection).
If the fuel level is incorrect, inspect the rest of the carbu-
retor before correcting it.
• Slide the choke plunger lever [A] right to the left to check
that the choke plungers move smoothly.
If the choke plungers do not work properly, replace the
carburetors.
• Turn the throttle cable pulley to check that the throttle but-
terfly valves [B] move smoothly and return by spring ten-
sion.
If the throttle valves do not move smoothly, replace the
carburetors.
FUEL SYSTEM 3-21
Carburetor Inspection
Halaman 96
3-22 FUEL SYSTEM
Carburetors
• Disassemble the carburetors (see Carburetor Disassem-
bly).
• Clean the carburetors (see Carburetor Cleaning).
• Check that the O-rings on the float bowl and pilot screw
and the diaphragm on the vacuum piston are in good con-
dition.
If any of the O-rings or diaphragms are not in good con-
dition, replace them.
• Check the O-ring and diaphragm of coasting enricher sys-
tem.
If any of the O-ring or diaphragm are not in good condition,
replace them.
• Check the plastic tip [A] of the float valve needle [B]. It
should be smooth, without any grooves, scratches, or
tears.
If the plastic tip is damaged [C], replace the needle.
• Push the rod [D] in the other end of the float valve needle,
and then release it [E].
If the rod does not spring out, replace the needle.
• Check the tapered portion [A] of the pilot screw [B] for
wear or damage.
If the pilot screw is worn or damaged on the tapered por-
tion, it will prevent the engine from idling smoothly. Re-
place it.
• Check that the vacuum piston [A] moves smoothly in the
carburetor body. The surface of the piston must not be
excessively worn.
If the vacuum piston does not move smoothly, or if it is
very loose in carburetor body, replace the carburetor.
Air Cleaner Housing Removal
Halaman 97
Air Cleaner
Air Cleaner Element Removal
• Refer to Air Cleaner Cleaning in the Periodic Maintenance
chapter (see Air Cleaner Cleaning in the Periodic Mainte-
nance chapter).
Air Cleaner Element Installation
• Refer to Air Cleaner Cleaning in the Periodic Maintenance
chapter (see Air Cleaner Cleaning in the Periodic Mainte-
nance chapter).
Air Cleaner Housing Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Rear Seat (see Rear Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
• Pull out the rear axle and place the rear wheel [A] on the
ground.
• Take out the bolts [A] and remove the fuel tank bracket
[B].
• Pull out the starter relay [C].
• Remove the rear brake reservoir bolt [A] and disconnect
the clamp [B], and free the rear brake reservoir and main
harness from the frame.
• Remove the air cleaner cap [C].
• Remove:
Carburetor Holder Clamps [A] (Loosen)
Air Cleaner Housing Mounting Bolts [B]
Air Suction Valve Hose [C]
• Remove the air cleaner housing [D], pulling out the duct
portion [E] from the grommet.
FUEL SYSTEM 3-23
Air Cleaner Housing Assembly
Halaman 98
3-24 FUEL SYSTEM
Air Cleaner
• Cover the carburetors intakes with a clean, lint-free towel
to keep dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the car-
buretors, the butterfly valves may become stuck,
possibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
Air Cleaner Housing Installation
• Install the air cleaner housing clamps [A] as shown.
Approx. 18° [B]
Air Cleaner Housing Disassembly
• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal)
Air Cleaner Element (see Air Element Removal in the
Periodic Maintenance chapter)
Screw [A]
Right Cover [B]
Flame Arrester
Air Cleaner Housing Assembly
• Install the flame arrester [A].
• Be sure the O-ring [B] is in position.
Oil Draining
Halaman 99
Air Cleaner
• Apply a bonding agent to the slash portion [A] of the air
cleaner housing.
Oil Draining
• Remove the drain cap [A] at the lower end of the air
cleaner housing and drain water or oil accumulates in the
air cleaner housing.
• Be sure to install the cap firmly, or the air is drawn in
through it.
WARNING
Be sure to install the cap in the air cleaner housing
after draining. Oil on tires make them slippery and
can cause an accident and injury.
FUEL SYSTEM 3-25
Fuel Tank Installation
Halaman 100
3-26 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explo-
sive under certain conditions. Make sure the area
is well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light. Do not smoke. Turn the ignition switch OFF.
Be prepared for fuel spillage; any spilled fuel must
be completely wiped up immediately.
• Remove the side covers (see Side Covers Removal in the
Frame chapter).
• Turn the fuel tap position to the ON [A] position.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank Mounting Bolts [A]
Fuel Hose [B]
Vacuum Hose [C]
Fuel Level Sensor Connector [D]
Fuel Tank
• Drain the fuel tank if necessary.
○Arrange a suitable container under the fuel tap.
○Turn the fuel tap position to the PRI position to drain the
fuel into the container.
Fuel Tank Installation
• Read the above WARNING mentioned in Fuel Tank Re-
moval.
• Route the hose correctly.
• Be sure the hoses are clamped securely to prevent fuel
leaks.
• Be sure the rubber dampers [A] are in position.
If any dampers is damaged or deteriorated, replace it.
Fuel Tank and Tap Cleaning
Halaman 101
Fuel Tank
Fuel Tap Removal
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well-ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
• Remove the fuel tank (see Fuel Tank Removal).
• Drain the fuel into a suitable container.
• Remove the bolts [A] and take out the fuel tap [B].
Fuel Tap Installation
• Fuel tap installation is the reverse of removal. Note the
following.
Torque - Fuel Tap Mounting Bolts: 2.5 N·m (0.25 kgf·m, 22
in·lb)
• Be sure to clamp the fuel hose to the tap to prevent leaks.
• Be sure the fuel level sensor leads [A] are routed as
shown.
Fuel Tank and Tap Cleaning
WARNING
Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area. Because of the danger of
highly flammable liquids, do not use gasoline or low
flash- point solvents to clean the tank.
• Remove the fuel tank and drain it.
• Pour some high flash-point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
• Pour high flash-point solvent.
• Pour the solvent out of the tank.
• Remove the fuel tap from the tank by taking out the bolts.
• Clean the fuel tap in a high flash-point solvent.
• Pour high flash-point solvent through the tap in ON and
PRI positions.
• Dry the tank and tap with compressed air.
• Install the tap in the tank.
• Install the fuel tank (see Fuel Tank Installation).
FUEL SYSTEM 3-27
Fuel Tank and Cap Inspection
Halaman 102
3-28 FUEL SYSTEM
Fuel Tank
Fuel Tap Inspection
• Remove the fuel tap (see Fuel Tap Removal).
• Check the fuel tap filter screen [A] for any breaks or dete-
rioration.
If the fuel tap screens have any breaks or are deterio-
rated, they may allow dirt to reach the carburetor, causing
poor running. Replace the fuel tap.
If the fuel tap leaks, or allows fuel to flow when it is at
ON or PRI without engine running, replace the damaged
gasket [B] or O-rings [C].
Fuel Tank and Cap Inspection
• Open the tank cap.
• Visually inspect the gaskets [A] on the tank cap for any
damage.
Replace the gaskets if they are damaged.
• Remove the drain pipes and check to see if the pipes in
the tank do not clogged up. Check the tank cap breather
also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.
CAUTION
Do not apply compressed air to the air vent holes
[B] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.
Cooling System
Halaman 103
Cooling System
Table of Contents
Exploded View........................................................................................................................
4-2
Specifications .........................................................................................................................
4-4
Sealant ...................................................................................................................................
4-5
Coolant Flow Chart.................................................................................................................
4-6
Coolant ...................................................................................................................................
4-8
Coolant Deterioration Inspection.......................................................................................
4-8
Coolant Level Inspection...................................................................................................
4-8
Coolant Draining ...............................................................................................................
4-8
Coolant Filling ...................................................................................................................
4-8
Pressure Testing ...............................................................................................................
4-8
Cooling System Flushing ..................................................................................................
4-9
Water Pump............................................................................................................................
4-10
Pump Cover Removal.......................................................................................................
4-10
Pump Cover Installation....................................................................................................
4-10
Water Pump Removal.......................................................................................................
4-10
Water Pump Installation....................................................................................................
4-10
Pump Impeller Inspection .................................................................................................
4-11
Radiator, Radiator Fan ...........................................................................................................
4-12
Radiator and Radiator Fan Removal ................................................................................
4-12
Radiator Inspection...........................................................................................................
4-13
Radiator Cleaning .............................................................................................................
4-13
Radiator Cap Inspection ...................................................................................................
4-13
Radiator Filler Neck Inspection.........................................................................................
4-14
Thermostat .............................................................................................................................
4-15
Thermostat Removal.........................................................................................................
4-15
Thermostat Installation......................................................................................................
4-15
Thermostat Housing Removal ..........................................................................................
4-15
Thermostat Housing Installation Note...............................................................................
4-15
Thermostat Inspection ......................................................................................................
4-16
Hoses and Pipes ....................................................................................................................
4-17
Hose Installation ...............................................................................................................
4-17
Hose Inspection ................................................................................................................
4-17
Radiator Fan Switch, Water Temperature Switch...................................................................
4-18
Radiator Fan Switch, Water Temperature Switch Removal ..............................................
4-18
Radiator Fan Switch, Water Temperature Switch Installation ...........................................
4-18
Radiator Fan Switch, Water Temperature Switch Inspection............................................
4-18
COOLING SYSTEM 4-1
4
Cooling System
Halaman 104
4-2 COOLING SYSTEM
Exploded View
Cooling System
Halaman 105
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Water Temperature Switch
7.5
0.76
66 in·lb
SS
2
Thermostat Cover Bolts
9.8
1.0
87 in·lb
3
Thermostat Housing Mounting Bolts
9.8
1.0
87 in·lb
4
Radiator Fan Switch
23.5
2.4
17
5
Radiator Bolts
9.8
1.0
87 in·lb
6
Radiator Cap Bracket Bolt
9.8
1.0
87 in·lb
7
Water Pipe Bolts
9.8
1.0
87 in·lb
8
Water Hose Clamp Screws
1.5
0.15
13 in·lb
9
Drain Bolt
9.8
1.0
87 in·lb
10
Water Pump Cover Bolts
9.8
1.0
87 in·lb
11
Water Pump Bolts
9.8
1.0
87 in·lb
12
Reserve Tank Cap
–
–
–
Hand-Tighten
13
Reserve Tank Bolts
9.8
1.0
87 in·lb
14
Reserve Tank Bracket Bolt
9.8
1.0
87 in·lb
15. Radiator Fan
16. Reserve Tank
17. Thermostat
18. Radiator
19. Water Pump
G: Apply grease.
R: Replacement Part
SS: Apply silicone sealant to the threads.
COOLING SYSTEM 4-3
Cooling System
Halaman 106
4-4 COOLING SYSTEM
Specifications
Item
Standard
Coolant
Type
Permanent type of antifreeze (soft water and ethylene glycol plus
corrosion and rust inhibitor chemicals for aluminum engines and
radiators)
Mixed Ratio
Soft water 50%, coolant 50%
Freezing Point
−35°C (−31°F)
Total Capacity
1.5 L (1.59 US qt)
Radiator
Radiator Cap Relief Pressure 93 ∼123 kPa (0.95 ∼1.25 kgf/cm², 14 ∼18 psi)
Thermostat
Valve Opening Temperature
63.5 ∼66.5°C (146 ∼152°F)
Valve Full Opening Lift
More than 6 mm (0.24 in.) @80°C (176°F)
Kawasaki Bond (Silicone Sealant):
Halaman 107
Sealant
Kawasaki Bond (Silicone Sealant):
56019-120
COOLING SYSTEM 4-5
Permanent type antifreeze is used as a coolant to protect the co
Halaman 108
4-6 COOLING SYSTEM
Coolant Flow Chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.
When the engine starts, the water pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The
thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
When coolant temperature is below 63.5 ∼66.5°C (146 ∼152°F), the thermostat closes so that the
coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
When coolant temperature is more than 63.5 ∼66.5°C (146 ∼152°F), the thermostat opens and the
coolant flows.
When the coolant temperature goes up beyond 96 ∼100°C (205 ∼212°F), the radiator fan switch
conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there
is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.
When the temperature is below 91°C (196°F), the fan switch opens and the radiator fan stops.
In this way, this system controls the engine temperature within narrow limits where the engine op-
erates most efficiently even if the engine load varies.
The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles
which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.
The radiator cap has two valves. One is a pressure valve which holds the pressure in the system
when the engine is running. When the pressure exceeds 93 ∼123 kPa (0.95 ∼1.25 kgf/cm², 14 ∼18
psi) the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure
escapes, the valve closes, and keeps the pressure at 93 ∼123 kPa (0.95 ∼1.25 kgf/cm², 14 ∼18 psi).
When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.
Permanent type antifreeze is used as a coolant to protect the co
Halaman 109
COOLING SYSTEM 4-7
**Coolant Flow Chart**
* **Hot Coolant**
* **Cold Coolant**
Radiator Cap
Reserve Tank Overflow Hose
Reserve Tank Hose
Thermostat Housing
Radiator Fan
Reserve Tank
Cylinder/
Cylinder Head
Jacket
Water Pump
GD04090B G
Pressure Testing
Halaman 110
4-8 COOLING SYSTEM
Coolant
Coolant Deterioration Inspection
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Visually inspect the coolant in the reserve tank.
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded.
If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
Coolant Level Inspection
• Refer to Coolant Level Inspection in the Periodic Mainte-
nance chapter (see Coolant Level Inspection in the Peri-
odic Maintenance chapter).
Coolant Draining
• Refer to Coolant Change in the Periodic Maintenance
chapter (see Coolant Change in the Periodic Mainte-
nance chapter).
Coolant Filling
• Refer to Coolant Change in the Periodic Maintenance
chapter (see Coolant Change in the Periodic Mainte-
nance chapter).
Pressure Testing
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Remove the radiator cap, and install a cooling system
pressure tester [A] on the filler neck.
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
• Build up pressure in the system carefully until the pres-
sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
CAUTION
During pressure testing, do not exceed the pres-
sure for which the system is designed. The maxi-
mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
• Watch the gauge for at least 6 seconds.
If the pressure holds steady, the system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
water pump.
• Remove the pressure tester, replenish the coolant, and
install the radiator cap.
Cooling System Flushing
Halaman 111
Coolant
Cooling System Flushing
Over a period of time, the cooling system accumulates
rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool-
ing system. If this accumulation is not removed, it will clog
up the water passage and considerable reduce the effi-
ciency of the cooling system.
• Drain the cooling system (see Coolant Change in the Pe-
riodic Maintenance chapter).
• Fill the cooling system with fresh water mixed with a flush-
ing compound.
CAUTION
Do not use a flushing compound which is harmful to
the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cleaning product.
• Warm up the engine, and run it at normal operating tem-
perature for about ten minutes.
• Stop the engine, and drain the cooling system.
• Fill the system with fresh water.
• Warm up the engine and drain the system.
• Repeat the previous two steps once more.
• Fill the system with a permanent type coolant and bleed
the air from the system (see Coolant Change in the Peri-
odic Maintenance chapter).
COOLING SYSTEM 4-9
Water Pump Installation
Halaman 112
4-10 COOLING SYSTEM
Water Pump
Pump Cover Removal
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Coolant Pipes [A], [B]
Engine Sprocket Cover [C] (see Engine Sprocket Re-
moval in the Final chapter)
• Remove the water pump mounting bolts [A] and water
pump cover [B].
Pump Cover Installation
• Fit the O-ring [A] into the groove of the pump cover [B].
• Install the removed parts
Torque - Water Hose Clamp Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Water Pump Removal
• Remove:
Pump Cover (see Pump Cover Removal)
• Remove the water pump mounting bolts [A], and remove
the water pump [B].
Water Pump Installation
• Check the O-ring [A] visually whether or not there is a
damage on it.
• Grease the O-ring.
• Install the water pump aligning the slit [B] of water pump
shaft with the oil pump shaft.
Pump Impeller Inspection
Halaman 113
Water Pump
Pump Impeller Inspection
• Visually check the impeller [A].
If the surface is corroded or if the blades are damaged,
replace the water pump unit.
COOLING SYSTEM 4-11
Radiator and Radiator Fan Removal
Halaman 114
4-12 COOLING SYSTEM
Radiator, Radiator Fan
Radiator and Radiator Fan Removal
WARNING
The radiator fan is connected directly to the bat-
tery. The radiator fan may start even if the ignition
switch is off. NEVER TOUCH THE RADIATOR FAN
UNTIL THE RADIATOR FAN CONNECTOR IS DIS-
CONNECTED. TOUCHING THE FAN BEFORE THE
CONNECTOR IS DISCONNECTED COULD CAUSE
INJURY FROM THE FAN BLADES.
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Disconnect the fan motor lead connector [A] before re-
moval of the radiator or radiator fan.
• Disconnect the fan switch lead connector [A].
Fan Switch [B]
• Loosen the hose clamp [C] and pull off the water hose [D].
• Loosen the hose clamp [A] and pull off the water hose [B].
• Remove the radiator bolts [C] and take the radiator [D] off
the frame.
• Separate the filler and water hose from the radiator.
• Separate the radiator fan [A] from the radiator.
Radiator Fan Screws [B]
CAUTION
Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi-
ciency.
Radiator Cap Inspection
Halaman 115
Radiator, Radiator Fan
Radiator Inspection
• Check the radiator core.
If there are obstructions to air flow, remove them.
If
the
corrugated
fins
[A]
are
deformed,
carefully
straighten them.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably de-
formed fins, replace the radiator with a new one.
Radiator Cleaning
CAUTION
When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [A] away more than 0.5 m (1.6
ft) [B] from the radiator core.
Hold the steam gun perpendicular to the core sur-
face.
Run the steam gun following the core fin direction.
Radiator Cap Inspection
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Check the condition of the top and bottom valve seals [A]
and valve spring [B].
If any one of them shows visible damage, replace the cap
with a new one.
• Install the cap [A] on a cooling system pressure tester [B].
NOTE
○Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
• Watching the pressure gauge, pump the pressure tester
to build up the pressure until the relief valve opens: the
gauge hand flicks downward. Stop pumping and measure
leak time at once. The relief valve must open within the
specified range in the table below and the gauge hand
must remain within the same range at least 6 seconds.
Radiator Cap Relief Pressure
Standard: 93 ∼123 kPa (0.95 ∼1.25 kgf/cm², 14 ∼18
psi)
If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.
COOLING SYSTEM 4-13
Radiator Filler Neck Inspection
Halaman 116
4-14 COOLING SYSTEM
Radiator, Radiator Fan
Radiator Filler Neck Inspection
• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
Thermostat Housing Installation Note
Halaman 117
Thermostat
Thermostat Removal
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Thermostat Cover Bolts [A]
• Move the thermostat cover [A] outwards and remove the
thermostat [B].
Thermostat Installation
• Install the removed part in reverse of removal.
• Fit the thermostat [A] in the housing so that the air bleeder
hole [B] faces as shown.
• Fill the radiator with coolant.
Thermostat Housing Removal
• Drain the Coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
• Disconnect the water temperature switch lead connector
[A].
• Loosen the water hose clamps [B] and slide the hoses
[C], [D] back and forth from the thermostat housing [E]
and cover [F].
Water Temperature Switch [G]
• Remove the thermostat housing mounting bolts [H] and
pull the housing out of the frame.
• Remove the thermostat cover and pull out the thermostat
if necessary.
Thermostat Housing Installation Note
• Be sure to install the ground lead on the thermostat hous-
ing mounting bolt.
COOLING SYSTEM 4-15
Thermostat Inspection
Halaman 118
4-16 COOLING SYSTEM
Thermostat
Thermostat Inspection
• Remove the thermostat, and visually inspect the thermo-
stat valve [A] at room temperature.
If the valve is open, replace the thermostat with a new
one.
• To check valve opening temperature, suspend the ther-
mostat [A] in a container of water and raise the tempera-
ture of the water.
○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an ac-
curate thermometer [B] in the water so that the heat sen-
sitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
63.5 ∼66.5°C (146 ∼152°F)
Hose Inspection
Halaman 119
Hoses and Pipes
Hose Installation
• Install the hoses and pipes, being careful to follow bend-
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
• Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to pre-
vent the clamps from contacting anything.
Torque - Water Hose Clamp Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Hose Inspection
• Refer to Radiator Hose and Connection Inspection in the
Periodic Maintenance chapter (see Radiator Hose and
Connection Inspection in the Periodic Maintenance chap-
ter).
COOLING SYSTEM 4-17
Radiator Fan Switch, Water Temperature Switch Inspection
Halaman 120
4-18 COOLING SYSTEM
Radiator Fan Switch, Water Temperature Switch
Radiator Fan Switch, Water Temperature Switch
Removal
CAUTION
The fan switch or the water temperature switch
should never be allowed to fall on a hard surface.
Such a shock to their parts can damage them.
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Radiator Fan Switch Lead Connector [A]
Radiator Fan Switch [B]
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Water Temperature Switch Lead Connector [A]
Water Temperature Switch [B]
Radiator Fan Switch, Water Temperature Switch
Installation
• Apply silicone sealant to the threads of the water temper-
ature switch.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
• Tighten the fan switch and water temperature sensor.
Torque - Radiator Fan Switch: 23.5 N·m (2.4 kgf·m, 17 ft·lb)
Water Temperature Switch: 7.5 N·m (0.76 kgf·m,
66 in·lb)
• Fill the coolant and bleed the air from cooling system (see
Coolant Change in the Periodic Maintenance chapter).
Radiator Fan Switch, Water Temperature Switch
Inspection
• Refer to Water Temperature Switch Inspection in the Elec-
trical System chapter (see Water Temperature Switch In-
spection in the Electrical System chapter).
Engine Top End
Halaman 121
Engine Top End
Table of Contents
Exploded View...................................
5-2
Exhaust System.................................
5-6
Specifications ....................................
5-7
Special Tools .....................................
5-9
Clean Air System...............................
5-11
Vacuum Switch Valve Removal ...
5-11
Vacuum Switch Valve Installation
5-11
Vacuum Switch Valve Operation
Test............................................
5-11
Vacuum Switch Valve Unit Test....
5-11
Air Suction Valve Removal...........
5-12
Air Suction Valve Installation........
5-12
Air Suction Valve Inspection ........
5-12
Clean Air System Hose
Inspection..................................
5-13
Cylinder Head Cover .........................
5-14
Cylinder Head Cover Removal ....
5-14
Cylinder Head Cover Installation .
5-14
Camshaft Chain Tensioner ................
5-15
Camshaft Chain Tensioner
Removal....................................
5-15
Camshaft Chain Tensioner
Installation.................................
5-15
Camshaft, Camshaft Chain ...............
5-17
Camshaft Removal ......................
5-17
Camshaft Installation ...................
5-17
Camshaft and Sprocket
Assembly...................................
5-19
Camshaft and Camshaft Cap
Wear Inspection ........................
5-19
Camshaft Runout Inspection........
5-20
Cam Wear Inspection ..................
5-20
Camshaft Chain Guide Wear
Inspection..................................
5-20
Cylinder Head....................................
5-21
Cylinder Compression
Measurement ............................
5-21
ENGINE TOP END 5-1
Cylinder Head Removal...............
5-22
Cylinder Head Installation............
5-22
Cylinder Head Warp Inspection ...
5-23
Cylinder Head Cleaning...............
5-24
Valves................................................
5-25
Valve Clearance Inspection .........
5-25
Valve Clearance Adjustment .......
5-25
Valve Removal.............................
5-25
Valve Installation..........................
5-25
Valve Guide Removal ..................
5-25
Valve Guide Installation ...............
5-25
Valve-to-Guide Clearance
Measurement (Wobble
Method).....................................
5-26
Valve Seat Inspection ..................
5-27
Valve Seat Repair ........................
5-27
Cylinder, Pistons................................
5-32
Cylinder Removal.........................
5-32
Cylinder Installation......................
5-32
Piston Removal............................
5-33
Piston Installation.........................
5-33
Cylinder Wear Inspection.............
5-34
Piston Wear Inspection................
5-34
Piston Ring, Piston Ring Groove
Wear Insepction ........................
5-35
Piston Ring Groove Width
Inspection..................................
5-35
Piston Ring Thickness Inspection
5-35
Piston Ring End Gap Inspection..
5-36
Boring, Honing .............................
5-36
Carburetor Holder..............................
5-37
Carburetor Holder Installation......
5-37
Muffler................................................
5-38
Muffler Removal...........................
5-38
Muffler Installation........................
5-38
Exhaust System Inspection..........
5-39
5
Engine Top End
Halaman 122
5-2 ENGINE TOP END
Exploded View
Engine Top End
Halaman 123
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Cylinder Head Cover Bolts
9.8
1.0
87 in·lb
2
Camshaft Sprocket Bolts
15
1.5
11
L
3
Chain Tensioner Cap Bolt
5.0
0.5
44 in·lb
4
Air Suction Cover Bolts
9.8
1.0
87 in·lb
5
Vacuum Switch Valve Bracket Bolts
9.8
1.0
87 in·lb
6
Rear Camshaft Chain Guide Bolt-Lower
17
1.7
13
7
Chain Tensioner Mounting Bolts
9.8
1.0
87 in·lb
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disufide
grease in a weight ratio 10 : 1).
R: Replacement Parts
SS: Apply silicon sealant (Kawasaki Bond: 92104-0004).
ENGINE TOP END 5-3
Engine Top End
Halaman 124
# 5-4 ENGINE TOP END
## Exploded View
* (1) (S)
* (1) (S)
* (1) (S)
* (R)
* (R)
* (7) (MO)
* (R)
* (R)
* (10)
* (R)
* (MO)
* (R)
* (R)
* (6)
* (4) (S) (MO)
* (4) (S) (MO)
* (11) (R)
* (11)
* (P)
* (1) (8)
* (8)
* (9)
* (14)
* (R)
* (MO)
* (R)
* (13)
* (12) (10) (R)
### Inset View
* (4) (S) (MO)
* (1) (2) (3)
* (4) (S) (MO)
S-32317/RO Z
Engine Top End
Halaman 125
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Camshaft Cap Bolts
12
1.2
106 in·lb
S
2
Camshaft Cap Bolts
12
1.2
106 in·lb
S
3
Cylinder Head Bolt (M6)
12
1.2
106 in·lb
S
4
Cylinder Head Bolts (M8)
24.5
2.5
18
MO, S
5
Water Passage Plugs
20
2.0
15
L
6
Carburetor Holder Clamp Screws
2.0
0.2
18 in·lb
7
Water Drain Bolt
5.9
0.6
52 in·lb
8
Muffler Body Rear Cover Bolts
9.8
1.0
87 in·lb
L
9
Muffler Body Mounting Bolt
30
3.1
22
10
Muffler Body Clamp Bolt
17
1.7
13
11
Muffler Cover Bolts
9.8
1.0
87 in·lb
12
Muffler Cover Clamp Screw
6.9
0.70
61 in·lb
13
Exhaust Pipe Mounting Bolt
9.8
1.0
87 in·lb
14
Exhaust Pipe Holder Nuts
12
1.2
104 in·lb
EO: Apply engine oil.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disufide
grease in a weight ratio 10 : 1).
S: Follow the specific tightening sequence.
SS: Apply silicon sealant.
ENGINE TOP END 5-5
Exhaust System
Halaman 126
5-6 ENGINE TOP END
Exhaust System
Exhaust System
| MANIFOLD | SILENCER | SPECIFICATION | MODEL |
| :------------------------ | :--------------------------------------------- | :------------ | :-------- |
| **Honeycomb Type Catalyst** | **Honeycomb Type Catalyst** | US | EX250.8F |
| P/No. 39178 0076 | P/No. 18091 0395 | US (CALIF) | EX250.8F2 |
| Mark: KHI M 121 | Mark: KAW5340250 | CANADA | EX250.8F |
| | EPA Noise Emission Control Information | INDONESIA | EX250.8F |
| | | MALAYSIA | EX250.8F |
| | **Non-Catalyst** | | |
| | P/No. 18091 0536 | AUSTRALIA | EX250.8F |
| | Mark: KHI K 535 | PHILIPPINE | EX250.8F |
H: Honeycomb Type Catalyst
**Manifold Mark Position [A]**
![Manifold Mark Position [A]](GE24018 S.png)
**Honeycomb Type Catalyst Position [D] of Manifold**
![Honeycomb Type Catalyst Position [D] of Manifold](3J1312361.png)
**Silencer Mark Position [B]**
![Silencer Mark Position [B]](GE24019 S.png)
**Honeycomb Type Catalyst Position [C] of Silencer**
![Honeycomb Type Catalyst Position [C] of Silencer](3J131236_0.png)
Exhaust System
Halaman 127
ENGINE TOP END 5-7
# Specifications
| Item | Standard | Service Limit |
| :---------------------------------------------------------- | :--------------------------------------------------------------------------------- | :---------------------------- |
| **Clean Air System** | | |
| Vacuum Switch Valve Closing Pressure | Open → Close <br> 41.3 ~ 49.3 kPa (310 ~ 370 mmHg) | --- |
| **Camshafts, Camshaft Chain, Rocker Arms** | | |
| Cam Height: | | |
| Exhaust | 32.843 ~ 32.957 mm (1.2930 ~ 1.2975 in.) | 32.74 mm (1.289 in.) |
| Inlet | 33.843 ~ 33.957 mm (1.3324 ~ 1.3369 in.) | 33.74 mm (1.328 in.) |
| Camshaft Journal, Camshaft Cap Clearance | 0.028 ~ 0.071 mm (0.0011 ~ 0.0071 in.) | 0.16 mm (0.0063 in.) |
| Camshaft Journal Diameter | 23.950 ~ 23.972 mm (0.9429 ~ 0.9438 in.) | 23.92 mm (0.942 in.) |
| Camshaft Bearing Inside Diameter | 24.000 ~ 24.021 mm (0.9449 ~ 0.9457 in.) | 24.08 mm (0.948 in.) |
| Camshaft Runout | TIR 0.02 mm (0.0008 in.) or less | TIR 0.1 mm (0.004 in.) |
| **Cylinder Head** | | |
| Cylinder Compression | (Usable Range) <br> 980 ~ 1 500 kPa (10.0 ~ 15.3 kgf/cm², <br> 142 ~ 218 psi) @470 r/min (rpm) | --- |
| Cylinder Head Warp | --- | 0.05 mm (0.002 in.) |
| **Valves** | | |
| Valve Clearance: | | |
| Inlet | 0.15 ~ 0.24 mm (0.0059 ~ 0.0094 in.) | --- |
| Exhaust | 0.22 ~ 0.29 mm (0.0087 ~ 0.0114 in.) | --- |
| Valve Head Thickness: | | |
| Inlet | 0.50 mm (0.0197 in.) | 0.3 mm (0.012 in.) |
| Exhaust | 0.80 mm (0.0315 in.) | 0.5 mm (0.020 in.) |
| Valve Stem Bend | --- | 0.05 mm (0.002 in.) TIR |
| Valve Stem Diameter: | | |
| Inlet | 4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in.) | 4.46 mm (0.176 in.) |
| Exhaust | 4.455 ~ 4.470 mm (0.1754 ~ 0.1760 in.) | 4.44 mm (0.175 in.) |
| Valve Guide Inside Diameter | 4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in.) | 4.58 mm (0.180 in.) |
| Valve/valve Guide Clearance <br> (Wobble Method): | | |
| Inlet | 0.03 ~ 0.09 mm (0.0012 ~ 0.0035 in.) | 0.27 mm (0.011 in.) |
| Exhaust | 0.08 ~ 0.15 mm (0.0031 ~ 0.0059 in.) | 0.33 mm (0.013 in.) |
| Valve Seating Surface: <br> Outside Diameter: | | |
| Inlet | 21.9 ~ 22.1 mm (0.8622 ~ 0.8701 in.) | --- |
| Exhaust | 19.3 ~ 19.5 mm (0.7598 ~ 0.7677 in.) | --- |
| Width | 0.5 ~ 1.0 mm (0.0197 ~ 0.0394 in.) | --- |
| Valve Spring Free Length: | | |
| Inlet | 39.5 mm (1.555 in.) | 38.0 mm (1.15 in.) |
| Exhaust | 39.5 mm (1.555 in.) | 38.0 mm (1.31 in.) |
| Valve Seat Cutting Angle | 32°, 45°, 67.5° | --- |
Exhaust System
Halaman 128
5-8 ENGINE TOP END
Specifications
Item
Standard
Service Limit
Cylinder, Piston
Cylinder Inside Diameter
62.000 ∼62.012 mm (2.4409 ∼2.4414 in.)
62.10 mm (2.44 in.)
Piston Diameter
61.942 ∼61.957 mm (2.4387 ∼2.4392 in.)
61.80 mm (2.43 in.)
Piston/Cylinder Clearance
0.043 ∼0.070 mm (0.0017 ∼0.0028 in.)
– – –
Oversize Pistons and Rings
+0.5 mm (0.020 in.)
– – –
Piston Ring/Groove
Clearance:
Top
0.03 ∼0.07 mm (0.0012 ∼0.0028 in.)
0.17 mm (0.0067 in.)
Second
0.02 ∼0.06 mm (0.0008 ∼0.0024 in.)
0.16 mm (0.0063 in.)
Piston Ring Groove Width:
Top
0.82 ∼0.84 mm (0.0323 ∼0.0331 in.)
0.92 mm (0.0362 in.)
Second
0.81 ∼0.83 mm (0.0319 ∼0.0327 in.)
0.91 mm (0.0358 in.)
Oil
1.51 ∼1.53 mm (0.0594 ∼0.0602 in.)
1.61 mm (0.0634 in.)
Piston Ring Thickness:
Top, Second
0.77 ∼0.79 mm (0.0303 ∼0.0311 in.)
0.7 mm (0.028 in.)
Piston Ring End Gap:
Top
0.15 ∼0.30 mm (0.0059 ∼0.0118 in.)
0.6 mm (0.024 in.)
Second
0.40 ∼0.55 mm (0.0157 ∼0.0217 in.)
0.9 mm (0.035 in.)
Oil
0.20 ∼0.80 mm (0.0079 ∼0.0315 in.)
1.1 mm (0.043 in.)
Compression Gauge, 20 kgf/cm :
Halaman 129
ENGINE TOP END 5-9
Special Tools
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Seat Cutter Holder Bar:
57001-1128
Valve Spring Compressor Assembly:
57001-241
Valve Seat Cutter, 32° - φ22:
57001-1206
Piston Pin Puller Assembly:
57001-910
Valve Seat Cutter, 67.5° - φ22:
57001-1207
Valve Seat Cutter, 45° - φ24.5:
57001-1113
Valve Spring Compressor Adapter, φ16:
57001-1305
Valve Seat Cutter, 32° - φ25:
57001-1118
Compression Gauge Adapter, M10 × 1.0:
57001-1317
Compression Gauge, 20 kgf/cm :
Halaman 130
## 5-10 ENGINE TOP END
### Special Tools
* **Valve Seat Cutter Holder, φ4.5:**
57001-1330
[Image of Valve Seat Cutter Holder]
* **Piston Base, φ2.3:**
57001-1336
[Image of Piston Base]
* **Valve Guide Arbor, φ4.5:**
57001-1331
[Image of Valve Guide Arbor]
* **Valve Guide Driver:**
57001-1564
[Image of Valve Guide Driver]
* **Valve Guide Reamer, φ4.5:**
57001-1333
[Image of Valve Guide Reamer]
* **Washer:**
57001-1720
[Image of Washer]
Special Tool -
Halaman 131
Clean Air System
Vacuum Switch Valve Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
Chapter)
Vacuum Switch Valve Hose Ends [A]
Vacuum Switch Valve [B]
Vacuum Switch Valve Installation
• Install the vacuum switch valve so that the vacuum hose
fitting [A] faces downwards (see Cable, Wire, and Hose
Routing in the Appendix chapter).
NOTE
○This hose fitting [B] side is plugged.
Vacuum Switch Valve Operation Test
• Refer to Air Suction System Damage Inspection in the
Periodic Maintenance chapter (see Air Suction System
Damage Inspection in the Periodic Maintenance chapter).
Vacuum Switch Valve Unit Test
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
○Do not remove the vacuum switch valve.
• Connect a vacuum gauge [A] and syringe [B] or the fork
oil level gauge to the vacuum hose as shown.
Special Tool - Fork Oil Level Gauge: 57001–1290
Air Flow [C]
• Gradually raise the vacuum (lower the pressure) applied
to the vacuum switch valve, and check the valve opera-
tion. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum is raised to
valve closing pressure, the valve should stop air flow.
Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [D]
Secondary Air Flow [E]
ENGINE TOP END 5-11
Air Suction Valve Inspection
Halaman 132
5-12 ENGINE TOP END
Clean Air System
If the vacuum switch valve does not operate as described,
replace it with a new one.
NOTE
○To check air flow through the vacuum switch valve, just
blow through the vacuum switch hose [C].
Vacuum Switch Valve Closing Pressure (Open →Close)
Standard:
41.3 ∼49.3 kPa (310 ∼370 mmHg)
High Vacuum [A]
Secondary air cannot flow [B]
Air Suction Valve Removal
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Vacuum Switch Valve (see Vacuum Switch Valve Re-
moval)
• Unscrew the bolts [A] and remove the air suction valve
covers [B].
Air Suction Valve Installation
• Install the air suction valve [A] so that its reed opening
side [B] faces backwards.
Torque - Air Suction Valve Cover Bolts : 9.8 N·m (1.0 kgf·m,
87 in·lb)
Air Suction Valve Inspection
• Remove the air suction valve (see Air Suction Valve Re-
moval).
• Visually inspect the reeds for cracks, folds, warps, heat
damage or other damage.
If there is any doubt as to the condition of the reeds [A],
replace the air suction valve as an assembly.
• Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat damage.
• If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
• If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high-flash point solvent.
CAUTION
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.
Clean Air System Hose Inspection
Halaman 133
Clean Air System
Clean Air System Hose Inspection
• Be certain that all the hoses are routed without being flat-
tened or kinked, and are connected correctly to the air
cleaner housing, carburetor assembly and cylinder head
cover (see Cable, Wire, and Hose Routing section in the
Appendix chapter).
If they are not, correct them. Replace them if they are
damaged.
ENGINE TOP END 5-13
Torque -
Halaman 134
5-14 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal
• Drain the Coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Spark Plug Caps
Radiator [A] (see Radiator and Radiator Fan Removal in
the Cooling System chapter)
• Disconnect the primary lead [B] and ground lead [C] con-
nectors of the #2(right) ignition coil [D].
• Remove the right engine bracket mounting bolts [E], and
remove the engine bracket with the right ignition coil.
• Disconnect the air suction valve hose.
• Remove the cylinder head cover bolts [A].
• Remove the cylinder head cover [B].
Cylinder Head Cover Installation
• Scrape off the old silicone sealant [A] on the cylinder head
mating surface, and apply silicone sealant [A] on the mat-
ing surface.
• Be sure the water pipe [B] is in place.
• Be sure the damper [A] on the water pipe is in position.
• Install the new cylinder head cover gasket and install the
cylinder head cover with the specified torque.
Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
• Install the removed parts.
Camshaft Chain Tensioner Installation
Halaman 135
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
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:
When 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 “Camshaft Chain Ten-
sioner Installation”.
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing and damage the valves.
• Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).
• Loosen the cap bolt [A]
• Remove the tensioner mounting bolts [B], and remove the
chain tensioner body [C].
Camshaft Chain Tensioner Installation
• Remove the tensioner cap bolt and O-ring.
• While compressing the push rod [A], turn it clockwise with
a suitable screwdriver until the rod stopped.
CAUTION
Do not turn the rod counterclockwise at installation.
This could detach the rod and the tensioner cannot
be reinstalled.
• While holding the rod in position with a suitable push rod
holder plate [A] install the tensioner on the cylinder block.
ENGINE TOP END 5-15
Torque -
Halaman 136
5-16 ENGINE TOP END
Camshaft Chain Tensioner
• Replace the chain tensioner gasket with a new one.
• Tighten:
Torque - Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0
kgf·m, 87 in·lb)
• Take out the holder plate [B].
• Install the O-ring and tighten the cap bolt.
Torque - Chain Tensioner Cap Bolt: 5.0 N·m (0.5 kgf·m, 44
in·lb)
Camshaft Installation
Halaman 137
Camshaft, Camshaft Chain
Camshaft Removal
• Remove the cylinder head cover (see Cylinder Head
Cover Removal).
• Remove the inspection plugs on the alternator cover.
• Position the crankshaft at #2 piston TDC.
○Using a wrench on the crankshaft rotation bolts, turn the
crankshaft clockwise until the “2T” mark [A] on the alterna-
tor rotor is aligned with the projection [B] in the inspection
window on the alternator cover.
• Remove:
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal).
Camshaft Cap Bolts [A]
Plates
Camshaft Top Chain Guide [B]
Camshaft Caps [C]
Camshafts [D]
• Stuff a clean cloth into the camshaft chain tunnel to keep
any parts from dropping into the crankcase.
CAUTION
The crankshaft may be turned while the camshafts
are removed.
Always pull the chain taut while turning the crank-
shaft. This avoids kinking the chain on the lower
(crankshaft) sprocket. A kinked chain could dam-
age both the chain and the sprocket.
Camshaft Installation
• Apply molybdenum disulfide oil solution to the cam and
journal surfaces.
NOTE
○Be sure to operate from the engine left side.
• Position the crankshaft at #2 piston TDC (see Camshaft
Removal).
CAUTION
The crankshaft may be turned while the camshafts
are removed.
Always pull the chain taut while turning the crank-
shaft. This avoids kinking the chain on the lower
(crankshaft) sprocket. A kinked chain could dam-
age both the chain and the sprocket.
ENGINE TOP END 5-17
Torque -
Halaman 138
5-18 ENGINE TOP END
Camshaft, Camshaft Chain
• Engage the camshaft chain [A] with the camshaft sprock-
ets.
○Pull the tension side (exhaust side) of the chain taut to
install the chain on the sprockets.
○Timing marks [B] align with the cylinder head upper sur-
face.
Exhaust Camshaft Sprocket [C]
Inlet Camshaft Sprocket [D]
○Count the camshaft chain link pins as shown to verify that
the sprocket are positioned correctly.
• Place the six dowel pins on the
marks [A].
• Install the camshaft caps as shown, noting the “EX” [B]
and “IN” [C] marks.
CAUTION
The camshaft caps are machined with the cylinder
head. So, if a cap is installed in a wrong location,
the camshaft may seize because of improper oil
clearance in the bearings.
• Put the plates on the bearing caps.
○The exhaust side plates [A] is longer the inlet side plates
[B].
• First tighten down the chain guide [A] and bearing caps
[B] evenly to seat the camshafts in place, then tighten all
bolts following the specified tightening sequence.
Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
Plates (EX) [C]
Plates (IN) [D]
• Install the camshaft chain tensioner (see Camshaft Chain
Tensioner Installation).
• Check the chain timing.
• Finally, inject [A] engine oil into 8 places on the cylinder
head, as shown.
Torque -
Halaman 139
Camshaft, Camshaft Chain
Camshaft and Sprocket Assembly
• Install the cam sprockets as shown in figure.
Exhaust Cam Sprocket [A]
Inlet Cam Sprocket [B]
• Apply a non-permanent locking agent to the camshaft
sprocket bolts and tighten them.
Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)
If a new camshaft is to be used, apply a thin coat of a
molybdenum disulfide grease to the cam surfaces.
NOTE
○The exhaust camshaft has a groove [A] and the inlet
camshaft has no groove. Be careful not to mix up these
shafts.
Camshaft and Camshaft Cap Wear Inspection
• Remove:
Camshaft Top Guide
Camshaft Caps
• Cut the strips of plastigauge to journal parallel to the
camshaft installed in the correct position.
• Measure each clearance between the camshaft journal
and the camshaft cap using the plastigauge (press gauge)
[A].
• Tighten:
Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
NOTE
○Do not turn the camshaft when the plastigauge is be-
tween the journal and camshaft cap.
Camshaft Journal, Camshaft Cap Clearance
Standard:
0.028 ∼0.071 mm (0.0011 ∼0.0071 in.)
Service Limit: 0.16 mm (0.0063 in.)
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
Standard:
23.950 ∼23.972 mm (0.9429 ∼0.9438 in.)
Service Limit: 23.92 mm (0.942 in.)
If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the service limit, re-
place the cylinder head unit.
ENGINE TOP END 5-19
Camshaft Chain Guide Wear Inspection
Halaman 140
5-20 ENGINE TOP END
Camshaft, Camshaft Chain
Camshaft Runout Inspection
• Remove the camshaft.
• Set the camshaft in a camshaft alignment jig or on V
blocks.
• Measure the runout with a dial gauge at the specified
place as shown.
If the runout exceeds the service limit, replace the shaft.
Camshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.)
Service Limit: TIR 0.1 mm (0.004 in.)
Cam Wear Inspection
• Remove the camshaft (see Camshaft Removal).
• Measure the height [A] of each cam with a micrometer.
If the cams are worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust
32.843 ∼32.957 mm (1.2930 ∼1.2975 in.)
Inlet
33.843 ∼33.957 mm (1.3324 ∼1.3369 in.)
Service Limit:
Exhaust
32.74 mm (1.289 in.)
Inlet
33.74 mm (1.328 in.)
Camshaft Chain Guide Wear Inspection
• Visually inspect the rubber [A] on the guide.
• If the rubber is damaged or cut, replace the guides.
Torque -
Halaman 141
Cylinder Head
Cylinder Compression Measurement
NOTE
○Use the battery which is fully charged.
• Warm up the engine thoroughly.
• Stop the engine.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Spark Plug (see Spark Plug Replacement in the Periodic
Maintenance chapter)
• Attach the compression gauge [A] and adapter [B] firmly
into the spark plug hole.
• Using the starter motor, turn the engine over with the throt-
tle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.
Special Tool - Compression Gauge: 57001-221
Compression Gauge Adapter M10 × 1.0:
57001-1317
Cylinder Compression
Usable Range: 961 ∼1 471 kPa (9.8 ∼15.0 kgf/cm², 139
∼213 psi) @470r/min (rpm)
• Repeat the measurement for the other cylinder.
• Install the spark plugs.
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)
Problem
Diagnosis
Remedy (Action)
Cylinder
compression is
higher than usable
range
Carbon accumulation on piston and in
combustion chamber possibly due to
damaged valve stem oil seal and/or
damaged piston oil rings (This may be
indicated by white exhaust smoke.)
Incorrect cylinder head gasket thickness
Replace the gasket with a
standard part.
Gas leakage around cylinder head
Replace damaged gasket and
check cylinder head warp.
Bad condition of valve seating
Repair if necessary.
Cylinder
compression is
lower than usable
range
Incorrect valve clearance
Adjust the valve clearance.
Incorrect piston/cylinder clearance
Replace the piston and/or cylinder
Piston seizure
Inspect the cylinder and
replace/repair the cylinder
and/or piston as necessary.
Bad condition of piston ring and/or piston
ring grooves
ENGINE TOP END 5-21
Remove the carbon deposits
and replace damaged parts if
necessary.
Replace the piston and/or the
piston rings.
Cylinder Head Installation
Halaman 142
5-22 ENGINE TOP END
Cylinder Head
Cylinder Head Removal
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Radiator (see Radiator, Radiator Fan Removal in the
Cooling System chapter)
Muffler (see Muffler Removal)
Camshaft Chain Tensioner (see Camshaft Chain Ten-
sioner Removal)
Left and Right Engine Bracket with Ignition Coils
• Remove:
Cylinder Head Cover
Camshafts
Rear Camshafts Chain Guide Bolt (Lower) [A] and Chain
Guide [B]
Front Camshaft Chain Guide [C]
• Pull out the water pipe.
• Remove the 6 mm cylinder head bolt [A] first, then remove
the 8 mm cylinder head bolts.
• Remove the oil hose banjo bolt [B].
• Before removing the cylinder head, hold the carburetor to
the air cleaner ducts securely.
Cylinder Head Installation
NOTE
○The camshaft cap is machined with the cylinder head,
so if a new cylinder head is installed, use the cap that
is supplied with the new head.
• Install the pin and new cylinder head gasket.
• Apply molybdenum disulfide oil to the both sides [A] of the
8 mm cylinder head bolt washers.
Cylinder Head Warp Inspection
Halaman 143
Cylinder Head
• Tighten the 8 mm cylinder head bolts [1 ∼7] following the
tightening sequence.
Torque - Cylinder Head Bolts: 24.5 N·m (2.5 kgf·m, 18 ft·lb)
• Tighten the 6 mm cylinder head bolt [8] following the tight-
ening sequence.
Torque - Cylinder Head Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
• After cylinder head installation, install the front camshaft
chain guide [A].
• Tighten the rear camshaft chain guide bolt (lower) [B] to
the specified torque.
• Tighten the oil hose banjo bolt to the specified torque.
Torque - Camshaft Chain Guide Bolt (lower): 17 N·m (1.7
kgf·m, 13 ft·lb)
Oil Hose Banjo Bolt: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)
Cylinder Head Warp Inspection
• Lay a straightedge across the lower surface of the cylinder
head at several positions.
• Use a thickness gauge [A] to measure the space between
the straightedge [B] and the head.
Cylinder Head Warp
Standard:
– – –
Service Limit: 0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
ENGINE TOP END 5-23
Cylinder Head Cleaning
Halaman 144
5-24 ENGINE TOP END
Cylinder Head
Cylinder Head Cleaning
• Remove:
Cylinder Head (see Cylinder Head Removal)
Valves (see Valve Removal)
• Scrape [A] the carbon out of the combustion chamber and
exhaust port with a suitable tool.
• Wash the cylinder head with a high-flash point solvent.
• Using compressed air, blow out any particles which may
obstruct the oil passage [A] in the cylinder head.
• Install the valve (see Valve Installation).
• Install the cylinder head (see Cylinder Head Installation).
Valve Guide Installation
Halaman 145
Valves
Valve Clearance Inspection
• Refer to Valve Clearance Inspection in the Periodic Main-
tenance chapter.
Valve Clearance Adjustment
• Refer to Valve Clearance Adjustment in the Periodic
Maintenance chapter.
Valve Removal
• Remove the cylinder head (see Cylinder Head Removal).
• Use the valve spring compressor assembly and the
adapter to press down the valve spring retainer.
Special Tools - Valve Spring Compressor Assembly: 57001
-241 [A]
Valve Spring Compressor Adapter,
16:
57001-1305 [B]
Valve Installation
• Replace the oil seal with a new one.
• Apply engine oil to the lip of oil seal.
• Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
• Install the spring so that the closed coil end faces down-
wards.
[A] Valve Stem
[B] Spring Seat
[C] Spring
[D] Oil Seal
[E] Retainer
[F] Split Keepers
[G] Closed Coil End
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
Oil Seal
Spring Seat
• Heat the area around the valve guide to 120 ∼150°C (248
∼302°F), and hammer lightly on the valve guide arbor [A]
to remove the guide from the top of the head.
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head in
oil and heat the oil.
Special Tool - Valve Guide Arbor,
4.5: 57001-1331
Valve Guide Installation
• Apply a thin coat of oil to the outer surface of the valve
guide.
• Heat the area around the valve guide up to 120 ∼150°C
(248 ∼302°F).
CAUTION
Do not heat the cylinder head with a torch. This will
warp the cylinder head. Soak the cylinder head and
heat the oil.
ENGINE TOP END 5-25
Valve-to-Guide Clearance Measurement (Wobble Method)
Halaman 146
5-26 ENGINE TOP END
Valves
• Using the valve guide driver [A] and washer [B], press
and insert the valve guide in until the washer surface [C]
touches the head surface [D].
15.3 ∼15.5 mm [E]
Special Tools - Valve Guide Driver,
4.5: 57001-1564
Washer: 57001-1720
• Wait until the cylinder head cools down and then ream the
valve guide with the valve guide reamer [A] even if the old
guide is reused.
○Turn the reamer in a clockwise direction until the reamer
turns freely in the guide. Never turn the reamer counter-
clockwise or it will be dulled.
○Once the guides are reamed they must be cleaned thor-
oughly.
Special Tool - Valve Guide Reamer,
4.5: 57001-1333
Valve-to-Guide Clearance Measurement (Wobble
Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
• Insert a new valve [A] into the guide [B] and set a dial
gauge against the stem perpendicular to it as close as
possible to the cylinder head mating surface.
• Move the stem back and forth [C] to measure valve/valve
guide clearance.
• Repeat the measurement in a direction at a right angle to
the first.
If the reading exceeds the service limit, replace the guide.
NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Inlet
0.03 ∼0.09 mm (0.0012 ∼0.0035 in.)
Exhaust
0.08 ∼0.15 mm (0.0031 ∼0.0059 in.)
Service Limit:
Inlet
0.27 mm (0.011 in.)
Exhaust
0.33 mm (0.013 in.)
Special Tools -
Halaman 147
Valves
Valve Seat Inspection
• Remove the valve (see Valve Removal).
• Check the valve seating surface [A] between the valve [B]
and valve seat [C].
○Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seating Surface Outside Diameter
Standard:
Inlet
21.9 ∼22.1 mm (0.8622 ∼0.8701 in.)
Exhaust 19.3 ∼19.5 mm (0.7598 ∼0.7677 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Valve Seat Repair).
Valve Seating Surface Width
Standard:
Inlet, Exhaust 0.5 ∼1.0 mm (0.0197 ∼0.0394 in.)
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder,
4.5: 57001-1330
[B]
Valve Seat Cutter Holder Bar: 57001-1128
[C]
For Inlet Valve Seat
Valve Seat Cutter, 45° -
24.5: 57001-1113
Valve Seat Cutter, 32° -
25: 57001-1118
Valve Seat Cutter, 67.5° -
22: 57001-1207
For Exhaust Valve Seat
Valve Seat Cutter, 45° -
24.5: 57001-1113
Valve Seat Cutter, 32° -
22: 57001-1206
Valve Seat Cutter, 67.5° -
22: 57001-1207
If the manufacturer’s instructions are not available, use
the following procedure.
ENGINE TOP END 5-27
Operating Procedures
Halaman 148
5-28 ENGINE TOP END
Valves
Seat Cutter Operation Cares
1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond 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.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer
of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
37.5
....................... Outer diameter of cutter [C]
Operating Procedures
• Clean the seat area carefully.
• Coat the seat with machinist’s dye.
• Fit a 45° cutter into 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.
CAUTION
Do not grind the seat too much. 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 cylin-
der head must be replaced.
Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 67.5° cutter
67.5° [F]
Operating Procedures
Halaman 149
Valves
• Measure the outside diameter (O.D.) of the seating sur-
face with a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 67.5° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
If the outside diameter of the seating surface is too large,
make the 32° grind described below.
• If the outside diameter [A] of the seating surface is within
the specified range, measure the seat width as described
below.
• Grind the seat at a 32° angle [B] until the seat O.D. is
within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat O.D. mea-
surement step above.
• To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral 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
O.D. measurement step above.
If the seat width is too wide, make the 67.5° [A] grind
described below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
• Grind the seat at a 67.5° angle until the seat width is within
the specified range.
○To make the 67.5° grind, fit a 67.5° cutter into the holder,
and slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 67.5° grind, return to the seat width mea-
surement step above.
Correct Width [B]
ENGINE TOP END 5-29
Operating Procedures
Halaman 150
5-30 ENGINE TOP END
Valves
• Lap the valve to the seat, once the seat width and O.D.
are within the ranges specified above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with a fine grinding compound.
[A] Lapper
[B] Valve Seat
[C] Valve
• The 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 part. If it is, it may have
been refaced too much; replace it.
• Be sure to remove all grinding compound before assem-
bly.
• When the engine is assembled, be sure to adjust the valve
clearance (see Engine Top End in the Periodic Mainte-
nance chapter).
Operating Procedures
Halaman 151
ENGINE TOP END 5-31
Valves
### Valve Seat Repair
1. **START**
2. Machinist's eye or seat
3. **Process:**
* **Tool:** 45° Cutter
* **Purpose:** Make sealing area smooth & round
4. **Measure Sealing Area O.D.**
* **Tool:** Vernier Caliper
* **Purpose:** Check seat O.D. against spec
* **Result:**
* **OK:** Continue to step 5.
* **Too big:**
* Machinist's dye on seat
* **Process:**
* **Tool:** 32° Cutter
* **Purpose:** Reduce O.D. of seal area to spec
* *(Return to "Measure Sealing Area O.D.")*
5. **Measure Sealing Width**
* **Tool:** Vernier Caliper
* **Purpose:** Check seal width against spec
* **Result:**
* **OK:** Continue to step 6.
* **Too narrow:**
* **Process:**
* **Tool:** 45° Cutter
* **Purpose:** Increase width of seal area beyond spec. to increase O.D.
* *(Return to "Measure Sealing Width")*
* **Too wide:**
* Machinist's dye on seat
* **Process:**
* **Tool:** 57.5° Cutter
* **Purpose:** Reduce seal width to spec
* *(Return to "Measure Sealing Width")*
6. **Lap Valve**
* **Tool:** Valve Lapper, Grinding Compound
* **Purpose:** Perfectly match valve and seat area, check valve head for damage.
7. **FINISHED**
Special Tool -
Halaman 152
5-32 ENGINE TOP END
Cylinder, Pistons
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
• Loosen the clamps [A], and take off the water hose [B]
and pipe [C].
• Remove the cylinder [D].
Cylinder Installation
NOTE
○If a new cylinder is used, use a new piston ring.
• Install the pins [A] and new cylinder gasket [B].
• Apply molybdenum disulfide oil solution to the cylinder
bore, piston rings and pistons.
• The piston ring openings must be positioned as shown in
the figure. The openings of the oil ring steel rails must be
about 30-40° of angle from the opening of the top ring.
[A] Top Ring
[B] Second Ring
[C] Oil Ring Steel Rail (Lower)
[D] Oil Ring Steel Rail (Upper)
[E] Oil Ring Expander
[F] Arrow Mark
[G] 30 ∼40°
• Slip the piston base [A] as shown to hold piston level, and
install the cylinder.
Special Tool - Piston Base,
2.3: 57001-1336
Piston Installation
Halaman 153
Cylinder, Pistons
Piston Removal
• Remove the cylinder (see Cylinder Removal).
• Place a clean cloth under the pistons and remove the pis-
ton pin snap ring [A] from the outside of each piston.
• Remove the piston pins.
Special Tool - Piston Pin Puller Assembly: 57001-910 [A]
• Carefully spread the ring opening with your thumbs and
then push up on the opposite side of the ring [A] to remove
it.
• Remove the 3-piece oil ring with your thumbs in the same
manner.
Piston Installation
NOTE
○If a new piston is used, use a new piston ring.
• Install the piston with its marking hollow facing forward.
• Fit a new piston pin snap ring into the side of the piston
so that the ring opening [A] does not coincide with the slit
[B] of the piston pin hole.
○When installing the piston pin snap ring, compress it only
enough to install it and no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them.
They could fall out and score the cylinder wall.
ENGINE TOP END 5-33
Piston Wear Inspection
Halaman 154
5-34 ENGINE TOP END
Cylinder, Pistons
• Install the oil ring expander [A] in the bottom piston ring
groove so the ends [B] butt together.
• Install the oil ring steel rails, one above the expander and
one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
NOTE
○The oil ring rails have no “top” or “bottom”.
• Do not mix up the top and second ring.
• Install the top ring [A] so that the “R” mark [B] faces up.
• Install the second ring [C] so that the “RN” mark [D] faces
up.
○Apply molybdenum disulfide oil solution to the piston
rings.
Cylinder Wear Inspection
• Since there is a difference in cylinder wear in different di-
rections, take a side-to-side and a front-to-back measure-
ment at each of the two locations (total of four measure-
ments) shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, replace the cylinder.
[A] 10 mm
[B] 60 mm
Cylinder Inside Diameter
Standard:
62.000 ∼62.012 mm (2.4409 ∼2.4414 in.)
Service Limit: 62.10 mm (2.44 in.)
Piston Wear Inspection
• Measure the outside diameter [A] of each piston 5 mm
[B] up from the bottom of the piston at a right angle to the
direction of the piston pin.
If the measurement is under service limit, replace the pis-
ton.
Piston Diameter
Standard:
61.942 ∼61.957 mm (2.4387 ∼2.4392 in.)
Service Limit: 61.80 mm (2.43 in.)
Piston Ring Thickness Inspection
Halaman 155
Cylinder, Pistons
Piston Ring, Piston Ring Groove Wear Insepction
• Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings.
• With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring/groove clearance.
Piston Ring/Groove Clearance
Standard:
Top
0.03 ∼0.07 mm (0.0012 ∼0.0028 in.)
Second
0.02 ∼0.06 mm (0.0008 ∼0.0024 in.)
Service Limit:
Top
0.17 mm (0.0067 in.)
Second
0.16 mm (0.0063 in.)
Piston Ring Groove Width Inspection
• Measure the piston ring groove width.
○Use a vernier caliper at several points around the piston.
Piston Ring/Groove Width
Standard:
Top
0.82 ∼0.84 mm (0.0323 ∼0.0331 in.)
Second
0.81 ∼0.83 mm (0.0319 ∼0.0327)
Oil
1.51 ∼1.53 mm (0.0594 ∼0.0602 in.)
Service Limit:
Top
0.92 mm (0.0362 in.)
Second
0.91 mm (0.0358 in.)
Oil
1.61 mm (0.0634 in.)
If the width of any two grooves is wider than the service
limit at any point, replace the piston.
Piston Ring Thickness Inspection
• Measure the piston ring thickness.
○Use the micrometer to measure at several points around
the ring.
Piston Ring Thickness
Standard:
Top
0.77 ∼0.79 mm (0.0303 ∼0.0311 in.)
Second
0.77 ∼0.79 mm (0.0303 ∼0.0311 in.)
Service Limit:
Top
0.70 mm (0.028 in.)
Second
0.70 mm (0.028 in.)
If any of the measurements is less than the service limit
on either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel
to the groove sides. If not, replace the piston.
ENGINE TOP END 5-35
Boring, Honing
Halaman 156
5-36 ENGINE TOP END
Cylinder, Pistons
Piston Ring End Gap Inspection
• Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
• Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top
0.15 ∼0.30 mm (0.0059 ∼0.0118 in.)
Second
0.40 ∼0.55 mm (0.0157 ∼0.0217 in.)
Oil
0.20 ∼0.80 mm (0.0079 ∼0.0315 in.)
Service Limit:
Top
0.6 mm (0.024 in.)
Second
0.9 mm (0.035 in.)
Oil
1.1 mm (0.043 in.)
If the end gap of either ring is greater than the service
limit, replace all the rings.
Boring, Honing
When boring and honing a cylinder, note the following:
○There is one size of oversize piston available. Oversize
piston require oversize rings.
Oversize Piston and Ring
0.5 mm
Oversize
○Before boring a cylinder, first measure the exact diameter
of the oversize piston, and then, according to the standard
clearance in the Service Specification Section, determine
the rebore diameter. However, if the amount of boring
necessary would make the inside diameter greater than
0.5 mm oversize, the cylinder block must be replaced.
○Cylinder inside diameter must not vary more than 0.01
mm (0.0004 in.) at any point.
○Be wary of measurements taken immediately after boring
since the heat affects cylinder diameter.
○In the case of a rebored cylinder and oversize piston, the
service limit for the cylinder is the diameter that the cylin-
der was bored to plus 0.1 mm (0.004 in.) and the service
limit for the piston is the oversize piston original diameter
minus 0.15 mm (0.006 in.). If the exact figure for the re-
bored diameter is unknown, it can be roughly determined
by measuring the diameter at the base of the cylinder.
○Never separate the liner from the cylinder, because the
top surface of cylinder and liner is machined at the factory
as an assembly.
Carburetor Holder Installation
Halaman 157
Carburetor Holder
Carburetor Holder Installation
• Install the carburetor holders [A] so that the “HEAD” marks
[B] faces forward (cylinder head side), and “CARB” mark
[C] faces backward (carburetor side).
• Install the holder clamps as shown being careful of the
screw [D] position and the screw head direction.
WARNING
Install the clamp screws horizontally. Otherwise the
screws could come in contact with the vacuum ad-
justing screws, resulting in an unsafe riding condi-
tion.
ENGINE TOP END 5-37
Muffler Installation
Halaman 158
5-38 ENGINE TOP END
Muffler
Muffler Removal
• Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
• Remove:
Muffler Cover Bolts [A]
Muffler Cover Clamp Bolt [B]
Muffler Cover [C]
• Loosen the muffler clamp bolt [A] until the clamp turns
freely on the mufflers..
• Remove the muffler mounting bolt [B] and nuts at the rear
footpeg bracket, and take off the left and right mufflers.
• Remove the exhaust pipe holder nuts [A], and slide the
holders [B] [C] off its cylinder head studs.
• Remove the split keepers.
• Pull the exhaust pipe toward the front and remove it.
• Remove the gaskets and the exhaust pipe holders from
the exhaust pipe.
CAUTION
Be careful not to touch the radiator fins during
work. The fins are easily deformed.
Muffler Installation
• Smear a little grease on a new exhaust pipe gasket and
stick it into the exhaust port in the cylinder head.
• Slip the exhaust pipe holder over the exhaust pipe.
• Attach the exhaust pipe loosely to the cylinder head.
○Position the exhaust pipe in the exhaust port.
○Slide the holders into the studs holding the split keeper in
place.
○Screw in the nuts loosely on the studs so that the holders
does not fall down.
• Slip the muffler into place from the rear of the frame so
that it fits over the exhaust pipe.
• Install the gasket [A] so that its chamfer side [B] faces
manifold side.
Manifold Side [C]
Muffler Side [D]
• Hold the muffler up and install the mounting bolts not to
tighten them securely.
• Tighten the exhaust pipe holder nuts evenly and securely.
• Tighten the muffler mounting bolts securely.
Exhaust System Inspection
Halaman 159
Muffler
• Tighten the muffler clamp bolt [A] securely waving the di-
rection of the clamp bolts.
74° ∼84° [B]
○Be sure that the distance between the clamp bolt end and
the swingarm [C] is more than 15 mm [D].
• Insert the claw [A] into the cover clamp [B] and tighten the
clamp screw securely.
○Be sure that the position of muffler cover clamp screw [A]
is as shown.
approx. 15° [B]
Exhaust System Inspection
• Before removing the exhaust system, check for signs of
leakage at the exhaust pipe gasket in the cylinder head
and at the muffler clamp.
If there are signs of leakage around the exhaust pipe gas-
ket, it should be replaced. If the muffler to exhaust pipe
joint leaks, tighten the clamp.
• Remove the exhaust system (see Muffler Removal).
• Inspect the gasket for damage and signs of leakage.
If the gasket is damaged or has been leaking, replace it.
• Check the exhaust pipe and muffler for dents, cracks, rust
and holes.
If the exhaust pipe or muffler is damaged or holes, it
should be replaced for best performance and least noise.
ENGINE TOP END 5-39
Clutch
Halaman 161
Clutch
Table of Contents
Exploded View........................................................................................................................
6-2
Specifications .........................................................................................................................
6-4
Special Tool and Sealant........................................................................................................
6-5
Clutch Lever and Cable..........................................................................................................
6-6
Clutch Lever Free Play Inspection....................................................................................
6-6
Clutch Lever Free Play Adjustment ..................................................................................
6-6
Clutch Cable Removal ......................................................................................................
6-6
Clutch Cable Lubrication...................................................................................................
6-6
Clutch Lever Removal.......................................................................................................
6-6
Clutch Cover...........................................................................................................................
6-7
Clutch Cover Removal......................................................................................................
6-7
Clutch Cover Installation Note ..........................................................................................
6-7
Clutch Release Shaft Removal.........................................................................................
6-7
Clutch Release Shaft Installation......................................................................................
6-7
Clutch .....................................................................................................................................
6-8
Clutch Removal.................................................................................................................
6-8
Clutch Installation..............................................................................................................
6-8
Clutch Plate Wear and Damage Inspection......................................................................
6-10
Clutch Plate Warp Inspection............................................................................................
6-10
Clutch Spring Free Length Inspection...............................................................................
6-10
Clutch Housing Finger Damage Inspection ......................................................................
6-11
Clutch Hub Spline Damage Inspection .............................................................................
6-11
CLUTCH 6-1
6
Clutch
Halaman 162
6-2 CLUTCH
Exploded View
Clutch
Halaman 163
CLUTCH 6-3
Exploded View
| No. | Fastener | Torque | | Remarks |
|:----|:--------------------------------|:----------------|:--------|:-------------|
| | | N·m | kgf·m | ft·lb |
| 1 | Clutch Lever Holder Clamp Bolts | 8.8 | 0.9 | 78 in·lb |
| 2 | Clutch Spring Bolts | 8.8 | 0.9 | 78 in·lb |
| 3 | Clutch Hub Nut | 132 | 13.5 | 97.4 |
| 4 | Oil Filler Plug | – | – | – | Hand-Tighten |
| 5 | Clutch Cover Bolts | 9.8 | 1.0 | 87 in·lb |
6. Starter Lockout Switch
7. Clutch Lever Pivot Nut
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
Si: Apply silicone grease.
W: Apply water.
Clutch
Halaman 164
6-4 CLUTCH
Specifications
Item
Standard
Service Limit
Clutch
Clutch Lever Play
2 ∼3 mm (0.08 ∼0.12 in.)
– – –
Clutch Spring Free Play
38.5 mm (1.52 in.)
36.8 mm (1.45 in.)
Friction Plate Thickness
2.92 ∼3.08 mm (0.115 ∼0.121 in.)
2.6 mm (0.10 in.)
Friction and Steel Plate Warp
0.15 mm (0.0059 in.) or less
0.3 mm (0.012 in.)
Clutch Housing Gear Selection when Replacing Clutch Housing Gear
Crankshaft
Clutch Housing
Primary Gear
Marking [C]
Color [D]
Gear Marking [E]
Color [F]
Part Number
A
White
A
White
13095-0095
A
White
B
Red
13095-0096
B
Red
B
Red
13095-0096
B
Red
C
None
13095-0097
C
None
C
None
13095-0097
C
None
D
Yellow
13095-0098
D
Yellow
D
Yellow
13095-0098
Clutch Holder:
Halaman 165
Special Tool and Sealant
Clutch Holder:
57001-1243
CLUTCH 6-5
Kawasaki Bond (Silicone Sealant):
56019-120
Clutch Lever Removal
Halaman 166
6-6 CLUTCH
Clutch Lever and Cable
Clutch Lever Free Play Inspection
• Refer to Clutch Operation Inspection in the Periodic Main-
tenance chapter (see Clutch Operation Inspection in the
Periodic Maintenance chapter).
Clutch Lever Free Play Adjustment
• Refer to Clutch Operation Inspection in the Periodic Main-
tenance chapter (see Clutch Operation Inspection in the
Periodic Maintenance chapter).
Clutch Cable Removal
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
• Loosen the knurled locknut [A] at the clutch lever, and
screw in the adjuster [B].
• Line up the slots [C] in the clutch lever, locknut, and ad-
juster and then free the cable from the lever.
• Remove the lower cable adjuster of clutch cable from the
cable holder [A] loosening the cable adjuster lock nuts [B].
• Free the clutch inner cable tip from the clutch release
lever.
Clutch Cable Lubrication
• Refer to Chassis Parts Lubrication in the Periodic Mainte-
nance chapter (see Chassis Parts Lubrication in the Pe-
riodic Maintenance chapter).
Clutch Lever Removal
• Remove the upper end of clutch cable.
• Remove the left switch housing [A].
• Remove the clutch lever mounting bolt [B] and nut, and
remove the clutch lever.
Clutch Release Shaft Installation
Halaman 167
Clutch Cover
Clutch Cover Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Clutch Cable (see Clutch Cable Removal)
Oil Filler Plug
• Remove the clutch cover mounting bolts [A] and the clutch
cable guide.
• Turn the clutch release lever couterclockwise fully to re-
lease the clutch release shaft.
Clutch Cover Installation Note
• Scrape the old gasket from the surface of clutch cover
and crankcase, and apply silicone sealant on the mating
surface [A] of the crankcases.
• Install the new clutch cover gasket.
Special Tool - Kawasaki Bond (Silicone Sealant): 92104
-0004
• Turn the clutch release lever [A] counterclockwise fully [B]
and install the clutch cover.
Clutch Release Shaft Removal
• Remove:
Clutch Cable (see Clutch Cable Removal)
Clutch Cover (see Clutch Cover Removal)
• Pull out the clutch release shaft from the clutch cover.
NOTE
○Do not damage the oil seal when it shall be inserted into
the clutch cover hole.
Clutch Release Shaft Installation
• Apply engine oil to the oil seal [A] and needle bearing [B].
• Insert the clutch release shaft into the clutch cover hole.
• Install:
Clutch Cover (see Clutch Cover Installation)
Clutch Cable (see Clutch Cable Installation)
CAUTION
When inserting the release shaft, be careful not to
remove the spring of the oil seal.
CLUTCH 6-7
Torque -
Halaman 168
6-8 CLUTCH
Clutch
Clutch Removal
• Remove:
Clutch Cable (see Clutch Cable Removal)
Clutch Cover (see Clutch Cover Removal)
• Remove the clutch spring mounting bolts [A], springs,
clutch operating plate [B] with the clutch push rod [C].
• Remove the clutch steel plates and friction plates.
• Remove the clutch hub nut using the special tool [A].
• Remove the washer, clutch housing, needle bearing,
bushing and the thrust spacer.
Special Tool - Clutch Holder: 57001-1243
Clutch Installation
• Install the thrust spacer [A] so that the chamfer side of it
faces to inside of the engine.
• Install the spacer bushing [A] and needle bearing [B].
○Install the snap ring [C] on the bushing so that it faces to
inside of the engine.
• Install the clutch housing, clutch hub, washer and the
clutch hub nut.
• Tighten the clutch hub nut with the specified torque.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 97.4 ft·lb)
Torque -
Halaman 169
Clutch
• If the clutch housing is replaced with a new one, select the
proper clutch housing in accordance with the combination
of the clutch housing gear and crankshaft primary gear
markings with colors.
Crankshaft Primary Gear [A]
Clutch Housing Gear [B]
• Be sure to confirm the marking and color on the clutch
housing gear.
Clutch Housing Gear Selection when Replacing Clutch Housing Gear
Crankshaft
Clutch Housing
Primary Gear
Marking [C]
Color [D]
Gear Marking [E]
Color [F]
Part Number
A
White
A
White
13095-0095
A
White
B
Red
13095-0096
B
Red
B
Red
13095-0096
B
Red
C
None
13095-0097
C
None
C
None
13095-0097
C
None
D
Yellow
13095-0098
D
Yellow
D
Yellow
13095-0098
NOTE
○If the selection mark and color are missing or not selec-
tion, refer to the selection section in the specifications
of the Crankshaft/Transmission chapter.
• Install the friction plate first and clutch steel plate, and
afterward install them alternately.
○The outer-end [A] and inner-end [B] friction plate blocks
are wider than the others.
Wider [C]
Narrower [D]
CLUTCH 6-9
Clutch Spring Free Length Inspection
Halaman 170
6-10 CLUTCH
Clutch
• Install the clutch operating plate [A] with the clutch push
rod [B].
• Install the springs and tighten the clutch spring bolts with
specified torque.
Torque - Clutch Spring Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
• Install the clutch cover (see Clutch Cover Installation).
Clutch Plate Wear and Damage Inspection
• Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
• Measure the thickness of each friction plate [A] at several
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.
Friction Plate Thickness
Standard:
2.92 ∼3.08 mm (0.115 ∼0.121 in.)
Service Limit:
2.6 mm (0.10 in.)
Clutch Plate Warp Inspection
• Place each friction plate or steel plate on a surface plate
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
Service Limit:
0.3 mm (0.012 in.)
Clutch Spring Free Length Inspection
• Measure the free length of the clutch springs [A].
If any spring is shorter than the service limit, it must be
replaced.
Clutch Spring Free Length
Standard:
38.5 mm (1.52 in.)
Service Limit:
36.8 mm (1.45 in.)
Clutch Hub Spline Damage Inspection
Halaman 171
Clutch
Clutch Housing Finger Damage Inspection
• Visually inspect the clutch housing fingers [A] that come
in contact with the friction plate tangs.
If they are damaged or if there are groove cuts in the areas
that come in contact with the tangs, replace the housing.
Replace the friction plates if their tangs are damaged as
well.
Clutch Hub Spline Damage Inspection
• Visually inspect the areas of the clutch hub splines that
come in contact with the teeth of the steel plates.
If there are notches worn into the clutch hub splines [A],
replace the clutch hub. Replace the steel plates if their
teeth are damaged as well.
CLUTCH 6-11
Engine Lubrication System
Halaman 173
Engine Lubrication System
Table of Contents
Exploded View........................................................................................................................
7-2
Specifications .........................................................................................................................
7-4
Special Tools and Sealant ......................................................................................................
7-5
Engine Oil Flow Chart.............................................................................................................
7-6
Engine Oil and Oil Filter..........................................................................................................
7-7
Oil Level Inspection...........................................................................................................
7-7
Engine Oil Change............................................................................................................
7-7
Oil Filter Replacement ......................................................................................................
7-7
Bypass Valve Disassembly...............................................................................................
7-8
Bypass Valve Assembly....................................................................................................
7-8
Bypass Valve Cleaning and Inspection.............................................................................
7-8
Oil Screen Cleaning and Inspection..................................................................................
7-9
Oil Pressure Relief Valve........................................................................................................
7-10
Oil Pressure Relief Valve Removal...................................................................................
7-10
Oil Pressure Relief Valve Installation................................................................................
7-10
Oil Pressure Relief Valve Inspection.................................................................................
7-10
Oil Pump.................................................................................................................................
7-11
Oil Pump Removal............................................................................................................
7-11
Oil Pump Installation.........................................................................................................
7-11
Oil Pump Disassembly......................................................................................................
7-11
Oil Pump Assembly...........................................................................................................
7-11
Oil Pump Inspection..........................................................................................................
7-11
Oil Pressure Measurement.....................................................................................................
7-12
Oil Pressure Measurement ...............................................................................................
7-12
Oil Pressure Switch ................................................................................................................
7-13
Oil Pressure Switch Removal ...........................................................................................
7-13
Oil Pressure Switch Installation ........................................................................................
7-13
ENGINE LUBRICATION SYSTEM 7-1
7
Engine Lubrication System
Halaman 174
## 7-2 ENGINE LUBRICATION SYSTEM
### Exploded View
7 S021 150B / 2
Engine Lubrication System
Halaman 175
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Oil Hose Banjo Bolts
19.6
2.0
14.5
2
Oil Pressure Relief Valve
15
1.5
11
L
3
Crankcase Oil Passage Plug
15
1.5
11
4
Oil Passage Plugs for Oil Pump
20
2.0
15
L
5
Oil Pipe Banjo Bolts
12
1.2
104 in·lb
6
Oil Drain Bolt
19.6
2.0
14.5
7
Oil Pressure Switch
15
1.5
11
SS
8
Oil Pressure Switch Terminal Bolt
1.5
0.15
13 in·lb
9
Oil Filter Mounting Bolts
19.6
2.0
14.5
10
Oil Breather Mounting Bolts
9.8
1.0
87 in·lb
L
11
Oil Pump Mounting Bolts
9.8
1.0
87 in·lb
L
12
Oil Screen Cover Bolts
9.8
1.0
87 in·lb
13
Plug
19.6
2.0
14.5
14
Breather Bolt
9.8
1.0
87 in·lb
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
ENGINE LUBRICATION SYSTEM 7-3
Engine Lubrication System
Halaman 176
7-4 ENGINE LUBRICATION SYSTEM
Specifications
Item
Standard
Engine Oil
Grade
API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity
SAE 10W-40
Capacity
1.3 L (1.37 US gt) (when filter is not removed)
1.6 L (1.69 US gt) (when filter is removed)
1.7 L (1.80 US gt) (when engine is completely dry)
Oil Pressure Measurement
Oil Pressure @4 000 r/min (rpm), Oil
Temperature 90°C (194°F)
98 ∼147 kPa (1.0 ∼1.5 kgf/cm², 14 ∼21 psi)
Outside Circlip Pliers:
Halaman 177
Special Tools and Sealant
Outside Circlip Pliers:
57001-144
Oil Pressure Gauge, 10 kgf/cm²:
57001-164
ENGINE LUBRICATION SYSTEM 7-5
Oil Pressure Gauge Adapter, M18 × 1.5:
57001-1278
Kawasaki Bond (Silicone Sealant):
56019-120
Outside Circlip Pliers:
Halaman 178
7-6 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart
Oil Filter Replacement
Halaman 179
Engine Oil and Oil Filter
WARNING
Motorcycle
operation
with
insufficient,
deteri-
orated,
or contaminated engine oil will cause
accelerated wear and may result in engine or trans-
mission seizure, accident, and injury.
Oil Level Inspection
• Check that the engine oil level is between the upper [A]
and lower [B] levels in the gauge.
If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening.
Use the same type and
make of oil that is already in the engine.
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground.
○If the motorcycle has just been used, wait several min-
utes for all the oil to drain down.
○If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.
○If the engine oil type and make are unknown, use any
brand of the specified oil to top up the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not function
properly, the oil pressure warning light will light. If
this light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.
Engine Oil Change
• Refer to Engine Oil Change in the Periodic Maintenance
chapter (see Engine Oil Change in the Periodic Mainte-
nance chapter).
Oil Filter Replacement
• Refer to Oil Filter Replacement in the Periodic Mainte-
nance chapter (see Oil Filter Replacement in the Periodic
Maintenance chapter).
ENGINE LUBRICATION SYSTEM 7-7
Bypass Valve Cleaning and Inspection
Halaman 180
7-8 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
Bypass Valve Disassembly
• Remove the oil filter (see Oil Filter Replacement in the
Periodic Maintenance chapter).
NOTE
○Oil draining is not necessary, but place the oil pan un-
der the oil filter because oil drain a little at the oil filter
removal.
• Drive the retaining pin [A] out of the filter mounting bolt
[B].
• Drop out the spring [C] and the bypass valve steel ball [D].
Bypass Valve Assembly
• Drop the bypass valve steel ball into the filter mounting
bolt.
• Put the spring into the mounting bolt and compress it be-
yond the small hole.
• Drive the retaining pin into the small hole to hold the
spring.
• Install the oil filter (see Oil Filter Replacement in the Pe-
riodic Maintenance chapter).
Bypass Valve Cleaning and Inspection
• Remove the oil filter (see Oil Filter Replacement in the
Periodic Maintenance chapter).
• Disassemble the bypass valve (see Bypass Valve Disas-
sembly).
• Clean the bypass valve parts in a high flash-point solvent.
WARNING
Clean the parts in a well-ventilated area, and take
care that there is no spark or flame anywhere near
the working area. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvent.
• Visually inspect the bypass valve parts.
If there is any damaged part, replace it.
Oil Screen Cleaning and Inspection
Halaman 181
Engine Oil and Oil Filter
Oil Screen Cleaning and Inspection
• Remove the oil screen cover [A].
• Clean the oil pump screen [B] with high flash-point solvent
and remove any particles stuck to it.
WARNING
Clean the screen in a well-ventilated area, and take
care that there is no spark or flame anywhere near
the working area. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
point solvents.
NOTE
○While cleaning the screen, check for any metal particles
that might indicate internal engine damage.
• Check the screen carefully for any damage: holes and
broken wires.
If the screen is damaged, replace the oil screen assembly.
ENGINE LUBRICATION SYSTEM 7-9
Oil Pressure Relief Valve Inspection
Halaman 182
7-10 ENGINE LUBRICATION SYSTEM
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
• Remove the clutch cover (see Clutch Cover Removal in
the Clutch chapter).
• Unscrew the oil pressure relief valve [A] from the
crankcase.
Oil Pressure Relief Valve Installation
• Apply a non-permanent locking agent to the threads of
the relief valve, and tighten it with the specified torque.
Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11
ft·lb)
CAUTION
Do not over apply a non-permanent locking agent
to the threads. This may block the oil passage.
Oil Pressure Relief Valve Inspection
• Check to see if the valve [A] slides smoothly when push-
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.
NOTE
○Inspect the valve in its assembled state. Disassembly
and assembly may change the valve performance.
If any rough spots are found during above inspection,
wash the valve clean with a high-flash point solvent and
blow out any foreign particles that may be in the valve with
compressed air.
WARNING
Clean the oil pressure relief valve in a well
-ventilated area, and take care that there is no
spark or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low-flash point solvent.
If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for re-
placement of individual parts.
Oil Pump Inspection
Halaman 183
Oil Pump
Oil Pump Removal
• Remove the clutch cover (see Clutch Cover Removal in
the Clutch chapter).
• Remove the clutch (see Clutch Removal in the Clutch
chapter).
• Remove the circlip and oil pump gear.
• Remove the oil pump mounting Allen bolts [A].
• Pull the oil pump [B] off the crankcase.
Oil Pump Installation
• Fill the oil pump with engine oil for initial lubrication.
• When installing the oil pump [A], note the position of the
water pump shaft slot [C] and turn the oil pump shaft so
that the projection [B] fits into the slot.
• Apply a non-permanent locking agent to the threads of the
oil pump mounting Allen bolts, and tighten them securely.
Torque - Oil Pump Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Oil Pump Disassembly
• Remove the circlip [A] with circlip plire on the oil pump
shaft end.
Special Tool - Outside Circlip Pliers: 57001-144
• Take off the gear [B] from the shaft [C].
• Loosen the screws [D] before removing the oil pump
mounting bolts [E].
• Remove the oil pump (see Oil Pump Removal).
• Unscrew the oil pump cover screws [D] and take off the
cover [F].
• Pull the oil pump shaft [A], washer [B], pins [C], inner rotor
[D] and outer rotor [E] from the pump body [F].
Oil Pump Assembly
• Oil pump assembly is the reverse of disassembly.
• After completing the oil pump assembly, check that the
rotor shaft and rotor turn smoothly.
Oil Pump Inspection
• Disassemble the oil pump (see Oil Pump Disassembly).
• Visually inspect the oil pump body, inner and outer rotors
and covers.
If there is any damage or uneven wear, replace the oil
pump as an assembly.
ENGINE LUBRICATION SYSTEM 7-11
Special Tools -
Halaman 184
7-12 ENGINE LUBRICATION SYSTEM
Oil Pressure Measurement
Oil Pressure Measurement
• Remove the lower fairing (see Lower Fairing Removal in
the Frame chapter).
• Remove the oil plug, and attach the adapter [B] and gauge
[A] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, M18 × 1.5:
57001-1278
• Start the engine and warm up the engine.
• Run the engine at the specified speed, and read the oil
pressure gauge.
If the oil pressure is much lower than the standard, check
the oil pump and oil pump relief valve.
If the reading is much higher than the standard, check the
oil passages for clogging.
Oil Pressure
Standard: 98 ∼147 kPa (1.0 ∼1.5 kgf/cm², 14 ∼21 psi)
@ 4 000 r/min (rpm), oil temperature 90°C
(194°F)
• Stop the engine.
• Remove the oil pressure gauge and adapter.
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
Torque -
Halaman 185
Oil Pressure Switch
Oil Pressure Switch Removal
• Remove:
Lower Fairing (see Lower Fairing Removal in the Frame
chapter)
Switch Cover [A]
Switch Terminal [B]
Oil Pressure Switch [C]
Oil Pressure Switch Installation
• Apply silicone sealant to the threads of the oil pressure
switch and tighten it.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
• Tighten the oil pressure switch terminal bolt.
Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15
kgf·m, 13 in·lb)
○Install the oil pressure switch lead [A] as shown.
Front [B]
45° [C]
• Apply grease to the terminal.
ENGINE LUBRICATION SYSTEM 7-13
Engine Removal/Installation
Halaman 187
ENGINE REMOVAL/INSTALLATION 8-1
# Engine Removal/Installation
## Table of Contents
* Exploded View.................................................................... 8-2
* Engine Removal/Installation ............................................ 8-4
* Engine Removal.......................................................... 8-4
* Engine Installation........................................................ 8-6
8
Engine Removal/Installation
Halaman 188
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
Engine Removal/Installation
Halaman 189
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Engine Mounting Bracket Bolts and Nuts
64
6.5
47
2
Engine Mounting Nuts
64
6.5
47
Engine Removal
Halaman 190
8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Drain the coolant (see Coolant Change in the Periodic
Maintenance chapter).
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Side Covers (see Side Cover Removal in the Frame
chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Upper Fairings (see Upper Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Throttle Cable (see Throttle Cable Removal in the Fuel
System chapter)
Choke Cable (see Choke Cable Removal in the Fuel
System chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Muffler (see Muffler Removal in the Engine Top End
chapter)
Engine Sprocket (see Drive Chain Removal in the Final
Drive chapter)
• Remove:
Left Side Coolant Pipe [A]
Oil Pressure Switch Lead Connector [B]
Neutral Switch Terminal [C]
Breather Hose [D] at Air Cleaner Housing
Carburetor Holder Clamp (Loosen) [E]
Spark Plug Caps [F]
Engine Removal
Halaman 191
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
• Remove or disconnect:
Cooling Hose [A] at Cylinder Head
Starter Motor Cable [B]
Engine Ground Terminal [C]
Alternator Lead Connector [D]
Crankshaft Sensor Lead Connector [E]
Air Suction Hose [F]
• Support the engine with a suitable stand [A].
• Remove the regulator/rectifier [A] and the engine mount-
ing bracket bolts and nuts.
• Remove:
Engine Mounting Bolts and Nuts [A]
Engine Assembly [B]
Torque -
Halaman 192
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Installation
• Engine installation is the reverse of removal, and note the
following point.
○Insert the lower engine mounting bolt [A] first while sup-
porting the engine. Then insert the upper engine mount-
ing bolt [B], and tighten the nut loosely.
○Before tightening the mounting bolts, install the engine
brackets. When inserting the front engine mounting bolt,
use the suitable stand under the engine to lift it.
Torque - Engine Mounting Bracket Bolts, Nuts: 64 N·m (6.5
kgf·m, 47 ft·lb)
Engine Mounting Nuts: 64 N·m (6.5 kgf·m, 47 ft·lb)
○Route the wiring harness correctly (see Cable, Wire and
Hose Routing in the Appendix chapter).
○Adjust the following items after engine installation.
Throttle cable (see Throttle Control System Inspection in
the Periodic Maintenance chapter)
Choke Cable (see Choke Cable Free Play Inspection in
the Fuel System chapter)
Clutch Cable (see Clutch Operation Inspection in the Pe-
riodic Maintenance chapter)
Drive Chain Slack (see Drive Chain Slack Inspection in
the Periodic Maintenance chapter)
Carburetor Idling (see Idle Speed Inspection in the Peri-
odic Maintenance chapter)
• Fill the engine oil (see Engine Oil Change in the Periodic
Maintenance chapter).
• Fill the coolant (see Coolant Change in the Periodic Main-
tenance chapter).
Crankshaft/Transmission
Halaman 193
Crankshaft/Transmission
Table of Contents
Exploded View...................................
9-2
Specifications ....................................
9-6
Special Tools and Sealants ...............
9-9
Crankcase .........................................
9-10
Crankcase Splitting......................
9-10
Crankcase Assembly ...................
9-11
Crankcase Exchange...................
9-13
Crankshaft and Connecting Rods......
9-14
Crankshaft Removal ....................
9-14
Crankshaft Installation .................
9-14
Connecting Rod Removal............
9-15
Connecting Rod Installation.........
9-15
Crankshaft/Connecting Rod
Cleaning....................................
9-16
Connecting Rod Bend Inspection
9-16
Connecting Rod Twist Inspection.
9-16
Connecting Rod Big End Side
Clearance Inspection ................
9-17
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection..................................
9-17
Crankshaft Side Clearance
Inspection..................................
9-18
Crankshaft Runout Inspection......
9-19
Crankshaft Main Bearing
Insert/Journal Wear Inspection .
9-19
Starter Motor Clutch ..........................
9-21
Starter Motor Clutch
Removal/Installation..................
9-21
Starter Motor Clutch Inspection ...
9-21
Starter Motor Clutch Disassembly
9-21
CRANKSHAFT/TRANSMISSION 9-1
Starter Motor Clutch Assembly ....
9-21
Balancer ............................................
9-22
Balancer Removal........................
9-22
Balancer Installation.....................
9-22
Balancer Shaft Bearing
Insert/Journal Wear Inspection .
9-22
Transmission .....................................
9-24
External Shift Mechanism
Removal....................................
9-24
External Shift Mechanism
Installation.................................
9-24
External Shift Mechanism
Inspection..................................
9-25
Transmission Removal ................
9-25
Transmission Installation .............
9-26
Transmission Shaft Disassembly.
9-26
Transmission Shaft Assembly......
9-27
Shift Drum and Fork Removal......
9-28
Shift Drum and Fork Installation...
9-28
Shift Drum Disassembly...............
9-29
Shift Drum Assembly ...................
9-29
Gear Backlash Inspection............
9-30
Shift Fork Bending Inspection......
9-30
Shift Fork/Gear Groove Wear
Inspection..................................
9-30
Shift Fork Guide Pin/Drum
Groove Wear Inspection ...........
9-30
Gear Dog and Gear Dog Hole
Damage Inspection ...................
9-31
Ball and Needle Bearing Wear
Inspection..................................
9-31
9
Crankshaft/Transmission
Halaman 194
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
(A) (M0)
(H)
(M0)
(M0)
(B)
(F)
(M0)
(M0)
(G)
(M0)
(M0)
(M0)
(M0)
(E)
(M0)
(C)
(M0)
(D)
(M0)
(M0)
(J)
(I)
(M0)
(K)
(L)
(M0)
(N)
(P)
(O)
(5) (M0)
(Q)
(M0)
(R)
(S)
(T)
(W)X2
(2)
(3)
(2)
(4)X(S)(M0)
(2)
(1)
(2)
(M0) (S)X(3)
(1)
(2)
(3)(S)(M0)
(2)(N)
(1)
(7)
T133511BA
7
Crankshaft/Transmission
Halaman 195
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Oil Breather Mounting Bolts
9.8
1.0
87 in·lb
L
2
Crankcase Bolts
6
12
1.2
104 in·lb
3
Crankcase Bolts
8 (L = 90)
24
2.4
18
MO, S
4
Crankcase Bolts
8 (L = 73)
19
1.9
14
MO, S
5
Starter Motor Clutch Bolts
34.3
3.5
25
L
6
Connecting Rod Big End Cap Nuts
27.5
2.8
20
MO
7
Shift Drum Bearing Holder Bolt
12
1.2
104 in·lb
L
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket (Kawasaki Bond: 92104-1064).
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide
grease in a weight ratio 10:1).
R: Replacement Parts
S: Follow the specified tightening sequence.
W: Washer
CRANKSHAFT/TRANSMISSION 9-3
Crankshaft/Transmission
Halaman 196
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
(R)
(FO)
(EO)
(FO)
(R)
(R)
(EO)
(R)
(FO)
(K)
(FO)
(K)
(EO)
(R)
(K)
(R)
(FO)
(EO)
(FO)
(4)
(EO)
(5)
(E)
(1L)
(6)
(7)
(2)
(EO)
(FO)
(B)
(FO)
(R)
7103217801 2
Crankshaft/Transmission
Halaman 197
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
| No. | Fastener | Torque | | Remarks |
| :-- | :---------------------------------------------- | :------------ | :--------- | :--------- |
| | | N·m | kgf·m | ft·lb |
| 1 | Shift Drum Pin Plate Bolt | 9.0 | 0.9 | 80 in·lb | L |
| 2 | Neutral Switch | 15 | 1.5 | 11 | |
| 3 | External Shift Mechanism Return Spring Pin | 19.6 | 2.0 | 14.5 | L |
| 4 | Shift Drum Positioning Bolt | 24.5 | 2.5 | 18 | |
| 5 | Shift Lever Link Bolt | 12 | 1.2 | 104 in·lb | |
| 6 | Front Tie-Rod Locknut (Left-Hand Threads) | 7.0 | 0.7 | 62 in·lb | |
| 7 | Rear Tie-Rod Locknut (Right-Hand Threads) | 7.0 | 0.7 | 62 in·lb | |
| 8 | Shift Pedal Mounting Bolt | 25 | 2.5 | 18 | |
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Crankshaft/Transmission
Halaman 198
# 9-6 CRANKSHAFT/TRANSMISSION
Specifications
| Item | Standard | Service Limit |
|:---|:---|:---|
| Crankshaft, Connecting Rods | | |
| Connecting Rod Bend | --- | 0.2/100 mm<br>(0.008/3.94 in.) |
| Connecting Rod Twist | --- | 0.2/100 mm<br>(0.008/3.94 in.) |
| Connecting Rod Big End Side Clearance | 0.13 ~ 0.38 mm<br>(0.005 ~ 0.015 in.) | 0.50 mm<br>(0.020 in.) |
| Connecting Rod Big End Bearing Insert/Crankpin Clearance | 0.031 ~ 0.059 mm<br>(0.0012 ~ 0.0023 in.) | 0.10 mm<br>(0.004 in.) |
| Crankpin Diameter: | 29.984 ~ 30.000 mm<br>(1.1805 ~ 1.1811 in.) | 29.97 mm<br>(1.18 in.) |
| Marking | | |
| None | 29.984 ~ 29.994 mm<br>(1.1805 ~ 1.1809 in.) | --- |
| O | 29.995 ~ 30.000 mm<br>(1.1809 ~ 1.1811 in.) | --- |
| Connecting Rod Big End Bore Diameter | 33.000 ~ 33.016 mm<br>(1.2992 ~ 1.2998 in.) | --- |
| Marking | | |
| None | 33.000 ~ 33.008 mm<br>(1.2992 ~ 1.2995 in.) | --- |
| O | 33.009 ~ 33.016 mm<br>(1.2996 ~ 1.2998 in.) | --- |
| Connecting Rod Big End Bearing Insert Thickness: | | |
| Brown | 1.480 ~ 1.485 mm<br>(0.0583 ~ 0.0585 in.) | --- |
| Black | 1.485 ~ 1.490 mm<br>(0.0585 ~ 0.0587 in.) | --- |
| Blue | 1.489 ~ 1.494 mm<br>(0.0586 ~ 0.0588 in.) | --- |
| Crankshaft Runout | --- | 0.05 mm<br>(0.0020 in.) TIR |
| Crankshaft Main Bearing Insert/Journal Clearance | 0.014 ~ 0.038 mm\*<br>(0.0006 ~ 0.0015 in.) | 0.08 mm<br>(0.0031 in.) |
| Crankshaft Main Journal Diameter: | 27.984 ~ 28.000 mm<br>(1.1017 ~ 1.1024 in.) | 27.96 mm<br>(1.101 in.) |
| Marking | | |
| None | 27.984 ~ 27.992 mm<br>(1.1017 ~ 1.1020 in.) | --- |
| 1 | 27.993 ~ 28.000<br>(1.1021 ~ 1.1024 in.) | --- |
| Crankcase Main Bearing Bore Diameter: | 31.000 ~ 31.016 mm<br>(1.2205 ~ 1.2211 in.) | --- |
| Marking | | |
| O | 31.000 ~ 31.008 mm<br>(1.2205 ~ 1.2208 in.) | --- |
Crankshaft/Transmission
Halaman 199
Specifications
Item
Standard
Service Limit
None
31.009 ∼31.016 mm
(1.2208 ∼1.2211 in.)
Crankshaft Main Bearing Insert Thickness:
Black
1.495 ∼1.499 mm
(0.0589 ∼0.0590 in.)
Blue
1.499 ∼1.503 mm
(0.0590 ∼0.0592 in.)
Yellow
1.503 ∼1.507 mm
(0.0592 ∼0.0593 in.)
0.40 mm
(0.016 in.)
Balancer
Crankshaft Side Clearance
0.05 ∼0.20 mm
(0.002 ∼0.008 in.)
Balancer Shaft Bearing Insert/Journal
Clearance
0.08 mm
(0.0031 in.)
Balancer Shaft Journal Diameter:
25.984 ∼26.000
(1.0230 ∼1.0236 in.)
0.020 ∼0.044 mm
(0.0008 ∼0.0017 in.)
25.96 mm
(1.022 in.)
Marking
None
25.984 ∼25.994 mm
(1.0230 ∼1.0234 in.)
○
25.995 ∼26.000 mm
(1.0234 ∼1.0236 in.)
Crankcase Balancer Shaft Bore Diameter:
29.000 ∼29.016 mm
(1.1417 ∼1.1424 in.)
Marking
○
29.000 ∼29.008 mm
(1.1417 ∼1.1420 in.)
None
29.009 ∼29.016 mm
(1.1421 ∼1.1424 in.)
Balancer Shaft Bearing Insert Thickness:
Brown
1.495 ∼1.499 mm
(0.0589 ∼0.0590 in.)
Black
1.499 ∼1.503 mm
(0.0590 ∼0.0592 in.)
Blue
1.503 ∼1.507 mm
(0.0592 ∼0.0593 in.)
Transmission
Gear Backlash
0 ∼0.17 mm
(0 ∼0.0067 in.)
0.25 mm
(0.010 in.)
Gear Shift Fork Groove Width
5.05 ∼5.15 mm
(0.1988 ∼0.2028 in.)
5.3 mm
(0.209 in.)
Shift Fork Ear Thickness
4.9 ∼5.0 mm
(0.1929 ∼0.1969 in.)
4.8 mm
(0.189 in.)
Shift Fork Guide Pin Diameter
5.9 ∼6.0 mm
(0.2323 ∼0.2362 in.)
5.8 mm
(0.228 in.)
Shift Drum Groove Width
6.05 ∼6.20 mm
(0.2382 ∼0.2441 in.)
*: Journal clearance less than 0.025 mm (0.0010 in.) can not be measured by plastigage, however,
using genuine parts maintains the minimum standard clearance.
CRANKSHAFT/TRANSMISSION 9-7
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
– – –
6.3 mm
(0.248 in.)
Crankshaft/Transmission
Halaman 200
9-8 CRANKSHAFT/TRANSMISSION
Specifications
Connecting Rod Big End Bearing Insert Selection
Bearing Insert
Con-rod Big End Bore
Diameter Marking
Crankpin Diameter
Marking
Size Color
Parts Number
○
○
None
None
Black
92028-1493
○
None
Blue
92028-1492
None
○
Brown
92028-1494
Crankshaft Main Bearing Insert Selection
Bearing Insert**
Crankcase Main
Bearing Bore
Diameter Marking
Crankpin Main
Journal Diameter
Marking
Size Color
Parts Number
Journal Nos.
92028-1487
1, 3
○
1
Black
92028-1490
2
92028-1582
1, 3
None
None
Yellow
92028-1586
2
○
None
92028-1486
1, 3
None
1
Blue
92028-1489
2
**: The bearing inserts for No.2 journal have an oil groove.
Balancer Shaft Bearing Insert Selection
Bearing Insert
Balancer Shaft
Journal Diameter
Marking
Crankcase Balancer
Shaft Bore Diameter
Marking
Size Color
Parts Number
○
○
Brown
92028-1424
○
None
None
○
Black
92028-1423
None
None
Blue
92028-1422
Crankshaft Selection when Replacing Crankshaft
Clutch Housing
Crankshaft
Gear Marking [E]
Color [F]
Primary Gear
Marking [C]
Color [D]
Part Number
A
White
A
White
13031-0111
B
Red
A
White
13031-0111
B
Red
B
Red
13031-0112
C
None
B
Red
13031-0112
C
None
C
None
13031-0113
D
Yellow
C
None
13031-0113
D
Yellow
D
Yellow
13031-0114
Bearing Puller:
Halaman 201
Special Tools and Sealants
Bearing Puller:
57001-135
Outside Circlip Pliers:
57001-144
Bearing Puller Adapter:
57001-317
CRANKSHAFT/TRANSMISSION 9-9
Kawasaki Bond (Silicone Sealant):
56019-120
Kawasaki Bond(Liquid Gasket - Black):
92104-1064
Crankcase Splitting
Halaman 202
9-10 CRANKSHAFT/TRANSMISSION
Crankcase
Crankcase Splitting
• Remove the engine (see Engine Removal in the Engine
Removal/Installation chapter).
• Set the engine on a clean surface or, preferably mount it
on an engine stand to hold the engine steady while parts
are being removed.
• Remove the water pipe and hose (cylinder rearward).
NOTE
○If the engine is to be mounted on an engine stand, the
upper crankcase half bolts [A] shown must be removed
before mounting the engine.
Washer [B]
• Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Water Pump, Hose and Pipe (see Water Pump Removal
in the Cooling System chapter)
Starter Motor Clutch Gear
Oil Pipe and Banjo Bolt
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubri-
cation System chapter)
Cylinder Head Cover (see Cylinder Head Cover Re-
moval in the Engine Top End chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
One Way Clutch Gear
Oil Hose Banjo Bolt
Camshafts Chain Tensioner (see Camshafts Chain Ten-
sioner Removal in the Engine Top End chapter)
Clutch Cover (see Clutch Cover Removal in the Clutch
chapter)
Camshafts (see Camshaft Removal in the Engine Top
End chapter)
Cylinder Head (see Cylinder Head Removal in the En-
gine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Pistons (see Piston Removal in the Engine Top End
chapter)
Crankcase Assembly
Halaman 203
Crankcase
• Remove the clutch only if the transmission drive shaft as-
sembly is to be removed.
• Remove the oil pressure bolt [A] with the oil pressure
switch [B] and oil hose [C].
• Remove the neutral switch [D].
• Remove the upper crankcase half bolt (1) (3 were re-
moved just after engine removal).
• Turn the engine upside down.
• Remove the oil filter mounting bolt, oil filter, and large
O-ring.
• Remove the oil screen cover [A] and screen [B].
• Remove the 6 mm [A] and 8 mm [B] lower crankcase half
bolt, ply the point [C] shown to split the two crankcase
halves apart, and lift off the lower crankcase half.
Washer [D]
Crankcase Assembly
NOTE
○The upper/lower crankcase halves are machined at the
factory as an assembly, so the crankcase halves must
be replaced as a set.
• Assembly is the reverse of splitting.
Be careful of the
following items.
○With a high flash-point solvent, clean off the mating sur-
face of the crankcase halves and wipe dry.
○When installing the output and drive shafts, the crankcase
set pins [A] must go into the holes in the needle bearing
outer races, and the set rings [B] must fit into the grooves
in the ball bearings.
CRANKSHAFT/TRANSMISSION 9-11
Special Tool -
Halaman 204
9-12 CRANKSHAFT/TRANSMISSION
Crankcase
○When the oil pressure switch is installed, apply the sili-
cone sealant to the threads of the switch.
Special Tool - Kawasaki Bond (Silicone Sealant): 56019
-120
CAUTION
Make sure the crankcase set pins are properly
aligned to avoid damage to the crankcases upon
installation.
Don’t use usual set pins because the set pins of
this model are different from usual pins. They are
hollow and also used to pass oil. If you use usual
pins by mistake, the engine always seized.
○Check that the knock pins (2) are in place.
○Apply a little engine oil to the transmission gears ball bear-
ings, shift drum, and crankshaft main bearing inserts.
• Apply liquid gasket to the mating surface of the lower
crankcase half.
Special Tool - Kawasaki Bond (Liquid Gasket - Black):
92104-1064 [A]
○After assembling the crankcase halves, wipe off excess
liquid gasket on the inside portion [B].
CAUTION
If liquid gasket adheres to any areas not indicated,
the engine oil passage may be obstructed, causing
engine seizure.
○Check to see that the shift drum is in the neutral position,
that is, the projection at operating plate is seen from neu-
tral switch hole at the upper crankcase half.
○When fitting the lower crankcase half on the upper
crankcase half, each shift fork must fit in its gear groove.
○Loosely tighten all lower crankcase half bolts to a snug fit.
Crankcase Exchange
Halaman 205
Crankcase
• Apply molybdenum disulfide oil solution to flange [A] and
the threads [B] of the M8 bolts which is tightening order is
[1 ∼8] only (see the next figure).
○Following the sequence numbers on the lower crankcase
half, tighten the 8 mm bolts [A] first to about one half of
the specified torque, and finally to the specified torque in
the same sequence.
○Replace the copper washer [C] with a new one.
○Tighten the 6 mm bolts [B] on the lower crankcase half to
the specified torque.
Torque - Crankcase Bolts ( 8, L = 90):
First: 10 N·m (1.0 kgf·m, 89 in·lb)
Final: 24 N·m (2.4 kgf·m, 18 ft·lb)
Crankcase Bolts ( 8, L = 73):
First: 10 N·m (1.0 kgf·m, 89 in·lb)
Final: 19 N·m (1.9 kgf·m, 14 ft·lb)
○Replace the copper washer [B] with a new one.
○Tighten the 6 mm bolts [A] on the upper crankcase half to
the specified torque.
Torque - Crankcase Bolts ( 6): 12 N·m (1.2 kgf·m, 104 in·lb)
• After tightening all crankcase bolts, check the following
items.
○Drive shaft and output shaft turn freely.
○While spinning the output shaft, shift the transmission
smoothly from 1st to 6th gear, and back,
○Unless the output shaft is turning, the transmission cannot
be shifted to 2nd gear or other higher gear positions.
Crankcase Exchange
If the crankcase is damaged, replace it with a new one.
• Remove the crankcase parts from the damaged case, and
install it to the new case. Pay attention to the following
items.
○When installing the oil passage plug must be inserted as
shown.
[1] Lower Crankcase Half
[2] Oil Passage Pipe
[3] Press
[4] Small Hall (Up)
[5] Slit (Horizontal)
○Fit the oil passage O-ring on the breather body. Replace
the O-ring with new ones, if deteriorated or damage. The
flat side of the O-ring must face down.
○Apply a non-permanent locking agent to the threads of
the breather bolts, and tighten them.
CRANKSHAFT/TRANSMISSION 9-13
Crankshaft Installation
Halaman 206
9-14 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Removal
• Split the crankcase (see Crankcase Splitting).
• Take the crankshaft out of the upper crankcase.
Crankshaft Installation
• If the crankshaft is replaced with a new one, select the
proper crankshaft in accordance with the combination
of the crankshaft primary gear and clutch housing gear
markings with colors.
Crankshaft Primary Gear [A]
Clutch Housing Gear [B]
• Be sure to confirm the marking and color on the crank-
shaft primary gear.
Crankshaft Selection when Replacing Crankshaft
Clutch Housing
Crankshaft
Gear Marking [E]
Color [F]
Primary Gear
Marking [C]
Color [D]
Part Number
A
White
A
White
13031-0111
B
Red
A
White
13031-0111
B
Red
B
Red
13031-0112
C
None
B
Red
13031-0112
C
None
C
None
13031-0113
D
Yellow
C
None
13031-0113
D
Yellow
D
Yellow
13031-0114
NOTE
○If the selection mark and color are missing or not selec-
tion, refer to the selection section in the specifications.
○If the crankshaft is replaced with a new one, refer to
the Connecting Rod Big End Bearing/Crankshaft Main
Bearing Insert Selection in the Selection Section.
CAUTION
If the crankshaft bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
(press gauge) before assembling engine to be sure
the correct bearing inserts are installed.
Connecting Rod Installation
Halaman 207
Crankshaft and Connecting Rods
• Align the timing mark [C] on the balancer drive gear [A]
with the timing mark [C] on the balancer gear [B].
• Apply molybdenum disulfide oil solution to the crankshaft
main bearing inserts.
• Install the crankshaft.
Connecting Rod Removal
• Split the crankcase (see Crankcase Splitting).
• Remove the connecting rod big end cap nuts.
• Remove the crankshaft.
NOTE
○Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.
• Remove the connecting rods from the crankshaft.
CAUTION
Discard the connecting rod bolts. To prevent dam-
age to the crankpin surfaces, do not allow the con-
necting rod bolts to bump against the crankpins.
Connecting Rod Installation
CAUTION
To minimize vibration, the connecting rods should
have the same weight mark.
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: “○” or no
mark
CAUTION
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select the
bearing insert and check clearance with a plasti-
gage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.
CAUTION
The connecting rod bolts are designed to stretch
when tightened. Never reuse them.
• Replace the connecting rod big end bolts and nuts with
new ones.
CRANKSHAFT/TRANSMISSION 9-15
Connecting Rod Twist Inspection
Halaman 208
9-16 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
• Apply molybdenum disulfide oil solution to the inner sur-
face of upper and lower bearing inserts [A].
• Apply molybdenum disulfide oil solution to the threads [B]
and seating surface [C] of the connecting rod nuts.
Torque - Connecting Rod Big End Cap Nuts: 27.5 N·m (2.8
kgf·m, 20 ft·lb)
Crankshaft/Connecting Rod Cleaning
• After removing the connecting rods from the crankshaft,
clean them with a high-flash point solvent.
• Blow the crankshaft oil passages with compressed air to
remove any foreign particles or residue that may have
accumulated in the passages.
Connecting Rod Bend Inspection
• Remove the connecting rod big end bearing inserts, and
reinstall the connecting rod big end cap.
• Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.
• Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.
• On a surface plate, set the big-end arbor on V block [C].
• With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If the connecting rod bend exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist Inspection
• With the big-end arbor [A] still on V block [C], hold the
connecting rod horizontally and measure the amount that
the arbor [B] varies from being paralleled with the surface
plate over a 100 mm (3.94 in.) length of the arbor to de-
termine the amount of connecting rod twist.
If the connecting rod twist exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Halaman 209
Crankshaft and Connecting Rods
Connecting Rod Big End Side Clearance
Inspection
• Measure the connecting rod big end side clearance [A].
○Insert a thickness gauge [B] between the big end and the
crank web to determine clearance.
Connecting Rod Big End Side Clearance
Standard:
0.13 ∼0.38 mm (0.005 ∼0.015 in.)
Service Limit: 0.5 mm (0.020 in.)
If the clearance exceeds the service limit, replace the con-
necting rod with new one and then check the clearance
again. If the clearance is too large after connecting rod
replacement, the crankshaft also must be replaced.
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
• Measure the bearing insert/crankpin clearance [B] with
plastigage [A].
• Tighten the big end nuts to the specified torque (see Con-
necting Rod Installation).
NOTE
○Do not move the connecting rod and crankshaft during
clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Standard:
0.031 ∼0.059 mm (0.0012 ∼0.0023 in.)
Service Limit: 0.10 mm (0.004 in.)
If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.059 mm (0.0023 in.) and
the service limit 0.10 mm (0.004 in.), replace the bear-
ing inserts [A] with inserts painted black [B]. Check the
insert/crankpin clearance with the plastigage. The clear-
ance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
Standard:
29.984 ∼30.000 mm (1.1805 ∼1.1811 in.)
Service Limit: 29.97 mm (1.18 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankpin Diameter Marks
None: 29.984 ∼29.994 mm (1.1805 ∼1.1809 in.)
○:
29.995 ∼30.000 mm (1.1809 ∼1.1811 in.)
◊: Crankpin Diameter Marks, "○" mark or no mark.
CRANKSHAFT/TRANSMISSION 9-17
Crankshaft Side Clearance Inspection
Halaman 210
9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
• Measure the connecting rod big end bore diameter, and
mark each connecting rod big end in accordance with the
bore diameter.
• Tighten the big end nuts to the specified torque (see Con-
necting Rod Installation).
NOTE
○The mark already on the big end should almost coincide
with the measurement because of little wear.
Connecting Rod Big End Bore Diameter Marks
None: 33.000 ∼33.008 mm (1.2992 ∼1.2995 in.)
○:
33.009 ∼33.016 mm (1.2996 ∼1.2998 in.)
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: “○” or no
mark
• Select the proper bearing insert [A] in accordance with the
combination of the connecting rod and crankshaft coding.
Size Color [B]
Bearing Insert
Con-rod Bid
End Bore
Diameter
Crankpin
Diameter
Marking
Size Color
Part Number
None
○
Brown
92028-1494
None
None
○
○
Black
92028-1493
○
None
Blue
92028-1492
• Install the new inserts in the connecting rod and check
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance Inspection
• Insert a thickness gauge [A] between the crankcase main
bearing and the crank web at the No. 2 journal [B] to
determine clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○The upper and lower crankcase halves are machined
at the factory in the assembled state, so the crankcase
halves must be replaced as a set.
Crankshaft Side Clearance
Standard:
0.05 ∼0.20 mm (0.002 ∼0.008 in.)
Service Limit: 0.40 mm (0.016 in.)
Crankshaft Main Bearing Insert/Journal Wear Inspection
Halaman 211
Crankshaft and Connecting Rods
Crankshaft Runout Inspection
• Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Service Limit: TIR 0.05 mm (0.002 in.)
Crankshaft Main Bearing Insert/Journal Wear
Inspection
• Using a plastigage (press gauge), measure the bearing
insert/journal [B] clearance [A].
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○Do not turn the crankshaft during clearance measure-
ment.
○Journal clearance less than 0.025 mm (0.001 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.
Crankshaft Main Bearing Insert/Journal Clearance
Standard:
0.014 ∼0.038 mm (0.0006 ∼0.0015 in.)
Service Limit: 0.08 mm (0.0031 in.)
If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.038 mm (0.0015 in.) and the
service limit 0.08 mm (0.0031 in.), replace the bearing in-
serts with inserts [A] painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.
Crankshaft Main Journal Diameter
Standard:
27.984 ∼28.000 mm (1.1017 ∼1.1024 in.)
Service Limit: 27.96 mm (1.101 in.)
If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None: 27.984 ∼27.992 mm (1.1017 ∼1.1020 in.)
1:
27.993 ∼28.000 mm (1.1021 ∼1.1024 in.)
□: Crankshaft Main Journal Diameter Marks, "1" mark
or no mark.
CRANKSHAFT/TRANSMISSION 9-19
Crankshaft Main Bearing Insert/Journal Wear Inspection
Halaman 212
9-20 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
• Measure the main bearing bore diameter, and mark the
upper crankcase half in accordance with the bore diame-
ter.
A: Crankcase Main Bearing Bore Diameter Marks, "○"
mark or no mark.
NOTE
○Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).
○The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Bore Diameter Marks
○:
31.000 ∼31.008 mm (1.2205 ∼1.2208 in.)
None: 31.009 ∼31.016 mm (1.2208 ∼1.2211 in.)
• Select the proper bearing insert [A] in accordance with the
combination of the crankcase and crankshaft coding.
Size Color [B]
Bearing Insert*
Crankcase Main
Bearing Bore
Diameter Marking
Crankshaft Main
Journal Diameter
Marking
Size Color
Part Number
Journal Nos.
92028-1487
1, 3
○
1
Black
92028-1490
2
None
1
29028-1486
1, 3
○
None
Blue
92028-1489
2
92028-1582
1, 3
None
None
Yellow
92028-1586
2
*The bearing insert for No.2 journal have an oil groove.
• Install the new inserts in the crankcase halves and check
insert/journal clearance with the plastigage.
Torque -
Halaman 213
Starter Motor Clutch
Starter Motor Clutch Removal/Installation
• Refer to Alternator Rotor Removal and Installation in the
Electrical System chapter (see Alternator Rotor Removal
and Installation in the Electrical System chapter).
Starter Motor Clutch Inspection
• Remove:
Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Starter Idle Gear
• Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
• Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
NOTE
○Examine the starter motor clutch gear as well. Replace
it if is worn or damage.
Starter Motor Clutch Disassembly
• Remove:
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Starter Motor Clutch Bolts [A] and Starter Motor Clutch
[B]
Alternator Rotor [C]
Starter Motor Clutch Assembly
• Apply a non-permanent locking agent to the threads of
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 34.3 N·m (3.5 kgf·m,
25 ft·lb)
CRANKSHAFT/TRANSMISSION 9-21
Torque -
Halaman 214
9-22 CRANKSHAFT/TRANSMISSION
Balancer
Balancer Removal
• Split the crankcase (see Crankcase Splitting).
• Pull the balancer shaft with the balancer gear out of the
crankcase.
Balancer Installation
• Balancer installation is the reverse of removal.
• Apply oil to the inside of the balancer shaft bearing insert.
• Align the timing mark [C] on the balancer gear [B] with
the timing mark [C] on the balancer drive gear [A] of the
crankshaft.
Balancer Shaft Bearing Insert/Journal Wear
Inspection
• Measure the bearing insert/journal clearance.
○Split the crankcase and wipe each bearing insert and jour-
nal [A] surface clean of oil.
○Cut strips of plastigage (press gauge) [B] to bearing insert
width, and place a strip on each journal parallel to the
balancer shaft so that the plastigage will be compressed
between the journal and the bearing insert.
○Install the lower crankcase half, and tighten the case bolts
to the specified torque.
Torque - Crankcase Bolts
8: 27 N·m (2.8 kgf·m, 20 ft·lb)
Crankcase Bolts
6: 12 N·m (1.2 kgf·m, 104 in·lb)
NOTE
○Do not turn the balancer shaft during clearance mea-
surement.
○Remove the lower crankcase half and measure the plas-
tigage width to determine the bearing insert/journal clear-
ance.
Balancer Shaft Bearing Insert/Journal Clearance
Standard:
0.020 ∼0.044 mm (0.0008 ∼0.0017 in.)
Service Limit: 0.08 mm (0.0031 in.)
If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.044 mm (0.0017 in.) and
the service limit 0.08 mm (0.0031 in.), replace the bear-
ing inserts with inserts painted blue. Check insert/journal
clearance with plastigage. The clearance may exceed the
standard slightly, but it must not be less than the minimum
in order to avoid bearing seizure.
If the clearance exceeds the service limit; measure the
diameter of the balancer shaft journal.
Balancer Shaft Journal Diameter
Standard:
25.984 ∼26.000 (1.0230 ∼1.0236 in.)
Service Limit: 25.96 mm (1.022 in.)
Torque -
Halaman 215
Balancer
If either journal has worn past the service limit, replace
the balancer shaft with a new one.
If the measured journal diameter is not less than the ser-
vice limit, but does not coincide with the original diameter
markings [A] on the balancer shaft, write new marks on it.
Balancer Shaft Journal Diameter Marks
None: 25.984 ∼25.994 (1.0230 ∼1.0234 in.)
○:
25.995 ∼26.000 mm (1.0234 ∼1.0236 in.)
• Put the lower crankcase half on the upper crankcase half
without bearing inserts, and tighten the case bolts to the
specified torque and sequence (see Crankcase Assem-
bly).
• Measure the main bearing inside diameter, and mark the
upper crankcase half in accordance with the inside diam-
eter.
NOTE
○The mark [A] already on the upper crankcase half
should almost coincide with the measurement.
Crankcase Bearing Inside Diameter Marks
○:
29.000 ∼29.008 mm (1.1417 ∼1.1420 in.)
None: 29.009 ∼29.016 mm (1.1421 ∼1.1424 in.)
• Select the proper bearing insert [A] in accordance with the
combination of the crankcase and balancer shaft coding.
• Install the new insert in the crankcase and check in-
sert/journal clearance with plastigage.
Size Color [B]
Bearing Insert
Crankcase
Bearing Inside
Diameter Mark
Balancer
Shaft Journal
Diameter Mark
Size Color
Part Number
○
○
Brown
92028-1424
None
None
Blue
92028-1422
○
None
None
○
Black
92028-1423
CRANKSHAFT/TRANSMISSION 9-23
External Shift Mechanism Installation
Halaman 216
9-24 CRANKSHAFT/TRANSMISSION
Transmission
External Shift Mechanism Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove the shift lever link bolt [A] and pull the lever link
off the shift shaft end.
• Remove the clutch (see Clutch Removal in the Clutch
chapter).
• Move the shift mechanism arm [A] and over shift limiter
[B] out of their positions on the end of the shift drum [C],
and pull out the shift shaft [D] with the arm, pawl spring
[E] and return spring [F].
External Shift Mechanism Installation
• Check that the return spring [A] and pawl spring [B] are
properly fitted on the mechanism, install the external shift
mechanism, and place the shift mechanism arm [C] and
over shift limiter [D] on the shift drum pins.
• Add the engine oil (see Lubrication System in the Periodic
Maintenance chapter).
• Be sure the sealing lip of the rubber boot [A] fits into the
groove of the ball joint after installing the shift lever link.
○Correctly Boot Fitting Position [A]
○Incorrectly Boot Position [B]
Transmission Removal
Halaman 217
Transmission
• Align the mark [A] on the shift shaft with the mark [B] on
the shift lever link.
• Position the shift lever [C] as shown.
Approx. 15° [D]
External Shift Mechanism Inspection
• Examine the shift shaft for any damage.
If the shift shaft [A] is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the return spring [C] or pawl spring [D] is broken or dis-
torted, replace them.
If the shift mechanism arm [E] or over shift limiter [F] is
distorted, replace the shift shaft.
• Check the return spring pin is not loose.
If it is loose, unscrew it and apply a non-permanent lock-
ing agent to the threads, and tighten it.
Torque - External Shift Mechanism Return Spring Pin: 19.6
N·m (2.0 kgf·m, 14.5 ft·lb)
• Visually inspect the shift drum pins [A], pin holder [B] and
pin plate [C].
If they are badly worn or if they show any damage, replace
them.
Transmission Removal
• Split the crankcase (see Crankcase Splitting).
• Remove the drive shaft [A] and output shaft [B].
CRANKSHAFT/TRANSMISSION 9-25
Special Tools -
Halaman 218
9-26 CRANKSHAFT/TRANSMISSION
Transmission
Transmission Installation
• With a high flash-point solvent, clean off the outer cir-
cumferences of the transmission ball bearings and needle
bearing housings, and wipe dry.
• Check to see that the set rings [A] and set pins [B] are
in place in the transmission bearing housings clean with
compressed air.
• Install the drive shaft and output shaft into the upper
crankcase half.
• Apply engine oil to the sliding surfaces of the gears and
bearings.
○The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they are properly matched, there is no clearance between
the crankcase [A] and the bearing outer races [B].
• Assemble the crankcase.
Transmission Shaft Disassembly
• Remove the transmission shafts (see Transmission Shaft
Removal).
• Remove the circlips,
disassemble the transmission
shafts.
Special Tool - Outside Circlip Pliers: 57001-144
• The 5th gear [A] on the output shaft has three steel balls
assembled into it for the positive neutral finder mecha-
nism. Remove the 5th gear.
○Set the output shaft in a vertical position holding the 3rd
gear [C].
○Spin the 5th gear quickly [B] and pull it off upward.
• Remove the ball bearing [A] from each shafts.
Special Tools - Bearing Puller: 57001-135 [B]
Bearing Puller Adapter: 57001-317 [C]
• Discard the bearing.
Transmission Shaft Assembly
Halaman 219
Transmission
Transmission Shaft Assembly
• Install the ball bearing on the drive shaft with the groove
toward the clutch side.
• Install the gear bushing [A] on the shafts with their oil
holes [B] aligned.
• The drive shaft gears can be recognized by size: the gear
with the smallest diameter is 1st gear, and the largest one
is 6th gear. Be sure that all parts are put back in the cor-
rect sequence and all circlips and washers are properly in
place.
• The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the small-
est one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.
• Fit the steel balls into the 5th gear holes in the output shaft
as shown.
View A - A’ (see CRANKSHAFT/TRANSMISSION 9-30)
[A] Gear (5th)
[B] Shaft
[C] Steel Balls
CAUTION
Do not apply grease to the steel balls to hold them
in place. This will cause the positive neutral finder
mechanism to malfunction.
○Check the ball-locking effect that the 5th gear does not
come out of the output shaft when moving it up and down
by hand.
• Replace any circlip that were removed with new ones.
• Install the circlips [A] so that opening [B] is aligned with a
spline groove [C].
• Check that each gear spins or slides freely on the trans-
mission shafts without binding after assembly.
CRANKSHAFT/TRANSMISSION 9-27
Shift Drum and Fork Installation
Halaman 220
9-28 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum and Fork Removal
• Split the crankcase (see Crankcase Splitting).
• Remove the neutral positioning bolt [A] and take off
the washer [B], spring [C] and pin [D] from the upper
crankcase half [E].
• Remove the shift drum bearing holder bolts [A] and take
the holder plate [D] out of the shift drum [B] and shift rod
[C].
• Pull the shift rods [A] off the right side of the upper
crankcase half, and take off the drive shaft shift fork [B]
and the output shaft shift forks [C].
• Pull out the shift drum [A] about half of it, and remove the
circlip [B] and the operating plate [C].
• Pull out the shift drum fully from the upper crankcase.
Shift Drum and Fork Installation
• Set the transmission gear in the neutral position.
• Insert the shift drum into the upper crankcase half, and
install the operating plate pin [A], operating plate [B] and
circlip [C].
NOTE
○When installing the operating plate the projection [D]
faces toward the outside.
Torque -
Halaman 221
Transmission
• Apply a little engine oil to the shift rods and shift fork fin-
gers.
• Insert the shift rods [D] running them through the shift
forks, fitting each shift fork guide pin into the shift drum
grooves.
○Position the one with shortest ear [A] on the drive shaft
and place the guide pin in the center groove in the shift
drum [B].
○The two forks [C] on the output shaft are identical.
• Install the shift drum bearing holder plate [A].
○Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolts [B], and tighten them
with the specified torque.
Torque - Shift Drum Bearing Holder Bolts:
12 N·m (1.2
kgf·m, 104 in·lb)
• Install the neutral positioning bolt with the specified torque
to the upper crankcase.
Torque - Shift Drum Positioning Bolt: 24.5 N·m (2.5 kgf·m,
18 ft·lb)
Shift Drum Disassembly
• Remove the shift drum (see Shift Drum Removal).
• When holding the shift drum with a vise, remove the shift
drum pin plate bolt.
Shift Drum Assembly
• Be sure to install the dowel pin [F].
• The shift drum pins [C] are identical.
• Apply a non-permanent locking agent to the threads of
the shift drum pin plate bolt [A], and tighten it.
Torque - Shift Drum Pin Plate Bolt: 9.0 N·m (0.9 kgf·m, 80
in·lb)
Shift Drum Pin Plate [B]
Shift Drum Bearing Holder [D]
Shift Drum Bearing [E]
Shift Drum [G]
Operating Plate Pin [H]
Operating Plate [I]
Circlip [J]
CRANKSHAFT/TRANSMISSION 9-29
Shift Fork Guide Pin/Drum Groove Wear Inspection
Halaman 222
9-30 CRANKSHAFT/TRANSMISSION
Transmission
Gear Backlash Inspection
• Split the crankcase leaving the transmission in place.
• Set a dial gauge against the teeth on one gear, and move
the gear back and forth [A] while holding the other gear
steady [B]. The difference between the highest and the
lowest gauge readings is the amount of backlash.
Replace both gears if the amount of backlash exceeds
the service limit.
Gear Backlash
Standard:
0 ∼0.17 mm (0 ∼0.0067 in.)
Service Limit: 0.25 mm (0.010 in.)
Shift Fork Bending Inspection
• Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]
Shift Fork/Gear Groove Wear Inspection
• Measure the thickness of the shift fork ears [A], and mea-
sure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
4.9 ∼5.0 mm (0.1929 ∼0.1969 in.)
Service Limit: 4.8 mm (0.189 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard:
5.05 ∼5.15 mm (0.1988 ∼0.2028 in.)
Service Limit: 5.3 mm (0.209 in.)
Shift Fork Guide Pin/Drum Groove Wear
Inspection
• Measure the diameter of each shift fork guide pin [A], and
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
5.9 ∼6.0 mm (0.2323 ∼0.2362 in.)
Service Limit: 5.8 mm (0.228 in.)
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
6.05 ∼6.20 mm (0.2382 ∼0.2441 in.)
Service Limit: 6.3 mm (0.248 in.)
Ball and Needle Bearing Wear Inspection
Halaman 223
Transmission
Gear Dog and Gear Dog Hole Damage Inspection
• Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
Ball and Needle Bearing Wear Inspection
• Check the following ball bearings: right hand drive shaft,
left hand output shaft, and right hand shift drum.
○Since the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement. Clean each bearing in a high flash-point sol-
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
• Check the following needle bearing: left hand drive shaft,
and right hand output shaft.
○The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bear-
ing, replace it.
CRANKSHAFT/TRANSMISSION 9-31
Ball and Needle Bearing Wear Inspection
Halaman 224
## 9-32 CRANKSHAFT/TRANSMISSION
### Transmission
1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th Gear
6. 6th (Top) Gear
7. Circlip
8. Circlip
9. Toothed Washer
10. Washer
11. Thrust Washer
12. Needle Bearing
13. Ball Bearing
14. Collar
15. Bearing Outer Race
16. Steel Ball
17. Drive Shaft
18. Output Shaft
Wheels/Tires
Halaman 225
WHEELS/TIRES 10-1
# Wheels/Tires
## Table of Contents
Exploded View .......................................................................................... 10-2
Specifications ......................................................................................... 10-4
Special Tools .......................................................................................... 10-5
Wheels (Rims) ....................................................................................... 10-6
Front Wheel Removal ........................................................................ 10-6
Front Wheel Installation ..................................................................... 10-6
Rear Wheel Removal ........................................................................ 10-7
Rear Wheel Installation ...................................................................... 10-7
Wheel Inspection ................................................................................ 10-9
Axle Inspection ................................................................................... 10-9
Balance Inspection ............................................................................ 10-10
Balance Adjustment ........................................................................... 10-10
Balance Weight Removal .................................................................. 10-10
Balance Weight Installation ............................................................... 10-10
Tires ..................................................................................................... 10-12
Air Pressure Inspection/Adjustment ................................................ 10-12
Tire Inspection ................................................................................... 10-12
Tire Removal ..................................................................................... 10-12
Tire Installation .................................................................................. 10-13
Tire Repair .......................................................................................... 10-15
Hub Bearing .......................................................................................... 10-16
Hub Bearing Removal ...................................................................... 10-16
Hub Bearing Installation ................................................................... 10-16
Hub Bearing Inspection .................................................................... 10-17
Hub Bearing Lubrication ................................................................... 10-17
Speedometer Gear Housing ................................................................ 10-18
Speedometer Gear Housing Disassembly ....................................... 10-18
Speedometer Gear Housing Assembly ............................................ 10-18
Speedometer Gear Housing Lubrication .......................................... 10-19
Wheels/Tires
Halaman 226
# 10-2 WHEELS/TIRES
Exploded View
R
G
H
R
I
R
H
B
G
2 400 13 A.D. 1
Wheels/Tires
Halaman 227
WHEELS/TIRES 10-3
Exploded View
| No. | Fastener | Torque | Remarks |
|-----|----------------|------------------|---------|
| | | N·m | kgf·m | ft·lb | |
| 1 | Front Axle Nut | 88 | 9.0 | 65 | |
| 2 | Rear Axle Nut | 98 | 10.0 | 72 | |
G: Apply grease.
R: Replacement Parts
Wheels/Tires
Halaman 228
10-4 WHEELS/TIRES
Specifications
Item
Standard
Service Limit
Wheels (Rims)
Rim Runout:
Axial
TIR 0.5 mm (0.02 in.) or less
TIR 1.0 mm (0.04 in.)
Radial
TIR 0.8 mm (0.03 in.) or less
TIR 1.0 mm (0.04 in.)
Axle Runout/100 mm (3.94 in.)
TIR 0.03 mm (0.0012 in.) or less
TIR 0.2 mm (0.008 in.)
Wheel Balance
10 g (0.35 oz.) or less
– – –
Balance Weights
10 g (0.35 oz.), 20 g (0.71 oz.), 30 g
(1.06 oz.)
Rim Size:
Front
17 × 2.75
– – –
Rear
17 × 3.50
– – –
Tires
Air Pressure (when Cold):
Front
Up to 170 kg (375 lb) load: 200 kPa
(2.00 kgf/cm², 28 psi)
– – –
Rear
Up to 170 kg (375 lb) load: 225 kPa
(2.25 kgf/cm², 32 psi)
Tread Depth:
Front:
BRIDGESTONE
4.6 mm (0.181 in.)
1 mm (0.04 in.)
DUNLOP
4.5 mm (0.177 in.)
Rear:
Up to 130 km/h (80 mph):
2 mm (0.08 in.)
Over 130 km/h (80 mph):
3 mm (0.12 in.)
Standard Tires:
Make, Type
Size
Front
BRIDGESTONE BATTLAX BT45F
DUNLOP GT 501FG T/L
BRIDGESTONE
7.0 mm (0.276 in.)
DUNLOP
7.4 mm (0.291 in.)
Rear
BRIDGESTONE BATTLAX BT45R
DUNLOP GT501 T/L
WARNING
Use the same manufacturer’s tires on both front and rear wheels.
– – –
– – –
110/70 17 M/C (54 H)
130/70 17 M/C (62 H)
Inside Circlip Pliers:
Halaman 229
WHEELS/TIRES 10-5
Special Tools
Inside Circlip Pliers:
57001-143
[Image of inside circlip pliers]
Rim Protector:
57001-1063
[Image of rim protectors]
Bead Breaker Assembly:
57001-1072
[Image of a bead breaker assembly]
Bearing Driver Set:
57001-1129
[Image of a bearing driver set]
Bearing Remover Shaft, φ9:
57001-1265
[Image of a bearing remover shaft]
Bearing Remover Head, φ15 × φ17:
57001-1267
[Image of a bearing remover head]
Torque -
Halaman 230
10-6 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove:
Speedometer Cable Lower End [A]
Axle Nut Cotter Pin [B]
Axle (Loosen) [C]
Front Caliper Mounting Bolts [D]
• Using a jack, raise the front wheel off the ground.
• Pull the axle and remove the front wheel.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Front Wheel Installation
• Apply a high-temperature grease to the grease seal lips.
• Install the speedometer gear housing to the front wheel.
• Install the front wheel so that the speedometer gear hous-
ing stop [A] fit into the fork leg stops [B].
• Install the speedometer cable so that the drive notch [B]
of it fits into the projection [A] of the speedometer gear in
the housing.
• Tighten the front axle nut with the specified torque.
Torque - Front Axle Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)
Rear Wheel Installation
Halaman 231
Wheels (Rims)
• Check the front brake effectiveness (see Brake Operation
Inspection in the Periodic Maintenance chapter).
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Wheel Removal
• Remove:
Axle Nut Cotter Pin [A]
Axle Nut [B] and Washer [C]
Chain Locknuts (Loosen) [D] and Adjusting Nuts [E]
Axle [F]
Alignment Indicators [G]
• Remove:
Rear Caliper Mounting Bolts [A]
Rear Caliper [B]
• Raise the rear wheel off the ground with the stand.
• Free the drive chain from the rear sprocket, and remove
the rear wheel.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Rear Wheel Installation
• Apply a high temperature grease to the grease seal lips
and coupling, wheel sliding portions.
WHEELS/TIRES 10-7
Torque -
Halaman 232
10-8 WHEELS/TIRES
Wheels (Rims)
• Fit the swingarm stop [A] into the caliper holder stops [B].
• Install:
Alignment Indicators
Axle
Chain Adjusting Nuts and Locknuts
Axle Nut and Washer
Axle Nut Cotter Pin
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
NOTE
○Insert the axle from the right side of the wheel, and
tighten the axle nut.
• Install a new cotter pin.
NOTE
○When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.
○It should be within 30 degree.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut.
• Adjust the drive chain slack (see Drive Chain Slack Ad-
justment in the Periodic Maintenance chapter).
• Check the rear brake (see Brake Operation Inspection in
the Periodic Maintenance chapter).
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.
Axle Inspection
Halaman 233
Wheels (Rims)
Wheel Inspection
• Raise the front/rear wheel off the ground.
• Spin the wheel lightly, and check for roughness or binding.
If the roughness or binding is found, replace the hub bear-
ings.
• Inspect the wheel for small cracks, dents, bending, or
warp.
If there is any damage to the wheel, replace the wheel.
• Measure the rim runout, radial [B] and axial [A], with a dial
gauge.
If the rim runout exceeds the service limit, check the hub
bearings.
If the problem is not due to the bearings, replace the
wheel.
Rim Runout (with tire installed)
Standard:
Axial
TIR 0.5 mm (0.02 in.) or less
Radial
TIR 0.8 mm (0.03 in.) or less
Service Limit:
Axial
TIR 1.0 mm (0.04 in.)
Radial
TIR 1.0 mm (0.04 in.)
WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condi-
tion.
Axle Inspection
• Remove the front and rear axles.
• Visually inspect the front and rear axle for damages.
If the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm (3.94 in.) [A]
apart, and set a dial gauge [B] on the axle at a point
halfway between the blocks. Turn [C] the axle to mea-
sure the runout. The difference between the highest and
lowest dial readings is the amount of runout.
If the axle runout exceeds the service limit, replace the
axle.
Axle Runout/100 mm (3.94 in.)
Standard:
TIR 0.10 mm (0.0394 in.) or less
Service Limit: TIR 0.2 mm (0.008 in.)
WHEELS/TIRES 10-9
Balance Weight Installation
Halaman 234
10-10 WHEELS/TIRES
Wheels (Rims)
Balance Inspection
• Remove the wheel.
• Support the wheel so that it can be spun freely.
• Spin the wheel lightly, and mark [A] the wheel at the top
when the wheel stops.
○Repeat this procedure several times. If the wheel stops
of its own accord in various positions, it is well balanced.
If the wheel always stops in one position, adjust the wheel
balance.
Balance Adjustment
• If the wheel always stops in one position, provisionally
attach a balance weight [A] on the rim at the marking using
adhesive tape.
• Rotate the wheel 1/4 turn [B], and see whether or not the
wheel stops in this position. If it does, the correct balance
weight is being used.
If the wheel rotates and the weight goes up, replace the
weight with the next heavier size. If the wheel rotates and
the weight goes down, replace the weight with the next
lighter size. Repeat these steps until the wheel remains
at rest after being rotated 1/4 turn.
• Rotate the wheel another 1/4 turn and then another 1/4
turn to see if the wheel is correctly balanced.
• Repeat the entire procedure as many times as necessary
to achieve correct wheel balance.
• Permanently install the balance weight.
Balance Weight Removal
• Insert a regular tip screwdrivers [A] [B] between the rib [C]
and weight [D] as shown.
• Pry the balance weight with two screwdrivers and remove
the balance weight.
• Discard the used balance weight.
CAUTION
Do not tap the screwdrivers. The rim could be dam-
aged.
Balance Weight Installation
• Check if the weight portion has any play on the blade [A]
and clip [B].
If it does, discard it.
WARNING
If the balance weight has any play on the rib of the
rim, the blade and/or clip have been stretched. Re-
place the loose balance weight.
Do not reuse used balance weight.
Unbalanced wheels can create an unsafe riding
condition.
Balance Weight Installation
Halaman 235
Wheels (Rims)
Balance Weight
Part Number
Weight
41075-0007
10 g (0.35 oz.)
41075-0008
20 g (0.71 oz.)
41075-0009
30 g (1.06 oz.)
NOTE
○Balance weights are available from Kawasaki dealers in
10, 20, and 30 gram (0.35 oz., 0.71 oz., and 1.06 oz.)
sizes. An imbalance of less than 10 grams (0.35 oz.)
will not usually affect running stability.
○Do not use four or more balance weight (more than 90
gram). If the wheel requires an excess balance weight,
disassemble the wheel to find the cause.
• Slip the balance weight [A] on to the rib [B], by pushing or
lightly hammering [C] the clip [D].
Left Side [E]
Right Side [F]
• Be sure to install the balance weight.
○Check that the blade [A] and clip [B] are fully seated on
the rim [C] and that the clip is hooked over the rib [D].
Left Side [E]
Right Side [F]
WHEELS/TIRES 10-11
Special Tools -
Halaman 236
10-12 WHEELS/TIRES
Tires
Air Pressure Inspection/Adjustment
• Refer to Air Pressure Inspection in the Periodic Mainte-
nance chapter (see Air Pressure Inspection in the Peri-
odic Maintenance chapter).
Tire Inspection
• Refer to Wheels/Tires Damage Inspection in the Periodic
Maintenance chapter (see Wheels/Tires Damage Inspec-
tion in the Periodic Maintenance chapter).
Tire Removal
• Remove:
Wheel (see Wheel Removal)
Disc
Valve Core (let out the air)
• To maintain wheel balance, mark the air valve position on
the tire with chalk so that the tire can be reinstalled in the
same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]
• 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.
CAUTION
Never lubricate with engine oil or petroleum distil-
lates because they will deteriorate the tire.
• Brake the beads away from both sides of the rim with the
bead breaker [A].
Special Tool - Bead Breaker Assembly: 57001-1072
• Step on the side of the tire opposite the valve stem and
start prying the tire off the rim near the air valve with tire
irons.
Special Tools - Rim Protector: 57001-1063 [A]
Tire Irons of the Bead Breaker Assembly:
57001-1072 [B]
Tire Installation
Halaman 237
Tires
NOTE
○For easier removal, always position the tire bead oppo-
site the valve stem in the rim well, and pry the tire bead
a little at a time.
CAUTION
Be careful not to scratch the inner liner and air seal-
ing surfaces of the rim and tire with the tire irons. A
scratched inner liner [B] or sealing surface [A] may
allow air to leak.
• After removing the bead on one side, remove the other
bead from the same side.
• Remove the rim from the tire.
Tire Installation
WARNING
Use the same manufacture’s on both front and rear
wheels.
• Inspect the rim and tire, and replace them if necessary.
• Clean the sealing surfaces of the rim and tire, and smooth
the sealing surfaces of the rim with a fine emery cloth if
necessary.
• Remove the air valve and discard it.
CAUTION
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.
• Install a new valve in the rim.
○Remove the valve cap, lubricate the stem seal [A] with
a soap and water solution or rubber lubricant, and pull
the valve stem through the rim from the inside out until it
snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to lu-
bricate the stem because they will deteriorate the
rubber.
○The air valve is shown in the figure.
[A] Valve Cap
[B] Valve Core
[C] Stem Seal
[D] Valve Stem
[E] Valve Seat
[F] Valve Opened
WHEELS/TIRES 10-13
Tire Installation
Halaman 238
10-14 WHEELS/TIRES
Tires
• Apply a soap and water solution, or rubber lubricant to the
rim flange and tire beads.
• Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]
• Position the tire on the rim so that the air valve [A] is at
the tire balance mark [B] (the chalk mark made during
removal, or the yellow paint mark on a new tire).
• By hand, slide as much as possible of the lower side of the
tire bead over the rim flange, starting at the side opposite
the valve.
• Fit the rim protectors and tire irons to install the remaining
part of the tire bead which cannot be installed by hand.
For easy tire installation, position the parts of the bead
which is already over the rim flange in the rim well.
NOTE
○To prevent rim damage, be sure to place the rim protec-
tors at any place the tire irons are applied.
• Install the other side of the tire bead onto the rim in the
same manner.
• Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
• Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.
WARNING
Be sure to install the valve core whenever inflating
the tire, and do not inflate the tire to more than 400
kPa (4.0 kgf/cm², 57 psi). Overinflation can explode
the tire with possibility of injury and loss of life.
Tire Repair
Halaman 239
Tires
• Check to see that the rim lines [A] on both sides of the tire
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.
• Lubricate the rim flanges and tire beads.
• Install the valve core and inflate the tire again.
• After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
• Adjust the air pressure to the specified pressure (see
Wheels/Tires in the Periodic Maintenance chapter).
• Install the brake disc(s) so that the marked side faces out
(see Brake Disc Installation in the Brakes chapter).
• Adjust the wheel balance (see Balance Adjustment).
Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) re-
pair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally under-
stood that higher running durability is obtained by perma-
nent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (exter-
nal) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.
WHEELS/TIRES 10-15
Special Tool -
Halaman 240
10-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal
• Remove the wheel, and take out the following.
Collars
Speedometer Gear Drive (out of front hub)
Coupling (out of rear hub)
Grease Seals
Circlips [A]
Special Tool - Inside Circlip Pliers: 57001-143 [B]
• Use the bearing remover to remove the hub bearing [A].
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Special Tools - Bearing Remover Shaft,
9: 57001-1265 [B]
Bearing Remover Head,
15 ×
17: 57001
-1267 [C]
Hub Bearing Installation
• Before installing the wheel bearings, blow any dirt or for-
eign particles out of the hub with compressed air to pre-
vent contamination of the bearings.
• Replace the bearings with new ones.
NOTE
○Install the bearings so that the marked side faces out.
• Install the bearings by using the bearing driver set which
does not contact the bearing inner race.
• Press in each bearings [A] until they are bottomed.
Special Tool - Bearing Driver Set: 57001-1129 [B]
• Replace the circlips with new ones.
Special Tool - Inside Circlip Pliers: 57001-143
• Replace the grease seals with new ones.
• Press in the grease seals [A] so that the seal surface is
flush [B] with the end of the hole.
○Apply high temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129 [C]
Hub Bearing Lubrication
Halaman 241
Hub Bearing
Hub Bearing Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance can not normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bear-
ings are removed, they will need to be replaced with
new ones.
• Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding.
If bearing play, roughness, or binding is found, replace
the bearing.
• Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication
NOTE
○Since the hub bearings are packed with grease and
sealed, lubrication is not required.
WHEELS/TIRES 10-17
Speedometer Gear Housing Assembly
Halaman 242
10-18 WHEELS/TIRES
Speedometer Gear Housing
Speedometer Gear Housing Disassembly
• Pull the speedometer gear housing [A] off the front wheel.
• Pull out the grease seal [C] using a hook.
• Pull out the speedometer gear [B].
• If the speedometer cable housing [F] or speedometer pin-
ion [E] needs to be removed, work in accordance with fol-
lowing procedures.
Pin [D]
• First drill the housing [A] through the spring pin [B] using
a 1.0 ∼1.5 mm drill bit [C].
• Drill the housing from the under side to the pin end [B]
using 3.0 ∼3.5 mm drill bit [A].
• Using a 3 mm (0.12 in.) rod [A], tap out the pin [B], and
then pull out the speedometer cable bushing, speedome-
ter pinion and washers.
NOTE
○It is recommended that the assembly be replaced rather
than attempting to repair the components.
Speedometer Gear Housing Assembly
• When assembling the speedometer gear housing, be
careful of the following items.
○After inserting a new pin, stake the housing hole to secure
the pin in place.
○Replace the grease seal with a new one. Apply a little
grease to the seal. Install it using a press or a suitable
driver so that the face of the seal is level with the surface
of the housing.
○Regrease the speedometer gear.
○Install the speedometer gear housing so that it fits in the
speedometer gear drive notches.
Speedometer Gear Housing Lubrication
Halaman 243
Speedometer Gear Housing
Speedometer Gear Housing Lubrication
• Clean and grease [A] the speedometer gear housing [B].
WHEELS/TIRES 10-19
Final Drive
Halaman 245
Final Drive
Table of Contents
Exploded View........................................................................................................................
11-2
Specifications .........................................................................................................................
11-4
Special Tool ...........................................................................................................................
11-5
Drive Chain.............................................................................................................................
11-6
Drive Chain Slack Inspection............................................................................................
11-6
Drive Chain Slack Adjustment ..........................................................................................
11-6
Wheel Alignment Inspection/Adjustment ..........................................................................
11-6
Drive Chain Wear Inspection ............................................................................................
11-6
Drive Chain Lubrication.....................................................................................................
11-6
Drive Chain Removal........................................................................................................
11-6
Drive Chain Installation.....................................................................................................
11-7
Drive Chain.............................................................................................................................
11-8
Drive Chain Replacement.................................................................................................
11-8
Sprocket, Coupling .................................................................................................................
11-11
Engine Sprocket Removal ................................................................................................
11-11
Engine Sprocket Installation .............................................................................................
11-11
Rear Sprocket Removal....................................................................................................
11-12
Rear Sprocket Installation.................................................................................................
11-12
Coupling Installation..........................................................................................................
11-12
Coupling Bearing Removal ...............................................................................................
11-12
Coupling Bearing Installation ............................................................................................
11-13
Coupling Bearing Inspection.............................................................................................
11-13
Coupling Bearing Lubrication............................................................................................
11-13
Coupling Damper Inspection.............................................................................................
11-14
Grease Seal Inspection and Lubrication...........................................................................
11-14
Sprocket Wear Inspection.................................................................................................
11-14
Rear Sprocket Warp Inspection ........................................................................................
11-14
FINAL DRIVE 11-1
11
Final Drive
Halaman 246
11-2 FINAL DRIVE
Exploded View
Final Drive
Halaman 247
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Engine Sprocket Cover Bolts
9.8
1.0
87 in·lb
2
Engine Sprocket Nut
127
13
94
MO
3
Rear Sprocket Nuts
59
6.0
44
4
Rear Sprocket Studs
–
–
–
L
5. Chain Adjusting Nuts and Locknuts
G: Apply grease.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution. (mixture of engine oil and molybdenum disulfide grease
in a weight ratio 10 : 1).
R: Replacement Parts
FINAL DRIVE 11-3
Final Drive
Halaman 248
# 11-4 FINAL DRIVE
Specifications
| Item | Standard | Service Limit |
| :------------------ | :------------------------------------- | :------------------------ |
| Drive Chain | | |
| Make | Enuma | --- |
| Type | EK520SR-O₂ | --- |
| Link | 106 Links | --- |
| Sprockets | | |
| Rear Sprocket Warp | TIR 0.4 mm (0.016 in.) or less | TIR 0.5 mm (0.02 in.) |
Bearing Driver Set:
Halaman 249
Special Tool
Bearing Driver Set:
57001-1129
FINAL DRIVE 11-5
Drive Chain Removal
Halaman 250
11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
• Refer to Drive Chain Slack Inspection in the Periodic
Maintenance chapter (see Drive Chain Slack Inspection
in the Periodic Maintenance chapter).
Drive Chain Slack Adjustment
• Refer to Drive Chain Slack Inspection in the Periodic
Maintenance chapter (see Drive Chain Slack Inspection
in the Periodic Maintenance chapter).
Wheel Alignment Inspection/Adjustment
• Refer to Wheel Alignment Inspection in the Periodic Main-
tenance chapter (see Wheel Alignment Inspection in the
Periodic Maintenance chapter).
Drive Chain Wear Inspection
• Refer to Drive Chain Wear Inspection in the Periodic
Maintenance chapter (see Drive Chain Wear Inspection
in the Periodic Maintenance chapter).
Drive Chain Lubrication
• Refer to Drive Chain Lubrication Condition in the Periodic
Maintenance chapter (see Drive Chain Lubrication Con-
dition in the Periodic Maintenance chapter).
Drive Chain Removal
• Remove:
Engine Sprocket Cover
Drive Chain Cover
Rear Shock Absorber (see Rear Shock Absorber Re-
moval in the Suspension chapter)
Swingarm Pivot Shaft (see Swingarm Removal in the
Suspension chapter)
• Flatten out the bended washer [A].
• Remove the engine sprocket nut [B] and washer.
NOTE
○When loosening the engine sprocket nut, hold the rear
brake on.
Torque -
Halaman 251
Drive Chain
• Raise the rear wheel off the ground.
• Remove the axle cotter pin, and loosen the rear axle nut.
• Loosen the both chain adjuster locknut to loosen the drive
chain.
• Remove the drive chain from the rear sprocket toward the
right.
• Pull the engine sprocket [A] with drive chain [B] off the
output shaft [C].
• Disengage the drive chain from the engine sprocket.
NOTE
○The swingarm may be moved with the rear wheel left
installed on it.
Drive Chain Installation
• Replace the sprocket washer and axle cotter pin.
• Install the engine sprocket onto the shaft the protruding
side [A] of it faces in.
• Apply molybdenum disulfide oil solution to the threads of
the output shaft and the seating surface of the engine
sprocket nut.
• After torquing the engine sprocket nut, bend the one side
of the washer over the nut.
NOTE
○Tighten the nut while applying the rear brake.
Torque - Engine Sprocket Nut: 127 N·m (13 kgf·m, 94 ft·lb)
• Adjust the drive chain slack after installing the sprocket
(see Drive Chain Slack Adjustment in the Periodic Main-
tenance chapter).
• Install:
Swingarm (see Swingarm Installation in the Suspension
chapter)
Rear Shock Absorber (see Rear Shock Absorber Instal-
lation in the Suspension chapter)
Drive Chain Cover
Engine Sprocket Cover
Torque - Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
Swingarm Pivot Nut: 98 N·m (10 kgf·m, 72 ft·lb)
• Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Inspection in the Periodic Maintenance
chapter).
FINAL DRIVE 11-7
Recommended Tool -
Halaman 252
11-8 FINAL DRIVE
Drive Chain
Drive Chain Replacement
CAUTION
For safety, if the drive chain shall be replaced, re-
place it using a recommended tool.
Recommended Tool - Type: EK JOINT Tool #50
Brand: ENUMA CHAIN
Body [A]
Handlebar [B]
Cutting and Riveting Pin [C]
For Cutting [D]
For Riveting [E]
Plate Holder (A) [F]
Plate Holder (B) [G]
Gauge [H]
• Remove:
Chain Cover (see Drive Chain Removal)
Engine Sprocket Cover (see Engine Sprocket Removal)
• Grind [A] the pin head to make it flat.
• Set the cutting and rivetting pin [B] as shown.
• Screw the pin holder until it touches the link pin.
• Be sure that the cutting pin hits center of the link pin.
• Screw the handlebar [A] into the body.
• Turn the pin holder with the wrench [B] clockwise to ex-
tract the link pin.
Recommended Tool -
Halaman 253
Drive Chain
• Replace the link pin, link plate and grease seals.
• Apply grease to the link pins [A] and grease the seals [B]
[C].
• Engage the drive chain on the engine and rear sprockets.
• Insert the link pins in the drive chain ends.
• Install the grease seals [C].
• Install the link plate [D] so that the mark faces out.
• Push the link plate by hand or plier to fix it.
• Be sure to set the grease seals correctly.
• Set the plate holder (A) [A] and plate holder (B) [B] on the
body.
• Fit the plate holder (A) to the link plate.
• Turn the pin holder by hand until the plate holder (B)
touches the other link plate.
• Turn the pin holder by a wrench clockwise until two pins
of link come into groove of the plate holder (A).
• Take off the plate holder.
• Set the plate holder (B) [A] and the cutting and rivetting
pin [B] as shown.
FINAL DRIVE 11-9
Recommended Tool -
Halaman 254
11-10 FINAL DRIVE
Drive Chain
• Turn the pin holder until the rivetting pin touches the link
pin.
• Turn the wrench clockwise until the tip of rivetting pin con-
tact with the link pin.
• Rivet it.
• Repeat the same procedure for the other link pin.
• After staking, check the staked area of the link pin for
cracks.
• Measure the outside diameter [A] of the link pin and link
plates width [B].
Link Pin Outside Diameter
Standard:
5.3 ∼5.7 mm (0.21 ∼0.22 in.)
Link Plates Outside Width
Standard:
17.35 ∼17.50 mm (0.68 ∼0.69 in.)
If the reading exceeds the specified length, cut and rejoin
the chain again.
• Check:
Movement of the Rollers
• Adjust the drive chain slack after installing the chain (see
Drive Chain Slack Inspection in the Periodic Maintenance
chapter).
Torque -
Halaman 255
Sprocket, Coupling
Engine Sprocket Removal
• Remove:
Shift Lever Link Bolt [A]
Shift Shaft [B]
Engine Sprocket Cover Bolts [C]
• Remove the engine sprocket cover [D].
• Flatten out the bended washer [A].
• Remove the engine sprocket nut [B] and washer.
NOTE
○When loosening the engine sprocket nut, hold the rear
brake on.
• Raise the rear wheel off the ground.
• Remove the axle cotter pin, and loosen the rear axle nut.
• Loosen the both chain adjuster locknut to loosen the drive
chain.
• Remove the drive chain from the rear sprocket toward the
right.
• Pull the engine sprocket [A] with drive chain [B] off the
output shaft [C].
• Disengage the drive chain from the engine sprocket.
Engine Sprocket Installation
• Replace the sprocket washer and axle cotter pin.
• Install the engine sprocket onto the shaft the protruding
side [A] of it faces in.
• Apply molybdenum disulfide oil solution to the threads of
the output shaft and the seating surface of the engine
sprocket nut.
• After torquing the engine sprocket nut, bend the one side
of the washer over the nut.
NOTE
○Tighten the nut while applying the rear brake.
Torque - Engine Sprocket Nut: 127 N·m (13 kgf·m, 94 ft·lb)
• Adjust the drive chain slack after installing the sprocket
(see Drive Chain Slack Adjustment in the Periodic Main-
tenance chapter).
• Install the new axle cotter pin, and bend the end of it
surely.
• Install the engine sprocket cover.
• Install the shift lever onto the shift shaft aligning the mark
which is marked before removing.
FINAL DRIVE 11-11
Coupling Bearing Removal
Halaman 256
11-12 FINAL DRIVE
Sprocket, Coupling
Rear Sprocket Removal
• Remove the rear wheel (see Rear Wheel removal in the
Wheel/Tires chapter).
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
• Pull out the coupling collar from the left, and coupling
sleeve from the right.
• Remove the rear sprocket nuts [A].
• Remove the rear sprocket [B].
Rear Sprocket Installation
• Install the sprocket with the tooth number marking [A] out-
ward.
• Install the rear sprocket nuts.
Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the rear wheel (see Rear Wheel Installation in the
Wheels/Tires chapter).
Coupling Installation
• Grease the following and install the coupling.
Coupling Grease Seal [A]
Coupling Internal Surface [A]
Ball Bearing [A]
Coupling Bearing Removal
• Remove:
Coupling
Grease Seal
Bearing [A]
Coupling Bearing Lubrication
Halaman 257
Sprocket, Coupling
• Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set: 57001-1129 [B]
Coupling Bearing Installation
• Replace the bearing with a new one.
• Press in the bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129 [B]
• Pack the bearing with high temperature grease.
• Replace the grease seal with a new one.
• Press in the grease seal so that the seal surface is flush
with the end of the hole.
○Apply high temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
○It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
• Turn the bearing in the coupling back and forth [A] while
checking for plays, roughness, or binding.
If the bearing play, roughness, or binding is found, replace
the bearing.
Coupling Bearing Lubrication
• Pack the bearing with high temperature grease. Turn the
bearing around by hand a few times to make sure the
grease is distributed uniformly inside the bearing.
FINAL DRIVE 11-13
Rear Sprocket Warp Inspection
Halaman 258
11-14 FINAL DRIVE
Sprocket, Coupling
Coupling Damper Inspection
• Remove the rear wheel coupling, and inspect the rubber
dampers [A].
• Replace the damper if it appears damaged or deterio-
rated.
Grease Seal Inspection and Lubrication
If the grease seals are examined without removing the
seals themselves, look for discoloration (indicating the rub-
ber has deteriorated), hardening, damage to the internal
ribbing, or other damage.
If the seal or internal ribbing
has hardened, the clearance between the seal and the axle
sleeve will not be take up, which will allow dirt and moisture
to enter and reach the bearing. If in doubt as to its condition
and whenever the seal is removed for greasing the bearing,
the seal should be replace. The seals are generally dam-
aged upon removal.
Sprocket Wear Inspection
• Visually inspect the engine and rear sprocket teeth for
wear and damage.
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain wear (see Drive Chain Wear
Inspection in the Periodic Maintenance chapter).
[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
Rear Sprocket Warp Inspection
• Raise the rear wheel off the ground using the jack so that
it will turn freely.
• Set a dial gauge [A] against the rear sprocket [B] near the
teeth as shown, and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard:
TIR 0.4 mm (0.016 in.) or less
Service Limit: TIR 0.5 mm (0.02 in.)
Brakes
Halaman 259
Brakes
Table of Contents
Exploded View .......................................................................................................................
12-2
Specifications ........................................................................................................................
12-6
Special Tool ............................................................................................................................
12-7
Brake Lever, Brake Pedal.......................................................................................................
12-8
Brake Pedal Position Inspection ......................................................................................
12-8
Brake Pedal Position Adjustment .....................................................................................
12-8
Calipers ..................................................................................................................................
12-9
Front Caliper Removal......................................................................................................
12-9
Rear Caliper Removal.......................................................................................................
12-9
Caliper Installation ............................................................................................................
12-9
Caliper Disassembly .........................................................................................................
12-10
Caliper Assembly..............................................................................................................
12-10
Caliper Fluid Seal Damage...............................................................................................
12-10
Rear Caliper Dust Boot and Friction Boot Damage ..........................................................
12-10
Caliper Piston and Cylinder Damage Inspection ..............................................................
12-11
Caliper Holder Shaft Wear................................................................................................
12-11
Brake Pads.............................................................................................................................
12-12
Brake Pad Removal..........................................................................................................
12-12
Brake Pad Installation.......................................................................................................
12-12
Brake Pad Wear Inspection ..............................................................................................
12-12
Master Cylinder ......................................................................................................................
12-13
Front Master Cylinder Removal ........................................................................................
12-13
Front Master Cylinder Installation .....................................................................................
12-13
Rear Master Cylinder Removal.........................................................................................
12-14
Rear Master Cylinder Installation......................................................................................
12-14
Rear Brake Reservoir Removal ........................................................................................
12-15
Rear Brake Reservoir Installation .....................................................................................
12-15
Front Master Cylinder Disassembly..................................................................................
12-15
Rear Master Cylinder Disassembly...................................................................................
12-15
Master Cylinder Assembly ................................................................................................
12-15
Master Cylinder Inspection ...............................................................................................
12-16
Brake Disc ..............................................................................................................................
12-17
Brake Disc Removal .........................................................................................................
12-17
Brake Disc Installation ......................................................................................................
12-17
Brake Disc Wear Inspection..............................................................................................
12-17
Brake Disc Warp Inspection..............................................................................................
12-17
Brake Fluid .............................................................................................................................
12-18
Brake Fluid Level Inspection.............................................................................................
12-18
Brake Fluid Change ..........................................................................................................
12-18
Brake Line Bleeding..........................................................................................................
12-18
Brake Hose.............................................................................................................................
12-21
Brake Hose Removal/Installation......................................................................................
12-21
Brake Hose Inspection......................................................................................................
12-21
BRAKES 12-1
12
Brakes
Halaman 260
12-2 BRAKES
Exploded View
(9)
(A)
(H)
(G)
(F)
(E)
(D)
(C)
(B)
(1)
(B)
(A)
(J)
(B)
(3) (5)
(1)
(2)
(4)
(6)
(10)
(13)
(14)
(12)
(15)
(4)
(16)
(11)
(5)
(8)
512-7B/1 2
Brakes
Halaman 261
Exploded View
Torque
No.
Fastener
N·m
kgf·m
ft·lb
Remarks
1
Brake Lever Pivot Bolt Locknut
5.9
0.6
52 in·lb
2
Bleed Valve
5.5
0.55
49 in·lb
3
Front Master Cylinder Clamp Bolts
8.8
0.9
78 in·lb
S
4
Brake Disc Mounting Bolts
27
2.8
20
L
5
Brake Hose Banjo Bolts
25
2.5
18
6
Front Caliper Mounting Bolts
25
2.5
18
7
Front Brake Light Switch Screw
1.0
0.1
9 in·lb
8
Brake Lever Pivot Bolt
1.0
0.1
9 in·lb
9
Front Reservoir Cap Screws
1.5
0.15
13 in·lb
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
R: Replacement parts
S: Follow the specific tightening sequence.
Si: Apply silicone grease.
BRAKES 12-3
Brakes
Halaman 262
## 12-4 BRAKES
Exploded View
J 352-18 / 1 7
Brakes
Halaman 263
BRAKES 12-5
Exploded View
| No. | Fastener | Torque | Remarks |
| :-- | :---------------------------------- | :----: | :----: | :-----: | :------ |
| | | **N·m** | **kgf·m** | **ft·lb** | |
| 1 | Reservoir Mounting Bolt | 6.9 | 0.7 | 61 in·lb | |
| 2 | Bleed Valve | 5.5 | 0.55 | 49 in·lb | |
| 3 | Brake Pedal Pivot Bolt | 8.8 | 0.9 | 78 in·lb | L |
| 4 | Push Rod Locknut | 18 | 1.8 | 13 | |
| 5 | Brake Disc Mounting Bolts | 27 | 2.8 | 20 | L |
| 6 | Brake Hose Banjo Bolts | 25 | 2.5 | 18 | |
| 7 | Rear Master Cylinder Mounting Bolts | 25 | 2.5 | 18 | |
| 8 | Rear Caliper Mounting Bolts | 25 | 2.5 | 18 | |
B: Apply brake fluid.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement parts
Si: Apply silicone grease.
Brakes
Halaman 264
12-6 BRAKES
Specifications
| Item | Standard | Service Limit |
| :------------------ | :-------------------------------------------- | :------------------------------------- |
| **Brake Pedal** | | |
| Pedal Free Play | Non-adjustable | --- |
| Pedal Position | About 40 mm (1.6 in.) below footpeg top | --- |
| **Brake Discs** | | |
| Thickness: | | |
| Front | 4.3 ~ 4.6 mm (0.17 ~ 0.18 in.) | 4.0 mm (0.16 in.) |
| Rear | 4.8 ~ 5.1 mm (0.19 ~ 0.20 in.) | 4.5 mm (0.18 in.) |
| Runout | TIR 0.15 mm (0.006 in.) or less | TIR 0.3 mm (0.01 in.) |
Inside Circlip Pliers:
Halaman 265
Special Tool
Inside Circlip Pliers:
57001-143
BRAKES 12-7
Torque -
Halaman 266
12-8 BRAKES
Brake Lever, Brake Pedal
Brake Pedal Position Inspection
• Check that the brake pedal [A] is in the correct position.
[B] Footpeg
Pedal Position
Standard:
About 40 mm (1.6 in.) [C] below top of
footpeg
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when push rod locknut has been
loosened.
• Loosen the locknut [A] and up or down the clevis [B] by
turning the adjuster [C] to adjust the brake pedal position.
• Tighten the locknut with specified torque.
Torque - Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb)
NOTE
○If the pedal position cannot be adjusted by turning the
clevis [A], the brake pedal may be deformed or incor-
rectly installed.
○If the brake rod [B] protrusion is 3.5 ∼5.5 mm (0.14 ∼
0.22 in.) [C] below the nut, the pedal position will be
with in the standard range (about 40 mm (1.6 in.)).
• Check the brake pedal position, and readjust it if neces-
sary.
Torque -
Halaman 267
Calipers
Front Caliper Removal
• Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
• Unscrew the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
CAUTION
Do not loosen the caliper assembly bolts. Take out
only the caliper mounting bolts for caliper removal.
Loosening the caliper assembly bolts will cause
brake fluid leakage.
• Unscrew the banjo bolt and remove the brake hose from
the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Rubber
Parts Replacement in the Periodic Maintenance chap-
ter).
Rear Caliper Removal
• Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
• Unscrew the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
• Unscrew the banjo bolt and remove the brake hose [D]
from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Rubber
Parts Replacement in the Periodic Maintenance chap-
ter).
Caliper Installation
• Install the caliper and brake hose lower end.
○Replace the washers on each side of hose fitting with new
ones.
• Tighten:
Torque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Rear Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
BRAKES 12-9
Rear Caliper Dust Boot and Friction Boot Damage
Halaman 268
12-10 BRAKES
Calipers
• Check the fluid level in the brake reservoirs.
• Bleed the brake line (see Brake Line Bleeding).
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal and the pads are against the
disc. The brakes will not function on the first appli-
cation of the lever or pedal if this is not done.
Caliper Disassembly
• Refer to Caliper Rubber Parts Replacement in the Peri-
odic Maintenance chapter (see Caliper Rubber Parts Re-
placement in the Periodic Maintenance chapter).
Caliper Assembly
• Refer to Caliper Rubber Parts Replacement in the Peri-
odic Maintenance chapter (see Caliper Rubber Parts Re-
placement in the Periodic Maintenance chapter).
Caliper Fluid Seal Damage
The fluid seal (piston seal) [A] is placed around the pis-
ton to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the tem-
perature of the discs or the brake fluid to increase.
• Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.
Rear Caliper Dust Boot and Friction Boot Damage
• Check that the dust boot [A] and friction boot [B] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
Caliper Holder Shaft Wear
Halaman 269
Calipers
Caliper Piston and Cylinder Damage Inspection
• Visually inspect the piston [A] and cylinder surfaces.
Replace the caliper if the cylinder and piston are badly
scores or rusty.
Fluid Seal [B]
Dust Seal [C]
Front Caliper [D]
Rear Caliper [E]
Dust Boot [F]
Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts [G]. 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 that the caliper holder shafts are not badly
worn or stepped, and that the rubber boots [H] are not
damaged.
If the rubber boot is damaged, replace the rubber boot. To
replace the rubber boot, remove the pads and the caliper
bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.
BRAKES 12-11
Brake Pad Wear Inspection
Halaman 270
12-12 BRAKES
Brake Pads
Brake Pad Removal
• Loosen the holder shaft [A].
• Remove the caliper (see Front/Rear Caliper Removal).
• Draw out the holder shaft.
• Remove the pads [B].
Brake Pad Installation
• Push the caliper pistons by hand as far as they will go.
• Install the pad on the piston side first, then install the other
pad.
• Install the anti-rattle spring [A] in its correct position.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal and the pads are against the
disc. The brake will not function on the first appli-
cation of the lever or pedal if this is not done.
Brake Pad Wear Inspection
• Refer to Brake Pad Wear Inspection in the Periodic Main-
tenance chapter (see Brake Pad Wear Inspection in the
Periodic Maintenance chapter).
Torque -
Halaman 271
Master Cylinder
Front Master Cylinder Removal
• Slide the dust cover [A], and remove the banjo bolt [B] to
disconnect the upper brake hose from the master cylinder
[C]. There are flat washers on each side of the hose fitting.
• Remove the front master cylinder clamp bolts [D], and
take off the master cylinder.
CAUTION
Immediately wash away any brake fluid that spills.
Front Master Cylinder Installation
• Install the front master cylinder so that the punch mark [A]
of the handlebar is aligned with the mating surface [B] of
the master cylinder clamp to level the reservoir.
• Install the master cylinder clamp [A] pointing with the ar-
row mark [B] upward.
• Tighten the upper clamp bolt [C] first, and then the lower
clamp bolt [D] with a specified torque. There will be a gap
[E] at the lower part of the clamp after tightening.
• Tighten the banjo bolt with a specified torque after in-
stalling a new flat washer on each side of the brake hose
fitting.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Bleed the brake line (see Brakes Line Bleeding).
• Check the brake for good braking power, no brake drag
and no brake fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
and the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
BRAKES 12-13
Torque -
Halaman 272
12-14 BRAKES
Master Cylinder
Rear Master Cylinder Removal
• Remove the cotter pin [A] and then pull the joint pin [B]
out of the push rod clevis [C] and brake pedal.
NOTE
○Pull off the joint pin while pressing down the brake
pedal.
• Slide the brake hose clamp [A] out of place (see Brake
Hose and Pipe Replacement in the Periodic Maintenance
chapter).
• Disconnect the brake hoses [B] from the brake hose con-
nector of the master cylinder [C], and temporarily secure
the end of the brake hose so some high place to keep fluid
loss to a minimum and immediately wipe up any brake
fluid that spills.
• Remove the master cylinder mounting bolts [D] and take
the master cylinder off the footpeg bracket.
• Remove the banjo bolt [E] to disconnect the brake hose
from the master cylinder and temporarily secure the end
of the brake hose to some high place to keep fluid loss to
a minimum. There are flat washers on each side of the
hose fitting.
CAUTION
Immediately wash away any brake fluid that spills.
Rear Master Cylinder Installation
• Tighten the banjo bolt with a specified torque after in-
stalling a new flat washer on each side of the brake hose
fitting. Be sure that the metal pipe is properly fitted into
the U-shaped notch in the master cylinder.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Tighten the rear master cylinder mounting bolts with a
specified torque.
Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5
kgf·m, 18 ft·lb)
• Connect the brake hose to the master cylinder and re-
place the brake hose clamp in place.
Master Cylinder Assembly
Halaman 273
Master Cylinder
• Connect the push rod clevis to the brake pedal with the
joint pin.
• Install the cotter pin and bend the end of it securely.
• Bleed the brake line (see Brake Line Bleeding).
• Check the brake for good braking power, no brake drag
and no brake fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
and the pads are against the disc. The brake will not
function on the first application of the pedal if this
is not done.
• Check the brake pedal position (see Brake Pedal Position
Inspection).
• Check the rear brake light switch (see Rear Brake Light
Switch Operation Inspection in the Periodic Maintenance
chapter).
Rear Brake Reservoir Removal
• Remove:
Reservoir mounting Bolt [A]
Brake Hose Clamp (Slide) [B]
Reservoir [C]
CAUTION
Immediately wash away any brake fluid that spills.
Rear Brake Reservoir Installation
• Install the clamp for the brake hose end.
• Fill the reservoir with fresh brake fluid and bleed the brake
line (see Brake Line Bleeding).
• Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until the resistance is felt fully; then,
tighten the cap an additional 1/6 turn [D] while holding the
brake fluid reservoir [A] body.
Front Master Cylinder Disassembly
• Refer to Master Cylinder Rubber Parts Replacement in
the Periodic Maintenance chapter (see Master Cylinder
Rubber Parts Replacement in the Periodic Maintenance
chapter).
Rear Master Cylinder Disassembly
• Refer to Master Cylinder Rubber Parts Replacement in
the Periodic Maintenance chapter (see Master Cylinder
Rubber Parts Replacement in the Periodic Maintenance
chapter).
Master Cylinder Assembly
• Refer to Master Cylinder Rubber Parts Replacement in
the Periodic Maintenance chapter (see Master Cylinder
Rubber Parts Replacement in the Periodic Maintenance
chapter).
BRAKES 12-15
Master Cylinder Inspection
Halaman 274
12-16 BRAKES
Master Cylinder
Master Cylinder Inspection
• Remove the master cylinders (see Front/Rear Master
Cylinder Removal).
• Disassemble the front and rear master cylinders.
• Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.
• Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cups.
Front Master Cylinder [J]
• Check the dust covers [E] for damage.
If they are damaged, replace them.
• Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
• Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
Rear Master Cylinder [K]
Brake Disc Warp Inspection
Halaman 275
Brake Disc
Brake Disc Removal
• Remove the wheel (see Front/Rear Wheel Removal in the
Wheels/Tires chapter).
• Unscrew the mounting bolts, and take off the disc.
Brake Disc Installation
• Install the brake disc on the wheel so that the marked side
[B] faces out.
• Apply a non-permanent locking agent to the threads of
the brake disc mounting bolts [A].
• Tighten:
Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20
ft·lb)
Brake Disc Wear Inspection
• Measure the thickness of each disc [A] at the point where
it has worn the most.
If the disc has worn past the service limit, replace it.
Measuring Area [B]
Disc Thickness
Standard:
Front
4.3 ∼4.6 mm (0.17 ∼0.18 in.)
Rear
4.8 ∼5.1 mm (0.19 ∼0.20 in.)
Service Limit:
Front
4.0 mm (0.16 in.)
Rear
4.5 mm (0.18 in.)
Brake Disc Warp Inspection
• Jack up the motorcycle so that the wheel is off the ground
(see Front/Rear Removal in the Wheels/Tires chapter).
○For front disc inspection, turn the handlebar fully to one
side.
• Set up a dial gauge against the disc [A] as shown and
measure the disc runout, while turning [B] the wheel by
hand.
If the runout exceeds the service limit, replace the disc.
Disc Runout
Service Limit:
0.3 mm (0.01 in.) TIR
BRAKES 12-17
Brake Line Bleeding
Halaman 276
12-18 BRAKES
Brake Fluid
Brake Fluid Level Inspection
• Refer to Brake Fluid Level Inspection in the Periodic Main-
tenance chapter (see Brake Fluid Level Inspection in the
Periodic Maintenance chapter).
Brake Fluid Change
• Refer to Brake Fluid Change in the Periodic Maintenance
chapter (see Brake Fluid Change in the Periodic Mainte-
nance chapter).
Brake Line Bleeding
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Be sure to bleed the air from the brake line when-
ever brake lever or pedal action feels soft or
spongy after the brake fluid is changed, or when-
ever a brake line fitting has been loosened for any
reason.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
• Remove the reservoir cap [A] and diaphragm.
• Fill the reservoir with fresh brake fluid to the upper level
line in the reservoir.
• Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.
• Remove the rubber cap from the bleed valve [A] on the
caliper.
• Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
Torque -
Halaman 277
Brake Fluid
• Bleed the brake line and the caliper.
○Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while hold-
ing the brake applied.
3. Release the brake [C].
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.
○Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.
• Remove the clear plastic hose.
• Install the diaphragm and reservoir cap.
• Tighten:
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15
kgf·m, 13 in·lb)
• Follow the procedure below to install the rear brake fluid
reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body, then tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir body [A].
• Tighten the bleed valve, and install the rubber cap.
Torque - Bleed Valve: 5.5 N·m (0.55 kgf·m, 49 in·lb)
• Check the fluid level (see Brake Fluid Level Inspection in
the Periodic Maintenance chapter).
• After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.
BRAKES 12-19
Torque -
Halaman 278
12-20 BRAKES
Brake Fluid
WARNING
When working with the disc brake, observe the pre-
cautions 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 point
and could cause the brake to be ineffective. 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 is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine oil,
or any other petroleum distillate will cause deterio-
ration of the rubber parts. Oil spilled on any part will
be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be 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 satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces;
any
spilled fluid should be completely wiped up imme-
diately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
Brake Hose Inspection
Halaman 279
Brake Hose
Brake Hose Removal/Installation
• Refer to the Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter (see Brake Hose and Pipe
Replacement in the Periodic Maintenance chapter).
Brake Hose Inspection
• Refer to Brake Hose Damage and Installation Condition
Inspection in the Periodic Maintenance chapter (see
Brake Hose Damage and Installation Condition Inspec-
tion in the Periodic Maintenance chapter).
BRAKES 12-21
Suspension
Halaman 281
SUSPENSION 13-1
# Suspension
## Table of Contents
Exploded View ........................................................................ 13-2
Specifications ......................................................................... 13-4
Special Tools ........................................................................... 13-5
Front Fork ................................................................................ 13-7
Front Fork Removal .............................................................. 13-7
Front Fork Installation (each fork leg) ................................. 13-7
Front Fork Oil Change .......................................................... 13-8
Front Fork Disassembly ....................................................... 13-9
Front Fork Assembly ........................................................... 13-10
Inner Tube/Outer Tube Inspection ....................................... 13-11
Fork Spring Inspection ........................................................ 13-11
Oil Seal/Dust Seal Inspection .............................................. 13-11
Rear Shock Absorber ............................................................. 13-12
Spring Preload Adjustment .................................................. 13-12
Rear Shock Absorber Removal ........................................... 13-12
Rear Shock Absorber Installation ....................................... 13-13
Rear Shock Absorber Scrapping ........................................ 13-13
Swingarm ............................................................................... 13-14
Swingarm Removal ............................................................. 13-14
Swingarm Installation ......................................................... 13-14
Swingarm Bearing Removal ................................................ 13-15
Swingarm Bearing Installation ............................................ 13-15
Swingarm Bearing, Sleeve Inspection ................................ 13-15
Swingarm Lubrication ......................................................... 13-16
Chain Guide Inspection ...................................................... 13-16
Tie-Rod, Rocker Arm ............................................................ 13-17
Tie-rods Removal ................................................................ 13-17
Tie-Rod Installation ............................................................. 13-17
Rocker Arm Removal .......................................................... 13-17
Rocker Arm Installation ...................................................... 13-17
Tie-rod, Rocker Arm Bushing Inspection ............................ 13-17
Tie-rod, Rocker Arm Sleeve Inspection .............................. 13-17
Suspension
Halaman 282
# 13-2 SUSPENSION
## Exploded View
Z-69322/28/1 2
Suspension
Halaman 283
SUSPENSION 13-3
Exploded View
| No. | Fastener | Torque | | | Remarks |
| :-- | :------------------------------ | :----- | :----- | :---- | :------ |
| | | N·m | kgf·m | ft·lb | |
| 1 | Front Fork Clamp Bolts (Upper) | 21 | 2.1 | 15 | |
| 2 | Front Fork Top Plugs | 23 | 2.3 | 16.5 | |
| 3 | Front Fork Clamp Bolts (Lower) | 30 | 3.1 | 22 | |
| 4 | Front Fork Bottom Allen Bolts | 20 | 2.0 | 15 | L |
| 5 | Rocker Arm Pivot Nut | 59 | 6.0 | 44 | |
| 6 | Tie-Rod Nuts | 59 | 6.0 | 44 | |
| 7 | Rear Shock Absorber Mounting Nuts | 59 | 6.0 | 44 | |
| 8 | Swingarm Pivot Nut | 98 | 10.0 | 72 | |
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
Suspension
Halaman 284
13-4 SUSPENSION
Specifications
Item
Standard
Service Limit
Front Fork
Fork oil:
Viscosity
KAYABA SS-8 or equivalent
– – –
Amount (Per Side)
310 mL (10.5 US oz) (when changing oil)
360 ±2.5 mL (12.2 ±0.08 US oz.) (after
disassembly and completely dry)
Fork oil level
108 ±2 mm (4.3 ±0.08 in.)
(Fully compressed, without spring)
– – –
Fork spring free length
420.5 mm (16.6 in.)
412 mm (16.2 in.)
Rear Suspension
Rear shock absorber spring
preload adjustment
1st position
1 ∼5
(Usable range)
Rear shock absorber gas pressure
(non-adjustable)
980 kPa (10 kgf/cm², 142 psi)
– – –
– – –
– – –
Inside Circlip Pliers:
Halaman 285
SUSPENSION 13-5
Special Tools
Inside Circlip Pliers:
57001-143
Fork Cylinder Holder Handle:
57001-183
Fork Cylinder Holder Adapter:
57001-1057
Oil Seal & Bearing Remover:
57001-1058
Steering Stem Nut Wrench:
57001-1100
Bearing Driver Set:
57001-1129
Fork Outer Tube Weight:
57001-1218
Front Fork Oil Seal Driver:
57001-1219
Jack:
57001-1238
Fork Oil Level Gauge:
57001-1290
Inside Circlip Pliers:
Halaman 286
13-6 SUSPENSION
Special Tools
Jack Attachment:
57001-1608
Torque -
Halaman 287
Front Fork
Front Fork Removal
NOTE
○Remove the handlebar holder and remove the fork top
plug [A] beforehand if the fork leg is to be disassembled.
• To remove the top plug, remove the snap ring [B] pushing
down the top plug with the screwdriver.
• Remove:
Front Brake Caliper (see Front Caliper Removal in the
Brakes chapter)
Front
Wheel
(see
Front
Wheel
Removal
in
the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
• Remove the clamps and free the brake hose from the fork
leg.
• Loosen the front fork upper [A] and lower [B] clamp bolts.
• With a twisting motion, remove the fork leg down and out.
Front Fork Installation (each fork leg)
• Insert the fork leg until the inner tube top hit the handlebar
holder lightly, that is, the distance between the inner tube
top [A] and the steering stem head surface [B] is approx-
imate 12 mm (0.47 in.) [C].
Torque - Front Fork Clamp Bolts (Upper):
21 N·m (2.1
kgf·m, 15 ft·lb)
Front Fork Clamp Bolts (Lower):
30 N·m (3.1
kgf·m, 22 ft·lb)
• Route the brake hoses and clamp it to the right fork leg.
• Install:
Handlebar Holder
Front Brake Caliper (see Caliper Installation in the
Brakes chapter)
Front Wheel (see Front Wheel Installation in the
Wheels/Tires chapter)
Front Fender
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Torque - Handlebar Holder Mounting Bolts: N·m (2.5
kgf·m, ft·lb)
SUSPENSION 13-7
Special Tool -
Halaman 288
13-8 SUSPENSION
Front Fork
Front Fork Oil Change
• Remove the front fork (see Front Fork Removal).
• Remove:
Snap Ring [A] (see Front Fork Removal)
Top Plug [B] with O-ring [C]
Collar [D]
Fork Spring Seat [E]
Fork Spring [F]
• Compress [A] the fork [B] upside down to draw out the oil
into the suitable container [C].
• Pour in the specified amount of oil.
Fork Oil
Viscosity:
KAYABA SS-8 or equivalent
Amount (Per Side):
When changing oil
310 mL (10.5 US oz.)
After disassembly
and completely dry
360 ±2.5 mL (12.2 ±0.08 US oz.)
NOTE
○Move the outer tube up and down a few times to remove
the air that is trapped in the fork oil in order to stabilize
the oil level.
• Hold the outer tube vertically in a vise and compress the
fork completely.
• Wait until the oil level stabilizes.
• Use the fork oil level gauge [A] to measure the distance
between the top of the inner tube to the oil level.
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil level gauge stopper [B] so that the distance [C]
from the bottom of the stopper to the lower end of the pipe
is the standard oil level distance.
○A correct measurement can not be obtained unless the
level gauge pipe is placed in the center of the inner tube.
Oil Level (fully compressed, without spring)
Standard:
108 ±2 mm (4.3 ±0.08 in.)
○Place the stopper of the level gauge at the top [D] of the
inner tube [E] and pull the handle slowly to draw out the
excess oil from fork into the gauge, thus attaining the stan-
dard level.
○If not oil is drawn out, there is not enough oil in the fork.
Pour in some more oil and measure again.
Special Tool -
Halaman 289
Front Fork
• Repeat the same procedure for adjusting the other fork.
• Install the fork spring [A], fork spring seat [B] and collar
[C].
• Inspect the top plug O-ring and snap ring and replace
them with new ones.
• Install the front fork (see Front Fork Installation).
Front Fork Disassembly
• Remove the front fork (see Front Fork Removal).
• Remove:
Snap Ring [A] (see Front Fork Removal)
Top Plug [B] with O-ring [C]
Collar [D]
Fork Spring Seat [E]
Fork Spring [F]
• Hold the front fork leg horizontally in a vise [A].
• Stop the cylinder unit [B] from turning by using the special
tools.
• Unscrew the front fork bottom Allen bolt [C], and then take
out the bolt and gasket out of the bottom of the outer tube.
Special Tools - Fork Cylinder Holder Handle: 57001-183 [D]
Fork Cylinder Holder Adapter: 57001-1057
[E]
• Take the cylinder unit out of the inner tube.
• Remove the following from the top of the outer tube.
Dust Seal [A]
Retaining Ring [B]
• Use the fork outer tube weight [A] to separate the inner
tube from the outer tube. Holding the inner tube by hand
in a vertical position, pull down the outer tube several
times to pull out the inner tube.
Special Tool - Fork Outer Tuber Weight: 57001-1218
• Take out the cylinder base from the outer tube bottom.
• Remove the inner guide bushing from the inner tube.
SUSPENSION 13-9
Torque -
Halaman 290
13-10 SUSPENSION
Front Fork
Front Fork Assembly
• Check the top plug O-ring and snap ring and replace them
with new ones if necessary.
• Replace the following parts with new ones.
Inner Guide Bushing [A]
Retaining Ring [B]
Oil Seal [C]
Outer Guide Bushing [D]
Bottom Allen Bolt Gasket [E]
• Put the cylinder unit [A] with the spring into the inner tube
[B] protruding from the inner tube, and install the cylinder
base [C] onto the bottom end of the cylinder unit.
○Install the cylinder base with the tapered end [D] facing
upward.
• Install the inner tube, cylinder unit, and cylinder base as
a set into the outer tube.
• Install the new guide bushing [A] with a use one [B] on it
by tapping the use one with the fork oil seal driver [C].
○The split [D] of the bushing should face toward the side of
the vehicle.
Special Tool - Front Fork Oil Seal Driver: 57001-1219
• Apply molybdenum disulfide grease to the oil seal lips and
install the washer and the oil seal [A] into the outer tube.
Special Tool - Front Fork Oil Seal Driver: 57001-1219 [B]
• Install the retaining ring on the outer tube.
• Install a new bottom Allen bolt gasket.
• Apply a non-permanent locking agent to the threads of the
bottom Allen bolt and screw the Allen bolt into the bottom
of the outer tube.
• Hold the outer tube in a vise [A], hold the cylinder unit [B]
with the special tools, then tighten the Allen bolt [C].
○Apply a non-permanent locking agent to the front fork bot-
tom Allen bolt.
Special Tools - Fork Cylinder Holder Handle: 57001-183 [D]
Fork Cylinder Holder Adapter: 57001-1057
[E]
Torque - Front Fork Bottom Allen Bolt: 20 N·m (2.0 kgf·m,
ft·lb)
Oil Seal/Dust Seal Inspection
Halaman 291
Front Fork
• Fill with the specified type of oil and install the parts re-
moved (see Fork Oil change).
• Install the dust seals.
Fork Oil:
KAYABA SS-8 or equivalent
Capacity (per
one unit):
360 ±2.5 mL (12.2 ±0.08 US oz), (after
fork disassembly and completely dry)
Inner Tube/Outer Tube Inspection
• Visually inspect the inner tube [A] and repair any damage.
• Nick or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replace.
CAUTION
If the inner tube is badly bent or creased, replace
it.
Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
• Temporarily assemble the inner tube and outer tube [B],
and pump them back and forth manually to check for
smooth operation.
If it does not operate smoothly, replace both the inner tube
and the outer tube.
WARNING
A straightened inner or outer fork tube may fail in
use, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect the
other tube carefully before reusing it.
Fork Spring Inspection
• Measure the free length [B] of the fork spring [A].
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of the replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Fork Spring Free Length
Standard:
420.5 mm (16.6 in.)
Service Limit:
412 mm (16.2 in.)
Oil Seal/Dust Seal Inspection
• Inspect the oil seal [A] and dust seal [B] for any signs of
deterioration or damage.
Replace it if necessary.
SUSPENSION 13-11
Special Tools -
Halaman 292
13-12 SUSPENSION
Rear Shock Absorber
Spring Preload Adjustment
• Remove the bolts [A], chain cover [B] and left foot guard
[C] to turn the wrench.
• Using the steering stem nut wrench [A], turn the adjusting
nut to adjust the spring preload.
Special Tool - Steering Stem Nut Wrench: 57001-1100
• The spring preload can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the spring action feels too soft or too
stiff, adjust it in accordance with the following table.
Spring Preload Adjustment
Adjuster
Position
Spring
Force
Setting
Load
Road
Speed
1
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
5
Strong
Hard
Heavy
Bad
High
• The standard adjuster setting for an average build rider of
68 kg (150 lb) with no passenger and no accessories is 1
step.
Rear Shock Absorber Removal
• Remove the lower fairings (see Lower Fairing in the
Frame chapter).
• Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Squeeze the brake lever slowly and hold it with the band
[A].
WARNING
Be sure to hold the front brake when removing the
shock absorber, or the motorcycle may tall over. It
could cause an accident and injury.
Rear Shock Absorber Scrapping
Halaman 293
Rear Shock Absorber
• Remove:
Tie-rod Lower and Bolt [A]
Rear Shock Absorber Nuts and Bolts [B]
Rear Shock Absorber Installation
• Install the rear shock absorber.
• Tighten the tie-rod lower bolt and nut.
Torque - Rear Shock Absorber Mounting Nuts: 59 N·m (6.0
kgf·m, 44 ft·lb)
Tie-rod Nut (Lower): 59 N·m (6.0 kgf·m, 44 ft·lb)
• Adjust the rear shock absorber spring preload in response
to riding condition (see Spring Preload Adjustment).
Rear Shock Absorber Scrapping
WARNING
Since the rear shock absorber contains nitrogen
gas, do not incinerate the rear shock absorber with-
out first releasing the gas or it may explode.
Before a rear shock absorber is scrapped, drill a
hole at the point [A] shown to release the nitrogen
gas completely. Wear safety glasses when drilling
the hole, as the gas may below out bits of drilled
metal when the hole opens.
• Drill the cylinder [A] of the shock absorber using about 2
mm (0.08 in.) drill bit.
SUSPENSION 13-13
Torque -
Halaman 294
13-14 SUSPENSION
Swingarm
Swingarm Removal
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Remove the bolts [A] and the chain cover [B].
• Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Rear
Wheel
(see
Rear
Wheel
Removal
in
the
Wheels/Tire chapter)
Rear Shock Absorber [A] (see Rear Shock Absorber Re-
moval)
Tie-rod [B] (see Tie-rod Removal)
• Remove:
Brake Hose Clamp Bolt [A]
Bracket [B] with Brake Hose
• Remove the swingarm pivot nut [A] and shaft, remove the
swingarm [B].
Swingarm Installation
• Installation is the reverse of removal.
○Apply grease to the lip of oil seals.
○Be sure to install the oil seal and collar to swingarm.
• Tighten the swingarm pivot nut.
Torque - Swingarm Pivot Nut: 98 N·m (10.0 kgf·m, 72 ft·lb)
• Install the removed parts.
Swingarm Bearing, Sleeve Inspection
Halaman 295
Swingarm
Swingarm Bearing Removal
• Remove:
Swingarm (see Swingarm Removal)
Grease Seal [A]
Sleeve [B]
Special Tool - Inside Circlip Pliers: 57001-143
• Remove the needle bearing.
Special Tool - Oil Seal & Bearing Remover: 57001-1058 [A]
Swingarm Bearing Installation
• Apply plenty of grease to the needle bearings.
• Install the needle bearings so that the manufacturer’s
marks faces out.
Special Tool - Bearing Driver Set: 57001-1129 [A]
Swingarm Bearing, Sleeve Inspection
CAUTION
Do not remove the bearings for inspection.
Re-
moval many damage them.
• The rollers in a needle bearing [A] normally wear very lit-
tle, and wear is difficult to measure. Instead of measuring,
inspect the bearing in the swingarm for abrasion, color
change, or other damage.
If there is any doubt as to the condition of any of the nee-
dle bearings or sleeve, replace the sleeve, and needle
bearings as a set.
SUSPENSION 13-15
Chain Guide Inspection
Halaman 296
13-16 SUSPENSION
Swingarm
Swingarm Lubrication
• Lubricate the swingarm needle bearings [A] according to
the Periodic Maintenance Chart. They are normal for a
small amount of grease to seep out around the grease
seals.
○If the swingarm pivots is disassembled, wipe all the old
grease off the bearings, sleeves, and grease seals, then
grease them.
Chain Guide Inspection
• Refer to the Chain Guide Wear Inspection in the Periodic
Maintenance chapter (see Chain Guide Wear Inspection
in the Periodic Maintenance chapter).
Tie-rod, Rocker Arm Sleeve Inspection
Halaman 297
Tie-Rod, Rocker Arm
Tie-rods Removal
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove the tie-rod lower bolt [A] and nut.
• Remove the tie-rod upper bolt [B] and nut, and take off
the tie-rod [C].
• Remove the other tie-rod.
Tie-Rod Installation
• Install the tie-rod upper bolt first and then the lower bolt.
Torque - Tie-rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
Rocker Arm Removal
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Raise the rear wheel off the ground with jack.
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
• Remove:
Rear Shock Absorber Lower Nut and Bolt [A]
Tie-rod Lower Nut and Bolt [B]
Rocker Arm Pivot Shaft [C]
Rocker Arm [D]
○Support the rear wheel to remove the bolts.
CAUTION
When pulling out the bolts, lift the rear wheel
slightly. Forcing or tapping on a bolt could damage
the bolt and sleeve.
Rocker Arm Installation
• Apply grease to all the O-ring, bushing, sleeve, grease
seal.
• Tighten:
Torque - Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Tie-rod Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)
Rear Shock Absorber Mounting Nut: 59 N·m (6.0
kgf·m, 44 ft·lb)
Tie-rod, Rocker Arm Bushing Inspection
• The busings wear so little that the wear is difficult to mea-
sure. Instead, inspect the bushings for abrasion, color
change or other damage.
If there is any doubt as to the condition of either bushings,
replace the busing with new one.
Tie-rod, Rocker Arm Sleeve Inspection
If there is visible damage, replace the sleeve with new
one.
SUSPENSION 13-17
Steering
Halaman 299
STEERING 14-1
Steering
Table of Contents
Exploded View .......................................................................................... 14-2
Special Tools ............................................................................................ 14-4
Steering ................................................................................................... 14-5
Steering Inspection ................................................................................ 14-5
Steering Adjustment .............................................................................. 14-5
Steering Stem .......................................................................................... 14-6
Steering Stem, Stem Bearing Removal ................................................... 14-6
Steering Stem, Stem Bearing Installation ................................................ 14-7
Stem Bearing Lubrication ....................................................................... 14-9
Grease Seal, Deterioration, Damage Inspection ...................................... 14-9
Steering Stem Warp Inspection .............................................................. 14-9
Handlebars .............................................................................................. 14-10
Right Handlebar Holder Removal .......................................................... 14-10
Right Handlebar Holder Installation ........................................................ 14-10
Left Handlebar Holder Removal ............................................................. 14-10
Left Handlebar Holder Installation Note .................................................. 14-11
14
Steering
Halaman 300
14-2 STEERING
Exploded View
Steering
Halaman 301
STEERING 14-3
Exploded View
| No | Item | N·m | Torque kgf·m | ft·lb | Remarks |
|----|-----------------------------|-----|--------------|---------|---------|
| 1 | Steering Stem Nut | 4.9 | 0.5 | 43 in·lb | |
| 2 | Handlebar Holder Mounting Bolts | 25 | 2.5 | 18 | |
| 3 | Steering Stem Head Bolt | 44 | 4.5 | 32 | |
| 4 | Front Fork Clamp Bolts (Upper) | 20 | 2.0 | 15 | |
| 5 | Front Fork Clamp Bolts (Lower) | 30 | 3.1 | 22 | |
AD: Apply adhesive agent.
G: Apply grease.
L: Apply a non-permanent locking agent.
Steering Stem Bearing Driver:
Halaman 302
# 14-4 STEERING
## Special Tools
---
### Steering Stem Bearing Driver:
**57001-137**
### Head Pipe Outer Race Press Shaft:
**57001-1075**
---
### Bearing Puller:
**57001-158**
### Head Pipe Outer Race Driver, φ51.5:
**57001-1076**
---
### Bearing Puller Adapter:
**57001-317**
### Steering Stem Nut Wrench:
**57001-1100**
---
### Oil Seal & Bearing Remover:
**57001-1058**
### Head Pipe Outer Race Driver, φ47:
**57001-1447**
---
### Steering Stem Bearing Driver Adapter, φ34.5:
**57001-1074**
Steering Adjustment
Halaman 303
Steering
Steering Inspection
• Refer to Steering Play Inspection in the Periodic Mainte-
nance chapter (see Steering Play Inspection in the Peri-
odic Maintenance chapter).
Steering Adjustment
• Refer to Steering Play Adjustment in the Periodic Mainte-
nance chapter (see Steering Play Inspection in the Peri-
odic Maintenance chapter).
STEERING 14-5
Special Tools -
Halaman 304
14-6 STEERING
Steering Stem
Steering Stem, Stem Bearing Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Steering Stem Head Bolt
Steering Stem Head with Handlebars
Front
Wheel
(see
Fuel
Wheel
Removal
in
the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)
Front Fork (see Front Fork Removal in the Suspension
chapter)
• Pushing up the stem base by the hand, and remove the
steering stem nut [A], stem cap [B], and then remove the
steering stem [C].
Special Tool - Steering Stem Nut Wrench: 57001-1100 [D]
NOTE
○Be aware of removing the steering stem so that the stem
bearing steel balls are not lost.
• Remove the upper ball bearing inner race.
• Remove the upper and lower outer races using the outer
race remover [A].
Special Tool - Oil Seal & Bearing Remover: 57001-1058
NOTE
○If either stem bearing is damaged, it is recommended
that both the upper and lower bearings (including the
outer races) should be replaced with new ones.
• Remove the lower bearing inner race [A] (with its grease
seal) which is pressed onto the steering stem using the
bearing puller [B] and adapter [C].
Special Tools - Bearing puller: 57001-158
Bearing Puller Adapter: 57001-317
Special Tools -
Halaman 305
Steering Stem
Steering Stem, Stem Bearing Installation
• Replace the bearing outer race with new ones.
• Apply grease to the outer races, and drive them into the
head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft: 57001
-1075 [A]
Head Pipe Outer Race Driver: 57001-1076
[B]
Head Pipe Outer Race Driver: 57001-1447
[C]
• Replace the bearing inner race with new one.
• Install the washer [D] and grease seal [E] on the steering
stem, and drive the ball bearing inner race [A] applied
grease onto the stem.
Special Tools - Steering Stem Bearing Driver:
57001-137
[B]
Steering
Stem
Bearing
Driver
Adapter:
57001- 1074 [C]
• Apply grease to the lower ball bearings (20) and stem
inner race and install them onto the steering stem.
• Apply grease to the upper ball bearing (19) [A] and outer
race [B], and install the ball bearings onto the outer race.
• Insert the steering stem [A] carefully through the head
pipe so that the steel balls on the steering stem does not
fall.
• Install the stem cap [B] and steering stem nut [C], and
tighten it by hand.
• Install the stem head [D] with the handlebars.
• Tighten the stem head bolt [E] lightly.
STEERING 14-7
Torque -
Halaman 306
14-8 STEERING
Steering Stem
• Settle the bearings in place as follows:
○Tighten the steering stem nut with 15 N·m (1.5 kgf·m, 11
ft·lb) of torque first, and loosen it a fraction of a turn until
it turns lightly. (To tighten the stem nut to the specified
torque, hook the wrench on the stem nut, and pull the
wrench at the hole by 84 N (8.3 kg) [B] force in the direc-
tion shown.).
○Tighten the steering stem nut with specified torque using
a special tool [A].
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearing
may be damaged.
○Again back out the stem nut a fraction of turn until it turns
lightly.
• Turn the stem nut lightly clockwise until it just becomes
hard to turn. Do not overtighten, or the steering will be
too tight.
Special Tool - Steering Stem Nut Wrench: 57001-1100 [A]
Torque - Steering Stem Nut: 4.9 N·m (0.5 kgf·m, 43 in·lb)
• Adjust the steering (see Steering Play Inspection in the
Periodic Maintenance chapter).
• Install the front fork (see Front Fork Installation Suspen-
sion chapter).
NOTE
○Tighten the fork upper clamp bolts first, next the stem
head bolt, last the fork lower clamp bolts.
Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32
ft·lb)
Front Fork Clamp Bolts (Upper):
20 N·m (2.0
kgf·m, 14.5 ft·lb)
Front Fork Clamp Bolts (Lower):
30 N·m (3.1
kgf·m, 22 ft·lb)
• Install:
Front Fender
Front Wheel (see Front Wheel Installation in the
Wheel/Tires chapter)
Fuel Tank (see Fuel Tank Installation in the Fuel System
chapter)
Lower Fairings (see Lower Fairing Installation in the
Frame chapter)
Front Seat (see Front Seat Installation in the Frame
chapter)
• Route the cables and harness correctly. (see Cable, Wire
and Hose Routing in the Appendix chapter).
WARNING
Do not impede the handlebar turning by routing the
cables, harnesses and hoses improperly.
• Check and adjust the following.
Front Brake
Clutch
Throttle Cable
Rear View Mirrors
Headlight Aim
Steering Stem Warp Inspection
Halaman 307
Steering Stem
Stem Bearing Lubrication
• Refer to Steering Stem Bearing Lubrication in the Periodic
Maintenance chapter (see Steering Stem Bearing Lubri-
cation in the Periodic Maintenance chapter).
Grease Seal, Deterioration, Damage Inspection
• Inspect the grease seal for any sign of deterioration or
damage.
Replace the grease seal if necessary.
Steering Stem Warp Inspection
• Whenever the steering stem is removed, or if the steering
can not be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem [A] is bent, replace the steering stem.
STEERING 14-9
Left Handlebar Holder Removal
Halaman 308
14-10 STEERING
Handlebars
Right Handlebar Holder Removal
• Remove:
Right Switch Housing [A]
Front Master Cylinder Clamp Bolts [B]
Handlebar Holder Mounting Bolts [C]
Right Handlebar [D]
Right Handlebar Holder Installation
• Install:
Right Handlebar Holder
Right Switch Housing
• Install the front master cylinder so that the punch mark [A]
of the handlebar is aligned with the mating surface [B] of
the master cylinder clamp to level the reservoir.
NOTE
○When the master cylinder clamp shall be installed, be
sure to install it so that the arrow mark [A] on it direct
upward.
○Tighten the upper clamp bolt [B] first, and then the lower
clamp bolt [C] with a specified torque so that there will
be a gap at the lower part of the clamp.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
Right Handlebar Holder Mounting Bolts: 25 N·m
(2.5 kgf·m, 18 ft·lb)
Left Handlebar Holder Removal
• Remove:
Left Switch Housing [A]
Clutch Lever Holder Clamp Bolt [B]
Handlebar Holder Mounting Bolts [C]
Left Handlebar [D]
Torque -
Halaman 309
Handlebars
Left Handlebar Holder Installation Note
• Install the clutch lever holder so that the punch mark [A]
of the handlebar is aligned with the mating surface [B] of
the clutch lever holders clamps.
• Tighten the following with the specified torque.
Torque - Clutch Lever Holder Clamp Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
Left Handlebar Holder Mounting Bolts: 25 N·m
(2.5 kgf·m, 18 ft·lb)
STEERING 14-11
Frame
Halaman 311
FRAME 15-1
---
# Frame
## Table of Contents
* **Exploded View** ............................................................................................................................ 15-2
* **Seat** ........................................................................................................................................... 15-6
* Front Seat Removal ........................................................................................................... 15-6
* Front Seat Installation .......................................................................................................... 15-6
* Rear Seat Removal............................................................................................................. 15-6
* Rear Seat Installation.......................................................................................................... 15-6
* **Fairings**..................................................................................................................................... 15-7
* Lower Fairing Removal ........................................................................................................ 15-7
* Lower Fairing Installation ..................................................................................................... 15-7
* Upper Fairing Removal ........................................................................................................ 15-8
* Upper Fairing Installation ..................................................................................................... 15-9
* Upper Cover Removal ........................................................................................................ 15-9
* Upper Cover Installation ..................................................................................................... 15-9
* **Side Cover**................................................................................................................................. 15-10
* Side Cover Removal........................................................................................................... 15-10
* Side Cover Installation ........................................................................................................ 15-10
* **Fenders** .................................................................................................................................... 15-11
* Front Fender Removal ........................................................................................................ 15-11
* Rear Fender Removal......................................................................................................... 15-11
* Rear Fender Installation...................................................................................................... 15-12
---
<div style="text-align: right; margin-top: 50px;">
<span style="border: 1px solid black; padding: 5px 10px; background-color: black; color: white; font-weight: bold; font-size: 1.2em;">15</span>
</div>
Frame
Halaman 312
# 15-2 FRAME
## Exploded View
### Diagram Labels & Markings
* **(Option)** (Indicated on the upper-right optional assembly)
* **T1** (Torque specification indicator located near the rear frame assembly)
#### Circled Numbers
* 1
* 2
* 3
* 4
* 7
#### Circled Letters
* A
* B
* C
* D
* E
* F
* G
* H
* I
* L
***
*Code in bottom-right corner:* `J132510017`
Frame
Halaman 313
# FRAME 15-3
## Exploded View
| No. | Fastener | Torque (N·m) | Torque (kgf·m) | Torque (ft·lb) | Remarks |
| :---: | :--- | :---: | :---: | :---: | :---: |
| 1 | Sidestand Nut | 44 | 4.5 | 32 | |
| 2 | Front Footpeg Bracket Mounting Bolts | 25 | 2.5 | 18 | |
| 3 | Rear Footpeg Bracket Mounting Bolts | 25 | 2.5 | 18 | |
| 4 | Sidestand Switch Bolt | 8.8 | 0.90 | 78 in·lb | L |
**G:** Apply grease.
**L:** Apply a non-permanent locking agent.
Frame
Halaman 314
# 15-4 FRAME
## Exploded View
### Diagram Labels
**Letters:**
* (A)
* (B)
* (C)
* (D)
* (E)
* (F)
* (G)
* (H)
* (I)
* (J)
* (K)
* (L)
* (M)
**Numbers:**
* (1)
* (2)
* (3)
* (4)
* (5)
* (6)
* (7)
* (8)
* (9)
* (10)
* (11)
* (12)
* (13)
* (14)
* (15)
* (16)
* (17)
* (18)
* (19)
* (20)
* (21)
* (22)
* (23)
* (24)
* (25)
* (26)
* (27)
* (28)
* (29)
* (30)
* (31)
* (32)
* (33)
* (34)
* (35)
* (36)
* (37)
* (38)
* (39)
73B12180 2
Frame
Halaman 315
**FRAME 15-5**
---
# Exploded View
| No. | Fastener | Torque (N·m) | Torque (kgf·m) | Torque (ft·lb) | Remarks |
| :---: | :--- | :---: | :---: | :---: | :--- |
| 1 | Windshield Mounting Screws | 0.42 | 0.043 | 3.7 in·lb | |
Rear Seat Installation
Halaman 316
15-6 FRAME
Seat
Front Seat Removal
• Remove the side covers (see Side Cover Removal).
• Remove the front seat bolts [A].
• Slide the front seat backwards [B] and remove the front
seat [C].
Front Seat Installation
• Slip [A] the hooks into the hollows and put [B] the projec-
tions on the frame.
Rear Seat Removal
• Insert the ignition switch key into the seat lock [A].
• Turning the key clockwise, raise the front of the seat up
[B], and pull the seat frontwards.
Rear Seat Installation
• Slip [A] the rear seat hook into the hollow cubic bracket
on the frame.
• Push down the front part of the seat until the lock clicks,
algining [B] the pin with the hole.
Lower Fairing Installation
Halaman 317
Fairings
Lower Fairing Removal
• Remove the side covers (see Side Cover Removal).
• Remove the rivets [A].
• Remove the lower fairing mounting screws [B] and mount-
ing Allen bolts [C].
• Disconnect the front turn signal light connectors [A] and
remove the lower fairings [B].
• Remove the radiator fairing screws [A] and the rivets [B],
and remove the radiator fairing [C].
Lower Fairing Installation
• Fit the front portions [A] of radiator fairing into the lower
portions [B] of upper fairing.
FRAME 15-7
Upper Fairing Removal
Halaman 318
15-8 FRAME
Fairings
• Route the front turn signal light lead [A] on the fooks [B].
• Install the lower fairing.
○Fit the front portion of the lower fairing in the rear portion
of the upper fairing.
○Install the tabs [B] on the lower fairing into the rescesses
[C] on the upper cover.
Upper Fairing Removal
• Remove:
Lower Fairings (see Lower Fairing Removal)
Radiator Fairing (see Lower Fairing Removal)
• Remove the windshield mounting screws [A] and take out
the windshield [B].
• Remove the upper fairing bolts [A] and pull the upper fair-
ing [B] forwards.
• Disconnect the headlight connectors [A] and remove the
upper fairing [B].
Upper Cover Installation
Halaman 319
Fairings
• Remove:
Bolts [A]
Headlight Unit [B]
Upper Fairing Installation
• When installing the windshield, align the windshield bot-
tom end [A] with the projection [B] on the upper fairing.
Upper Cover Removal
• Remove the upper fairing (see Upper Fairing Removal).
• Disconnect:
Speedometer Cable Lower End [A]
Meter Lead Connectors [B]
• Remove the upper cover [A].
• Remove the meter from the upper cover (see Meter Re-
moval in the Electrical System chapter).
Upper Cover Installation
• Route the cable and leads correctly (see Cable, Wire and
Harness Routing in the Appendix chapter).
FRAME 15-9
Side Cover Installation
Halaman 320
15-10 FRAME
Side Cover
Side Cover Removal
• Remove the side cover bolt [A].
• Pull the side cover outwards to clear the stoppers [B].
• Slide the side cover forwards [C] and remove the side
cover [D].
Side Cover Installation
• Slip [A] the hook into the brace and put [B] the stoppers
into the grommets.
• Tighten the side cover bolt securely.
Rear Fender Removal
Halaman 321
Fenders
Front Fender Removal
• Remove the front fender mounting bolts [A] (both sides)
and pull out the front fender [B] forward.
Rear Fender Removal
• Remove:
Rear Seat (see Rear Seat Removal)
Front Seat (see Front Seat Removal)
• Remove the seat cover screws [A] and pull the seat cov-
ers [B] to clear the stoppers [C].
• Remove the projection [A] from the hole [B], and slide [C]
the cover [D] frontwards.
• Remove:
Rear Footpeg Bracket Bolts
Rear Footpeg Bracket
• Remove the screws [A] (both sides).
• Disconnect the electrical connectors from the main har-
ness and remove the fender bolts (rear) [A].
FRAME 15-11
Rear Fender Installation
Halaman 322
15-12 FRAME
Fenders
• Remove the battery (see Battery Removal in the Electrical
System chapter).
• Take out the fuse box [A] and IC igniter [B].
• Remove:
Battery Case Screws [C]
Rear Fender Bolts (Front) [D]
• Remove the rear fender.
Rear Fender Installation
• Route the following therough the hole [A] on the rear
fender.
License Plate Light Leads
Rear Right and Left Turn Signal Light Leads
• Install the damper to the cover so that its flatten side [A]
faces downwards.
• Be sure that the damper [A] is in position.
Electrical System
Halaman 323
Electrical System
Table of Contents
Exploded View........................................................................................................................
16-4
Wiring Diagram (United States, Canada and Australia) .........................................................
16-10
Wiring Diagram (Indonesia)....................................................................................................
16-12
Specifications .........................................................................................................................
16-14
Special Tools and Sealant ......................................................................................................
16-15
Parts Location.........................................................................................................................
16-16
Precautions.............................................................................................................................
16-17
Electrical Wiring......................................................................................................................
16-19
Wiring Inspection ..............................................................................................................
16-19
Battery ....................................................................................................................................
16-20
Battery Removal ...............................................................................................................
16-20
Battery Installation ............................................................................................................
16-20
Battery Activation..............................................................................................................
16-20
Precautions.......................................................................................................................
16-22
Interchange.......................................................................................................................
16-23
Charging Condition Inspection..........................................................................................
16-23
Refreshing Charge............................................................................................................
16-24
Charging System....................................................................................................................
16-25
Alternator Cover Removal.................................................................................................
16-25
Alternator Cover Installation..............................................................................................
16-25
Stater Coil Removal..........................................................................................................
16-25
Stator Coil Installation.......................................................................................................
16-26
Alternator Rotor Removal .................................................................................................
16-26
Alternator Rotor Installation ..............................................................................................
16-26
Alternator Inspection.........................................................................................................
16-27
Regulator/Rectifier Inspection...........................................................................................
16-28
Charging Voltage Inspection.............................................................................................
16-30
Ignition System.......................................................................................................................
16-32
Crankshaft Sensor Removal.............................................................................................
16-33
Crankshaft Sensor Installation..........................................................................................
16-33
Crankshaft Sensor Inspection...........................................................................................
16-34
Crankshaft Sensor Peak Voltage Inspection.....................................................................
16-34
Ignition Coil Removal........................................................................................................
16-34
Ignition Coil Installation.....................................................................................................
16-35
Ignition Coil Inspection......................................................................................................
16-35
Ignition Coil Primary Peak Voltage....................................................................................
16-36
Spark Plug Removal .........................................................................................................
16-37
Spark Plug Installation ......................................................................................................
16-37
Spark Plug Condition Inspection.......................................................................................
16-37
IC Igniter Inspection..........................................................................................................
16-38
IC Igniter Operation Inspection .........................................................................................
16-38
Diodes Inspection .............................................................................................................
16-38
Electric Starter System...........................................................................................................
16-41
Starter Motor Removal......................................................................................................
16-41
Starter Motor Installation...................................................................................................
16-41
Starter Motor Disassembly................................................................................................
16-42
Starter Motor Assembly ....................................................................................................
16-42
Carbon Brush Inspection ..................................................................................................
16-43
Commutator Inspection, Cleaning.....................................................................................
16-43
Armature Inspection..........................................................................................................
16-44
ELECTRICAL SYSTEM 16-1
16
Electrical System
Halaman 324
16-2 ELECTRICAL SYSTEM
Starter System........................................................................................................................
16-45
Brush Lead Inspection ......................................................................................................
16-45
Terminal Bolt Inspection....................................................................................................
16-45
Starter Relay Inspection....................................................................................................
16-45
Starter Circuit Relay Inspection ........................................................................................
16-46
Lighting System......................................................................................................................
16-48
Headlight Beam Horizontal Adjustment ............................................................................
16-48
Headlight Beam Vertical Adjustment.................................................................................
16-48
Headlight Bulb Replacement ............................................................................................
16-48
Tail/Brake Light Bulb Replacement...................................................................................
16-49
Front Turn Signal Light Bulb Replacement .......................................................................
16-49
Rear Turn Signal Light Bulb Replacement........................................................................
16-50
Turn Signal Relay Inspection ............................................................................................
16-51
Headlight Circuit Relay Inspection....................................................................................
16-51
Radiator Fan System..............................................................................................................
16-55
Fan System Circuit Inspection ..........................................................................................
16-55
Fan Motor Inspection ........................................................................................................
16-55
Meters, Gauge and Indicator Unit...........................................................................................
16-56
Meter Unit Removal ..........................................................................................................
16-56
Meter Unit Disassembly....................................................................................................
16-56
Meter Unit Installation .......................................................................................................
16-56
Indicator Light Replacement .............................................................................................
16-57
Tachometer Inspection......................................................................................................
16-57
Water Temperature Warning System Inspection...............................................................
16-58
Switches and Sensor..............................................................................................................
16-59
Brake Light Timing Inspection...........................................................................................
16-59
Brake Light Timing Adjustment .........................................................................................
16-59
Switch Inspection..............................................................................................................
16-59
Radiator Fan Switch Inspection ........................................................................................
16-61
Water Temperature Switch Inspection ..............................................................................
16-61
Fuel Level Sensor Inspection............................................................................................
16-62
Fuses......................................................................................................................................
16-63
30 A Main Fuse Removal..................................................................................................
16-63
Fuse Removal...................................................................................................................
16-63
Fuse Installation................................................................................................................
16-63
Fuse Inspection.................................................................................................................
16-63
Electrical System
Halaman 325
# ELECTRICAL SYSTEM 16-3
---
Dummy Page
Electrical System
Halaman 326
**16-4 ELECTRICAL SYSTEM**
**Exploded View**
*(Exploded view diagram of motorcycle electrical components including headlight assembly, meter/instrument panel, wiring harness, handle switches, ignition, and turn signals / tail light assembly)*
* **①** *(Circled number located near the wiring harness center)*
---
Z-030417B61 G
Electrical System
Halaman 327
### ELECTRICAL SYSTEM 16-5
#### Exploded View
| No. | Fastener | Torque <br> N·m | Torque <br> kgf·m | Torque <br> ft·lb | Remarks |
| :---: | :--- | :---: | :---: | :---: | :--- |
| 1 | Tail/Brake Light Mounting Bolts | 5.9 | 0.6 | 52 in·lb | |
Electrical System
Halaman 328
# 16-6 ELECTRICAL SYSTEM
## Exploded View
(Labels around the diagram):
* 1
* 2
* 3
* 4
* 5
* 6
* 7
* 8
* 9
* 10
* 11
* 12
* 13
* 14
* 55
* B
* C
* D
* K
* L
* M
* R
(Small text at bottom right): 7-492417R/1 2
Electrical System
Halaman 329
**ELECTRICAL SYSTEM 16-7**
### Exploded View
| No. | Fastener | Torque N·m | Torque kgf·m | Torque ft·lb | Remarks |
| :---: | :--- | :---: | :---: | :---: | :--- |
| 1 | Plugs on Alternator Cover | — | — | — | Hand-Tighten |
| 2 | Alternator Cover Bolts | 9.8 | 1.0 | 87 in·lb | |
| 3 | Alternator Rotor Bolt | 68.6 | 7.0 | 51 | |
| 4 | Alternator Stator Bolts | 12 | 1.2 | 104 in·lb | |
| 5 | Regulator/Rectifier Bolts | 9.8 | 1.0 | 87 in·lb | |
| 6 | Starter Motor Clutch Bolts | 34.3 | 3.5 | 25 | L |
| 7 | Crankshaft Sensor Screws | 3.0 | 0.30 | 27 in·lb | |
| 8 | Ignition Coil Bolts | — | — | — | see text |
| 9 | Spark Plugs | 13 | 1.3 | 115 in·lb | |
| 10 | Starter Motor Terminal Locknut | 9.8 | 1.0 | 87 in·lb | |
| 11 | Starter Motor Assembly Bolts | 3.5 | 0.36 | 31 in·lb | |
| 12 | Starter Motor Mounting Bolts | 9.8 | 1.0 | 87 in·lb | |
| 13 | Starter Relay Terminal Nut | 5.0 | 0.5 | 44 in·lb | |
14. IC Igniter
* **G:** Apply grease.
* **L:** Apply a non-permanent locking agent.
* **M:** Apply molybdenum disulfide grease.
* **SS:** Apply silicone grease.
Electrical System
Halaman 330
# 16-8 ELECTRICAL SYSTEM
## Exploded View
### Diagram Key / Reference Numbers
* **①** (with **SS** symbol)
* **②**
* **③**
* **④**
* **⑤**
* **⑥**
* **⑦**
* **⑧**
* **⑨**
* **⑩**
* **⑪**
Electrical System
Halaman 331
### ELECTRICAL SYSTEM 16-9
#### Exploded View
| No. | Fastener | Torque N·m | Torque kgf·m | Torque ft·lb | Remarks |
| :--- | :--- | :---: | :---: | :---: | :--- |
| 1 | Oil Pressure Switch | 15 | 1.5 | 11 | SS |
| 2 | Neutral Switch | 15 | 1.5 | 11 | |
3. Rear Brake Light Switch
4. Side Stand Switch
5. Radiator Fan Switch
6. Water Temperature Switch
7. Ignition Switch
8. Turn Signal Relay
9. Fuse Box
10. Headlight Circuit Relay
11. Starter Circuit Relay
G: Apply grease.
L: Apply a non-permanent locking agent.
SS: Apply silicone grease.
Electrical System
Halaman 332
16-10 ELECTRICAL SYSTEM
Wiring Diagram (United States, Canada and Australia)
Electrical System
Halaman 333
Wiring Diagram (United States, Canada and Australia)
ELECTRICAL SYSTEM 16-11
Electrical System
Halaman 334
16-12 ELECTRICAL SYSTEM
Wiring Diagram (Indonesia)
Electrical System
Halaman 335
Wiring Diagram (Indonesia)
ELECTRICAL SYSTEM 16-13
Electrical System
Halaman 336
16-14 ELECTRICAL SYSTEM
Specifications
Item
Standard
Service Limit
Battery
Type
Sealed battery
– – –
Model Name
YTX7A-BS
– – –
Capacity
12 V 6 Ah
– – –
Voltage
12.8 V or more
– – –
Charging System
Alternator Output Voltage
40 V or more @4 000 r/min (rpm)
– – –
Alternator Stator Coil Resistance
0.05 ∼0.6 Ω
– – –
Ignition System
Crankshaft Sensor Air Gap
0.7 mm (0.028 in.)
– – –
Crankshaft Sensor Resistance
100 ∼150 Ω
– – –
Ignition Coil:
3 Needle Arcing Distance
7 mm (0.28 in.) or more
– – –
Primary Winding Resistance
2.1 ∼2.5 Ω
– – –
Secondary Winding Resistance
10 ∼16 kΩ
– – –
Spark Plug Gap
0.7 ∼0.8 mm (0.028 ∼0.032 in.)
Electrical Stater System
Starter Motor:
Carbon Brush Length
10 mm (0.39 in.)
5 mm (0.20 in.)
Commutator Diameter
28 mm (1.10 in.)
27 mm (1.06 in.)
Switches and Sensors
Rear Brake Light Switch
ON after about 10 mm (0.39 in.) pedal
travel
Radiator Fan Switch connections:
Rising Temperature
From OFF to ON @95 ∼101°C (196 ∼
203°F)
Falling Temperature
From ON to OFF within 3 ∼8°C (37 ∼
46°F) of “ON” temperature
ON: less than 0.5 Ω
OFF: More than 1 MΩ
Water Temperature Switch
Connections:
Rising Temperature
From OFF to ON @112 ∼118°C (226
∼232°F)
– – –
Falling Temperature
From ON to OFF @108°C (226°F) ∼
temperature less than ON
– – –
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
– – –
– – –
– – –
Flywheel Holder:
Halaman 337
Special Tools and Sealant
Flywheel Holder:
57001-1313
Hand Tester:
57001-1394
Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:
57001-1405
ELECTRICAL SYSTEM 16-15
Peak Voltage Adapter:
57001-1415
Needle Adapter Set:
57001-1457
Kawasaki Bond (Silicone Sealant):
56019-120
Flywheel Holder:
Halaman 338
# 16-16 ELECTRICAL SYSTEM
## Parts Location
| No. | Part Name | No. | Part Name | No. | Part Name |
| :--- | :--- | :--- | :--- | :--- | :--- |
| **1.** | Diode | **10.** | Main Fuse (30 A) | **19.** | #1 Spark Plug |
| **2.** | Horn | **11.** | Fuse Box | **20.** | Regulator/rectifier |
| **3.** | Radiator Fan Switch | **12.** | IC Igniter | **21.** | Front Brake Light Switch |
| **4.** | #1 Ignition Coil | **13.** | Starter Circuit Relay | **22.** | Starter Lockout Switch |
| **5.** | Oil Pressure Switch | **14.** | Headlight Circuit Relay | **23.** | #2 Spark Plug |
| **6.** | Alternator | **15.** | Diodes | **24.** | Radiator Fan |
| **7.** | Crankshaft Sensor | **16.** | Battery | **25.** | #1 Ignition Coil |
| **8.** | Neutral Switch | **17.** | Starter Relay | **26.** | Engine Ground Terminal |
| **9.** | Sidestand Switch | **18.** | Starter Motor | **27.** | Rear Brake Light Switch |
There are a number of important precautions that are musts when
Halaman 339
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○Do not reverse the battery lead connections.
This will
burn out the diodes in the electrical parts.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
○Because of the large amount of current, never keep the
starter button pushed when the starter motor will not turn
over, or the current may burn out the starter motor wind-
ings.
○Do not use a meter illumination bulb rated for other than
voltage or wattage specified in the wiring diagram, as the
meter or gauge panel could be warped by excessive heat
radiated from the bulb.
○Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
○Troubles 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 must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
leads and bad connections will affect electrical system
operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Color Codes
BK: Black
BL: Blue
BR: Brown
CH: Chocolate
DG: Dark green
G: Green
GY: Gray
LB: Light blue
LG: Light green
O: Orange
P: Pink
PU: Purple
R: Red
W: White
Y: Yellow
○Electrical Connectors
Connectors [A]
ELECTRICAL SYSTEM 16-17
There are a number of important precautions that are musts when
Halaman 340
16-18 ELECTRICAL SYSTEM
Precautions
Connectors [B]
Special Tool -
Halaman 341
Electrical Wiring
Wiring Inspection
• Visually inspect the wiring for signs of burning, fraying,
etc.
If any wiring is in poor, replace the damaged wiring.
• Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
• Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ωrange, and read the meter.
If the tester does not read 0 Ω, the lead is defective. Re-
place the lead or the wiring harness [B] if necessary.
ELECTRICAL SYSTEM 16-19
Battery Activation
Halaman 342
16-20 ELECTRICAL SYSTEM
Battery
Battery Removal
• Pull the diodes [A] and headlight circuit relay [B] out of the
cover.
• Unscrew the screw [C] and remove the cover [D], clearing
the projections [E].
• Disconnect the negative (–) cable [A] and then the positive
(+) cable [B].
CAUTION
Be sure to the disconnect the negative (–) cable
first.
• Remove the battery.
• To remove the battery case [B], remove the screws [A].
Battery Installation
• Be sure the battery damper [A] is in position.
• Connect the positive (+) cable first, then the negative (–)
cable to the battery.
Battery Activation
Electrolyte Filling
• Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for EX250J8F: YTX7A-BS
CAUTION
Be sure to use the electrolyte container with the
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type.
This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora-
tion of the battery performance.
Battery Activation
Halaman 343
Battery
CAUTION
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
• Place the battery on a level surface.
• Check to see that the sealing sheet has no peeling, tears,
or holes in it.
• Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
• Remove the electrolyte container from the vinyl bag.
• Detach the strip of caps [A] from the container and set
aside, these will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
• Place the electrolyte container upside down with the six
sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container
• Check the electrolyte flow.
If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap the
container [B] a few times.
• Keep the container in place for 20 minutes or more. Don’t
remove the container from the battery until it’s empty, the
battery requires all the electrolyte from the container for
proper operation.
CAUTION
Removal of the container before it is completely
empty can shorten the service life of the battery. Do
not remove the electrolyte container until it is com-
pletely empty and 20 minutes have elapsed.
ELECTRICAL SYSTEM 16-21
2)
Halaman 344
16-22 ELECTRICAL SYSTEM
Battery
• Gently remove the container from the battery.
• Let the battery sit for 30 minutes prior to charging to allow
the electrolyte to permeate into the plates for optimum
performance.
NOTE
○Charging the battery immediately after filling can
shorten service life. Let the battery sit for at least 60
minutes after filling.
Initial Charge
• Place the strip [A] of caps loosely over the filler ports.
• Newly activated sealed batteries require an initial charge.
Standard Charge: 0.7 A × 5 ∼10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9
If the above chargers are not available, use equivalent
one.
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used.
Let battery sit 30 minutes after initial
charge, then check voltage using a voltmeter. If it is
not at least 12.8 volts, repeat charging cycle.
• After charging is completed, press down firmly with both
hands to seat the strip of caps [A] into the battery (don’t
pound or hammer). When properly installed, the strip of
the caps will be level with the top of the battery.
CAUTION
Once the strip of the caps [A] is installed onto the
battery, never remove the caps, nor add water or
electrolyte to the battery.
NOTE
○To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 volts repeat the
charging cycle and load test. If still below 12.8 volts the
battery is defective.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
seal cap to add water is very dangerous. Never do that.
2) Refreshing charge
Charging Condition Inspection
Halaman 345
Battery
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see this chapter).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months:
Give a refresh charge before you store the motorcycle and store it with the negative cable re-
moved. Give a refresh charge once a month during storage.
4) Battery life:
If the battery will not start the engine even after several refresh charges, the battery has ex-
ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-
lem).
WARNING
Keep the battery away from sparks and open flames during charging, since the battery
gives off an explosive 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.
No fire should be drawn near the battery, or no terminals should have the tightening loos-
ened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
battery terminal voltage with a digital voltmeter [A].
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Battery Cover
• Disconnect the battery terminals.
CAUTION
Be sure to disconnect the negative (–) cable first.
• Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
ELECTRICAL SYSTEM 16-23
Refreshing Charge
Halaman 346
16-24 ELECTRICAL SYSTEM
Battery
If the reading is 12.8 V or more, no refresh charge is re-
quired, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
Standard:
12.8 V or more
Refreshing Charge
• Remove the battery [A] (see Battery Removal).
• Do refresh charge by following method according to the
battery terminal voltage.
WARNING
This battery is a sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.
Terminal Voltage: 11.5 ∼less than 12.8 V
Standard Charge: 0.7 A × 5 ∼10 h (see following chart)
Quick Charge:
4 A × 1 h
CAUTION
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method:
0.7 A × 20 h
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
• Determine the battery condition after refresh charge.
○Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria
Judgement
12.8 V or higher
Good
12.0 ∼lower than 12.8 V
Charge insufficient →Recharge
lower than 12.0 V
Unserviceable →Replace
Stater Coil Removal
Halaman 347
Charging System
Alternator Cover Removal
• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
• Remove:
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Shift Lever Link
Engine Sprocket Cover
Coolant Pipes [A], [B]
• Remove:
Alternator Cover Bolts [C]
Alternator Cover [D]
Alternator Cover Installation
• Apply silicone sealant to the alternator lead grommet and
crankcase halves mating surface [A] on the front and rear
side of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
• Check that the knock pins [B] are in place on the
crankcase.
• Install a new gasket and the alternator cover.
Torque - Water Hose Clamp Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Stater Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Crankshaft Sensor Screws [A] and Clamps
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
• Remove the stator coil [D] from the alternator cover.
ELECTRICAL SYSTEM 16-25
Alternator Rotor Installation
Halaman 348
16-26 ELECTRICAL SYSTEM
Charging System
Stator Coil Installation
• Install the alternator leads [A] and crankshaft sensor leads
[B] into the alternator cover as figure.
Stator Coil [C]
Crankshaft Sensor Coil [D]
Rubber Damper [E]
Clamp [F]
Grommet [G]
Silicone Sealant Applied Areas [H]
○Fit the alternator leads and crankshaft sensor leads into
the grommet.
○Apply silicone sealant to the grommet, and fit it into the
notch in the alternator cover.
Special Tool - Kawasaki Bond (Silicone Sealant): 56019
-120
• Install the crankshaft sensor.
• Clamp the harness of the crankshaft sensor leads.
• Tighten the stator bolts with the specified torque.
Torque - Alternator Stator Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
Alternator Rotor Removal
• Remove the alternator cover (see Alternator Cover Re-
moval).
• Hold the alternator rotor [A] steady with the flywheel
holder [B], and remove the rotor bolt [C].
Special Tool - Flywheel Holder: 57001-1313
• Remove the rotor [A] using the flywheel puller assembly
[B].
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1405
CAUTION
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.
Alternator Rotor Installation
• Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions, and dry them with a clean cloth.
Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]
• Apply a thin coat of molybdenum disulfide grease to the
crankshaft [C].
Alternator Inspection
Halaman 349
Charging System
• Install the starter gear [A] and washer [B].
• Again, clean the crankshaft tapered portion and dry there.
• Install the alternator rotor [A] while turning it counterclock-
wise to make easy to align the key [B] and key groove [C]
of the rotor.
NOTE
○Confirm the alternator rotor fit or not to the crankshaft
before tighten it with the specified torque.
○Install the rotor bolt and tighten it with 55 N·m (5.6 kgf·m,
41 ft·lb) of torque.
○Remove the rotor bolt.
○Check the tightening torque with flywheel puller.
If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 14.5
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with 20 N·m (2.0 kgf·m, 14.5 ft·lb)
of drawing torque, clean off any oil dirt or flaw of the crank-
shaft and rotor tapered portion and dry them with a clean
cloth. Then, confirm that it is not pulled out with above
torque.
• Tighten the alternator rotor bolt with holding the alternator
rotor steady with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313
Torque - Alternator Rotor Bolt: 68.6 N·m (7.0 kgf·m, 51 ft·lb)
• Apply a thin coat of molybdenum disulfide grease to the
shaft [A], and install it and starter idle gear [B].
• Install the alternator cover (see Alternator Cover Installa-
tion).
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
• To check the alternator output voltage, do the following
procedures.
○Turn off the ignition switch.
○Remove the right side cover (see Side Cover Removal in
the Frame chapter).
ELECTRICAL SYSTEM 16-27
Regulator/Rectifier Inspection
Halaman 350
16-28 ELECTRICAL SYSTEM
Charging System
○Disconnect the alternator lead connector [A].
○Connect the hand tester [B]as shown in the table 1.
○Start the engine, and run it 4 000 rpm 5 minutes.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
Connections
Tester
Range
Tester (+) to
Tester (–) to
Reading
@4 000 rpm
250 V AC One Yellow lead Another Yellow lead
about 40 V
If the output voltage shows the value in the table, the al-
ternator operates properly.
If the output voltage shows a much higher than the value
in the table, the regulator/rectifier is damaged. A much
lower reading than that given in the table indicates that
the alternator is defective.
• Check the stator coil resistance as follows.
○Stop the engine.
○Connect the hand tester as shown in the table 2.
○Note the readings (total 3 measurement).
Table 2 Stator Coil Resistance
Connections
Tester
Range
Tester (+) to
Tester (–) to
Reading
× 1 Ω
One Yellow lead
Another Yellow lead
0.05 ∼0.6 Ω
If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
• Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Special Tool - Hand Tester: 57001-1394
Regulator/Rectifier Inspection
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Bolts [A]
Regulator/Rectifier [B]
Connector [C] (Disconnect)
Regulator/Rectifier Inspection
Halaman 351
Charging System
• Check conductivity of the following pair of terminals.
Rectifier Circuit Inspection
W-Y1,
W-Y2,
W-Y3
Tester connection
BK/Y-Y1,
BK/Y-Y2,
BK/Y-Y3
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 the regulator/rectifier must be replaced.
NOTE
○The actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 ∼6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a cur-
rent limiter to protect the regulator/rectifier from ex-
cessive current. Do not use an ammeter instead of
a test light.
• Check to be sure the rectifier circuit is normal before con-
tinuing.
• Do the 1st step regulator circuit test.
○Connect the test light and the 12 V battery to the regula-
tor/rectifier as shown.
○Check the Y1, Y2 and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
• Do the 2nd step regulator circuit test.
○Connect the test light and the 12 V battery in the same
manner as specified in the “Regulator Circuit Test-1st
Step”.
○Apply 12 V to the voltage BR terminal.
○Check the Y1, Y2 and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.
ELECTRICAL SYSTEM 16-29
Special Tool -
Halaman 352
16-30 ELECTRICAL SYSTEM
Charging System
• Do the 3rd step regulator circuit test.
○Connect the test light and the 12 V battery in the same
manner as specified in the “Regulator Circuit Test-1st
Step”.
○Momentarily apply 24 V to the voltage BR terminal by
adding a 12 V battery.
○Check the Y1, Y2 and Y3 terminals respectively.
CAUTION
Do not apply more than 24 V. If more than 24 V is ap-
plied, the regulator/rectifier may be damaged. Do
not apply 24 V more than a few seconds. If 24 V
is applied for more than a few seconds, the regula-
tor/rectifier may be damaged.
If the test light did not light when the 24 V was applied
momentarily to the voltage monitoring terminal, the regu-
lator/rectifier is defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If 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.
Torque - Regulator/Rectifier Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
Charging Voltage Inspection
• Check the battery condition (see Charging Condition In-
spect).
• Warm up the engine to obtain actual alternator operating
conditions.
• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Check that the ignition switch is turned off, and connect
the hand tester [A] as shown in the table.
Special Tool - Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. (To turn off the headlight, disconnect the head-
light connector in the upper fairing.) The readings should
show nearly battery voltage when the engine speed is low,
and, as the engine speed rises, the readings should also
rise. But they must be kept under the specified voltage.
Charging Voltage
Connections
Tester Range
Tester (+) to
Tester (–) to
Reading
25 V DC
Battery (+)
Battery (–)
14 ∼15 V
Charging System Circuit
Halaman 353
Charging System
• Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
Charging System Circuit
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
ELECTRICAL SYSTEM 16-31
Ignition System Troubleshooting
Halaman 354
16-32 ELECTRICAL SYSTEM
Ignition System
Ignition System Troubleshooting
Special Tool -
Halaman 355
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plugs, ignition coil or
high tension lead while the engine is running, or
you could receive a severe electrical shock.
CAUTION
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
IC igniter damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and IC igniter.
Crankshaft Sensor Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Alternator Cover (see Alternator Cover Removal)
• Disconnect the crankshaft sensor connector [A].
• Remove the crankshaft sensor screws [A] and clamp [B],
and then remove the crankshaft sensor [C].
Crankshaft Sensor Installation
• Apply silicone sealant to the grommet and fit it into the
notch in the alternator cover.
• Install the clamp and crankshaft sensor to the alternator
cover.
• Clamp the harness of crankshaft sensor leads as shown.
• Apply silicone sealant to the mating surface [A] of the
crankcase.
• Install the alternator cover (see Alternator Cover Installa-
tion).
Special Tool - Kawasaki Bond (Silicone Sealant): 56019
-120
ELECTRICAL SYSTEM 16-33
Ignition Coil Removal
Halaman 356
16-34 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Inspection
• Remove the right side cover (see Side Cover Removal in
the Frame chapter).
• Disconnect the crankshaft sensor connector [A] from near
the right side of the carburetor.
• Set the hand tester [B] to the × 100 Ωrange and connect
the (+) lead [C] to the black lead and (–) lead [D] to the
yellow lead in the connector.
Special Tool - Hand Tester: 57001-1394
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Crankshaft Sensor Resistance: 100 ∼150 Ω
• Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor as-
sembly.
Crankshaft Sensor Peak Voltage Inspection
• Disconnect the crankshaft sensor connector [A].
• Set the hand tester [B] to the × 25 V DC range, and con-
nect it the peak voltage adapter [C] as shown in the dia-
gram.
• Using two auxiliary wires, connect the black lead (–) of the
adapter to black lead [D] and red lead (+) to yellow lead
[E] in the crankshaft sensor connector [A].
• Turn the ignition switch and engine stop switch on.
• Grasp the clutch lever and pushing the starter button, turn
the engine 4 ∼5 seconds with the transmission gear in
neutral to measure the crankshaft sensor peak voltage.
• Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
Standard:
3.2 V or more
Special Tool - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Ignition Coil Removal
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Right or Left Lower Fairing (see Lower Fairing Removal
in the Frame chapter)
• Disconnect the primary winding leads [A] from the ignition
coil.
• Pull out the spark plug cap from the spark plug.
• Remove the mounting bolts [B], and take out the ignition
coil [C].
Special Tool -
Halaman 357
Ignition System
Ignition Coil Installation
• Install the ignition coil as shown (both sides).
Ignition Coil (Right Side) [A]
Bolt [B]
Washer [C]
Nut [D]
Washer [E]
0 ∼3 mm (0.12 in.) [F]
Ignition Coil Inspection
• Remove the ignition coil (see ignition Coil Removal).
• Measure the arcing distance with the suitable commer-
cially available coil tester [B] to check the condition of the
ignition coil [A].
• Connect the ignition coil (with the spark plug cap left at-
tached at the end of the spark plug lead) to the tester in
the manner prescribed by the manufacturer and measure
the arcing distance.
WARNING
To avoid extremely high voltage shocks, do not
touch the coil body or leads.
If the distance reading is less than the specified value, the
ignition coil or spark plug cap is defective.
Ignition Coil Arcing Distance
Standard:
7 mm (0.28 in.) or more
• To determine which part is defective, measure the arcing
distance again with the spark plug cap removed from the
ignition coil. Remove the cap by turning it counterclock-
wise.
If the arcing distance is subnormal as before, the trouble
is with the ignition coil itself. If the arcing distance is now
normal, the trouble is with the spark plug cap.
If the coil tester is not available, the coil [C] can be
checked for a broken or badly shorted winding with the
hand tester (special tool).
Special Tool - Hand Tester: 57001-1394
NOTE
○The hand tester cannot detect layer shorts and shorts
resulting from insulation breakdown under high voltage.
• Measure the primary winding resistance [A] as follows.
○Connect the hand tester between the coil terminal and
primary winding terminal.
ELECTRICAL SYSTEM 16-35
Ignition Coil Primary Peak Voltage
Halaman 358
16-36 ELECTRICAL SYSTEM
Ignition System
• Measure the secondary winding resistance [B] as follows.
○Remove the plug cap by turning it counterclockwise.
○Connect the tester between the high tension lead and the
ignition coil terminal.
If the tester does not read as specified, replace the coil.
Ignition Coil Resistance
Standard:
Primary windings 2.1 ∼3.2 Ω(× 1 Ω)
Secondary windings 10 ∼16 kΩ(× 1 kΩ)
Special Tool - Hand Tester: 57001-1394
• Visually inspect the secondary winding lead.
If it is damaged, replace the ignition coil.
Ignition Coil Primary Peak Voltage
NOTE
○Be sure the battery is fully charged.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)
Right or Left Lower Fairing (see Lower Fairing in the
Frame chapter)
• Remove the spark plug cap.
• Measure the ignition coil primary peak voltage as follows.
• Install the new spark plug [G] into the spark plug cap, and
ground it onto the engine.
• Connect the peak voltage adapter [A] into the hand tester
[B] and set it to the × 250 V DC range.
Spark Plug Condition Inspection
Halaman 359
Ignition System
Adapter red lead →
Ignition Coil Primary Lead
Terminal [C]
Adapter black lead →
Ignition Coil Ground Terminal
IC Igniter [D]
Battery [E]
Ignition Coil [F]
Special Tool - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
WARNING
To avoid extremely high voltage shock, do not
touch the spark plug or tester connection.
• Turn the ignition switch and engine stop switch on.
• Pushing the starter button, turn the engine 4 ∼5 seconds
with the transmission in neutral to measure the ignition
coil primary peak voltage.
• Repeat the measurement 5 or more times.
Ignition Coil Primary Peak Voltage
Standard:
223 V or more
If the reading is less than the specified value, check the
following:
Ignition Coil (see Ignition Coil Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
IC Igniter (see IC Igniter Inspection)
Spark Plug Removal
• Refer to Spark Plug Replacement in the Periodic Mainte-
nance chapter (see Spark Plug Replacement in the Peri-
odic Maintenance chapter).
Spark Plug Installation
• Refer to Spark Plug Replacement in the Periodic Mainte-
nance chapter (see Spark Plug Replacement in the Peri-
odic Maintenance chapter).
Spark Plug Condition Inspection
• Remove the spark plugs (see Spark Plug Replacement).
• Visually inspect the spark plugs.
If the spark plug center electrode [A] and/or side elec-
trode [B] are corroded or damaged, or if the insulator [C]
is cracked, replace the plug.
If the spark plug is dirtied or the carbon is accumulated,
replace the spark plug.
• Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, replace the spark plug.
Spark Plug Gap:
0.7 ∼0.8 mm (0.03 ∼0.04 in.)
• Use the standard spark plug or its equivalent.
Spark Plug:
CR8E or U24ESR-N
ELECTRICAL SYSTEM 16-37
Diodes Inspection
Halaman 360
16-38 ELECTRICAL SYSTEM
Ignition System
IC Igniter Inspection
CAUTION
When inspecting the IC igniter [A], observe the fol-
lowing to avoid damage to the IC igniter.
Do not disconnect the IC igniter connector [B] with
the ignition switch on.
This may damage the IC igniter.
Do not disconnect the battery leads while the en-
gine is running. This may damage the IC igniter.
IC Igniter Operation Inspection
• Remove the seat cover (see Rear Fender Removal in the
Frame chapter).
• Disconnect the IC Igniter connector.
• Set the hand tester [A] to the × 25 V DC range, and con-
nect it to the connector [B] come from harness side as
follows.
Tester (+) terminal [C] →BR/BK lead
Tester (–) terminal [D] →BK/Y lead
Special Tool - Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
• Turn the ignition switch on, and read the voltage.
IC Igniter Operation Voltage: Battery Voltage
If the tester reading is not specified one, check the battery
voltage, ignition switch and ignition fuse.
Diodes Inspection
• Remove the left lower fairing (see Lower Fairing in the
Frame chapter).
• Disconnect the diode [A].
• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Disconnect the diode assemblies [A].
• Zero the hand tester, and connect it to each diode terminal
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 in both directions, the diode is defective
and the diode assembly must be replaced.
Diodes Inspection
Halaman 361
Ignition System
NOTE
○The actual meter reading varies with the meter used
and the individual diode, but, generally speaking, the
lower reading should be from zero to one half the scale.
ELECTRICAL SYSTEM 16-39
Ignition System Circuit
Halaman 362
# 16-40 ELECTRICAL SYSTEM
## Ignition System
### Ignition System Circuit
1. Ignition Switch
2. Engine Stop Switch
3. Ignition Coils
4. Spark Plugs
5. Diode A
6. Fuse Box
7. Ignition Fuse 10 A
8. Battery
9. Main Fuse 30 A
10. Pickup Coil
11. Neutral Switch
12. IC Igniter
13. Sidestand Switch
14. Starter Lockout Switch
Starter Motor Installation
Halaman 363
Electric Starter System
Starter Motor Removal
• Remove the lower fairings (see Lower Fairing Removal in
the Frame chapter).
• Disconnect the starter motor lead [A] from the starter mo-
tor [C].
• Remove the starter mounting bolts [B] and pull out [D] the
starter motor toward the left side.
Starter Motor Installation
• Clean the starter motor lugs [A] and crank case surface
[B] where the starter motor is grounded.
ELECTRICAL SYSTEM 16-41
Starter Motor Assembly
Halaman 364
16-42 ELECTRICAL SYSTEM
Electric Starter System
• Apply a small amount of engine oil to the O-ring [A].
• Put the starter motor on the crankcase.
• Press the part of the starter motor end cover and push the
starter motor into the crankcase hole.
• Tighten the starter motor mounting bolts.
• Connect the starter motor lead to the starter motor termi-
nal.
• Install:
Starter Idle Gear
Alternator Cover
Engine Sprocket Cover
Shift Lever
Water Pipes
Starter Motor Disassembly
• Remove the starter motor (see Starter Motor Removal).
• Remove the bolts [A] and take out both end covers [B].
• Take the armature off from the pinion gear side of the
yoke.
• Remove the terminal locknut [A] and washers, and then
remove the brush and terminal bolt [B] with the brush plate
[C] from the yoke.
Starter Motor Assembly
• Replace the O-rings with a new ones.
• Apply a thin coat of high-temperature grease to the oil seal
[A] and needle bearing [B].
• Fit the toothed washer [C] into the end cover.
Commutator Inspection, Cleaning
Halaman 365
Electric Starter System
• Install the brush, terminal bolt, washers with the brush
plate [A] and tighten the terminal locknut [B].
Torque - Starter Motor Terminal Locknut:
9.8 N·m (1.0
kgf·m, 87 in·lb)
• Fit the tongue [C] on the brush plate into the end cover
groove.
• Install the steel washer [A] and resin washer [B] into the
starter shaft, and insert the armature [C] between the
brushes.
• Align the end cover [A] with the mark [C] of the yoke [B].
Torque - Starter Motor Assembly Bolts:
3.5 N·m (0.36
kgf·m, 31 in·lb)
Carbon Brush Inspection
• Measure the length [C] of each brush [A].
If any is worn down to the service limit, replace the carbon
brush holder assembly [B].
Carbon Brush Length
Standard:
10 mm (0.39 in.)
Service Limit: 5 mm (0.20 in.)
Commutator Inspection, Cleaning
• Smooth the commutator surface [A] if necessary with fine
emery cloth [B], and clean out the grooves.
ELECTRICAL SYSTEM 16-43
Armature Inspection
Halaman 366
16-44 ELECTRICAL SYSTEM
Electric Starter System
• Measure the outer diameter [A] of the commutator [B].
Replace the starter motor with a new one if the commu-
tator diameter is less than the service limit.
Commutator Diameter
Standard:
28 mm (1.10 in.)
Service Limit: 27 mm (1.06 in.)
Armature Inspection
• Using the × 1 Ωhand tester range, measure the resis-
tance between any two commutator segments [A].
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
• Using the highest hand tester range, measure the resis-
tance between the segments and the shaft [B].
Starter Relay Inspection
Halaman 367
Starter System
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
Special Tool - Hand Tester: 57001-1394
NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. 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.
Brush Lead Inspection
• Using the × 1 Ωhand tester range, measure the continuity
between the following:
Terminal Bolt and Positive (+) Brush [A]
Brush Plate and Negative (–) Brush [B]
If there is not close to zero ohms, the brush lead has
an open. Replace the terminal bolt assembly and/or the
brush holder assembly.
Special Tool - Hand Tester: 57001-1394
Terminal Bolt Inspection
• Using the highest hand tester range, measure the resis-
tance as shown.
Terminal Bolt and Brush Plate [A]
Terminal Bolt and Negative Brush Holder [B]
Terminal Bolt and Yoke [C]
If there is any reading, the brush holder assembly and/or
terminal bolt assembly have a short. Replace the brush
holder assembly and the terminal bolt assembly.
Special Tool - Hand Tester: 57001-1394
Starter Relay Inspection
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
• Remove:
Fuel Tank Bracket Bolts [A]
Fuel Tank Bracket [B]
ELECTRICAL SYSTEM 16-45
Starter Circuit Relay Inspection
Halaman 368
16-46 ELECTRICAL SYSTEM
Starter System
• Disconnect the cables [A] and remove the starter relay [C]
with the main fuse [B].
• Remove the main fuse from the starter relay.
• Connect the hand tester [A] and 12 V battery [B] to the
starter relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Relay Function Test
Tester Range: × 1 Ωrange
Standard:
When battery is connected →0 Ω
When battery is disconnected →∞Ω
Special Tool - Hand Tester: 57001-1394
Starter Circuit Relay Inspection
• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Remove the starter circuit relay [A].
• Connect the hand tester [A] and 12 V battery [B] to the
starter circuit relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Tester Range: × 1 Ω
Criteria:
When battery is connected →0 Ω
When battery is disconnected →∞Ω
Relay Coil Terminal [1] and [2]
Relay Switch Terminals [3] and [4]
Electrical Starter Circuit
Halaman 369
ELECTRICAL SYSTEM 16-47
Starter System
Electrical Starter Circuit
①
② ③
④ ⑤
⑥ ⑦
⑧
⑭ ⑬ ⑫
⑩
⑪
⑨
1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
4. Diode A
5. Diode B
6. Starter Circuit Relay
7. Fuse Box
8. Ignition Fuse 10 A
9. Battery
10. Main Fuse 30 A
11. Starter Motor
12. Neutral Switch
13. Sidestand Switch
14. Starter Lockout Switch
Headlight Bulb Replacement
Halaman 370
16-48 ELECTRICAL SYSTEM
Lighting System
Headlight Beam Horizontal Adjustment
• Refer to Headlight Aiming Inspection in the Periodic Main-
tenance chapter (see Headlight Aiming Inspection in the
Periodic Maintenance chapter).
Headlight Beam Vertical Adjustment
• Refer to Headlight Aiming Inspection in the Periodic Main-
tenance chapter (see Headlight Aiming Inspection in the
Periodic Maintenance chapter).
Headlight Bulb Replacement
• Remove:
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
Headlight Connector
Headlight Bulb Dust Cover
Clip [A] (Disconnect)
Headlight Bulb [B]
CAUTION
When handling the quartz-halogen bulb, never
touch the glass portion 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.
NOTE
○Clean off any contamination that inadvertently gets on
the bulb with alcohol or soap and water solution.
• Fit the dust cover [A] firmly onto the bulb [B] as shown.
Dust Cover [A]
Top Mark [B]
Bulb [C]
Good [D]
Bad [E]
• Connect the headlight connector.
• Adjust the headlight beam (see Headlight Aiming Inspec-
tion in the Periodic Maintenance chapter).
Front Turn Signal Light Bulb Replacement
Halaman 371
Lighting System
Tail/Brake Light Bulb Replacement
• Remove the rear seat (see Rear Seat Removal in the
Frame chapter).
• Unscrew the socket [A] counterclockwise [B].
• Push [A] the bulb [B] in the socket, turn it counterclock-
wise [C], and pull it out.
• Push the bulb in and turn it clockwise.
• Screw in the socket [A] aligning the tabs [B] with the re-
cesses [C].
Front Turn Signal Light Bulb Replacement
• Remove the lens mounting screw [A] and remove lens.
ELECTRICAL SYSTEM 16-49
Rear Turn Signal Light Bulb Replacement
Halaman 372
16-50 ELECTRICAL SYSTEM
Lighting System
• Push [A] the bulb [B] in and turn [C] it counterclockwise
and then remove it.
• Insert the new bulb [A] by aligning the projections [B] with
the grooves [C] in the socket.
• Push the bulb and turn it clockwise and then replace it. It
should lock in lock position.
• Insert the socket by aligning the projection with the notch
in the wall and turn the socket clockwise.
Rear Turn Signal Light Bulb Replacement
• Remove the lens mounting screw [A] and remove the
lens.
• Push [A] the bulb [B] in and turn [C] it counterclockwise,
and then remove it.
• Insert the new bulb [A] by aligning the projections [B] with
the grooves [C] in the wall of the socket.
• Push the bulb in and turn it clockwise and then install it.
It should lock in position.
• Install the lens, and tighten the lens mounting screw. Be
careful not to overtighten the lens mounting screw.
Headlight Circuit Relay Inspection
Halaman 373
Lighting System
Turn Signal Relay Inspection
• Remove:
Seat Cover (see Rear Fender Removal in the Frame
chapter)
Turn Signal Relay Connector [A]
Turn Signal Relay [B]
• Connect one 12 V battery and turn signal lights as indi-
cated in the figure, and count how many times the lights
flash for one minute.
Turn Signal Relay [A]
Turn Signal Lights [B]
12 V Battery [C]
If the lights do not flash as specified, replace the turn sig-
nal relay.
Testing Turn Signal Relay
Load
The Number of
Turn Signal Lights
Wattage (W)
Flashing times (c/m*)
1**
21 or 23
Light stays on
2
42 or 46
75-95
(*): Cycle(s) per minute
(**): Correspond to “one light burned out”
Headlight Circuit Relay Inspection
• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Remove the headlight circuit relay [A].
ELECTRICAL SYSTEM 16-51
Headlight Circuit Relay Inspection
Halaman 374
16-52 ELECTRICAL SYSTEM
Lighting System
• Connect the hand tester [A] and 12 V battery [B] to the
starter circuit relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Tester Range: × 1 Ω
Criteria:
When battery is connected →0 Ω
When battery is disconnected →∞Ω
Relay Coil Terminal [1] and [2]
Relay Switch Terminals [3] and [4]
Headlight/Tail Light Circuit
Halaman 375
ELECTRICAL SYSTEM 16-53
================================================================================
### Lighting System
#### Headlight/Tail Light Circuit
*(Circuit Diagram)*
1. Ignition Switch
2. Diodes B
3. Headlight Relay
4. Fuse Box
5. Tail Light Fuse 10 A
6. Headlight Fuse 10 A
7. Tail/Brake Light
8. License Plate Light
9. Alternator
10. Battery
11. Main Fuse 30 A
12. Dimmer Switch
13. Headlight (Low Beam)
14. Headlight (High Beam)
Turn Signal Light Circuit
Halaman 376
# 16-54 ELECTRICAL SYSTEM
## Lighting System
### Turn Signal Light Circuit
1. Ignition Switch
2. Turn Signal Relay
3. Fuse Box
4. Turn Signal Relay Fuse 10 A
5. Rear Right Turn Signal Light
6. Rear Left Turn Signal Light
7. Battery
8. Main Fuse 30 A
9. Turn Signal Switch
10. Front Left Turn Signal Light
11. Front Right Turn Signal Light
12. Turn Signal Indicator Light
Radiator Fan Circuit
Halaman 377
Radiator Fan System
WARNING
The radiator fan is connected directly to the bat-
tery. The fan may start even if the ignition switch is
off. NEVER TOUCH THE RADIATOR FAN UNTIL THE
RADIATOR FAN CONNECTOR IS DISCONNECTED.
TOUCHING THE FAN BEFORE THE CONNECTOR
IS DISCONNECTED COULD CAUSE INJURY FROM
THE FAN BLADES.
Fan System Circuit Inspection
• Disconnect the leads [A] from the radiator fan switch.
• Using an auxiliary wire [B], connect the radiator fan switch
leads.
If the fan rotates, inspect the fan switch.
If the fan does not rotate, inspect the following.
Leads and Connectors
Main Fuse and Fan Fuse
Fan Motor
Fan Motor Inspection
• Remove the right lower fairing (see Frame chapter).
• Disconnect the 2-pin connector [A] in the fan motor leads.
• Using two auxiliary wires, supply battery [B] power to the
fan motor.
If the fan does not rotate, the fan motor is defective and
must be replaced.
Lead Connections
Battery (+) →BL Lead
Battery (–) →BK Lead
Radiator Fan Circuit
1. Radiator Fan
2. Radiator Fan Switch
3. Fuse Box
ELECTRICAL SYSTEM 16-55
4. Fan Fuse 10 A
5. Main Fuse (30 A)
6. Battery
Meter Unit Installation
Halaman 378
16-56 ELECTRICAL SYSTEM
Meters, Gauge and Indicator Unit
Meter Unit Removal
• Remove:
Upper Cover [A] (see Upper Cover Removal in the
Frame chapter)
• Unscrew the bolts [A] and remove the meter unit [B] from
the upper cover.
CAUTION
Place the meter unit so that the face is up. If a meter
unit is left upside down or sideways for any length
of time, it will malfunction.
Meter Unit Disassembly
• Remove:
Meter Unit (see Meter Unit Removal)
Reset Knob
Screws [A]
Meter Cover [B]
• Remove the speedometer [A], tachometer [B] and fuel
gauge [C] by removing screws [D].
CAUTION
Do not remove a meter pointer unless the meter is
to be replace. The pointers cannot be reinstalled.
The pointer mounting is different from replacement
meters.
Meter Unit Installation
• Check to see that the rubber damper [A] are installed on
the meter mounting bracket [B].
• The installation is a reverse of the meter unit removal.
Tachometer Circuit
Halaman 379
Meters, Gauge and Indicator Unit
Indicator Light Replacement
• Remove the meter unit (see Meter Unit Removal).
• To remove the wedge base type bulbs, pull out the bulb
sockets [A] and pull the bulbs [B] off the sockets.
CAUTION
Do not use bulbs rated for greater wattage than
the specified wattage, as the meter or gauge panel
could become warped by excessive heat radiated
from the bulbs.
Tachometer Inspection
• Check the tachometer circuit wiring.
If all wiring and components other than the tachometer
unit check out good, the unit is suspect. Check the unit
as shown.
• Remove the following.
Upper Fairing (see Upper Fairing Removal in the Frame
chapter)
• Disconnect the BK lead.
• Reinstall the BK terminal screw.
• Turn the engine stop switch to RUN position.
• Turn the ignition switch ON.
• Open or connect the BK lead [A] to the BK terminal screw
[B]. Then the pointer should flick.
• Turn the ignition switch OFF.
If the pointer does not flick, replace the tachometer unit.
Tachometer Circuit
1. Tachometer
2. Fuse Box
3. Ignition Fuse 10 A
4. Ignition Switch
5. Main Fuse 30 A
6. Battery
7. IC Igniter
ELECTRICAL SYSTEM 16-57
Water Temperature Warning System Circuit
Halaman 380
16-58 ELECTRICAL SYSTEM
Meters, Gauge and Indicator Unit
Water Temperature Warning System Inspection
The water temperature warning light goes on when the
ignition switch is turned on and goes off soon after the en-
gine starts running (oil pressure switch off) to ensure that
its circuit functions properly. The warning light also goes
on whenever the coolant temperature rises to 110 ∼120°C
(230 ∼248°F) when the motorcycles is in operation. If it
stays on, stop the engine and check the coolant level in the
reserve tank after the engine cools down.
• Inspect the water temperature warning light and the sys-
tem wiring (see Wiring Inspection).
• Turn on the ignition switch.
• Disconnect the water temperature switch lead [A] and oil
pressure switch lead, then ground them together to the
frame or engine using auxiliary lead.
If the warning light is lit, inspect the water temperature
switch (see Specifications) and the oil pressure switch [B].
Replace any switch if damaged.
If the warning light is not lit, check the warning light bulb.
Water Temperature Warning System Circuit
1. Ignition Switch
2. Fuse Box
3. Ignition Fuse 10 A
4. Starter Relay
5. Main Fuse (30 A)
6. Water Temperature Warning Light
7. Oil Pressure Waning Light
8. Diode
9. Water Temperature Switch
10. Oil Pressure Switch
11. Battery
Special Tool -
Halaman 381
Switches and Sensor
Brake Light Timing Inspection
• Refer to Brake Light Switch Operation Inspection in the
Periodic Maintenance chapter.
Brake Light Timing Adjustment
• Refer to Brake Light Switch Operation Inspection in the
Periodic Maintenance chapter.
Switch Inspection
• Using a hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
○For the handlebar switches and the ignition switch, refer
to the tables in the Wiring Diagram.
If the switch has an open or short, repair it or replace it
with a new one.
Special Tool - Hand Tester: 57001-1394
*: Engine lubrication system is in good condition.
ELECTRICAL SYSTEM 16-59
Fuel Gauge Circuit
Halaman 382
16-60 ELECTRICAL SYSTEM
Switches and Sensor
Fuel Gauge Circuit
1. Ignition Switch
2. Fuel Gauge
3. Fuse Box
4. 10 A Ignition Fuse
5. Fuel Level Sensor
6. Battery
7. 30 A Main Fuse
8. Starter Relay
Special Tool -
Halaman 383
Switches and Sensor
Radiator Fan Switch Inspection
• Remove the fan switch.
• Suspend the switch [A] in a container of coolant so that
the temperature-sensing projection and threaded portion
are submerged.
• Suspend an accurate thermometer [B] in the coolant so
that the sensitive portions [C] are located in almost the
same depth.
NOTE
○The switch and thermometer must not touch the con-
tainer sides or bottom.
• Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
coolant gently.
• Using the hand tester, measure the internal resistance
of the switch across the terminals at the temperatures
shown in the table.
Special Tool - Hand Tester: 57001-1394
If the hand tester does not show the specified values, re-
place the switch.
Fan Switch Resistance
○Rising temperature:
From OFF to ON at 95 ∼101°C (196 ∼203°F)
○Falling temperature:
From ON to OFF within 3 ∼8°C (37 ∼46°F) of “ON”
temperature
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
Water Temperature Switch Inspection
• Remove the water temperature switch.
• Suspend the switch [A] in a container of coolant so that
the temperature-sensing projection and threaded portion
are submerged.
• Suspend an accurate thermometer [B] in the coolant so
that the sensitive portions [C] are located in almost the
same depth.
NOTE
○The switch and thermometer must not touch the con-
tainer side or bottom.
• Place the container over a source of heat and gradu-
ally raise the temperature of the coolant while stirring the
coolant gently.
• Using the hand tester, measure the internal resistance of
the sensor across the terminal and the body at the tem-
peratures shown in the table.
Special Tool - Hand Tester: 57001-1394
ELECTRICAL SYSTEM 16-61
Special Tool -
Halaman 384
16-62 ELECTRICAL SYSTEM
Switches and Sensor
If the hand tester does not show the specified values, re-
place the switch.
Water Temperature Switch Connections
Rising temperature:
From OFF to ON at 112 ∼118°C (226 ∼232°F)
Falling temperature:
From ON to OFF at 108°C (226°F) ∼temperature less
than ON temperature
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
Fuel Level Sensor Inspection
• Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
• Remove the fuel level sensor from the fuel tank.
• Check that the float moves up and down smoothly without
binding. It should go down under its own weight.
If the float does not move smoothly, replace the sensor.
[A] Float in Full Position
[B] Float in Empty Position
[C] Float Arm Stoppers
• Using a hand tester, measure the resistance across the
terminals in the fuel level sensor lead connector [A].
If the tester reading are not as specified, or do not change
smoothly according as the float moves up and down, re-
place the sensor.
Fuel Level Sensor Resistance
Standard:
Full position:
4 ∼10 Ω
Empty position:
90 ∼100 Ω
Special Tool - Hand Tester: 57001-1394
Fuse Inspection
Halaman 385
Fuses
30 A Main Fuse Removal
• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Unlock the hook to clear the lids of the main fuse cover
[A].
• Pull up the main fuse cover with the starter relay connec-
tor.
Fuse Removal
• Remove the front seat (see Front Seat Removal in the
Frame chapter).
• Unlock the hook to lift up the lid from the fuse case.
• Pull the fuses [A] straight up from the fuse case with the
nose plier.
Fuse Installation
If a fuse fails during operation, inspect the electrical sys-
tem to determine the cause, and then replace it with a
new fuse of proper amperage.
• Install the junction box fuses on the original position as
specified on the lid.
Fuse Inspection
• Remove the fuse, and inspect the fuse element.
If the fuse element is blown, replace the fuse.
Housing [A]
Fuse Element [B]
Terminal [C]
Blown Element [D]
NOTE
○Before replacing a blown fuse, always check the am-
perage 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.
CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring ad components, and installation
of a fuse with a lower rating may cause the fuse to
be blown quickly.
ELECTRICAL SYSTEM 16-63
Fuse Inspection
Halaman 386
#
Appendix
Halaman 387
Appendix
Table of Contents
Cable, Wire, and Hose Routing..............................................................................................
17-2
Troubleshooting Guide ...........................................................................................................
17-38
APPENDIX 17-1
17
Appendix
Halaman 388
**17-2 APPENDIX**
**Cable, Wire, and Hose Routing**
---
*(Diagram showing upper front fork area routing with callouts ① to ⑫)*
---
*(Diagram showing lower handlebar/steering area routing detail with callouts ⑬ to ⑯)*
---
GB09697C G
Appendix
Halaman 389
Cable, Wire, and Hose Routing
1. Right Switch Housing Leads
2. Ignition Switch Leads
3. Left Switch Housing Leads
4. Choke Cable
5. Guide
6. Guide
7. Guide
8. Speedometer Cable
9. Throttle Cable (Accelerator)
10. Throttle Cable (Decelerator)
11. Brake Hose
12. Throttle Cables
13. Guide
14. Guide
15. Left Switch Housing Leads
16. Right Switch Housing Leads
APPENDIX 17-3
Appendix
Halaman 390
# 17-4 APPENDIX
## Cable, Wire, and Hose Routing
***
*(Diagram showing motorcycle cable, wire, and hose routing with numbered labels 1 through 12)*
***
<p align="right">GB09698C G</p>
Appendix
Halaman 391
Cable, Wire, and Hose Routing
1. Choke Cable
2. Clutch Cable
3. Left Switch Housing Leads
4. Meter Leads Connectors
5. Band
6. Guide
7. Band
8. Headlight Leads Connectors
9. Guide
10. Speedometer Cable
11. Guide
12. Starter Locknut Switch Lead
APPENDIX 17-5
Appendix
Halaman 392
# 17-6 APPENDIX
## Cable, Wire, and Hose Routing
### Labels in Diagram:
* **1**
* **2**
* **3**
* **4**
* **5**
* **6**
* **7**
* **8**
* **9**
* **10**
* **11**
* **12**
* **13**
* **14**
* **15**
* **16**
* **17**
---
GB09699C G
Appendix
Halaman 393
Cable, Wire, and Hose Routing
1. Throttle Cables
2. Guide
3. Radiator Fan Leads Connectors
4. Clamp
5. Right Switch Housing Leads
6. Water Temperature Switch
7. #2 Ignition Coil
8. Clutch Cable
9. Front Right Turn Signal Light Connector
10. #2 Ignition Coil
11. Water Temperature Switch
12. Main Harness
13. Guide
14. Front Left Turn Signal Light Connector
15. Bracket
16. Bracket
17. Ignition Switch Leads Connector
APPENDIX 17-7
Appendix
Halaman 394
# 17-8 APPENDIX
## Cable, Wire, and Hose Routing
*(Diagrams illustrating cable, wire, and hose routing configurations with numbered labels)*
### Diagram Component Labels:
* **Main Center View:** 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13
* **Top-Left Inset:** 14, 15
* **Bottom-Left Detail View:** 20, 21, 22
* **Bottom-Right Detail View:** 16, 17, 18, 19
***
GB09700C G
Appendix
Halaman 395
Cable, Wire, and Hose Routing
1. Left Switch Housing Leads
2. Clutch Cable
3. Clamp
4. Left Switching Housing Leads Connector
5. Guide
6. Front Left Turn Signal Light Connector
7. Guide
8. #1 Ignition Coil
9. Oil Pressure Switch Connector
10. Radiator Fan Switch
11. Radiator/Rectifier
12. Guide
13. Choke Cable
14. Horn
15. Guide
16. Guide
17. Coolant Reserver Tank Breather Hose
18. Guide
19. Fuel Tank Tank Breather Hose
20. Fuel Tank Tank Breather Hose
21. Guide
22. Guide
APPENDIX 17-9
Appendix
Halaman 396
**17-10 APPENDIX**
### Cable, Wire, and Hose Routing
---
*(Diagrams showing cable, wire, and hose routing with annotated callout numbers 1, 2, 3, 4, 5, and 6)*
---
<p align="right">GB09701C G</p>
Appendix
Halaman 397
Cable, Wire, and Hose Routing
1. Alternator Leads
2. Crankshaft Sensor Leads
3. Brackets
4. Engine Ground Lead
5. Clutch Cable
6. Guide
APPENDIX 17-11
Appendix
Halaman 398
# 17-12 APPENDIX
## Cable, Wire, and Hose Routing
*[Diagram showing cable, wire, and hose routing labeled 1 through 6]*
---
GB09702C G
Appendix
Halaman 399
Cable, Wire, and Hose Routing
1. Neutral Switch Connector
2. Clamp
3. Sidestand Switch Connector
4. Sidestand Switch Leads
5. Clamp
6. Sidestand Switch
APPENDIX 17-13
Appendix
Halaman 400
**17-14 APPENDIX**
**Cable, Wire, and Hose Routing**
---
*(Diagram showing cable, wire, and hose routing with numbered labels 1 through 20)*
* **1**
* **2**
* **3**
* **4**
* **5**
* **6**
* **7**
* **8**
* **9**
* **10**
* **11**
* **12**
* **13**
* **14**
* **15**
* **16**
* **17**
* **18**
* **19**
* **20**
---
GB09703C G
Appendix
Halaman 401
Cable, Wire, and Hose Routing
1. Rear Left Turn Signal Light Connector
2. Rear Right Turn Signal Light Connector
3. IC Igniter
4. Fuse Box
5. Headlight Circuit Relay
6. Starter Circuit Relay
7. Diodes
8. Starter Relay
9. Fuel Level Sensor Connector
10. Clamp
11. Alternator Connector
12. Crankshaft Connector
13. Clamp
14. Battery (+) Cable
15. Starter Relay
16. Starter Motor Cable
17. Battery (–) Cable
18. Rear Brake Switch
19. Clamp
20. Rear Brake Switch Connector
APPENDIX 17-15
Appendix
Halaman 402
# 17-16 APPENDIX
## Cable, Wire, and Hose Routing
---
### [Diagram Callout Numbers]
* **(1)**
* **(2)**
* **(3)**
* **(4)**
* **(5)**
* **(6)**
* **(7)**
* **(8)**
* **(9)**
* **(10)**
* **(11)**
---
GB09704C G
Appendix
Halaman 403
Cable, Wire, and Hose Routing
1. Rear Left Turn Signal Light Connector
2. Rear Right Turn Signal Light Connector
3. Brake/Tail Light Connector
4. License Plate Light Connector
5. Clamps
6. Clamp
7. Rear Left Turn Signal Light Connector
8. Rear Right Turn Signal Light Connector
9. License Plate Light Connector
10. Turn Signal Relay
11. Bracket
APPENDIX 17-17
Appendix
Halaman 404
# 17-18 APPENDIX
## Cable, Wire, and Hose Routing
*(Diagram showing top and side views of the cable, wire, and hose routing on the vehicle frame, with numbered callouts from 1 to 23)*
---
7-180-029-A
Appendix
Halaman 405
Cable, Wire, and Hose Routing
1. Headlight (High) Connector
2. Headlight (Low) Connector
3. Bands
4. Horn Connector
5. Meter Connector
6. Diode Connector
7. Regulator/Rectifier Connector
8. Ignition Coil Connector
9. Radiator Fan Switch Connector
10. Oil Pressure Switch Connector
11. Left Switch Housing Connectors
12. Front Turn Signal Light Connector
13. Neutral Switch Connector
14. Sidestand Switch Connector
15. Bands
16. Starter Relay
17. Fuse Box
18. Turn Signal Relay
19. Clamp
20. Choke Cable
APPENDIX 17-19
Appendix
Halaman 406
# 17-20 APPENDIX
## Cable, Wire, and Hose Routing
*(Diagram illustrating top-down and side-profile views of the vehicle frame with cable, wire, and hose routing paths indicated by numbered callouts 1 through 22)*
Appendix
Halaman 407
Cable, Wire, and Hose Routing
1. License Plate Light Connector
2. Tail/Brake Light Connector
3. IC Igniter Connector
4. Rear Right Turn Signal Light Connector
5. Rear Left Turn Signal Light Connector
6. Brake Light Switch Connector
7. Starter Relay Connector
8. Headlight Circuit Relay
9. Diode
10. Diode
11. Battery (–) Cable
12. Alternator Connector
13. Crankshaft Sensor Connector
14. Front Turn Signal Light Connector
15. Fuel Level Sensor Connector
16. Ignition Switch Connector
17. Frame Ground Terminal
18. Radiator Fan Switch Connector
19. Ignition Coil Connector
20. Right Switch Housing Connector
21. Radiator Fan Connector
22. Bands
APPENDIX 17-21
Appendix
Halaman 408
# 17-22 APPENDIX
## Cable, Wire, and Hose Routing
***
### Diagram Labels and Section Views
* **Section B-B**
* **View A**
* Upper
* **View B**
### Diagram Markers / Callouts
* **1** (Thermostat / Hose connection)
* **2** (Water hose)
* **3** (Hose)
* **4** (Coolant reservoir / Cap)
* **5** (Angle reference in Section B-B)
* **6** (Angle reference in Section B-B)
* **7** (Clamps / Bands)
* **8** (Alignment indicator in View A)
* **9** (Engine cover section)
* **10** (Clamping point in View B)
* **11** (Engine cylinder / Crankcase area)
* **12** (Hose connection)
* **A**, **B** (Directional view arrows)
Appendix
Halaman 409
Cable, Wire, and Hose Routing
1. Thermostat
2. Radiator Cap
3. Install the hose so that its white mark side faces the radiator.
4. Radiator
5. Clamp Screw
6. 45°
7. Cylinder Head
8. 45° ∼55°
9. Align the white mark on the hose with the projection mark on the fitting.
10. Install the hose so that its end cover the white mark on the pipe.
11. Cylinder
12. Install the hose so that its white mark side faces the pipe.
APPENDIX 17-23
Appendix
Halaman 410
17-24 APPENDIX
Cable, Wire, and Hose Routing
Appendix
Halaman 411
Cable, Wire, and Hose Routing
1. Run the reserver tank vent hose into the guide (2 places).
2. Reserver Tank Vent Hose
3. Bracket
4. Run the clutch cable and over flow hose into the hole of the reserver tank.
5. Clutch Cable
6. Radiator Overflow Hose
7. Radiator Cap
8. Coolant Reserver Tank
9. Clamp
10. Hose Curve Side
11. Run the only reserver tank vent hose into the bracket guide.
APPENDIX 17-25
Appendix
Halaman 412
# 17-26 APPENDIX
## Cable, Wire, and Hose Routing
***
### Diagram Labels & Callouts
* **View A** (Detail view indicated by arrow **A**)
* **Numbered Components:**
* **2**
* **3**
* **4**
* **5**
* **6**
* **7**
* **8**
<br>
---
`J136110243 C`
Appendix
Halaman 413
Cable, Wire, and Hose Routing
1. Air Suction Valve Cover
2. Vaccum Switch Valve
3. Carburetor
4. Install the vaccum switch valve hose so that its white mark faces the air cleaner box.
5. Air Cleaner Box
6. Install the vaccum valve switch fitting so that its white mark side faces the air suction valve hose.
7. This side is closed.
8. Air Suction Valve Hose
APPENDIX 17-27
Appendix
Halaman 414
# 17-28 APPENDIX
## Cable, Wire, and Hose Routing
*(The diagram displays a technical schematic with numbered labels indicating routing paths and component locations)*
* **1**
* **2**
* **3**
* **4**
* **5**
---
<p align="right">710113071 B</p>
Appendix
Halaman 415
Cable, Wire, and Hose Routing
1. Air Cleaner Box
2. Battery
3. Run the carburetor vent hose between the air cleaner box and battery.
4. Fuel Hose
5. Run the fuel hose inside of the frame.
APPENDIX 17-29
Appendix
Halaman 416
# 17-30 APPENDIX
## Cable, Wire, and Hose Routing
*(Diagram illustrating cable, wire, and hose routing with labeled callouts 1 through 9)*
### Labels:
* **①**
* **②**
* **③** *(Detail inset)*
* **④**
* **⑤**
* **⑥**
* **⑦**
* **⑧**
* **⑨**
Appendix
Halaman 417
Cable, Wire, and Hose Routing
1. Front Master Cylinder
2. Front Brake Hse
3. Bracket
4. Clamp
5. Front Brake Caliper
6. Rear Brake Resevvoir
7. Rear Brake Caliper
8. Clamp
9. Rear Master Cylinder
APPENDIX 17-31
California Model
Halaman 418
17-32 APPENDIX
Cable, Wire, and Hose Routing
California Model
California Model
Halaman 419
Cable, Wire, and Hose Routing
1. Install the clamps as shown, noting their clip direction.
2. Vaccum Switch Valve
3. Fitting
4. To Air Cleaner Box
5. To Carburetor
6. Regulator/Rectifier
7. Bracket
8. Canister
9. Align the hole on the separator with the white mark on the hose.
10. Align the hole on the separator with the hose direction.
11. Run the hoses through the guide of the bracket.
12. To Air Suction Volve Cover.
APPENDIX 17-33
California Model
Halaman 420
17-34 APPENDIX
Cable, Wire, and Hose Routing
California Model
California Model
Halaman 421
Cable, Wire, and Hose Routing
1. Fuel Tank
2. Blue Mark
3. Red Mark
4. Hose (Blue)
5. Hose (Red)
6. Separator
7. Hose (White)
8. Hose (Green)
9. Hose (Blue)
10. Canister
APPENDIX 17-35
Australia Model
Halaman 422
17-36 APPENDIX
Cable, Wire, and Hose Routing
Australia Model
Australia Model
Halaman 423
Cable, Wire, and Hose Routing
1. Filter Body
2. Clamps
3. Cooling Hose
4. Water Pipe
5. Carburetor
6. Coolant Valve Assmbly
7. Damper
8. Run the cooling hose inside of the water pipe.
APPENDIX 17-37
Compression low:
Halaman 424
17-38 APPENDIX
Troubleshooting Guide
NOTE
○This is not an exhaustive list, giving every
possible cause for each problem listed. It
is meant simply as a rough guide to assist
the troubleshooting for some of the more
common difficulties.
Engine Doesn’t Start, Starting
Difficulty:
Starter motor not rotating:
Starter lockout switch or neutral switch trou-
ble
Starter motor trouble
Battery voltage low
Starter relays not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Main fuse blown
Starter motor rotating but engine doesn’t
turn over:
Starter motor clutch trouble
Engine won’t turn over:
Valve seizure
Valve lifter seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Starter idle gear seizure
No fuel flow:
No fuel in fuel tank
Fuel tap vacuum hose clogged
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level in carburetor float bowl too high
Float valve worn or stuck open
Starting technique faulty (When flooded,
crank the engine with the throttle fully
opened to allow more air to reach the
engine.)
No spark; spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap not in good contact
Spark plug incorrect
IC igniter trouble
Neutral, starter lockout, or sidestand switch
trouble
Crankshaft sensor trouble
Ignition coil trouble
Ignition or engine stop switch shorted
Wiring shorted or open
Main fuse blown
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Fuel/air mixture incorrect:
Pilot screw or idle adjusting screw malad-
justed
Pilot jet or air bleed hole clogged
Air cleaner clogged, poorly sealed, element
missing
Starter jet clogged
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trou-
ble
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
IC igniter trouble
Crankshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Pilot screw maladjusted
Pilot jet, or air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly sealed, or ele-
ment missing
Choke plunger stuck open
Fuel level in carburetor float bowl too high
or too low
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cooling system component incorrect:
Halaman 425
Troubleshooting Guide
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head warped
Cylinder head gasket damaged
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface)
Other:
IC igniter trouble
Carburetor not synchronizing
Vacuum piston doesn’t slide smoothly
Engine oil viscosity too high
Drive train trouble
Brake dragging
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug cap shorted or not in good con-
tact
Spark plug incorrect
IC igniter trouble
Crankshaft sensor trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Choke plunger stuck open
Main jet clogged or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level in carburetor float bowl too high
or too low
Bleed holes of needle jet holder or needle
jet clogged
Air cleaner clogged, poorly sealed, or miss-
ing
Air cleaner duct poorly sealed
Water or foreign matter in fuel
Fuel to carburetor insufficient
Fuel tank air vent obstructed
Carburetor holder loose
Fuel tap clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
APPENDIX 17-39
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent,
worn, or carbon accumulation on the
seating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
IC igniter trouble
Miscellaneous:
Throttle valve won’t fully open
Vacuum piston doesn’t slide smoothly
Brake dragging
Clutch slipping
Overheating
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
IC Igniter trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl too low
Carburetor holder loose
Air cleaner poorly sealed, or missing
Air cleaner duct poorly sealed
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Cooling system component incorrect:
Radiator fin damaged
Thermostat trouble
Radiator cap trouble
Radiator fan switch trouble
Fan relay trouble
Fan motor broken
Fan blade damaged
Water pump not turning
Water pump impeller damaged
Front fork noise:
Halaman 426
17-40 APPENDIX
Troubleshooting Guide
Over Cooling:
Cooling system component incorrect:
Radiator fan switch trouble
Thermostat trouble
Gauge incorrect:
Water temperature gauge broken
Water temperature sensor broken
Clutch Operation Faulty:
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Clutch inner cable trouble
No clutch lever play
Clutch spring broken or weak
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch plate warped or too rough
Clutch spring compression uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
Clutch hub spline damaged
Clutch friction plate installed wrong
Clutch lever play excessive
Clutch hub nut loose
Gear Shifting Faulty:
Doesn’t go into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Shift return spring weak or broken
Shift return spring pin loose
Pawl spring broken
Shift mechanism arm broken
Shift pawl broken
Jumps out of gear:
Shift fork ear worn
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Neutral positioning pin spring weak or bro-
ken
Shift fork guide pin worn
Drive shaft,
output shaft,
and/or gear
splines worn
Overshifts:
Neutral positioning lever spring weak or
broken
Pawl spring broken
Abnormal Engine Noise:
Knocking:
IC igniter trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Other noise:
Connecting rod small end clearance exces-
sive
Connecting rod big end clearance exces-
sive
Piston ring worn, broken, or stuck
Piston seizure, damage
Piston ring groove worn
Piston ring/groove clearance excessive
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
nection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Alternator rotor loose
Primary gear worn or broken
Abnormal Drive Train Noise:
Clutch noise:
Weak or damaged damper
Clutch housing/friction plate clearance ex-
cessive
Clutch housing gear worn
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Battery overcharged:
Halaman 427
Troubleshooting Guide
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Other noise:
Bracket,
nut,
bolt,
etc.
not properly
mounted or tightened
Oil Pressure Warning Light Goes On:
Engine oil pump damaged
Engine oil screen clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearings worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
damaged
Engine oil filter clogged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high
Black smoke:
Air cleaner clogged
Main jet too large or fallen off
Choke plunger stuck open
Fuel level in carburetor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem locknut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-
quate
Steering stem bent
Tire air pressure too low
APPENDIX 17-41
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearings worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar clamp bolts loose
Steering stem head nut loose
Front/rear axle runout too large
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Steering maladjusted
Front fork bent
Right and left front fork oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Rear shock absorber adjustment too hard
Tire air pressure too high
Front fork bent
(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 oil leaking
Rear shock absorber adjustment too soft
Tire air pressure too low
Brake Doesn’t Hold:
Air in the brake line
Pad or disc worn
Brake fluid leakage
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged
Master cylinder scratched inside
Battery Trouble:
Battery discharged:
Battery
faulty
(e.g.,
plates
sulphated,
shorted
through
sedimentation,
elec-
trolyte insufficient)
Battery cables making poor contact
Load excessive (e.g., bulb of excessive
wattage)
Ignition switch trouble
Alternator trouble
Wiring faulty
Regulator/rectifier trouble
Battery overcharged:
Regulator/rectifier trouble
Battery faulty
Battery overcharged:
Halaman 428
MODEL APPLICATION
Year
Model
Beginning Frame No.
2008
EX250J8F
JKAEXMJ1□8DA00001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1391-01
Printed in Japan
