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Kawasaki KLR 650 - BROCHURE 2009 Service Manual

Summary of KLR 650 - BROCHURE 2009

  • Page 1

    Klr650 motorcycle service manual.

  • Page 3: Quick Reference Guide

    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 th...

  • Page 5: Klr650

    Klr650 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 divisi...

  • Page 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...

  • Page 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....

  • Page 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 ...

  • Page 9: Foreword

    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 prope...

  • Page 11: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 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...

  • Page 13

    General information 1-3 before servicing arrangement and cleaning of removed parts disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of removed parts after all the parts including subas...

  • Page 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 l...

  • Page 15

    General information 1-5 before servicing press for items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball bearing and needle bearing do not remove presse...

  • Page 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 rotati...

  • Page 17

    General information 1-7 model identification kl650e8 left side view kl650e8 right side view frame number engine number.

  • Page 18

    1-8 general information general specifications items kl650e8 ∼ ec dimensions overall length 2 295 mm (90.4 in.) overall width 960 mm (37.8 in.) overall height 1 350 mm (53.1 in.) wheelbase 1 480 mm (58.3 in.) road clearance 210 mm (8.27 in.) seat height 890 mm (35.0 in.) dry mass kl650e8 175 kg (386...

  • Page 19

    General information 1-9 general specifications items kl650e8 ∼ ec valve timing: inlet open 19° btdc close 69° abdc duration 268° exhaust open 57° bbdc close 37° atdc duration 274° lubrication system forced lubrication engine oil: type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae10...

  • Page 20

    1-10 general information general specifications items kl650e8 ∼ ec frame type tubular, double cradle caster (rake angle) 28° trail 112 mm (4.41 in.) rim size: front 21 × 1.60 rear 17 m/c × mt2.50 front tire: type tube size 90/90-21 m/c 54s rear tire: type tube size 130/80-17 m/c 65s front suspension...

  • Page 21

    General information 1-11 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)...

  • Page 23: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-3 torque and locking agent..................................................................................

  • Page 24

    2-2 periodic maintenance rear shock absorber oil leak inspection ........................................................................ 2-38 rocker arm operation inspection..................................................................................... 2-38 rocker arm bearing lubrication .......

  • Page 25

    Periodic maintenance 2-3 periodic maintenance chart the scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic inspection frequency whichever comes first * odom...

  • Page 26

    2-4 periodic maintenance periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 inspection every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) see page wheels and tires tire air pressure - inspect year • • • 2-26 wheel/tire damage ...

  • Page 27

    Periodic maintenance 2-5 periodic maintenance chart frequency whichever comes first * odometer reading × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 inspection every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) see page steering stem bearings - lubricate 2 years • 2-40 electrical system lights and ...

  • Page 28

    2-6 periodic maintenance torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: al: tighten the two clamp bolts alternately two times to ensure...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks coolant hose fitting bolts 8.8 0.90 78 in·lb cylinder bolt (m6) 9.8 1.0 87 in·lb cylinder bolt (m8) 18 1.8 13 cylinder head bolts (first) 20 2.0 15 m cylinder head bolts (final) 65 6.6 48 m cylinder head cover ...

  • Page 30

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks oil pipe banjo bolts 20 2.0 15 oil pipe bolt 8.8 0.90 78 in·lb s oil pressure relief valve 15 1.5 11 l oil pump mounting screws 4.4 0.45 39 in·lb oil pump cover screw 4.2 0.43 37 in·lb l engine removal/installa...

  • Page 31

    Periodic maintenance 2-9 torque and locking agent torque fastener n·m kgf·m ft·lb remarks bleed valve 7.8 0.80 69 in·lb front brake disc mounting bolts 27 2.8 20 front brake light switch screw 1.2 0.12 11 in·lb front brake pad pins 17 1.7 12 front caliper holder shaft 17 1.7 12 si front caliper moun...

  • Page 32

    2-10 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks sidestand switch mounting bolt 8.8 0.9 78 in·lb l upper fairings mounting bolts 0.9 0.09 8 in·lb upper left and right fairings mounting screws 0.4 0.04 4 in·lb upper rear frame bolts 44 4.5 33 windshieid mount...

  • Page 33

    Periodic maintenance 2-11 torque and locking agent the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cl...

  • Page 34

    2-12 periodic maintenance specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – choke lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 1 300 ±100 r/min (rpm) – – – air cleaner element polyurethane foam – – – cooling system coolant:...

  • Page 35

    Periodic maintenance 2-13 specifications item standard service limit final drive drive chain slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.) – – – drive chain wear (20-link length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) (kl650e8 ∼ ea) 319 mm (12.56 in.) (kl650eb ∼ ec) standard chain: make enuma (kl...

  • Page 36

    2-14 periodic maintenance special tools inside circlip pliers: 57001-143 spark plug wrench, hex 18: 57001-1024 steering stem nut wrench: 57001-1100 jack: 57001-1238 filler cap driver: 57001-1454.

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures fuel system air cleaner element cleaning note ○ in dusty areas, the element should be cleaned more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be cleaned immediately. Warning...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures throttle control system inspection • check that the throttle grip [a] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not retur...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures • push the choke lever [a] all the way to the front [b]. • check the choke lever free play [c]. Choke lever free play standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) if the free play is incorrect, adjust the choke cable as fol- lows. ○ remove the fuel t...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures fuel hose inspection (fuel leak, damage, installation condition) ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [a] or the hose burst. • remove the starter relay bracket (see fuel ...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures 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 with the mo- torcycle held perpendicular (do not use the sidestand.). If the...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures • remove the cylinder head cover (see cylinder head cover removal in the engine top end chapter). • remove the timing inspection cap [a] and alternator rotor bolt cap [b], using the filler cap driver. Special tool - filler cap driver: 57001-1...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures note ○ mark and record the locations of the shims so that they can be reinstalled in their original positions. • clean the shim to remove any dust or oil. • measure the thickness of the removed shim. • select a new shim thickness calculation ...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures adjustment shims thickness part number mark 2.00 12037-001 200 or 0200 2.05 12037-002 205 or 0205 2.10 12037-003 210 or 0210 2.15 12037-004 215 or 0215 2.20 12037-005 220 or 0220 2.25 12037-006 225 or 0225 2.30 12037-007 230 or 0230 2.35 1203...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures notice be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve...

  • Page 46

    2-24 periodic maintenance periodic maintenance procedures air suction system (other than au model) air suction system damage inspection • remove the fuel tank (see fuel tank removal in the fuel system chapter). • separate the vacuum switch valve hose [a] from the fitting on the frame. • install the ...

  • Page 47

    Periodic maintenance 2-25 periodic maintenance procedures warning the engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • slide the dust cover [a] at the clutch cable lower end out of plac...

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures • remove the engine guard (see engine guard removal in the frame chapter). • remove the plug [a], and loosen the idle shaft lever bolt [b] a few turns. • tighten the idle shaft lever bolt to the specified torque. Torque - idle shaft lever bol...

  • Page 49

    Periodic maintenance 2-27 periodic maintenance procedures tread depth standard: front 6.4 mm (0.25 in.) (au) 6.9 mm (0.27 in.) rear 8.8 mm (0.35 in.) service limit: front 2 mm (0.08 in.) rear 2 mm (0.08 in.) warning some replacement tires may adversely affect han- dling and cause an accident resulti...

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures spoke tightness and rim runout inspection • check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - spoke nipples: 4.0 n·m (0.41 kgf·m, 35 in·lb) • check the rim runout...

  • Page 51

    Periodic maintenance 2-29 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 cha...

  • Page 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 out the right and left chain adjusters [d] evenly. If the chain is too tight...

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures wheel alignment inspection • check that the notch [a] on the right alignment indicator [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 alig...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures drive chain wear inspection • remove the chain cover (see drive chain removal in the final drive chapter). • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, repla...

  • Page 55

    Periodic maintenance 2-33 periodic maintenance procedures chain guide wear inspection • visually inspect the front chain guide [a], rear chain guide [b] and chain slipper [c]. If the chain guides and chain slipper show any signs of abnormal wear or damage, replace them..

  • Page 56

    2-34 periodic maintenance periodic maintenance procedures 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] and fittings [b]. If the brake fluid leaked from any position, inspect or re- place the ...

  • Page 57

    Periodic maintenance 2-35 periodic maintenance procedures brake hose and pipe damage and installation condition inspection • inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ the high pressure inside the brake line can cause fluid to leak [a] or the hose to burst...

  • Page 58

    2-36 periodic maintenance periodic maintenance procedures • 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 mixing brands and types of br...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures if it does not, adjust the brake light switch. • while holding the switch body, turn the adjusting nut to adjust the switch. Switch body [a] adjusting nut [b] light sooner as the body rises [c] light later as the body lowers [d] notice to avo...

  • Page 60

    2-38 periodic maintenance periodic maintenance procedures front fork oil leak inspection • slide the fork boot upward. • 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 abs...

  • Page 61

    Periodic maintenance 2-39 periodic maintenance procedures tie-rod operation inspection • pump the tail grip down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rods [a] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see rocker arm/tie-rod bearin...

  • Page 62

    2-40 periodic maintenance periodic maintenance procedures steering play adjustment • remove: upper fairing (see upper fairing removal in the frame chapter) lower fairings (see lower fairing removal in the frame chapter) handlebar (see handlebar removal in the steering chapter) • loosen: upper fork c...

  • Page 63

    Periodic maintenance 2-41 periodic maintenance procedures electrical system lights and switches operation inspection first step • turn the ignition switch on. • the following lights should go on according to below table. Headlights (high and/or low) [a] go on taillight [b] goes on license plate ligh...

  • Page 64

    2-42 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 sh...

  • Page 65

    Periodic maintenance 2-43 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...

  • Page 66

    2-44 periodic maintenance periodic maintenance procedures note ○ 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 b...

  • Page 67

    Periodic maintenance 2-45 periodic maintenance procedures if the sidestand switch operation does not work, inspect or replace the following item. Battery (see battery condition in the electrical system chapter) main fuse 20 a (see fuse inspection in the electrical system chapter) ignition switch (se...

  • Page 68

    2-46 periodic maintenance periodic maintenance procedures battery electrolyte level inspection • remove the battery (see battery removal in the electrical system chapter). • visually check the electrolyte level in the battery. If the electrolyte level in any cell is lower than the lower level line [...

  • Page 69

    Periodic maintenance 2-47 periodic maintenance procedures • with the cable disconnected at both ends, the 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..

  • Page 70

    2-48 periodic maintenance 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 wh...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures replacement parts air cleaner element replacement note ○ in dusty areas, the element should be replaced more frequently than the recommended interval. ○ after riding through rain or on muddily roads, the ele- ment should be replaced immediate...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures • install the frame into the new element. • install the element and tighten the wring bolt securely. • fit the tongue [a] of the air cleaner cap into the slot [b] of the air cleaner housing and tighten the screw securely. Fuel hose replacemen...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures coolant change warning coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spi...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures • when filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. Notice soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, i...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures radiator hose and o-ring replacement • drain the coolant (see coolant change). • remove: water hose fitting [a] water pump impeller [b] (see water pump removal in the cooling system chapter) o-rings [c] hoses [d] • apply grease to the new o-r...

  • Page 76

    2-54 periodic maintenance periodic maintenance procedures recommended engine oil type: api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity: sae 10w-40 capacity: 1.9 l (2.0 us qt) (when filter is not removed) 2.0 l (2.1 us qt) (when filter is removed) 2.1 l (2.2 us qt) (when engine is complet...

  • Page 77

    Periodic maintenance 2-55 periodic maintenance procedures • remove the bypass valve [a] from the oil filter [b]. • replace the oil filter with a new one. • apply grease to the grommets. • insert the bypass valve [a] into the oil filter. Note ○ align the stepped portion [b] of the bypass valve and up...

  • Page 78

    2-56 periodic maintenance periodic maintenance procedures brake hose and pipe replacement notice brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • remove the brake hose banjo bolts [a]. • when removing the brake hose, take care not ...

  • Page 79

    Periodic maintenance 2-57 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 conta...

  • Page 80

    2-58 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 [a] and diaphragm [b], and pour the brake fl...

  • Page 81

    Periodic maintenance 2-59 periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Notice except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake...

  • Page 82

    2-60 periodic maintenance periodic maintenance procedures front caliper assembly • clean the caliper parts except for the pads. Notice for cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • install the bleed valve and rubber cap. Torque - bleed valve: 7.8 n·m (0.80...

  • Page 83

    Periodic maintenance 2-61 periodic maintenance procedures rear caliper disassembly • remove: rear caliper (see rear caliper removal in the brakes chapter) brake pads (see rear brake pad removal in the brakes chapter) • using compressed air, remove the pistons. ○ cover the piston area with a clean, t...

  • Page 84

    2-62 periodic maintenance periodic maintenance procedures • install the anti-rattle spring [a] in the caliper as shown. • apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • replace the shaft rubber friction boot [a] and dust boot [b] if they are damaged. • apply...

  • Page 85: Fuel System

    Fuel system 3-1 3 fuel system table of contents exploded view........................................................................................................................ 3-2 specifications ......................................................................................................

  • Page 86

    3-2 fuel system exploded view kl650e8 ∼ kl650e9 models.

  • Page 87

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle case screws 3.8 0.39 34 in·lb 2 carburetor holder clamp screw 2.0 0.20 18 in·lb 3. Throttle cables 4. Choke cable 5. Pilot screw 6. Pilot jet 7. Float valve 8. Jet needle 9. Needle jet 10. Needle jet holder 11. Main...

  • Page 88

    3-4 fuel system exploded view kl650ea ∼ ec model.

  • Page 89

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle case screws 3.8 0.39 34 in·lb 2 carburetor holder clamp screw 2.0 0.20 18 in·lb 3. Throttle cables 4. Choke cable 5. Pilot screw 6. Pilot jet 7. Float valve 8. Jet needle 9. Needle jet 10. Needle jet holder 11. Main...

  • Page 90

    3-6 fuel system exploded view.

  • Page 91

    Fuel system 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air cleaner duct clamp screw 2.0 0.20 18 in·lb 2 fuel tap diaphragm cover screws 1.0 0.10 9.0 in·lb 3 fuel tap bolts 2.5 0.25 22 in·lb 4 fuel tap lever plate screws 0.8 0.08 7 in·lb 5 air cleaner housing bolt 8.8 0.90 78 in·...

  • Page 92

    3-8 fuel system exploded view cal model (kl650e8).

  • Page 93

    Fuel system 3-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 separator bracket bolts 8.8 0.90 78 in·lb 2 canister bracket bolts 8.8 0.90 78 in·lb 3. Canister 4. Separator 5. Green hose 6. Blue hose 7. Blue hose 8. Red hose 9. White hose.

  • Page 94

    3-10 fuel system exploded view cal model (kl650e9 ∼ ec).

  • Page 95

    Fuel system 3-11 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 separator bracket bolts 8.8 0.90 78 in·lb 2 canister bracket bolts 8.8 0.90 78 in·lb 3. Canister 4. Separator 5. Green hose 6. Blue hose 7. Blue hose 8. Red hose 9. White hose.

  • Page 96

    3-12 fuel system specifications item standard carburetors mark, type keihin cvk40 idle speed 1 300 ±100 r/min (rpm) pilot screw (turns out) 1 5/8 (for reference) service fuel level 0.5 ±1 mm (0.02 ±0.04 in.) above the bottom edge of carburetor body float height 17.5 ±2 mm (0.69 ±0.08 in.) main jet #...

  • Page 97

    Fuel system 3-13 special tools fuel level gauge: 57001-1017 pilot screw adjuster, b: 57001-1240

  • Page 98

    3-14 fuel system throttle grip and cables throttle grip free play inspection • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle grip free play adjustment • refer to the throttle control system inspection in the pe- riodic maintenance chapter. Throttle c...

  • Page 99

    Fuel system 3-15 throttle grip and cables throttle cable lubrication • refer to the chassis parts lubrication perform in the pe- riodic maintenance chapter..

  • Page 100

    3-16 fuel system choke cable choke lever free play inspection • refer to the choke operation inspection in the periodic maintenance chapter. Choke lever free play adjustment • refer to the choke operation inspection in the periodic maintenance chapter. Choke cable removal • remove: fuel tank (see fu...

  • Page 101

    Fuel system 3-17 carburetor idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Idle speed adjustment • refer to the idle speed adjustment in the periodic main- tenance chapter. Pilot screw adjustment (au model) note ○ for the other than australia model,...

  • Page 102

    3-18 fuel system carburetor • remove the carburetor, and hold it upright on a stand (see carburetor removal). • prepare an auxiliary fuel tank and connect the fuel hose to the carburetor. • pour the fuel into the carburetor. • prepare a rubber hose (6 mm (0.24 in.) inside diameter and about 300 mm (...

  • Page 103

    Fuel system 3-19 carburetor if the float height is out of the standard range, adjust the float height according to the following procedure. ○ bend the tang [a] on the float arm very slightly to change the float height. ○ increasing the float height lowers the fuel level and de- creasing the float he...

  • Page 104

    3-20 fuel system carburetor • remove: starter relay (see starter relay inspection in the elec- trical system chapter) starter relay bracket (see fuel hose replacement in the periodic maintenance chapter) • for the other than australia model, drain the coolant and remove the water hoses from the fitt...

  • Page 105

    Fuel system 3-21 carburetor • insert the air cleaner duct into the carburetor until the stopper [a] attach to the duct end [b]. • install the duct clamp screw [c] in the direction as shown and tighten it. Torque - air cleaner duct clamp screw: 2.0 n·m (0.20 kgf·m, 18 in·lb) • check the fuel leakage ...

  • Page 106

    3-22 fuel system carburetor • remove: spring [a] diaphragm [b] and vacuum piston [c] • remove the jet needle [a] from the vacuum piston [b] along with the spring seat [c]. • remove: screws [a] float bowl [b] • remove: pivot pin [a] float [b] and float valve pilot jet [c] main jet [d] needle jet hold...

  • Page 107

    Fuel system 3-23 carburetor kl650e8 ∼ e9 models • remove: screws [a] plate [b] coasting enricher cover [c] • remove: spring [a] diaphragm [b] o-ring [c] kl650ea ∼ ec model • remove: screws [a] coasting enricher cover [b] spring [c] diaphragm [d] o-ring [e] carburetor assembly warning gasoline is ext...

  • Page 108

    3-24 fuel system carburetor • install the following on the pilot screw [a]. Spring [b] spring seat [c] o-ring [d] • turn in the pilot screw [a] fully but not tightly, and then back it same number of turns counted during disassem- bly. • for the other than australia model, install the plug [b] on the...

  • Page 109

    Fuel system 3-25 carburetor • carefully screw in the pilot jet [a] on the carburetor. • hook the needle hanger [b] onto the float tangs [c] and install the float valve needle in the valve seat. • insert the float pivot pin [d]. • after installation, check the float height (see float height adjustmen...

  • Page 110

    3-26 fuel system carburetor carburetor cleaning warning gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any ap...

  • Page 111

    Fuel system 3-27 carburetor • turn the throttle cable pulley [a] to check that the throttle valve [b] moves smoothly and returns by spring force. If the throttle valve does not move smoothly, replace the carburetor. • disassemble the carburetor (see carburetor disassem- bly). • clean the carburetor ...

  • Page 112

    3-28 fuel system air cleaner air cleaner element removal/installation • refer to the air cleaner element replacement in the pe- riodic maintenance chapter. Air cleaner element cleaning • refer to the air cleaner element cleaning in the periodic maintenance chapter. Air cleaner element inspection • r...

  • Page 113

    Fuel system 3-29 air cleaner air cleaner housing installation • insert the air cleaner duct into the carburetor until the stopper [a] attach to the duct end [b]. • install the duct clamp screw [c] in the direction as shown and tighten it. Torque - air cleaner duct clamp screw: 2.0 n·m (0.20 kgf·m, 1...

  • Page 114

    3-30 fuel system fuel tank fuel tank 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 pilo...

  • Page 115

    Fuel system 3-31 fuel tank • for the california model, note the following. Notice for the california model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new...

  • Page 116

    3-32 fuel system fuel tank • be sure that the trim [a] is on the fuel tank as shown. • when installing the fuel tank, fit the stoppers [a] to the dampers [b] on the frame securely. • be sure the hoses are clamped securely. Fuel tank inspection • visually inspect the gasket [a] on the tank cap for an...

  • Page 117

    Fuel system 3-33 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...

  • Page 118

    3-34 fuel system evaporative emission control system (cal model) the evaporative emission control system routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spec...

  • Page 119

    Fuel system 3-35 evaporative emission control system (cal model) separator operation test warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch off. Make sure the area is well-ventilated and free from any source of flame or sp...

  • Page 121: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 coolant flow chart.............................................................................................

  • Page 122

    4-2 cooling system exploded view.

  • Page 123

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 reserve tank bolts 8.8 0.90 78 in·lb 2 reserve tank cap – – – hand-tighten 3 radiator bolts 8.8 0.90 78 in·lb 4 radiator fan switch 18 1.8 13 5 water hose fitting bolts 8.8 0.90 78 in·lb 6 water temperature sensor 15 1.5 ...

  • Page 124

    4-4 cooling system coolant flow chart.

  • Page 125

    Cooling system 4-5 coolant flow chart 1. Radiator 2. Radiator fan 3. Radiator cap 4. Radiator overflow hose 5. Reserve tank 6. Reserve tank overflow hose 7. Outlet hose 8. Inlet hose 9. Thermostat 10. Water pump 11. Cylinder water jacket 12. Cylinder head water jacket 13. Coolant filter 14. Coolant ...

  • Page 126

    4-6 cooling system specifications item standard coolant provided when shipping type (recommended) permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing poi...

  • Page 127

    Cooling system 4-7 special tool and sealant bearing driver set: 57001-1129 liquid gasket, tb1211: 56019-120

  • Page 128

    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 co...

  • Page 129

    Cooling system 4-9 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...

  • Page 130

    4-10 cooling system water pump water pump removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: water hoses [a] water pump cover bolts [b] water pump cover [c] • for the australia model, remove the water hose of the carburetor system. • shift the transmissio...

  • Page 131

    Cooling system 4-11 water pump • install the water hoses [a] and clamps [b] as shown. White marks [c] • tighten the water hose clamp screw securely. • fill the radiator with the coolant (see coolant change in the periodic maintenance chapter). Water pump inspection • remove the engine guard (see eng...

  • Page 132

    4-12 cooling system water pump mechanical seal replacement • remove the water pump impeller (see water pump re- moval in this section). • pry the mechanical seal flange off with a small chisel [a]. • pull the mechanical seal out of the clutch cover with nee- dle nose pliers. • discard the mechanical...

  • Page 133

    Cooling system 4-13 radiator radiator fan removal • turn the ignition switch off. • remove the fuel tank (see fuel tank removal in the fuel system chapter). • disconnect the radiator fan lead connector [a]. • open the clamps [b]. • remove: radiator fan mounting bolts [c] radiator fan [d] radiator fa...

  • Page 134

    4-14 cooling system radiator radiator inspection • remove the radiator (see radiator and radiator fan re- moval). • 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 cor...

  • Page 135

    Cooling system 4-15 radiator radiator filler neck inspection • remove the radiator cap (see coolant change in the pe- riodic maintenance chapter). • 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 smoo...

  • Page 136

    4-16 cooling system thermostat thermostat removal • drain the coolant (see coolant change in the periodic maintenance chapter). • remove: water hose [a] thermostat housing bolts [b] thermostat housing [c] • for the australia model, remove the following. Water hose (from carburetor) thermostat housin...

  • Page 137

    Cooling system 4-17 thermostat thermostat inspection • remove the thermostat (see thermostat removal), and inspect the thermostat 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 contai...

  • Page 138

    4-18 cooling system hose and pipes hose installation • install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • run the hoses (see cable, wire, and hose routing sec- tion in the appendix chapter). • install the clamp [a] as nea...

  • Page 139

    Cooling system 4-19 radiator fan switch, water temperature sensor radiator fan switch removal/installation notice the radiator fan switch should never be allowed to fall on a hard surface. Such a shock to the switch can damage it. • drain the coolant (see coolant change in the periodic maintenance c...

  • Page 141: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 exhaust system identification ........... 5-8 specifications .................................... 5-10 special tools and sealant ................. 5-12 clean air system (other than au model)......

  • Page 142

    5-2 engine top end exploded view.

  • Page 143

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts (l = 34.5) 7.8 0.80 69 in·lb 2 cylinder head cover bolts (l = 46.5) 7.8 0.80 69 in·lb 3 camshaft cap bolts 12 1.2 106 in·lb 4 clean air system pipe bolt (m5) (other than au model) 5.9 0.60 52 in·...

  • Page 144

    5-4 engine top end exploded view kl650e8 ∼ e9 models.

  • Page 145

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 4.4 0.45 39 in·lb 2 exhaust pipe holder nuts 21 2.1 15 3 exhaust pipe holder clamp bolt 21 2.1 15 4 muffler joint clamp bolt 21 2.1 15 5 heat guard plate bolts 4.4 0.45 39 in·lb muffler body mount...

  • Page 146

    5-6 engine top end exploded view kl650ea ∼ ec model.

  • Page 147

    Engine top end 5-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 4.4 0.45 39 in·lb 2 exhaust pipe holder nuts 21 2.1 15 3 exhaust pipe holder clamp bolt 21 2.1 15 4 muffler joint clamp bolt 21 2.1 15 5 heat guard plate bolts 4.4 0.45 39 in·lb 6 muffler body mou...

  • Page 148

    5-8 engine top end exhaust system identification full: full power.

  • Page 149

    Engine top end 5-9 exhaust system identification muffler body mark position [a] pipe type catalyst position [b].

  • Page 150

    5-10 engine top end specifications item standard service limit clean air system vacuum switch valve closing pressure (other than au model) open → close 42.7 ∼ 53.3 kpa (320 ∼ 400 mmhg) – – – camshafts cam height: exhaust 36.243 ∼ 36.357 mm (1.4269 ∼ 1.4314 in.) 36.14 mm (1.423 in.) inlet 36.742 ∼ 36...

  • Page 151

    Engine top end 5-11 specifications item standard service limit outside diameter: exhaust 31.9 ∼ 32.1 mm (1.256 ∼ 1.264 in.) – – – inlet 36.9 ∼ 37.1 mm (1.453 ∼ 1.461 in.) – – – valve spring free length: inner 37.6 mm (1.480 in.) 36.2 mm (1.425 in.) outer 40.5 mm (1.594 in.) 39.0 mm (1.535 in.) cylin...

  • Page 152

    5-12 engine top end special tools and sealant valve guide reamer, 7: 57001-162 valve guide arbor, 7: 57001-163 compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston pin puller assembly: 57001-910 spark plug wrench, hex 18: 57001-1024 valve spring compressor adap...

  • Page 153

    Engine top end 5-13 special tools and sealant valve seat cutter holder, 7: 57001-1126 valve seat cutter holder bar: 57001-1128 compression gauge adapter, m12 × 1.25: 57001-1183 piston pin puller adapter, 14: 57001-1211 valve seat cutter, 55° - 35: 57001-1247 fork oil level gauge: 57001-1290 piston r...

  • Page 154

    5-14 engine top end special tools and sealant valve seat cutter, 32°- 44: 57001-1515 valve guide driver: 57001-1564 valve guide driver attachment h: 57001-1734 liquid gasket, tb1211f: 92104-0004.

  • Page 155

    Engine top end 5-15 clean air system (other than au model) vacuum switch valve removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) air hoses [a] vacuum hose [b] vacuum switch valve bolts [c] and nuts vacuum switch valve [d] vacuum switch valve installation • install the va...

  • Page 156

    5-16 engine top end clean air system (other than au model) clean air system hose inspection • be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the right air cleaner housing, vacuum switch valve, carbure- tor holder, and air suction valve cove...

  • Page 157

    Engine top end 5-17 cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) radiator (see radiator removal in the cooling system chapter) right lower fairing bracket (see engine removal in the engine removal/installation chapter) • disco...

  • Page 158

    5-18 engine top end cylinder head cover other than au model • be sure to install the o-ring [a] to the clean air system pipe. • install the clean air system pipe [a]. • tighten: torque - clean air system pipe bolt (m5) [b]: 5.9 n·m (0.60 kgf·m, 52 in·lb) clean air system pipe bolt (m6) [c]: 9.8 n·m ...

  • Page 159

    Engine top end 5-19 camshaft chain tensioner camshaft chain tensioner removal notice 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 tens...

  • Page 160

    5-20 engine top end camshaft chain tensioner • tighten: torque - camshaft chain tensioner bolts [a]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • replace the gasket [a] with a new one. • install the spring [b] together with the gasket and cap bolt [c]. • for kl650ec model, install the rod into the spring. • tig...

  • Page 161

    Engine top end 5-21 camshaft camshaft removal • remove: timing inspection cap [a] alternator rotor bolt cap [b] special tool - filler cap driver: 57001-1454 • first, bring the piston to the tdc (of either the compres- sion or exhaust stroke). ○ place a wrench over the alternator rotor bolt and turn ...

  • Page 162

    5-22 engine top end camshaft notice 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. • remove: bolt...

  • Page 163

    Engine top end 5-23 camshaft 1st pin [a] 2nd pin [b] 47th pin [c] arrow mark [d] cylinder head upper surface [e] • be sure to install the dowel pins [a]. • plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase. • install: upper cam...

  • Page 164

    5-24 engine top end camshaft • install the camshaft caps [a] and oil pipe [b] so that note the identification mark of the “ex” and “in”. • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. Torque - camshaft cap bolts: 12 n·m (1.2 kgf·m, 106 in·lb) • i...

  • Page 165

    Engine top end 5-25 camshaft • hang the camshaft chain [a] to the crankshaft sprocket. • install: front camshaft chain guide [b] rear camshaft chain guide [c] • tighten: torque - rear camshaft chain guide bolt [d]: 19 n·m (1.9 kgf·m, 14 ft·lb) • install: lower camshaft chain guide [e] • apply a non-...

  • Page 166

    5-26 engine top end camshaft camshaft journal diameter standard: 22.959 ∼ 22.980 mm (0.90390 ∼ 0.90472 in.) service limit: 22.93 mm (0.9027 in.) if the clearance still remains out of the service limit, re- place the cylinder head unit. Camshaft runout • remove the camshaft (see camshaft removal). • ...

  • Page 167

    Engine top end 5-27 cylinder head cylinder compression measurement note ○ use the battery which is fully charged • thoroughly warm up the engine so that engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • stop the engine. • remove: fuel ...

  • Page 168

    5-28 engine top end cylinder head the following table should be consulted if the obtainable compression reading is not within the us- able range. Problem diagnosis remedy (action) carbon accumulation on piston and in cylinder head (combustion chamber) is suspected due to damaged valve stem or piston...

  • Page 169

    Engine top end 5-29 cylinder head • remove: cylinder head bolts [a] • loosen the left side front bolt [b] fully. • tap lightly up with a plastic mallet [a] to separate the cylin- der head [b] from the cylinder. • remove the cylinder head gasket. Cylinder head installation • fit the projections [a] o...

  • Page 170

    5-30 engine top end cylinder head • insert the cylinder head left side front bolt [a] to the origi- nal position. • insert the cylinder head [b] together with the left side front bolt. • tighten the cylinder head bolts [a] diagonally with the specified torque. Torque - cylinder head bolts (first): 2...

  • Page 171

    Engine top end 5-31 valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and the shim from the valve. Note ○ use the valve spring compressor ass...

  • Page 172

    5-32 engine top end valves • hammer lightly on the valve guide arbor [a] to remove the guide. Special tool - valve guide arbor, 7: 57001-163 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 ∼ 30...

  • Page 173

    Engine top end 5-33 valves valve/valve guide clearance measurement (wobble method) ○ if a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the guide [b] and set a dial...

  • Page 174

    5-34 engine top end valves valve seat repair • for the instructions on how to use the valve seat cutter [a], follow the operation manual provided by the to man- ufacturer. Special tools - valve seat cutter holder, 7: 57001-1126 [b] valve seat cutter holder bar: 57001-1128 exhaust: valve seat cutter,...

  • Page 175

    Engine top end 5-35 valves marks stamped on the cutter the marks stamped on the back of the cutter [a] represent the following. 60° ........................... Cutter angle [b] 37.5 ....................... Cutter outer diameter [c] repair operating procedures • clean the seat area carefully. • coat ...

  • Page 176

    5-36 engine top end valves if the outside diameter [a] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. • grind the seat at a 32° angle [b] until the sea...

  • Page 177

    Engine top end 5-37 valves valve seat repair.

  • Page 178

    5-38 engine top end cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide • remove: radiator hose [a] cylinder nuts [b] • remove: cylinder bolt [a] • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remo...

  • Page 179

    Engine top end 5-39 cylinder and piston • 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 oil ring in the same procedure. Cylinder and piston installation note ○ the oil ring rails have no “top” or “bottom”. • instal...

  • Page 180

    5-40 engine top end cylinder and piston • 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. Notice do not r...

  • Page 181

    Engine top end 5-41 cylinder and piston 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 three locations (total of six measure- ments) shown in the figure. 10 mm (0.39 in.) [a] 55 m...

  • Page 182

    5-42 engine top end cylinder and piston cylinder boring and honing ○ there is an oversize piston available. The oversize piston requires oversize rings. Oversize piston and rings 0.5 mm oversize 1.0 mm oversize • before boring a cylinder [a], first measure the exact di- ameter of the oversize piston...

  • Page 183

    Engine top end 5-43 cylinder and piston piston ring groove width inspection • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: top 1.22 ∼ 1.24 mm (0.0480 ∼ 0.0488 in.) second 1.21 ∼ 1.23 mm (0.0476 ∼ 0.0484 in.) service limit: to...

  • Page 184

    5-44 engine top end carburetor holder carburetor holder removal • remove: carburetor (see carburetor removal in the fuel system chapter) carburetor holder screws [a] carburetor holder [b] carburetor holder installation • install the o-ring [a] to the carburetor holder [b]. • tighten: torque - carbur...

  • Page 185

    Engine top end 5-45 muffler warning the exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Exhaust pipe removal • remove: screws [a] cover [b] and bracket • loosen the muffler joi...

  • Page 186

    5-46 engine top end muffler muffler body removal • loosen the muffler joint clamp bolt (see exhaust pipe re- moval). • remove: right side cover (see side cover removal in the frame chapter) muffler body mounting bolts [a] and nut [b] • remove the muffler body [c] to backward. Exhaust pipe, muffler b...

  • Page 187: Clutch

    Clutch 6-1 6 clutch table of contents exploded view........................................................................................................................ 6-2 specifications ................................................................................................................

  • Page 188

    6-2 clutch exploded view.

  • Page 189

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks clutch spring bolts (kl650e8 ∼ ea) 9.8 1.0 87 in·lb 1 clutch spring bolts (kl650eb ∼ ec) 9.1 0.93 81 in·lb 2 clutch hub nut 135 14 100 r 3 clutch cable holder bolt 8.8 0.90 78 in·lb 4 oil filler cap – – – hand-tighten 5 clutch cove...

  • Page 190

    6-4 clutch specifications item standard service limit clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – clutch friction plate thickness 2.90 ∼ 3.10 mm (0.114 ∼ 0.122 in.) 2.7 mm (0.106 in.) friction plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.2 mm (0.008 in.) or...

  • Page 191

    Clutch 6-5 special tool clutch holder: 57001-1243.

  • Page 192

    6-6 clutch clutch lever and cable clutch lever free play inspection • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch lever free play adjustment • refer to the clutch operation inspection in the periodic maintenance chapter. Clutch cable removal • remove the left...

  • Page 193

    Clutch 6-7 clutch cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: water pump impeller (see water pump removal in the cooling system chapter) oil filter (see oil filter replacement in the periodic maintenance chapter) brake pe...

  • Page 194

    6-8 clutch clutch cover • be sure that the dowel pins [a] are in position. • replace the clutch cover gasket with a new one. • tighten: torque - clutch cover bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) release shaft removal notice do not remove the clutch release lever and shaft assembly unless it is abso...

  • Page 195

    Clutch 6-9 clutch clutch removal • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] clutch springs clutch spring plate [b] (with bearing) pusher [c] • remove: friction plates steel plates • hold the clutch hub [a] steady with the clutch holder [b], and remove the clutch hub nu...

  • Page 196

    6-10 clutch clutch • install: clutch housing [a] spacer [b] ○ engage the clutch housing gear with primary gear on the balancer shaft. • install the clutch hub. • install the washer so that the out side mark [a] faces outward. • replace the clutch hub nut [a] with a new one. • hold the clutch hub [b]...

  • Page 197

    Clutch 6-11 clutch • apply molybdenum disulfide grease to the pusher end [a]. • install the pusher [b] to the drive shaft direction as shown. • apply engine oil to the sliding surfaces of the bearing [a]. • install the bearing on the spring plate [b]. • install the spring plate on the clutch hub [c]...

  • Page 198

    6-12 clutch clutch clutch spring free length measurement • 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: 38.7 mm (1.52 in.) service limit: 37.2 mm (1.46 in.) clutch housing finger inspectio...

  • Page 199: Engine Lubrication System

    Engine lubrication system 7-1 7 engine lubrication system table of contents exploded view........................................................................................................................ 7-2 engine oil flow chart....................................................................

  • Page 200

    7-2 engine lubrication system exploded view.

  • Page 201

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter cap bolts 6.9 0.70 61 in·lb 2 oil pressure relief valve 15 1.5 11 l 3 oil filler cap – – – hand-tighten 4 oil pipe banjo bolts 20 2.0 15 5 oil pipe bolt 8.8 0.90 78 in·lb s 6 engine oil feed fitting ...

  • Page 202

    7-4 engine lubrication system engine oil flow chart.

  • Page 203

    Engine lubrication system 7-5 engine oil flow chart 1. Exhaust camshaft 2. Inlet camshaft 3. Oil pipe (cylinder head) 4. Oil pipe (main) 5. Oil pressure relief valve 6. Oil filter 7. Bypass valve 8. Oil pump 9. Oil screen 10. Engine oil feed fitting 11. Output shaft 12. Drive shaft 13. Idle shaft 14...

  • Page 204

    7-6 engine lubrication system specifications item standard engine oil grade api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 1.9 l (2.0 us qt.) (when filter is not removed) 2.0 l (2.1 us qt.) (when filter is removed) 2.1 l (2.2 us qt.) (when engine is completely dry) l...

  • Page 205

    Engine lubrication system 7-7 special tools oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, m10 × 1.25: 57001-1182.

  • Page 206

    7-8 engine lubrication system engine oil and oil filter warning vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter accordin...

  • Page 207

    Engine lubrication system 7-9 oil screen oil screen removal • remove: clutch cover (see clutch cover removal in the clutch chapter) oil screen [a] oil screen installation note ○ clean the oil screen thoroughly whenever it is removed for any reason. ○ while cleaning the screens, check for any metal p...

  • Page 208

    7-10 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: clutch cover (see clutch cover removal in the clutch chapter) oil pressure relief valve [a] oil pressure relief valve installation • apply a non-permanent locking agent to the threads of the oil pres...

  • Page 209

    Engine lubrication system 7-11 oil pump oil pump removal • remove: clutch cover (see clutch cover removal in the clutch chapter) oil pump mounting screws [a] oil pump [b] note ○ do not remove the oil pump cover screw [c]. Oil pump installation • replace the oil pump gasket with a new one. • be sure ...

  • Page 210

    7-12 engine lubrication system oil pump • fit the hole [a] of the oil pump cover on the dowel pin [b]. • install the dowel pins [a] onto the oil pump cover tempo- rary. • apply a non-permanent locking agent to the threads of the oil pump cover screw, and tighten it. Torque - oil pump cover screw: 4....

  • Page 211

    Engine lubrication system 7-13 oil pressure measurement oil pressure measurement • remove: engine guard (see engine guard removal in the frame chapter) oil passage plug [a] • attach the adapter [a] and gauge [b] to the plug hole. Special tools - oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure...

  • Page 212

    7-14 engine lubrication system oil pipe oil pipe removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) starter motor (see starter motor removal in the electri- cal system chapter) engine sprocket cover (see engine sprocket removal in the final drive chapter) oil pipe banjo b...

  • Page 213: Engine Removal/installation

    Engine removal/installation 8-1 8 engine removal/installation table of contents exploded view........................................................................................................................ 8-2 special tool ........................................................................

  • Page 214

    8-2 engine removal/installation exploded view.

  • Page 215

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine bracket nuts 25 2.5 18 r, s 2 upper engine mounting bolt 25 2.5 18 l 3 front engine mounting nut 44 4.5 32 s 4 front engine bracket nuts 25 2.5 18 r, s 5 lower engine mounting nut 44 4.5 32 l: ap...

  • Page 216

    8-4 engine removal/installation special tool jack: 57001-1238.

  • Page 217

    Engine removal/installation 8-5 engine removal/installation engine removal • place the jack under the frame to raise the rear wheel off the ground. Special tool - jack: 57001-1238 warning when the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the...

  • Page 218

    8-6 engine removal/installation engine removal/installation • remove: engine guard (see engine guard removal in the cool- ing system chapter) brake pedal (see brake pedal removal in the brakes chapter) clutch cable lower end (see clutch cable removal in the clutch chapter) exhaust pipe (see exhaust ...

  • Page 219

    Engine removal/installation 8-7 engine removal/installation • disconnect: ignition coil connectors [a] horn connectors [b] • remove: ignition coil bolt [c] frame ground terminal [d] • remove: bolts [a] ignition coil bracket [b] right lower fairing bracket [c] • remove: breather hose [a] starter moto...

  • Page 220

    8-8 engine removal/installation engine removal/installation • remove the drive chain from the output shaft. • remove the engine [a] from the left side of the motorcy- cle. Engine installation • replace: upper engine bracket nuts front engine bracket nuts • install: front chain guide [a] lower engine...

  • Page 221

    Engine removal/installation 8-9 engine removal/installation • apply non-permanent locking agent to the threads of the upper engine mounting bolt [a]. • install the bracket so that the hook portion [b] faces right side of the motorcycle. ○ attach the hook portion to the upper engine bracket. • tighte...

  • Page 223: Crankshaft/transmission

    Crankshaft/transmission 9-1 9 crankshaft/transmission table of contents exploded view........................................................................................................................ 9-2 specifications ..............................................................................

  • Page 224

    9-2 crankshaft/transmission exploded view.

  • Page 225

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 primary gear nut 155 16 114 2 bearing retaning screws 4.4 0.45 39 in·lb l 3 engine oil drain bolt 29 3.0 21 4 engine oil feed fitting bolts 8.8 0.90 78 in·lb 5 crankcase bolts (l = 30) 8.8 0.90 78 in·lb 6 crank...

  • Page 226

    9-4 crankshaft/transmission exploded view.

  • Page 227

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 front right balancer weight nut 44 4.5 32 2 rear balancer chain guide bolts 8.8 0.90 78 in·lb l 3 idle shaft lever bolt 8.8 0.90 78 in·lb 4 shift drum cam bolt 12 1.2 106 in·lb l 5 neutral switch 15 1.5 11 6 sh...

  • Page 228

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rods connecting rod bend – – – tir 0.2/100 mm (0.008/3.94 in.) connecting rod twist – – – tir 0.2/100 mm 0.008/3.94 in.) connecting rod big end side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) 0.6 mm (0.0...

  • Page 229

    Crankshaft/transmission 9-7 special tools and sealant outside circlip pliers: 57001-144 bearing puller adapter: 57001-317 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 gear holder: 57001-1602 liquid gasket, tb1216: 92104-1063.

  • Page 230

    9-8 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine removal in the engine removal/installation chapter). • set the engine on clean surface while parts are being re- moved. • remove: cylinder head cover (see cylinder head cover re- moval in the e...

  • Page 231

    Crankshaft/transmission 9-9 crankcase • remove: circlip [a] collar [b] special tool - outside circlip pliers: 57001-144 • remove the crankcase bolts [a]. • install the jig [a] between the crankshaft flywheels. Special tool - crankshaft jig: 57001-1174 • attach the crankcase splitting tool [b] to the...

  • Page 232

    9-10 crankshaft/transmission crankcase crankcase assembly notice right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set. • remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high...

  • Page 233

    Crankshaft/transmission 9-11 crankcase • apply a non-permanent locking agent to the retaining screws [a]. • tighten: torque - bearing retaining screws: 4.4 n·m (0.45 kgf·m, 39 in·lb) • install the crankshaft. • apply engine oil to the transmission gears, bearings, shift forks, shift drum and cranksh...

  • Page 234

    9-12 crankshaft/transmission crankcase • be sure to install the o-ring [a] on the engine oil feed fitting [b]. • tighten: torque - engine oil feed fitting bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install: dowel pins [a] • with the connecting rod positioned at the bottom-dead -center, install the cran...

  • Page 235

    Crankshaft/transmission 9-13 crankcase • install the clamp [a]. • apply a non-parmanent locking agent to the crankcase bolt [b]. • tighten the crankcase bolts [b] [c], starting with the pe- riphery of the crankshaft, then outward. Torque - crankcase bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) note ○ after...

  • Page 236

    9-14 crankshaft/transmission crankcase • install the collar [a]. • replace the circlip [b] with a new one, and install it to the output shaft..

  • Page 237

    Crankshaft/transmission 9-15 crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • using the hand, pull out the crankshaft [a] from the right crankcase [b]. Crankshaft installation • install the crankshaft to the right crankcase. • apply engine oil to the connect...

  • Page 238

    9-16 crankshaft/transmission crankshaft crankshaft inspection connecting rod big end radial clearance • set the crankshaft on v blocks, and place a dial gauge [a] against the connecting rod big end. • push [b] the connecting rod first towards the gauge and then in the opposite direction. The differe...

  • Page 239

    Crankshaft/transmission 9-17 crankshaft • first correct the horizontal misalignment by striking the projecting crank half [a] with a plastic, soft lead, or brass hammer as shown. • recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit. • next, co...

  • Page 240

    9-18 crankshaft/transmission crankshaft • 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 length to determine the amount of connecting rod bend. If connecting rod bend exceeds the service limit, th...

  • Page 241

    Crankshaft/transmission 9-19 external shift mechanism shift pedal removal • remove the shift pedal bolt [a]. • pull out the shift pedal [b]. Shift pedal installation • install the shift pedal so that the top of the shift pedal pad [a] position is lower than the punch mark [b] on the alternator outer...

  • Page 242

    9-20 crankshaft/transmission external shift mechanism • holding the gear positioning lever [a] with the (–) driver [b] and install the shift dram cam [c] so that the hollow [d] fit to the shift drum pin [e]. • apply a non-permanent locking agent to the shift drum cam bolt. • tighten: torque - shift ...

  • Page 243

    Crankshaft/transmission 9-21 primary gear primary gear removal • remove: clutch (see clutch removal in the clutch chapter) oil pump (see oil pump removal in the engine lubri- cation system chapter) • flatten out the bended washer [a]. • install the clutch housing temporary (see clutch installa- tion...

  • Page 244

    9-22 crankshaft/transmission primary gear • install the primary gear [a]. • align the key groove [b] of the primary gear and the crank- shaft. • insert the woodruff key [c] into the key groove. • install the oil pump drive gear [a] while fitting the woodruff key [b] onto the groove [c]. • replace th...

  • Page 245

    Crankshaft/transmission 9-23 transmission transmission shaft removal • disassemble the crankcase halves (see crankcase dis- assembly). • pull out the shift rods [a] allowing the shift fork guide pins to free from the shift drum [b]. • remove the shift forks [c]. • remove the shift drum. • pull out t...

  • Page 246

    9-24 crankshaft/transmission transmission transmission shaft disassembly • remove the transmission shafts. • remove the circlips, washers, then gears. Special tool - outside circlip pliers: 57001-144 • do not reuse the removed circlips. Transmission shaft assembly • apply engine oil liberally to the...

  • Page 247

    Crankshaft/transmission 9-25 transmission 1. Circlip ( 23.5) 2. Needle bearing 3. Washer ( 30 × 20.5) 4. 2nd gear 5. Circlip ( 29) 6. Washer ( 29.5) 7. 4th gear 8. 3rd gear 9. Washer ( 30 × 25.3) 10. 5th gear 11. Drive shaft (1st gear) 12. O-ring 13. Output shaft 14. Collar 15. 2nd gear 16. Washer (...

  • Page 248

    9-26 crankshaft/transmission transmission shift fork bending • visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear • measure the thicknes...

  • Page 249

    Crankshaft/transmission 9-27 balancer balancer removal • remove: camshaft chain (see camshaft chain removal in the engine top end chapter) clutch cover (see clutch cover removal in the clutch chapter) oil pump (see oil pump removal in the engine lubri- cation system chapter) • flatten the bended fro...

  • Page 250

    9-28 crankshaft/transmission balancer • install: spacer (t = 3) [a] washer (t = 2) [b] • align the punch mark [c] on the camshaft sprocket and tdc adjusting line [d]. • engage the balancer chain [a] with the sprockets as shown. ○ fit the single glossy link plate [b] to the sprocket tooth of the punc...

  • Page 251

    Crankshaft/transmission 9-29 balancer • replace the circlips [a] with new ones. • install: washer [b] circlips special tool - outside circlip pliers: 57001-144 • install the rear balancer chain guide [c]. • apply a non-parmanent locking agent to the rear balancer chain guide bolts [d]. • tighten: to...

  • Page 252

    9-30 crankshaft/transmission bearings/oil seals bearing replacement notice do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • remove the ball bearing and/or needle bearing outer race using a press or puller. Note ○ in the absence of the above mentioned tools, satis...

  • Page 253

    Crankshaft/transmission 9-31 bearings/oil seals • check the needle bearing. ○ 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 ...

  • Page 255: Wheels/tires

    Wheels/tires 10-1 10 wheels/tires table of contents exploded view........................................................................................................................ 10-2 specifications .................................................................................................

  • Page 256

    10-2 wheels/tires exploded view.

  • Page 257

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples 4.0 0.41 35 in·lb 2 front axle clamp bolts 20 2.0 15 3 front axle nut 88 9.0 65 4 rear axle nut 98 10 72 g. Apply grease. Hg. Apply high-temperature grease. R. Replacement parts wl. Apply soap and water solut...

  • Page 258

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 0.5 mm (0.02 in.) or less tir 2.0 mm (0.08 in.) radial tir 0.8 mm (0.03 in.) or less tir 2.0 mm (0.08 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 bala...

  • Page 259

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 oil seal & bearing remover: 57001-1058 rim protector: 57001-1063 bead breaker assembly: 57001-1072 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 15 × 17: 57001-1267 bearing remover head, 20 × 22: 57001-1293 bear...

  • Page 260

    10-6 wheels/tires wheels (rims) front wheel removal • loosen the front axle nut [a]. • remove the speedometer cable lower end [a]. • loosen the front axle clamp bolts [a]. • raise the front wheel off the ground wtih jack. Special tool - jack: 57001-1238 • pull out the axle to the right and drop the ...

  • Page 261

    Wheels/tires 10-7 wheels (rims) • fit the collar [a] on the wheel hub [b]. • fit the speedometer gear housing stop [a] to the fork leg projection [b]. • insert the front axle, and tighten the axle nut. Torque - front axle nut: 88 n·m (9.0 kgf·m, 65 ft·lb) • before tightening the axle clamp bolts on ...

  • Page 262

    10-8 wheels/tires wheels (rims) rear wheel removal • remove: brake hose clamp bolt [a] brake caliper mounting bolts [b] rear brake caliper [c] • remove the cotter pin [a] and loosen the rear axle nut [b]. • raise the rear wheel off the ground with jack. Special tool - jack: 57001-1238 • remove: rear...

  • Page 263

    Wheels/tires 10-9 wheels (rims) • 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 degrees. ○ loosen once and tighten again when t...

  • Page 264

    10-10 wheels/tires wheels (rims) rim installation position • when installing the rim, set the rim following position. ○ the distance [a] from the brake disc seating surface [b] of the front hub [c] to left end of the front rim [d] should be as follows. View from rear [e] distance: 31.75 ±0.5 mm (1.2...

  • Page 265

    Wheels/tires 10-11 wheels (rims) balance adjustment • if the wheel always stops in one position, provisionally attach a balance weight [a] on the spoke at the marking using adhesive tape. • rotate the wheel 1/4 turn [b], and see whether or not the stops in this position. If it does, the correct bala...

  • Page 266

    10-12 wheels/tires tires air pressure inspection/adjustment • refer to the air pressure inspection in the periodic main- tenance chapter. Tire inspection • refer to the wheel/tire damage inspection in the peri- odic maintenance chapter. Tire removal • remove the wheel (see front/rear wheel removal)....

  • Page 267

    Wheels/tires 10-13 tires • step on the side of the tire opposite air valve, and pry the tire off the rim with the tire iron [b] of the bead breaker protecting the rim with rim protectors [a]. Special tools - rim protector: 57001-1063 bead breaker assembly: 57001-1072 notice take care not to insert t...

  • Page 268

    10-14 wheels/tires hub bearing hub bearing removal • remove the wheel (see front/rear wheel removal), and take out the following. Front grease seal [a] circlip [b] special tool - inside circlip pliers: 57001-143 rear coupling [a] collar [b] circlip [c] special tool - inside circlip pliers: 57001-143...

  • Page 269

    Wheels/tires 10-15 hub bearing hub bearing installation • before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. • replace the bearings with new ones. • install the front hub bearings in the following sequen...

  • Page 270

    10-16 wheels/tires speedometer gear disassembly and assembly note ○ it is recommended that the assembly be replaced rather than attempting to repair the components. • install the speedometer gear so that it fits in the speedometer gear drive notches (see front wheel installation). Lubrication • clea...

  • Page 271: Final Drive

    Final drive 11-1 11 final drive table of contents exploded view........................................................................................................................ 11-2 specifications ...................................................................................................

  • Page 272

    11-2 final drive exploded view.

  • Page 273

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine sprocket nut 98 10 72 mo 2 engine sprocket cover bolts 8.8 0.90 78 in·lb 3 rear sprocket nuts 32 3.3 24 g: apply grease. Mo: apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfid...

  • Page 274

    11-4 final drive specifications item standard service limit drive chain chain slack 35 ∼ 45 mm (1.4 ∼ 1.8 in.) – – – 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make enuma (kl650e8 ∼ ea) – – – daido (kl650eb ∼ ec) – – – type ek525sr-o 2 (kl650e8 ∼ ea) – – – ...

  • Page 275

    Final drive 11-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129 jack: 57001-1238.

  • Page 276

    11-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection/adjustment • refer to th...

  • Page 277

    Final drive 11-7 drive chain • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) swingarm (see swingarm removal in the suspension chapter). Engine sprocket cover (see engine sprocket removal) • disengage the drive chain [a] from the engine sprocket [b], and pull out the drive c...

  • Page 278

    11-8 final drive drive chain • grind [a] the pin head to make it flat. • set the cutting and riveting pin [b] as shown. • screw the pin holder until it touches chain pin. • be sure that the cutting pin hits center of chain pin. • screw the handlebar [a] into body. • turn the pin holder with wrench [...

  • Page 279

    Final drive 11-9 drive chain • set the plate holder (a) [a] and plate holder (b) [b] on the body. • fit the plate holder (a) to link plate. • turn the pin holder by hand until plate holder (b) touches the other link plate. • turn the pin holder by wrench clockwise until two pins of link come into gr...

  • Page 280

    11-10 final drive drive chain • turn the wrench clockwise until tip of riveting pin hits of link pin. • rivet it. • same work 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 ...

  • Page 281

    Final drive 11-11 drive chain • remove: body [a] pin holder [b] positioning pin [c] “u” holder [d] plate holder [e] cutting and riveting pin [f] part for riveting [g] part for cutting [h] • grind [a] the heads of the link pin to make it flat. • set the cutting and riveting pin [c] in the pin holder ...

  • Page 282

    11-12 final drive drive chain • set the cutting and riveting pin [b] and plate holder [c] on the pin holder [a] as shown in the figure. • set the “u” holder and body, align the positioning pin [a] with the “a mark” [b]. • hold the body with a wrench [c]. • turn the pin holder clockwise [d] with anot...

  • Page 283

    Final drive 11-13 drive chain • after riveting, check the ends of the riveted pins for cracks. • measure the outside diameter [a] of the link pin and width [b] of the link plates. Link pin outside diameter standard: 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) link plate outside width standard: 17.25 ∼ 17.55 mm (...

  • Page 284

    11-14 final drive sprocket, coupling engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] • 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 re...

  • Page 285

    Final drive 11-15 sprocket, coupling • after tightening the engine sprocket nut, bend [a] the one side of the washer over the nut. • install the engine sprocket cover. Torque - engine sprocket cover bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) • adjust the drive chain slack after installing the sprocket (s...

  • Page 286

    11-16 final drive sprocket, coupling coupling bearing removal • remove: coupling collar [a] (from inside) circlip [b] special tool - inside circlip pliers: 57001-143 • remove the bearing by tapping from the wheel side. Special tool - bearing driver set [a]: 57001-1129 coupling bearing installation •...

  • Page 287

    Final drive 11-17 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. Sprocket wear inspection • visually inspect the engine and rear sprocket teeth for wear and damage. If t...

  • Page 289: Brakes

    Brakes 12-1 12 brakes table of contents exploded view........................................................................................................................ 12-2 specifications .............................................................................................................

  • Page 290

    12-2 brakes exploded view.

  • Page 291

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake lever pivot bolt 5.9 0.60 52 in·lb si 2 front master cylinder reservoir cap screws 1.5 0.15 13 in·lb 3 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 4 brake lever adjusting bolt locknut 5.9 0.60 52 in·lb 5 brake hose ba...

  • Page 292

    12-4 brakes exploded view.

  • Page 293

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 25 2.5 18 3 rear master cylinder reservoir tank mounting bolt 6.9 0.70 61 in·lb 4 rear master cylinder push rod locknut 17 1.7 12 5 rear caliper mounting bol...

  • Page 294

    12-6 brakes specifications item standard service limit brake lever, brake pedal brake lever free play non-adjustable – – – lever position adjust (to suit rider) – – – brake pedal free play non-adjustable – – – pedal position about 1.1 mm (0.043 in.) below top of footpeg – – – brake fluid grade dot4 ...

  • Page 295

    Brakes 12-7 special tools inside circlip pliers: 57001-143 jack: 57001-1238.

  • Page 296

    12-8 brakes brake lever, brake pedal brake lever position adjustment the brake lever can be adjusted to suit the operator’s hand by turning the adjusting bolt [a]. ○ loosen the locknut [b] and turn the bolt to either side. ○ after adjustment, tighten the locknut. Torque - brake lever adjusting bolt ...

  • Page 297

    Brakes 12-9 brake lever, brake pedal • remove: rear brake light switch spring [a] brake pedal [b] shaft [c] return spring [d] brake pedal installation • apply grease to the sliding surface of the shaft [a]. • install the return spring [b] to the shaft as shown. ○ hook the upper end of the spring to ...

  • Page 298

    12-10 brakes calipers front caliper removal • loosen the banjo bolt [a] at the brake hose lower end, and tighten it loosely. • unscrew the brake hose clamp bolt [b]. • unscrew the caliper mounting bolts [c], and detach the caliper [d] from the disc. • unscrew the banjo bolt and remove the brake hose...

  • Page 299

    Brakes 12-11 calipers caliper installation • install the caliper and brake hose lower end. ○ replace the washers on each side of hose fitting with new ones. • tighten: torque - caliper mounting bolts front: 34 n·m (3.5 kgf·m, 25 ft·lb) rear: 25 n·m (2.5 kgf·m, 18 ft·lb) brake hose banjo bolt: 25 n·m...

  • Page 300

    12-12 brakes calipers 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 ...

  • Page 301

    Brakes 12-13 calipers caliper piston and cylinder damage • visually inspect the pistons [a] and cylinder surfaces [b]. Replace the caliper if the cylinder and piston are badly scores or rusty. Front caliper [c] rear caliper [d] caliper holder shaft wear the caliper body must slide smoothly on the ca...

  • Page 302

    12-14 brakes brake pads front brake pad removal • loosen the pad pins [a]. • remove the front caliper with the hose installed (see front caliper removal). • remove the pad pins. • remove the pad [a] of the jaw side. • remove the pad [b] on the piston side. Front brake pad installation • push the cal...

  • Page 303

    Brakes 12-15 brake pads • remove the rear caliper with the hose installed (see rear caliper removal). • remove the pad pins. • remove the pad [a] of the jaw side. • remove the pad [b] on the piston side. Rear brake pad installation • push the caliper piston in by hand as far as it will go. • install...

  • Page 304

    12-16 brakes master cylinder front master cylinder removal • remove the right handle cover (see handle cover re- moval in the frame chapter). • remove the banjo bolt [a] to disconnect the brake hose from the master cylinder [b] (see brake hose and pipe replacement in the periodic maintenance chapter...

  • Page 305

    Brakes 12-17 master cylinder • 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. • the master cylinder clamp must be installed with the ar- row mark [a] upward. • tighten the upper...

  • Page 306

    12-18 brakes master cylinder • replace the cotter pin [a] with a new one. • insert the cotter pin and bend the pin ends. • bleed the brake line (see brake line bleeding). • check the brake for good braking power, no brake drag, and no fluid leakage. Front master cylinder disassembly • refer to the m...

  • Page 307

    Brakes 12-19 brake disc brake disc removal • remove the wheel (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • tighten: torque - ...

  • Page 308

    12-20 brakes brake fluid brake fluid level inspection • refer to the brake fluid level inspection in the periodic maintenance chapter. Brake fluid change • refer to the brake fluid change in the periodic mainte- nance chapter. Brake line bleeding the brake fluid has a very low compression coefficien...

  • Page 309

    Brakes 12-21 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...

  • Page 310

    12-22 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 th...

  • Page 311

    Brakes 12-23 brake hose brake hose removal/installation • refer to the brake hose and pipe replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose damage and installation condi- tion inspection in the periodic maintenance chapter..

  • Page 313: Suspension

    Suspension 13-1 13 suspension table of contents exploded view........................................................................................................................ 13-2 specifications .....................................................................................................

  • Page 314

    13-2 suspension exploded view.

  • Page 315

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper fork clamp bolts 20 2.0 15 al 2 lower fork clamp bolts 20 2.0 15 3 front fork top plugs 30 3.0 22 4 front axle clamp bolts 20 2.0 15 5 front fork bottom allen bolts 30 3.0 22 l al: tighten the two clamp bolts alternate...

  • Page 316

    13-4 suspension exploded view.

  • Page 317

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper rear shock absorber bolt 59 6.0 44 2 swingarm pivot shaft nut 88 9.0 65 3 lower rear shock absorber nut 98 10 72 4 rocker arm nut 98 10 72 5 tie-rod nuts 98 10 72 g: apply grease..

  • Page 318

    13-6 suspension specifications item standard front fork (per one unit) fork inner tube diameter 41 mm (1.6 in.) air pressure atmospheric pressure (non-adjustable) fork spring setting non-adjustable damper setting non-adjustable fork oil: type kayaba khl34-g10 or equivalent amount approx. 500 ml (16....

  • Page 319

    Suspension 13-7 special tools fork cylinder holder handle: 57001-183 fork cylinder holder adapter: 57001-1057 oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 jack: 57001-1238 fork oil seal driver, 41: 57001-1288 fork oil level gauge: 57001-1290

  • Page 320

    13-8 suspension front fork front fork removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front caliper (with the hose installed, see front caliper removal in the brakes chapter) reflectors [a] (other than au model) bolts [b] speedometer cable clamp [c] brake hose cla...

  • Page 321

    Suspension 13-9 front fork front fork oil change • remove the front fork (see front fork removal). • loosen the clamp screw [a], and remove the fork boot [b]. • remove: top plug [a] with o-ring collar [b] fork spring seat [c] fork spring [d] • compress [a] the fork [b] upside down to draw out the oi...

  • Page 322

    13-10 suspension front fork • 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: 57001-12...

  • Page 323

    Suspension 13-11 front fork • remove the cylinder unit [a], washer, and the spring [b] from the inner tube. • remove the following from the top of the outer tube. Dust seal [a] retaining ring [b] • separate the inner tube [a] from the outer tube [b]. Note ○ from the compressed state, firmly pull dow...

  • Page 324

    13-12 suspension front fork front fork assembly • replace the following parts with new ones. Retaining ring [a] dust seal [b] oil seal [c] inner guide bushing [d] outer guide bushing [e] fork bottom allen bolt gasket [f] • install the guide bushing on the end of the inner tube. • insert the cylinder...

  • Page 325

    Suspension 13-13 front fork inner tube, outer tube inspection • visually inspect the inner tube [a], and repair any dam- age. • 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 t...

  • Page 326

    13-14 suspension rear shock absorber rebound damping force adjustment • to adjust the rebound damping force, turn the lower damping adjuster [a] to the desired position, until you feel a click. ○ the standard adjuster setting is the 1 turns out from the fully clockwise position. Rebound damping forc...

  • Page 327

    Suspension 13-15 rear shock absorber • if the compression of the spring is not suited to the op- erating conditions, adjust it to an appropriate position by referring to the table below. Spring preload adjustment adjuster position damping force shock absorber hardness load road conditions driving sp...

  • Page 328

    13-16 suspension rear shock absorber rear shock absorber installation • install the rear shock absorber so that the spring preload adjusting bolt [a] faces left side of motorcycle. • tighten: torque - upper rear shock absorber bolt: 59 n·m (6.0 kgf·m, 44 ft·lb) lower rear shock absorber nut : 98 n·m...

  • Page 329

    Suspension 13-17 swingarm swingarm removal • remove: chain cover (see chain removal in the final drive chapter) rear wheel (see rear wheel removal in the wheels/tiers chapter) bolts [a] clamps [b] • remove the upper tie-rod nut and bolt [a]. • unscrew the swingarm pivot shaft nut [b]. • pull off the...

  • Page 330

    13-18 suspension swingarm • remove the needle bearings using the oil seal & bearing remover [a]. Special tool - oil seal & bearing remover: 57001-1058 swingarm bearing installation • replace the needle bearings with new ones. • apply plenty of grease to the new needle bearings. • install the needle ...

  • Page 331

    Suspension 13-19 swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] installed in the swingarm. ○ the rollers in a bearing normally wear very little, and wear is difficult to measure. Instead of m...

  • Page 332

    13-20 suspension tie-rod, rocker arm tie-rod removal • squeeze the brake lever slowly and hold it with a band [a]. • raise the rear wheel off the ground with the jack. Special tools - jack: 57001-1238 • remove: upper tie-rod nut and bolt [a] lower tie-rod nut and bolt [b] tie-rods tie-rod installati...

  • Page 333

    Suspension 13-21 tie-rod, rocker arm • remove: plug (both sides) rocker arm nut [a] and bolt [b] • remove the rocker arm downward. Rocker arm installation • apply plenty of grease to the needle bearings [a]. • apply grease to the lip of the oil seals [b]. • be sure to install the oil seals and sleev...

  • Page 334

    13-22 suspension tie-rod, rocker arm ○ remove the needle bearings, using the oil seal & bearing remover [a]. Special tool - oil seal & bearing remover: 57001-1058 tie-rod and rocker arm bearing installation • replace the needle bearings with new ones. • apply plenty of grease to the new needle beari...

  • Page 335

    Suspension 13-23 tie-rod, rocker arm rocker arm/tie-rod bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • visually inspect the rocker arm, or tie-rod sleeves [a] and needle bearings [b]. ○ the rollers in a needle bearing normally wear very litt...

  • Page 337: Steering

    Steering 14-1 14 steering table of contents exploded view........................................................................................................................ 14-2 special tools ..........................................................................................................

  • Page 338

    14-2 steering exploded view.

  • Page 339

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle case screws 3.8 0.39 34 in·lb 2 left switch housing screws 3.5 0.36 31 in·lb 3 handlebar clamp bolts 25 2.5 18 s 4 upper fork clamp bolts 20 2.0 15 al 5 lower fork clamp bolts 20 2.0 15 6 brake hose clamp bolt 6.9 0.7...

  • Page 340

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 head pipe outer race driver, 54.5: 57001-1077 steering stem ...

  • Page 341

    Steering 14-5 steering steering inspection • refer to the steering play inspection in the periodic main- tenance chapter. Steering adjustment • refer to the steering play adjustment in the periodic maintenance chapter..

  • Page 342

    14-6 steering steering stem stem, stem bearing removal • remove: upper fairing (see upper fairing removal in the frame chapter) lower fairings (see lower fairing removal in the frame chapter) front fender (see front fender removal in the frame chapter) handlebar (see handlebar removal) front wheel (...

  • Page 343

    Steering 14-7 steering stem • remove the upper stem bearing inner race (tapered roller) [a]. • drive out the bearing outer races from the head pipe. ○ remove the outer races pressed into the head pipe, using the head pipe outer race remover [a], and hammer the head pipe outer race remover to drive i...

  • Page 344

    14-8 steering steering stem • replace the lower inner races with new ones. ○ apply grease to the lower tapered roller bearing [a], and drive it onto the stem using the steering stem bearing driver [b] and adapter [c]. Special tools - steering stem bearing driver: 57001-137 steering stem bearing driv...

  • Page 345

    Steering 14-9 steering stem • install the stem head. • install the washer, and tighten the stem head nut tempo- rary. • install the front forks (see front fork installation in the suspension chapter). Note ○ tighten the upper fork clamp bolts first, next the stem head nut, last the lower fork clamp ...

  • Page 346

    14-10 steering handlebar handlebar removal • remove: left handle cover [a] (see handle cover removal in the frame chapter) left handlebar weight [b] left handlebar grip [c] clutch cable upper end (see clutch cable removal in the clutch chapter) left switch housing [d] clutch lever assembly [e] clamp...

  • Page 347

    Steering 14-11 handlebar • tighten the front clamp bolts [a] first, and then the rear clamp bolts [b]. ○ there will be a gap [c] at the rear part of the handlebar holder after tightening. Torque - handlebar clamp bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the clutch lever (see clutch lever instal...

  • Page 348

    14-12 steering handlebar • install the throttle grip [a] and right handlebar weight [b] so that distance [c] between the grip and weight is the 2.5 mm (0.098 in.). • tighten: torque - throttle case screws: 3.8 n·m (0.39 kgf·m, 34 in·lb) • apply a non-permanent locking agent to the right handle- bar ...

  • Page 349: Frame

    Frame 15-1 15 frame table of contents exploded view........................................................................................................................ 15-2 special tool .................................................................................................................

  • Page 350

    15-2 frame exploded view.

  • Page 351

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front footpeg bracket bolts 25 2.5 18 2 rear footpeg bracket bolts 25 2.5 18 3 sidestand bolt and nut 44 4.5 33 r (1) 4 sidestand switch mounting bolt 8.8 0.9 78 in·lb l 5 lower rear frame bolts 25 2.5 18 6 upper rear frame bolts...

  • Page 352

    15-4 frame exploded view.

  • Page 353

    Frame 15-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 windshieid mounting screws 0.4 0.04 4 in·lb 2 upper fairings mounting bolts 0.9 0.09 8 in·lb 3 upper left and right fairings mounting screws 0.4 0.04 4 in·lb 4 lower fairing mounting bolts 8.8 0.90 78 in·lb 5. Cal model 6. Other ...

  • Page 354

    15-6 frame special tool jack: 57001-1238.

  • Page 355

    Frame 15-7 seat seat removal • remove the side covers (see side cover removal). • remove the seat mounting bolts [a] on both sides. • pulling up on the rear of seat [b], and pulling the seat backward. Seat installation • insert the hook [a] of the seat under the fuel tank bracket [b]. ○ take care no...

  • Page 356

    15-8 frame fairings lower fairing removal • remove the bolt [a]. • remove: bolts [a] screw [b] lower fairing [c] ○ when removing the left lower fairing, remove the radiator screen together with lower fairing. Lower fairing installation • before installing the left lower fairing, insert the projec- t...

  • Page 357

    Frame 15-9 fairings • remove the upper fairing mounting bolts [a] [b] on both sides. • clear the turn signal light leads from the clamps of the upper fairing. • disconnect: headlight lead connectors [a] turn signal light lead connectors [b] • remove: headlight assy (see headlight removal in the elec...

  • Page 358

    15-10 frame fairings • remove: bolts and nuts [a] upper fairing bracket [b] upper fairing bracket installation • installation in the reverse of removal. ○ run the harness and leads correctly (see cable, wire, and hose routing section in the appendix chapter)..

  • Page 359

    Frame 15-11 side covers side cover removal • remove: side cover mounting bolts [a] side cover [b] side cover installation • installation is the reverse of removal. ○ insert the projection [a] into the grommet [b] on the rear frame..

  • Page 360

    15-12 frame fenders front fender removal • remove the speedometer cable lower end [a]. • remove the front fender mounting bolts [a], and pull out the front fender [b]. Rear fender rear removal • remove: side covers (see side covers removal) seat (see seat removal) carrier (see carrier removal) • tur...

  • Page 361

    Frame 15-13 fenders rear fender front installation • installation is the reverse of removal. ○ insert the ledges [a] of the rear fender front into the slits [b] of the rear frame securely..

  • Page 362

    15-14 frame frame rear frame removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) battery (see battery removal in the electrical system chapter) muffler body (see muffler body removal in the engine top end chapter) rear fender front (see rear fender front removal) flap (see...

  • Page 363

    Frame 15-15 frame frame inspection • visually inspect the frame [a] for cracks, dents, bending, or warping. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or ...

  • Page 364

    15-16 frame windshield windshield removal • remove the windshield mounting screws [a], and the windshield [b]. Windshield installation • tighten: torque - windshield mounting screws: 0.4 n·m (0.04 kgf·m, 4 in·lb).

  • Page 365

    Frame 15-17 guard, carrier engine guard removal • remove: bolts [a] engine guard [b] carrier removal • remove the side covers (see side covers removal). • remove the seat (see seat removal). • disconnect the turn signal light connectors [a], and tail/brake light connector [b]. • remove the rear fend...

  • Page 366

    15-18 frame handle covers handle cover removal • remove: bolt [a] and nut [b] handle cover [c] handle cover installation • installation is the reverse of removal. ○ replace the handle cover nut with new one..

  • Page 367

    Frame 15-19 sidestand sidestand removal • raise the rear wheel off the ground with the jack. Special tool - jack: 57001-1238 • remove: sidestand switch mounting bolt [a] sidestand switch cover [b] sidestand switch [c] • remove: spring [a] sidestand nut [b] sidestand bolt [c] sidestand [d] sidestand ...

  • Page 368

    15-20 frame sidestand • install the sidestand switch cover [a] as follows. ○ insert the projections [b] into the holes [c]. • apply a non-permanent locking agent to the threads of the sidestand switch mounting bolt, and tighten it. Torque - sidestand switch mounting bolt: 8.8 n·m (0.90 kgf·m, 78 in·...

  • Page 369

    Frame 15-21 rear view mirrors rear view mirrors removal • when removing the rear view mirror of the right side, re- move the handle cover (see handle cover removal). • slide up the rubber cap [a]. • loosen the lower adapter nut [b] for tightening to remove the rear view mirror from the holder. ○ do ...

  • Page 371: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-3 specifications .......................................................................................

  • Page 372

    16-2 electrical system electric starter system ........................................................................................................... 16-48 starter motor removal...................................................................................................... 16-48 starter m...

  • Page 373

    Electrical system 16-3 exploded view this page intentionally left blank..

  • Page 374

    16-4 electrical system exploded view.

  • Page 375

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor mounting bolts 8.8 0.90 78 in·lb 2 starter motor through bolts 4.9 0.50 43 in·lb 3 starter relay terminal screws 4.4 0.45 39 in·lb 4 starter motor terminal locknut 10.8 1.1 96 in·lb 5 starter motor cable...

  • Page 376

    16-6 electrical system exploded view.

  • Page 377

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 tail/brake light mounting nuts 5.9 0.60 52 in·lb 2 license plate light lens screws 0.9 0.09 8 in·lb 3 license plate light mounting screws 5.9 0.60 52 in·lb 4 meter unit mounting screws 1.2 0.12 11 in·lb.

  • Page 378

    16-8 electrical system exploded view.

  • Page 379

    Electrical system 16-9 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 right handlebar switch housing screws 3.5 0.36 31 in·lb 2 front brake light switch screw 1.2 0.12 11 in·lb 3 left handlebar switch housing screws 3.5 0.36 31 in·lb 4 sidestand switch mounting bolt 8.8 0.90 78 in·lb l ...

  • Page 380

    16-10 electrical system specifications item standard battery capacity 12 v 14 ah electrolyte level between upper and lower level lines specific gravity 1.280 at 20°c (68°f) charging system alternator type three-phase ac alternator output voltage 43 v or more at 4 000 r/min (rpm) stator coil resistan...

  • Page 381

    Electrical system 16-11 special tools and sealant rotor holder, hex 32: 57001-1184 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 jack: 57001-1238 timing light: 57001-1241 hand tester: 57001-1394 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 liquid gasket, tb1211f: 92104-0004.

  • Page 382

    16-12 electrical system parts location.

  • Page 383

    Electrical system 16-13 parts location 1. Ic igniter 2. Starter circuit relay 3. Turn signal relay 4. Interlock diode unit 5. Meter unit 6. Ignition switch 7. Ignition coil 8. Horn 9. Regulator/rectifier 10. Water temperature sensor 11. Spark plug 12. Rear brake light switch 13. Fuse box (headlight ...

  • Page 384

    16-14 electrical system wiring diagram.

  • Page 385

    Electrical system 16-15 wiring diagram.

  • Page 386

    16-16 electrical system 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 cable connections. This will burn out the diodes on the electrical parts. ○ always check battery con...

  • Page 387

    Electrical system 16-17 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is 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, clea...

  • Page 388

    16-18 electrical system battery precautions following a few simple rules will greatly extend the life of the battery. ○ when the level of the electrolyte in the battery is low, add only distilled water to each cell, until the level is at the upper level line marked on the outside of the battery. Or-...

  • Page 389

    Electrical system 16-19 battery • pull the battery [a] out of the air cleaner housing. Battery installation • visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from sides of the battery. • insert the battery into the air cleaner housing so that th...

  • Page 390

    16-20 electrical system battery • look for sediment and white sulfation inside the cells on the bottom of the plates. Sulfation here [a] sediment here [b] • see the battery troubleshooting guide in test charging. If the specific gravity is below 1.200 the battery needs to be charged. Note ○ the spec...

  • Page 391

    Electrical system 16-21 battery note ○ if the electrolyte level drops, add electrolyte to the upper level line before charging. • leaving the caps off the cells, connect the battery to a charger, set the charging rate at 1/10 the battery capacity, and charge it for 10 hours. For example, if the batt...

  • Page 392

    16-22 electrical system battery ordinary charging • remove the battery from the motorcycle. Notice always remove the battery from the motorcycle for charging. If the battery is charged while still in- stalled, battery electrolyte may spill and corrode the frame or other parts of the motorcycle. • cl...

  • Page 393

    Electrical system 16-23 battery charging rate/time table (12 v 14 ah) notice do not use a high rate battery charger as is typi- cally employed at automotive service stations, un- less the charging rate can be reduced to the level required. Charging the battery at a rate higher than specified may rui...

  • Page 394

    16-24 electrical system battery test charging • if the battery is suspected of being defective, sulfated, or unable to take a charge, consult the table. • to test charge a battery, perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below. If the batt...

  • Page 395

    Electrical system 16-25 charging system alternator outer cover removal • remove: engine guard (see engine guard removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system chapter) engine sprocket cover (see engine sprocket removal in the final drive chapter) starter relay cove...

  • Page 396

    16-26 electrical system charging system alternator outer cover installation • apply silicone sealant [a] to the crankshaft sensor lead grommets. Sealant - liquid gasket, tb1211f: 92104-0004 • replace the alternator outer cover gasket with a new one. • be sure that the dowel pins [a] are in position....

  • Page 397

    Electrical system 16-27 charging system • install the idle shaft lever [a]. • replace the o-ring [b] of the idle shaft lever bolt [c] with a new one. • apply grease to the o-ring. • tighten: torque - idle shaft lever bolt: 8.8 n·m (0.90 kgf·m, 78 in·lb) stator coil removal • remove: alternator outer...

  • Page 398

    16-28 electrical system charging system alternator rotor removal • remove: alternator outer cover (see alternator outer cover re- moval) shaft [a] starter idle gear [b] with needle bearings torque limiter [c] ○ there are washers on both sides onto he starter idle gear and torque limiter. • wipe oil ...

  • Page 399

    Electrical system 16-29 charging system • remove the spacers [a]. Alternator rotor installation • install the spacers [a] on the crankshaft. • apply molybdenum disulfide oil solution to the inner sur- face [b] of the starter motor clutch gear [c]. • install the starter motor clutch gear and washer [...

  • Page 400

    16-30 electrical system charging system • apply a thin coat of molybdenum disulfide grease to the shafts of the torque limiter [a]. • apply engine oil to the needle bearings [b], and install them into the starter idle gear [c]. • be sure install the washers [d] on both sides onto the starter idle ge...

  • Page 401

    Electrical system 16-31 charging system • to check the alternator output voltage, do the following procedures. ○ turn the ignition switch off. ○ remove the fuel tank (see fuel tank removal in the fuel system chapter). ○ disconnect the alternator lead connector [a]. ○ connect the hand tester as shown...

  • Page 402

    16-32 electrical system charging system regulator/rectifier inspection • remove the fuel tank (see fuel tank removal in the fuel system chapter). • disconnect the regulator/rectifier connector [a]. • remove: bolts [b] clamp [c] regulator/rectifier [d] rectifier circuit check • check conductivity of ...

  • Page 403

    Electrical system 16-33 charging system • 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 t...

  • Page 404

    16-34 electrical system charging system charging voltage inspection • check the battery condition (see battery condition). • warm up the engine to obtain actual alternator operating conditions. • remove the seat (see seat removal in the frame chap- ter). • check that the ignition switch is turned of...

  • Page 405

    Electrical system 16-35 charging system charging system circuit 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 12 v 14 ah 5. Main fuse 20 a 6. Load.

  • Page 406

    16-36 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plugs while the engine is running, or you could receive a severe electrical shock. Notice do not disconnect the battery cables or any other electrical connections when the ig...

  • Page 407

    Electrical system 16-37 ignition system crankshaft sensor removal • remove: alternator outer cover (see alternator outer cover re- moval) hold plate screws [a] plates [b] crankshaft sensor lead grommets [c] crankshaft sensor screws [d] crankshaft sensor [e] crankshaft sensor installation • install t...

  • Page 408

    16-38 electrical system ignition system 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. • using the highest resistance range of the tester, measure the resistance bet...

  • Page 409

    Electrical system 16-39 ignition system ignition coil inspection • remove the ignition coil (see ignition coil removal). • measure the arcing distance with a suitable commercially available coil tester [a] to check the condition of the igni- tion coil [b]. • connect the ignition coil (with the spark...

  • Page 410

    16-40 electrical system ignition system ignition coil primary peak voltage inspection • refer to the ic igniter inspection. Spark plug removal • refer to the spark plug replacement in the periodic maintenance chapter. Spark plug installation • refer to the spark plug replacement in the periodic main...

  • Page 411

    Electrical system 16-41 ignition system 2nd check • start the engine to the following conditions. Condition transmission gear → 1st position clutch lever → pulled in sidestand → up ○ turn the ignition switch on and push the starter button. ○ then the starter motor should turn when the starter sys- t...

  • Page 412

    16-42 electrical system ignition system ic igniter removal notice never drop the ic igniter, especially on a hard sur- face. Such a shock to igniter can damage it. • remove: upper fairing (see upper fairing removal in the frame chapter) connector [a] ic igniter [b] ic igniter inspection notice when ...

  • Page 413

    Electrical system 16-43 ignition system • pull off the spark plug cap from the spark plug (see igni- tion coil removal). ○ do not remove the spark plug. • measure the primary peak voltage as follows. ○ install the new spark plug [a] into the plug cap, and ground it onto the engine. ○ connect the pea...

  • Page 414

    16-44 electrical system ignition system check3: crankshaft sensor primary peak voltage check note ○ be sure the battery is fully charged. ○ using the peak voltage adapter [a] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measureme...

  • Page 415

    Electrical system 16-45 ignition system.

  • Page 416

    16-46 electrical system ignition system ignition system circuit 1. Engine stop switch 2. Starter button 3. Ignition switch 4. Sidestand switch 5. Interlock diode unit 6. Starter lockout switch 7. Ignition coil 8. Spark plug 9. Neutral switch 10. Crankshaft sensor 11. Ic igniter 12. Main fuse 20 a 13...

  • Page 417

    Electrical system 16-47 starter motor clutch starter motor clutch removal/installation • refer to the alternator rotor removal/installation. Starter motor clutch inspection • remove: alternator outer cover (see alternator outer cover re- moval) starter idle gear and torque limiter (see alternator re...

  • Page 418

    16-48 electrical system electric starter system starter motor removal notice do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • remove the exhaust pipe (see exhaust pipe removal in the engine top end chapter). • slide back the rubber cap [a]. • remove the...

  • Page 419

    Electrical system 16-49 electric starter system starter motor disassembly • remove the starter motor (see starter motor disassem- bly). • take off the starter motor through bolts [a] and remove the both end covers [b]. • pull the armature [a] out of the yoke [b]. • remove: terminal locknut [a] washe...

  • Page 420

    16-50 electrical system electric starter system • clamp the springs [a] with the suitable plates [b]. • insert the armature [c] into the yoke [d]. • remove the suitable plates. • replace the o-ring [a] with new one and install it. • install: washers [b] terminal locknut [c] • tighten: torque - start...

  • Page 421

    Electrical system 16-51 electric starter system • install the thrust washer(s) [a] to the right-hand end cover [b]. • align the lines [a] of the yoke and end covers. • tighten: torque - starter motor through bolts: 4.9 n·m (0.50 kgf·m, 39 in·lb) • install the starter motor (see starter motor install...

  • Page 422

    16-52 electrical system electric starter system armature inspection • using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [a]. Special tool - hand tester: 57001-1394 if there is a high resistance or no reading (∞) between any two segments, a winding is ope...

  • Page 423

    Electrical system 16-53 electric starter system starter relay inspection • remove the battery negative (–) cable from the battery negative (–) terminal (see battery removal). • remove: screw [a] starter relay cover [b] • disconnect the connector [a]. • remove the starter relay [b] from the bracket [...

  • Page 424

    16-54 electrical system electric starter system starter circuit relay inspection • remove: upper fairing (see upper fairing removal in the frame chapter) connector [a] starter circuit relay [b] • connect the hand tester [a] and a 12 v battery [b] to the starter circuit relay [c] as shown. If the rel...

  • Page 425

    Electrical system 16-55 electric starter system electric starter circuit 1. Engine stop switch 2. Starter button 3. Ignition switch 4. Sidestand switch 5. Interlock diode unit 6. Starter circuit relay 7. Starter lockout switch 8. Neutral switch 9. Starter motor 10. Starter relay 11. Main fuse 20 a 1...

  • Page 426

    16-56 electrical system lighting system headlight beam horizontal adjustment • refer to the headlight aiming inspection in the periodic maintenance chapter. Headlight beam vertical adjustment • refer to the headlight aiming inspection in the periodic maintenance chapter. Headlight bulb replacement •...

  • Page 427

    Electrical system 16-57 lighting system • fit the dust cover [a] with the projection upward onto the bulb [b] firmly as shown. Good [c] bad [d] projection [e] • after installation, adjust the headlight aim (see headlight aiming inspection in the periodic maintenance chapter). ○ other bulb: repeat th...

  • Page 428

    16-58 electrical system lighting system license plate light bulb replacement • remove: screws [a] license plate light cover [b] • remove: screws [a] license plate light lens [b] • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pin...

  • Page 429

    Electrical system 16-59 lighting system headlight/tail light circuit 1. Ignition switch 2. Headlight fuse 15 a 3. Tail/brake light 12 v 5/21 w 4. License plate light 12 v 5 w 5. Headlight (high) 12 v 55 w 6. Headlight (low) 12 v 55 w 7. High beam indicator light 12 v 1.7 w 8. Dimmer switch 9. Main f...

  • Page 430

    16-60 electrical system lighting system • turn the turn signal light lens [a] counterclockwise, and remove it. • push and turn the bulb [a] counterclockwise and remove it. • insert the new bulb [a] by aligning its upper and lower pins [b] with the upper and lower grooves [c] in the socket, and turn ...

  • Page 431

    Electrical system 16-61 lighting system • connect one 12 v battery and turn signal lights as indi- cated in the figure, and count how may 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...

  • Page 432

    16-62 electrical system radiator fan system fan system circuit inspection • disconnect the radiator fan switch connector [a]. • using an auxiliary lead [b], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch (see radiator fan switch inspection). If the fan does not rot...

  • Page 433

    Electrical system 16-63 meter, gauge, indicator unit meter unit removal/installation • remove: upper fairing (see upper fairing removal in the frame chapter) speed meter cable upper end [a] • disconnect the connector [b]. • remove the meter unit by taking off the mounting screws [c] with the washers...

  • Page 434

    16-64 electrical system meter, gauge, indicator unit • fit the rod [a] into the hole [b] of the reset button. • install the sockets and terminals according to the lead color marks of the lower meter cover. Meter, indicator light bulb replacement • remove the meter unit (see meter unit removal/instal...

  • Page 435

    Electrical system 16-65 meter, gauge, indicator unit • then the tachometer needle [a] should flick [b]. If the needle does not flick, replace the meter assembly. Tachometer circuit 1. Tachometer 2. Ignition switch 3. Ic igniter 4. Main fuse 20 a 5. Battery 12 v 14 ah water temperature gauge inspecti...

  • Page 436

    16-66 electrical system meter, gauge, indicator unit • connect the variable rheostat [a] to the y lead terminal [b] as shown. • adjust the resistance value to the approximately 30 Ω. • the water temperature gauge [a] indicate the position [b] of the about 100 °c. If the water temperature gauge does ...

  • Page 437

    Electrical system 16-67 switches and sensors brake light timing inspection • refer to the brake light switch operation inspection in the periodic maintenance chapter. Brake light timing adjustment • refer to the brake light switch operation inspection in the periodic maintenance chapter. Switch insp...

  • Page 438

    16-68 electrical system switches and sensors radiator fan switch inspection • remove the radiator fan switch (see radiator fan switch removal in the cooling system chapter). • suspend the switch [a] in a container of coolant so that the thread portion is submerged. • suspend an accurate thermometer ...

  • Page 439

    Electrical system 16-69 fuse 20 a main fuse removal • remove the starter relay cover (see starter relay inspec- tion). • disconnect the connector [a]. • pull out the main fuse [a] from the starter relay with needle nose pliers. Fuse box fuse removal • remove the seat (see seat removal in the frame c...

  • Page 440

    16-70 electrical system fuse fuse inspection • remove the fuse (see 20 a main/fuse box fuse re- moval). • inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the ...

  • Page 441: Appendix

    Appendix 17-1 17 appendix table of contents cable, wire, and hose routing .............................................................................................. 17-2 troubleshooting guide ...........................................................................................................

  • Page 442

    17-2 appendix cable, wire, and hose routing.

  • Page 443

    Appendix 17-3 cable, wire, and hose routing 1. Run the speedometer cable to the inside of the brake hose. 2. Speedometer cable 3. Throttle cable (decelerator) 4. Throttle cable (accelerator) 5. Brake hose 6. Clamp (run the right switch housing lead in the clamp, and insert the clamp in the handlebar...

  • Page 444

    17-4 appendix cable, wire, and hose routing.

  • Page 445

    Appendix 17-5 cable, wire, and hose routing 1. Clutch cable 2. Choke cable 3. Damper 4. Main harness 5. Band (fix the main harness, alternator lead and crankshaft sensor lead at the frame pipe.) 6. Dampers 7. 97 mm (3.82 in.) 8. 195 mm (7.68 in.) 9. 0 ∼ 30 mm (1.18 in.) 10. Throttle cables 11. Clamp...

  • Page 446

    17-6 appendix cable, wire, and hose routing.

  • Page 447

    Appendix 17-7 cable, wire, and hose routing 1. Ic igniter 2. Starter circuit relay 3. Turn signal relay 4. Headlight leads 5. Meter unit lead 6. Interlock diode unit 7. Fix the main harness at the upper fairing bracket. 8. Bands (insert the band in the upper fairing bracket and fix the main harness....

  • Page 448

    17-8 appendix cable, wire, and hose routing kl650e8 ∼ e9 models.

  • Page 449

    Appendix 17-9 cable, wire, and hose routing 1. Left switch housing lead 2. Clamps 3. Alternator lead connector 4. Ignition switch lead 5. Right switch housing lead 6. Frame ground lead 7. Clamps (clamp the main harness.) 8. Main harness 9. Run the main harness between the clamp bolt and horn nut. 10...

  • Page 450

    17-10 appendix cable, wire, and hose routing kl650ea ∼ ec models.

  • Page 451

    Appendix 17-11 cable, wire, and hose routing 1. Left switch housing lead 2. Clamps 3. Alternator lead connector 4. Ignition switch lead 5. Right switch housing lead 6. Frame ground lead 7. Clamps (clamp the main harness.) 8. Main harness 9. Run the main harness between the clamp bolt and horn nut. 1...

  • Page 452

    17-12 appendix cable, wire, and hose routing.

  • Page 453

    Appendix 17-13 cable, wire, and hose routing 1. Ignition coil 2. Clamp 3. Reguretor/rectifier 4. Viewed from a - a 5. Clamp the ignition coil lead and reguretor/rectifier lead so that they do not touch the regure- tor/rectifier. 6. Spark plug lead 7. Water temperature sensor 8. 0 ∼ 15 mm (0 ∼ 0.6 in...

  • Page 454

    17-14 appendix cable, wire, and hose routing kl650e8 ∼ e9 models.

  • Page 455

    Appendix 17-15 cable, wire, and hose routing 1. Starter motor cable 2. Engine ground terminal 3. Rear brake light switch 4. Battery negative cable 5. Battery positive cable 6. Clamp (clamp the battery cables.) 7. Starter relay 8. Clamp (insert the clamp in the starter relay bracket from inside of mo...

  • Page 456

    17-16 appendix cable, wire, and hose routing kl650ea ∼ ec models.

  • Page 457

    Appendix 17-17 cable, wire, and hose routing 1. Starter motor cable 2. Engine ground terminal 3. Rear brake light switch 4. Battery negative cable 5. Band 6. Battery positive cable 7. Clamp (clamp the battery cables.) 8. Starter relay 9. Clamp (insert the clamp in the starter relay bracket from insi...

  • Page 458

    17-18 appendix cable, wire, and hose routing kl650ea ∼ ec models.

  • Page 459

    Appendix 17-19 cable, wire, and hose routing 1. Main harness 2. Ignition switch lead 3. Right switch housing lead 4. Band (clamp the right switch housing lead, ignition switch lead and main harness.) 5. Left switch housing lead connector 6. Band (clamp the right switch housing lead connector and ign...

  • Page 460

    17-20 appendix cable, wire, and hose routing.

  • Page 461

    Appendix 17-21 cable, wire, and hose routing 1. Clamp (clamp the coolant reserve tank overflow hose and main harness.) 2. Clamps 3. Rear right turn signal lead 4. Tail/brake light lead 5. License plate light lead 6. Rear left turn signal lead 7. Clamps (clamp the rear turn signal leads as shown.) 8....

  • Page 462

    17-22 appendix cable, wire, and hose routing.

  • Page 463

    Appendix 17-23 cable, wire, and hose routing 1. Radiator overflow hose 2. Clamp (clamp the radiator fan lead and radiator fan switch lead.) 3. Water hose (to thermostat housing) 4. Radiator fan lead 5. Radiator fan switch lead 6. Clamp (clamp the radiator fan switch lead.) 7. Viewed from a - a 8. Wa...

  • Page 464

    17-24 appendix cable, wire, and hose routing.

  • Page 465

    Appendix 17-25 cable, wire, and hose routing 1. Carburetor 2. Air vent hose 3. Run the air vent hose to the right side of motorcycle. 4. Run the air vent hose under the rear frame fitting. 5. Run the air vent hose between rear frame and air cleaner housing. 6. Vacuum hose (carburetor ∼ fitting) 7. A...

  • Page 466

    17-26 appendix cable, wire, and hose routing.

  • Page 467

    Appendix 17-27 cable, wire, and hose routing 1. Front brake hose 2. Clamp 3. Viewed from a 4. Clamp bracket 5. Viewed from a - a 6. Rear view 7. Clamp 8. Clamp 9. Clamp 10. Rear brake hose 11. Clamp 12. Clamp.

  • Page 468

    17-28 appendix cable, wire, and hose routing other than au model.

  • Page 469

    Appendix 17-29 cable, wire, and hose routing 1. Clamp (position the pinch head between upper and front (within the range of 90°).) 2. Vacuum switch valve hose (to clean air system pipe) 3. Clamp (position the pinch head upward.) 4. Vacuum switch valve hose (to frame fitting) 5. Vacuum switch valve h...

  • Page 470

    17-30 appendix cable, wire, and hose routing cal model (kl650e8).

  • Page 471

    Appendix 17-31 cable, wire, and hose routing 1. Fuel hose 2. Coolant reserve tank overflow hose 3. Main harness 4. Blue hose 5. Red hose 6. Run the green hose between rear frame and canister bracket. 7. Green hose 8. Blue hose 9. Canister 10. Run the blue hose so that it does not slack. 11. Run the ...

  • Page 472

    17-32 appendix cable, wire, and hose routing cal model (kl650e9 ∼ ec).

  • Page 473

    Appendix 17-33 cable, wire, and hose routing 1. Fuel hose 2. Coolant reserve tank overflow hose 3. Main harness 4. Blue hose 5. Red hose 6. Run the green hose between rear frame and canister bracket. 7. Green hose 8. Blue hose 9. Canister 10. Run the blue hose between rear frame and breather hose. 1...

  • Page 474

    17-34 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 ro...

  • Page 475

    Appendix 17-35 troubleshooting guide 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 warped cylinder head gasket damaged val...

  • Page 476

    17-36 appendix troubleshooting guide 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 gauge incorrect: water temperature gauge broken water temperature sensor broken coolan...

  • Page 477

    Appendix 17-37 troubleshooting guide camshaft chain tensioner trouble camshaft chain, sprocket, guide worn vacuum switch valve damaged alternator rotor loose balancer gear worn or chipped balancer shaft position maladjusted balancer bearing worn balaucer chain, sprocket, guide worn abnormal drive tr...

  • Page 478

    17-38 appendix troubleshooting guide battery trouble: battery discharged: battery faulty (e.G., plates sulphated, shorted through sedimentation, elec- trolyte insufficient) battery leads making poor contact load excessive (e.G., bulb of excessive wattage) ignition switch trouble alternator trouble w...

  • Page 479

    Model application year model beginning frame no. 2008 kl650e8 jkaklee1 □ 8da00101, jkaklee1 □ 8da00701 2009 kl650e9 jkaklee1 □ 9da15801, jkaklee1 □ 9da16243 2010 kl650ea jkaklee1 □ ada29521, jkaklee1 □ ada29561 2011 kl650eb jkaklee1 □ bda34207 2012 kl650ec jkaklee1 □ cda40279 □ :this digit in the fr...