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Kawasaki KLX 450R - BROCHURE 2010 Service Manual

Other manuals for KLX 450R - BROCHURE 2010: Brochure, Brochure

Summary of KLX 450R - BROCHURE 2010

  • Page 1

    Klx450r 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: Klx450R

    Klx450r 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 divis...

  • 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 10

    Instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly..

  • 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 klx450a8f left side view klx450a8f right side view frame number engine number.

  • Page 18

    1-8 general information general specifications items klx450a8f ∼ abf dimensions overall length 2 180 mm (85.83 in.), (au) (eur) 2 175 mm (85.63 in.) overall width 820 mm (32.3 in.) overall height 1 255 mm (49.41 in.), (au) (eur) 1 250 mm (49.21 in.) wheelbase 1 480 mm (58.27 in.) road clearance 320 ...

  • Page 19

    General information 1-9 general specifications items klx450a8f ∼ abf transmission: type 5-speed, constant mesh, return shift gear ratios: 1st 2.167 (26/12) 2nd 1.533 (23/15) 3rd 1.188 (19/16) 4th 0.950 (19/20) 5th 0.810 (17/21) final drive system: type chain drive reduction ratio 3.846 (50/13) overa...

  • Page 20

    1-10 general information general specifications items klx450a8f ∼ abf tail light led magneto: rated output 2.0 a/14 v specifications subject to change without notice, and may not apply to every country..

  • 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 .............. 2-2 torque and locking agent................. 2-4 specifications .................................... 2-9 special tools ..................................... 2-11 periodic maintenance procedur...

  • Page 24

    2-2 periodic maintenance periodic maintenance chart the maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Periodic inspection frequency traveled distance km (mi) operation every 100 (60) or 2.5 hr every 500 (300) or 7.5 hr every 1 000 (600) or 1...

  • Page 25

    Periodic maintenance 2-3 periodic maintenance chart frequency traveled distance km (mi) operation every 100 (60) or 2.5 hr every 500 (300) or 7.5 hr every 1 000 (600) or 15 hr every 1 500 (900) or 30 hr every 2 000 (1 200) or 60 hr see page rear sprocket-inspect † • • • • • 2 - 35 front fork-inspect...

  • Page 26

    2-4 periodic maintenance torque and locking agent tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for t...

  • Page 27

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks vacuum hose fitting 8.8 0.90 78 in·lb l cylinder head pipe mounting bolt 9.8 1.0 87 in·lb exhaust pipe cover bolts 12 1.2 106 in·lb rear muffler mounting bolt 20 2.0 15 front muffler mounting bolt (first) 9.8 1...

  • Page 28

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks gear set lever nut 8.8 0.90 78 in·lb engine oil drain plug (m6)(sub) 7.0 0.71 62 in·lb engine oil drain plug (m10)(main) 20 2.0 15 shift drum cam bolt 24 2.4 18 l piston oil nozzle 4.0 0.41 35 in·lb bearing ret...

  • Page 29

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks locknut/adjuster assembly 29 3.0 21 adjuster assembly 55 5.6 41 l front axle clamp bolts 20 2.0 15 al swingarm pivot shaft nut 98 10 72 r rocker arm pivot nut 59 6.0 44 r tie-rod mounting nut (front, rear) 59 6...

  • Page 30

    2-8 periodic maintenance torque and locking agent basic torque for general fasteners threads dia. Torque (mm) n·m kgf·m ft·lb 5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ...

  • Page 31

    Periodic maintenance 2-9 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – hot starter lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – air cleaner element oil high quality foam air filter oil – – – cooling system coolant: type (recom...

  • Page 32

    2-10 periodic maintenance specifications item standard service limit standard tire: front: size 80/100-21 51m – – – (au) (eur) 80/100-21 m/c 51p – – – make bridgestone – – – type d401, tube – – – (au) (eur) ed03, tube – – – rear: size 110/100-18 64m – – – (au) (eur)120/90-18 m/c 65p – – – make bridg...

  • Page 33

    Periodic maintenance 2-11 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 filler cap driver: 57001-1454 top plug wrench, 49 mm: 57001-1653.

  • Page 34

    2-12 periodic maintenance periodic maintenance procedures fuel system fuel hose and connection inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to ...

  • Page 35

    Periodic maintenance 2-13 periodic maintenance procedures warning operation with an improperly adjusted, incorrectly routed or damaged cables could result in an un- safe riding condition. Follow the service manual to make sure to correct any of these conditions. Hot starter lever free play inspectio...

  • Page 36

    2-14 periodic maintenance periodic maintenance procedures • start the engine and warm it up thoroughly. • with the engine idling, turn the handlebar to both sides [a]. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be da...

  • Page 37

    Periodic maintenance 2-15 periodic maintenance procedures warning gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well ventilated area, and take care that there is no spark or flame any- where near the working areas. Do not use g...

  • Page 38

    2-16 periodic maintenance periodic maintenance procedures • squeeze it dry in a clean towel [a]. Do not wring the ele- ment or blow it dry; the element can be damaged. • check all the parts of the element for visible damage. If any of the parts of the element are damaged, replace them. • after clean...

  • Page 39

    Periodic maintenance 2-17 periodic maintenance procedures • turn the fuel tap to the off position. • place a suitable container beneath the carburetor drain hose [b]. • loosen the drain plug [a] from the bottom of the float bowl and check for water or dirt in the fuel. If any water or dirt comes out...

  • Page 40

    2-18 periodic maintenance periodic maintenance procedures coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • lean the motorcycle slightly to the left until the radiator cap is level to the ground so that the radiator cap is located uppermost in...

  • Page 41

    Periodic maintenance 2-19 periodic maintenance procedures radiator hoses and connections inspection ○ the high pressure inside the radiator hoses and water hoses [a] can cause coolant to leak [b] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of det...

  • Page 42

    2-20 periodic maintenance periodic maintenance procedures if the vacuum switch valve does not operate as described, replace it with a new one. Note ○ to check air flow through the vacuum switch valve, just blow through the air cleaner hose. Vacuum switch valve closing pressure (open → close) standar...

  • Page 43

    Periodic maintenance 2-21 periodic maintenance procedures valve clearance adjustment • remove the camshaft caps [a] (see camshaft removal in the engine top end chapter). • remove the camshafts [b] (see camshaft removal in the engine top end chapter). • remove the valve lifters [c] of the applicable ...

  • Page 44

    2-22 periodic maintenance periodic maintenance procedures adjustment shims thick- ness p/no. Mark thick- ness p/no. Mark 2.00 92025-1870 0 2.55 92025-1881 55 2.05 92025-1871 5 2.575 92025-1985 58 2.10 92025-1872 10 2.60 92025-1882 60 2.15 92025-1873 15 2.625 92180-1059 63 2.20 92025-1874 20 2.65 920...

  • Page 45

    Periodic maintenance 2-23 periodic maintenance procedures cylinder head warp inspection • remove the cylinder head (see cylinder head removal in the engine top end chapter). • lay a straightedge [a] across the lower surface of the head at several different points, and measure warp by inserting a thi...

  • Page 46

    2-24 periodic maintenance periodic maintenance procedures piston/cylinder clearance the piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced. If only a piston ...

  • Page 47

    Periodic maintenance 2-25 periodic maintenance procedures • remove: spark arrester mounting bolts [a] spark arrester [b] • with a wire brush, remove the carbon off the inside of the spark arrester [a] and muffler. • inspect the spark arrester. If the spark arrester is damaged, replace it with a new ...

  • Page 48

    2-26 periodic maintenance periodic maintenance procedures clutch lever free play adjustment • slide the clutch lever dust cover out of place. • turn the adjuster [a] so that the clutch lever will have 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. Note ○ be sure that the outer cable end at the clutch lever is f...

  • Page 49

    Periodic maintenance 2-27 periodic maintenance procedures • remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely. Drain plug (sub) [a] drain plug (main) [b] note ○ hold the motorcycle upright so that the oil may drain completely. • replace the gaskets at th...

  • Page 50

    2-28 periodic maintenance periodic maintenance procedures • remove the oil filter [a]. • install the spring [a] to the right engine cover. • apply grease to the grommet [b]. • be sure to install the filter with the grommet facing outside as shown. Notice inside out installation stop oil flow, causin...

  • Page 51

    Periodic maintenance 2-29 periodic maintenance procedures crankshaft/transmission crankshaft inspection connecting rod big end side clearance • remove the cylinder head (see cylinder head removal in the engine top end chapter). • remove the cylinder (see cylinder removal in the engine top end chapte...

  • Page 52

    2-30 periodic maintenance periodic maintenance procedures tires inspection as the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • remove any imbedded stones or other foreign particles from the tread. • visually inspect the tire for cracks and cuts, replacing th...

  • Page 53

    Periodic maintenance 2-31 periodic maintenance procedures rim runout inspection • place the jack under the frame so that the front/rear wheel off the ground. Special tool - jack: 57001-1238 • inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must b...

  • Page 54

    2-32 periodic maintenance periodic maintenance procedures final drive drive chain slack inspection • raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • check the wheel alignment (see wheel alignment inspec- tion in ...

  • Page 55

    Periodic maintenance 2-33 periodic maintenance procedures note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [a] up to next alignment. ○ it should be within 30 degree. ○ loosen one and tighten again when th...

  • Page 56

    2-34 periodic maintenance periodic maintenance procedures warning a chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before e...

  • Page 57

    Periodic maintenance 2-35 periodic maintenance procedures rear sprocket warp inspection • using the jack, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • set a dial gauge [a] against the rear sprocket [b] near the teeth as shown and rotate [c] the rear wheel to measure the spr...

  • Page 58

    2-36 periodic maintenance periodic maintenance procedures ○ loosen the push rod locknut [a]. ○ replace the cotter pin with a new one. ○ remove: cotter pin [b] washer joint pin [c] ○ turn the bracket [d] to obtain the specified length. ○ tighten the locknut. Torque - rear master cylinder push rod loc...

  • Page 59

    Periodic maintenance 2-37 periodic maintenance procedures brake fluid change in accordance with the periodic maintenance chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the ai...

  • Page 60

    2-38 periodic maintenance periodic maintenance procedures note ○ the procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove the screws [a], reservoir cap [b] and diaphragm [c]. • remove the rubber cap...

  • Page 61

    Periodic maintenance 2-39 periodic maintenance procedures • remove the clear plastic hose. • tighten the bleed valves, and install the rubber caps. Torque - caliper bleed valve: 7.8 n·m (0.80 kgf·m, 69 in·lb) brake reservoir cap screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) • after changing the fluid, chec...

  • Page 62

    2-40 periodic maintenance periodic maintenance procedures notice do not remove the secondary cup from the piston since removal will damage it. • remove the rear master cylinder (see rear master cylin- der removal in the brakes chapter). Note ○ do not remove the push rod clevis for master cylinder di...

  • Page 63

    Periodic maintenance 2-41 periodic maintenance procedures caliper piston seal and dust seal replacement • loosen the brake pad pin [a] and banjo bolt [b], and tighten them loosely. • remove: front caliper mounting bolts [c] banjo bolt brake hose [e] front caliper [d] (see front caliper removal in th...

  • Page 64

    2-42 periodic maintenance periodic maintenance procedures • remove the rear caliper (see caliper removal in the brakes chapter). • remove the pads (see brake pad removal in the brakes chapter). • separate the caliper holder [b] from the caliper [a]. • using compressed air, remove the piston. ○ cover...

  • Page 65

    Periodic maintenance 2-43 periodic maintenance procedures • install the anti-rattle spring [a] in the caliper as shown. • replace the shaft rubber friction boot [a] and dust boot [b] if they are damaged. • apply a thin coat of pbc (poly butyl cuprysil) grease to the caliper holder shafts [c] and hol...

  • Page 66

    2-44 periodic maintenance periodic maintenance procedures brake hose and connection check • inspect the brake hose 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 if the line is not properly main-...

  • Page 67

    Periodic maintenance 2-45 periodic maintenance procedures for rear brake • remove: master cylinder [a] hose clamps [b] caliper cover [c] • when installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses according to cable, wire, and hose routing section in the ap...

  • Page 68

    2-46 periodic maintenance periodic maintenance procedures • loosen the fork top plug [a]. Special tool - top plug wrench, 49 mm [b]: 57001-1653 • remove: front wheel (see front wheel removal in the wheels/tires chapter) front brake caliper (see caliper removal in the brakes chapter) brake hose clamp...

  • Page 69

    Periodic maintenance 2-47 periodic maintenance procedures • place a drain pan under the front fork and drain fork oil [a]. Note ○ pump the fork tube several times to discharge the fork oil. • raise the outer tube and temporarily install the fork top plug [a] (subtank) to the outer tube [b] with the ...

  • Page 70

    2-48 periodic maintenance periodic maintenance procedures • hold the locknut [a] with a wrench [b] and remove the adjuster assembly [c]. • remove the push rod [a]. • with the outer tube compressed by hands, remove the top plug wrench [a]. Notice removing the locknut and pushing the piston rod thread...

  • Page 71

    Periodic maintenance 2-49 periodic maintenance procedures • holding the top plug wrench [a] with a vise, loosen the base valve assembly [b] on the subtank [c]. Special tool - top plug wrench, 49 mm: 57001-1653 • remove the base valve assembly [a] from the subtank [b]. Note ○ slowly compress the pist...

  • Page 72

    2-50 periodic maintenance periodic maintenance procedures • with the piston rod in fully compressed position, pour the specified amount of fork oil [a]. Recommended oil: khl15-10 (kayaba01) or equivalent recommended quantity: 189 ml (6.4 us oz.) note ○ plug the two oil holes on the subtank [b] with ...

  • Page 73

    Periodic maintenance 2-51 periodic maintenance procedures • holding the top plug wrench [a] with a vise. Special tool - top plug wrench, 49 mm: 57001-1653 • holding the subtank [b] with the top plug wrench, torque the base valve assembly [c]. Torque - base valve assembly: 28 n·m (2.9 kgf·m, 21 ft·lb...

  • Page 74

    2-52 periodic maintenance periodic maintenance procedures • completely wipe of the fork oil from the spring [a], spacer [b] and cylinder unit [c]. • insert above-mentioned parts into the fork. • temporarily tighten the fork top plug [a] (subtank) using the top plug wrench. Special tool - top plug wr...

  • Page 75

    Periodic maintenance 2-53 periodic maintenance procedures • replace the o-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the o-ring. • turn the locknut [a] counterclockwise until it contacts with the adjuster assembly [b]. • with the locknut held immovable usi...

  • Page 76

    2-54 periodic maintenance periodic maintenance procedures rear shock absorber inspection • bounce [a] the rear of the motorcycle up and down and check for smooth suspension stroke. • remove the rear frame (see rear frame removal in the frame chapter). • check for a broken or collapsed spring. • chec...

  • Page 77

    Periodic maintenance 2-55 periodic maintenance procedures • using the suitable tool [a] and press, push the reservoir cap [b] in 10 mm (0.39 in.). • remove the circlip [c] from the gas reservoir. • pull the gas reservoir cap [b] out of the gas reservoir using the pliers [a]. • pry or tap [a] at the ...

  • Page 78

    2-56 periodic maintenance periodic maintenance procedures • using the grinder, shave off the stopper portion [a] of the rod. • remove: nut [b] washer [c] piston [d] • install the new piston and tighten the locknut. ○ discard a washer or two. • pour kyb k2-c (sae 5w or bel-ray se2 #40) oil into the g...

  • Page 79

    Periodic maintenance 2-57 periodic maintenance procedures • mount the circlip [a] in the groove in the gas reservoir. • pull up the gas reservoir cap [a] against the circlip. The end of the gas reservoir cap must align [b] with the end of the gas reservoir [c]. Warning pressurized nitrogen gas can e...

  • Page 80

    2-58 periodic maintenance periodic maintenance procedures • insert the piston end [a] of the piston rod assembly into the rear shock body [c] slowly. Do not insert the seal assembly [b] yet. Pump the piston rod until all the air is forced out of the rear shock body. • push the seal assembly into the...

  • Page 81

    Periodic maintenance 2-59 periodic maintenance procedures swingarm and uni-trak linkage inspection • check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-12...

  • Page 82

    2-60 periodic maintenance periodic maintenance procedures • remove: handlebar pad [a] headlight [b] (see headlight removal/installation in the electrical system chapter) • remove: handlebar clamp bolts [a] handlebar clamps [b] handlebar [c] (from holder) • loosen the front fork upper clamp bolts [a]...

  • Page 83

    Periodic maintenance 2-61 periodic maintenance procedures • install the handlebar [b] on the handlebar holder so that the protruded scales of the both side adjust to the same width [a]. • route the hose according to cable, wire, and hose rout- ing section in the appendix chapter. • apply 2-stroke oi...

  • Page 84

    2-62 periodic maintenance periodic maintenance procedures electrical system spark plug cleaning and inspection • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system chapter) spark plug cap • clean the plug hole [a], using the compressed air [b]. •...

  • Page 85

    Periodic maintenance 2-63 periodic maintenance procedures points: lubricate with grease. Clutch inner cable upper and lower ends [a] hot start inner cable upper end throttle inner cable upper end cables: lubricate with rust inhibitor. Throttle cables clutch cable hot starter cable • with the cable d...

  • Page 86

    2-64 periodic maintenance periodic maintenance procedures if there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the torque and locking agent section of the general information chapter for torque specifications. For each fastener, fi...

  • Page 87: Fuel System

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

  • Page 88

    3-2 fuel system exploded view.

  • Page 89

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolt 3.4 0.35 30 in·lb 2 throttle cable mounting bolts 6.9 0.70 61 in·lb 3. Hot starter cable 4. Throttle cables 5. Throttle grip 6. Carburetor cap 7. Throttle valve plate 8. Throttle valve 9. Jet needl...

  • Page 90

    3-4 fuel system exploded view.

  • Page 91

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 vacuum switch valve bracket bolts 9.8 1.0 87 in·lb 2 fuel tap knob screws 0.80 0.080 7.0 in·lb 3 rear frame mounting bolts 34 3.5 25 4. Fuel tank cap 5. Fuel tank 6. Fuel tap 7. Element 8. Frame 9. Holder 10. Air cleaner duc...

  • Page 92

    3-6 fuel system specifications item standard throttle grip and cable throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) hot starter lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) carburetor make/type keihin fcr-mx40 starter jet #55 leak jet #50 main jet #145 throttle valve cutaway 1.5 jet needle nlz...

  • Page 93

    Fuel system 3-7 special tool fuel level gauge, m18 × 1.0: 57001-122.

  • Page 94

    3-8 fuel system throttle grip and cable if the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle wi...

  • Page 95

    Fuel system 3-9 throttle grip and cable • remove the exhaust pipe (see muffler removal in the engine top end chapter). • unscrew the bolt [a]. • remove the throttle pulley cover [b]. • loosen the mounting bolts [a]. • remove the cables [b] from the carburetor. • free the tips [c] from the pulley. • ...

  • Page 96

    3-10 fuel system throttle grip and cable hot starter cable removal • slide the clutch lever dust cover [a] back. • loosen the locknut [b]. • turn in the adjuster [c] fully. • remove the cable end [d] from the hot starter lever [e]. • remove: fuel tank (see fuel tank removal) • unscrew the plunger ca...

  • Page 97

    Fuel system 3-11 throttle grip and cable hot starter lever free play adjustment • refer to the hot starter lever free play inspection in the periodic maintenance chapter. Hot starter cable lubrication • whenever the hot starter cable is removed or in accor- dance with the periodic maintenance chart,...

  • Page 98

    3-12 fuel system carburetor since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or im...

  • Page 99

    Fuel system 3-13 carburetor • read the fuel level in the gauge and compare it to the specification. Service fuel level (below the bottom edge of the carb. Body) standard: –6.5 ±1 mm (–0.26 ±0.04 in.) if the fuel level is incorrect, adjust it. • turn the fuel tap to the off position and remove the fu...

  • Page 100

    3-14 fuel system carburetor note ○ float height [a] is the distance from the float bowl mat- ing surface [b] of the carburetor body (with the gasket removed) to the top of the float [c]. Measure the height with the carburetor upside down. ○ do not push the needle rod [d] in during the float height m...

  • Page 101

    Fuel system 3-15 carburetor • loosen the clamp screw [a] fully. • remove: engine mounting bracket bolts [b] right engine mounting bracket [c] • remove: seat (see seat removal in the frame chapter) side covers (see side cover removal in the frame chapter) muffler (see muffler removal in the engine to...

  • Page 102

    3-16 fuel system carburetor • loosen the mounting bolts [a]. • pull out the end of the throttle cables [b]. • free the tips [c]. • remove the carburetor to the right side of the frame. • drain the fuel from the float bowl by removing the drain plug. After draining, install the drain plug securely. •...

  • Page 103

    Fuel system 3-17 carburetor ○ adjust the following items if necessary: throttle cable (see throttle grip free play adjustment in the periodic maintenance chapter) idle speed (see idle speed adjustment in the periodic maintenance chapter) fuel inspection • refer to the fuel inspection in the periodic...

  • Page 104

    3-18 fuel system carburetor • disassemble the throttle valve assembly; jet needle holder [a] (unscrew), spring [b], retainer [c], jet needle with circlip [d], o-ring with throttle valve plate [e], and throttle valve [f]. • remove the choke knob/starter plunger assembly [a] from the carburetor. • rem...

  • Page 105

    Fuel system 3-19 carburetor • unscrew the screws [a]. • remove the acceleration pump cover [b] from the carbu- retor. • remove the spring [a], diaphragm [b], and the o-rings [c]. • remove the following parts from the carburetor body. [a] idle adjusting screw [b] screws [c] clamps [d] float bowl [e] ...

  • Page 106

    3-20 fuel system carburetor • remove: e-clip [a] washer [b] • pull out the acceleration pump lever assembly [c] as a set. • remove the throttle sensor mounting bolt [a]. • before removing the throttle sensor [b], mark [c] the car- buretor body and sensor so that it can be installed later in the same...

  • Page 107

    Fuel system 3-21 carburetor • immerse all the metal parts in a carburetor cleaning solu- tion. • rinse the parts in water. • after the parts are cleaned, dry them with compressed air. • blow through the air and fuel passages with compressed air [a]. • assemble the carburetor, and install it on the m...

  • Page 108

    3-22 fuel system carburetor • remove the float valve needle. • check the plastic tip [a] of the float valve needle [b] for wear. If the needle is worn as shown right [c], replace the valve needle. • push the rod [d] in the valve needle, then release it. If the rod does not come out fully by spring t...

  • Page 109

    Fuel system 3-23 carburetor • install the return spring [a] to the acceleration pump lever [b]. • install the acceleration pump lever assembly to the car- buretor body. ○ fit the end [a] of the return spring into the recess [b] on the carburetor body. • install: washer [a] e-clip [b] • apply thin co...

  • Page 110

    3-24 fuel system carburetor ○ fit the end [a] of the return spring into the recess [b] of the carburetor body. • turn the pulley counterclockwise [a] while holding down the acceleration pump lever [b] and clear the stopper [c] of the pulley from the throttle stop screw head [d]. • install the push r...

  • Page 111

    Fuel system 3-25 carburetor • apply a grease to the o-ring [a]. • fit the stopper [b] of the throttle sensor onto the projection [c] on the throttle cable pulley shaft. ○ install the throttle sensor so that the marks aligns and check it position (see throttle sensor inspection in the electrical syst...

  • Page 112

    3-26 fuel system carburetor • install: leak jet [a] • replace the o-ring with new one. • fit the o-ring [b] onto the groove of the float chamber. • install: float bowl • tighten the screws with hose clamps [a] and cable holder [b] as shown. • replace the o-rings with new ones. • fit the o-rings [a]....

  • Page 113

    Fuel system 3-27 carburetor • install all hoses [a]. • install the carburetor (see carburetor installation). • if turn the adjusting screw of the acceleration pump, follow the procedures below. ○ adjust the acceleration pump timing. ○ select an arbor [a] of the same diameter as the throttle valve he...

  • Page 114

    3-28 fuel system air cleaner air cleaner housing removal • remove: side covers (see side cover removal in the frame chapter) seat (see seat removal in the frame chapter) muffler (see muffler removal in the engine top end chapter) rear fender (see rear fender removal in the frame chapter) rear frame ...

  • Page 115

    Fuel system 3-29 air cleaner element installation • when installing the element, coat the lip of the element with a thick layer of all purpose grease [a] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. • apply grease to all conne...

  • Page 116

    3-30 fuel system fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and 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 l...

  • Page 117

    Fuel system 3-31 fuel tank fuel tank, filter and tap cleaning • refer to the fuel tank, filter and tap cleaning in the periodic maintenance chapter. Fuel tap and filter inspection • refer to the fuel tap and filter inspection in the periodic maintenance chapter..

  • Page 119: Cooling System

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

  • Page 120

    4-2 cooling system exploded view.

  • Page 121

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump cover bolts 9.8 1.0 87 in·lb 2 coolant drain plug 7.0 0.70 62 in·lb 3 water pump impeller bolt 9.8 1.0 87 in·lb 4 right engine cover bolts 9.8 1.0 87 in·lb 5 radiator hose clamp screws 3.0 0.30 27 in·lb 6. Wate...

  • Page 122

    4-4 cooling system coolant flow chart.

  • Page 123

    Cooling system 4-5 coolant flow chart 1. Radiator cap 2. Radiators 3. Reserve tank hose 4. Reserve tank 5. Reserve tank over flow hose 6. Cylinder head jacket 7. Cylinder jacket 8. Impeller 9. Hot coolant 10. Cold coolant permanent type antifreeze is used as a coolant to protect the cooling system f...

  • Page 124

    4-6 cooling system specifications item service limit coolant type 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 point –35°c (–31°f) total amount 1....

  • Page 125

    Cooling system 4-7 special tool bearing driver set: 57001-1129.

  • Page 126

    4-8 cooling system coolant check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the periodic maintenance chart (see periodic maintenance chapter). Warning hot engine coolant can cause serious burns. To avoid...

  • Page 127

    Cooling system 4-9 coolant • place a container under the coolant drain plug [a], and drain the coolant from the radiator and engine by remov- ing the drain plug on the water pump cover. Immediately wipe or wash out any coolant that spills on the frame, or engine. • inspect the old coolant for visual...

  • Page 128

    4-10 cooling system coolant • fill the radiator up to the bottom of the radiator filler neck [b] with coolant [a], and install the cap, turning it clockwise about 1/4 turn. ○ lean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is lo...

  • Page 129

    Cooling system 4-11 coolant cooling system pressure testing notice during pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 141.7 kpa (1.445 kgf/cm², 20.55 psi). • remove the radiator cap, and install a cooling system pressure tester [a]...

  • Page 130

    4-12 cooling system coolant reserve tank removal • remove: seat (see seat removal in the frame chapter) left side cover (see left side cover removal in the frame chapter) • remove: bolts [a] cap [b] • drain the coolant to the suitable container. • remove: hose [c].

  • Page 131

    Cooling system 4-13 water pump water pump cover removal • remove engine guard (see coolant draining). • unscrew the drain plug [a], and drain the coolant (see coolant draining). • loosen the clamp screw [b], and remove the water hose [c] from the water pump cover. • unscrew the cover bolts [d]. • us...

  • Page 132

    4-14 cooling system water pump impeller removal • drain: coolant (see coolant draining) • remove: water pump cover (see water pump cover removal) impeller bolt [a] impeller [b] impeller installation • install: impeller [a] • tighten: torque - water pump impeller bolt [b]: 9.8 n·m (1.0 kgf·m, 87 in·l...

  • Page 133

    Cooling system 4-15 water pump • insert a bar [a] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [b] by tapping [c] evenly around the bearing in- ner race. • remove the spacer [d]. • remove the ball bearing [e] and oil seal [f] from the right e...

  • Page 134

    4-16 cooling system radiator radiator removal • drain the coolant (see coolant draining) • remove: radiator shrouds • loosen: clamp screws [a] clamps [b] • remove: radiator hoses [c] bolt [d] left radiator screen [e] • remove: bolts [a] left radiator [b] • loosen: clamp screws [a] • remove: radiator...

  • Page 135

    Cooling system 4-17 radiator radiator installation • fit the projections [a] of the screen in the holes [b] of the radiator. Torque - radiator hose clamp screws: 3.0 n·m (0.30 kgf·m, 27 in·lb) • route the radiator and breather hoses correctly (see cable, wire, and hose routing section in the appendi...

  • Page 136

    4-18 cooling system radiator • wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • install the cap [a] on a cooling system pressure tester [b]. • watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The gauge hand must remain within...

  • Page 137: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools and sealant ................. 5-9 clean air system (u.S.A., california, and canada models) ...................... 5-12 vacu...

  • Page 138

    5-2 engine top end exploded view.

  • Page 139

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 9.8 1.0 87 in·lb 2 cylinder head bolts (m10) 59 6.0 44 s, mo 3 cylinder head bolts (m6) 12 1.2 106 in·lb s 4 cylinder bolt 12 1.2 106 in·lb 5 camshaft cap bolts 9.8 1.0 87 in·lb s, mo 6 camshaft ...

  • Page 140

    5-4 engine top end exploded view.

  • Page 141

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 12 1.2 106 in·lb 2 rear muffler mounting bolt 20 2.0 15 front muffler mounting bolt (first) 9.8 1.0 87 in·lb 3 front muffler mounting bolt (final) 20 2.0 15 4 exhaust pipe holder nuts 20 2.0 15 5 ...

  • Page 142

    5-6 engine top end specifications item standard service limit camshafts cam height: exhaust 36.443 ∼ 36.557 mm (1.4348 ∼ 1.4392 in.) 36.34 mm (1.431 in.) intake 37.143 ∼ 37.257 mm (1.4623 ∼ 1.4668 in.) 37.04 mm (1.458 in.) camshaft journal, camshaft cap clearance 0.020 ∼ 0.061 mm (0.00079 ∼ 0.0024 i...

  • Page 143

    Engine top end 5-7 specifications item standard service limit valve spring free length: exhaust: outer 36.2 mm (1.43 in.) 34.6 mm (1.36 in.) intake 32.4 mm (1.28 in.) 30.9 mm (1.22 in.) intake: outer 39.3 mm (1.55 in.) 37.8 mm (1.49 in.) inner 36.0 mm (1.42 in.) 34.5 mm (1.36 in.) cylinder and pisto...

  • Page 144

    5-8 engine top end specifications cam height cam height [a] camshaft runout valve stem diameter valve stem diameter [a] 45° [b] valve stem bend dial gauge [a].

  • Page 145

    Engine top end 5-9 special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 valve guide arbor, 5.5: 57001-1021 valve guide reamer, 5.5: 57001-1079 piston ring compressor grip: 57001-1095 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, ...

  • Page 146

    5-10 engine top end special tools and sealant valve seat cutter, 55° - 35: 57001-1247 spark plug wrench, hex 16: 57001-1262 fork oil level gauge: 57001-1290 compression gauge adapter, m10 × 1.0: 57001-1317 piston ring compressor belt, 95 ∼ 108: 57001-1358 filler cap driver: 57001-1454 valve seat cut...

  • Page 147

    Engine top end 5-11 special tools and sealant valve spring compressor adapter, 24: 57001-1586 valve guide driver attachment d: 57001-1659 liquid gasket, tb1216b: 92104-1064.

  • Page 148

    5-12 engine top end clean air system (u.S.A., california, and canada models) 1. Air cleaner 2. Carburetor 3. Vacuum switch valve 4. View from a 5. Intake air 6. Exhaust gas 7. Secondary air.

  • Page 149

    Engine top end 5-13 clean air system (u.S.A., california, and canada models) vacuum switch valve removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) • slide out the clamp [a]. • remove the hose [b] from the cylinder head pipe [c]. • slide out the clamps [a] and take off th...

  • Page 150

    5-14 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) spark plug cap • remove the cylinder head cover bolts [a] and remove the cylinder head cover [b]. Cylinder head cover installation • wipe off any oil, dirt, and ...

  • Page 151

    Engine top end 5-15 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 152

    5-16 engine top end camshaft chain tensioner • replace the chain tensioner gasket with a new one. • tighten: torque - chain tensioner mounting bolts [a]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • take out the holder plate [b]. • install the o-ring and tighten the cap bolt. Torque - chain tensioner cap bolt: 5...

  • Page 153

    Engine top end 5-17 camshaft camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] crankshaft shaft cap [b] special tool - filler cap driver: 57001-1454 • first, bring the piston to the tdc of the compression stroke. ○ place a wrench over the fl...

  • Page 154

    5-18 engine top end camshaft • remove: bolts [a] auto-decompressor [b] (with the sprocket) • remove: circlips [a] camshaft installation • assemble the auto-decompressor weights [a] and spring [b] to install it to the sprocket [c]. • replace the circlips [d] with new ones, and install them. • apply a...

  • Page 155

    Engine top end 5-19 camshaft • engage the camshaft chain with the camshaft sprockets. ○ pull the tension side (exhaust side) of the chain taut to install the chain. ○ the timing marks on the sprocket must be aligned with the cylinder head upper surface. • pull the chain taut and fit it onto the cams...

  • Page 156

    5-20 engine top end camshaft • apply grease to the rubber portions of the oil pipes. • assemble: camshaft caps [a] oil pipes [b] • while keeping parallel, install them. • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ following the sequence numbe...

  • Page 157

    Engine top end 5-21 camshaft camshaft and camshaft cap wear • measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [a]. • install the camshaft caps (see camshaft installation). Note ○ do not turn the camshaft when the plastigauge is be- tween the journ...

  • Page 158

    5-22 engine top end cylinder head cylinder compression measurement • start the engine. • thoroughly warm up the engine so that the 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 tank (see fuel tank re...

  • Page 159

    Engine top end 5-23 cylinder head problem diagnosis remedy (action) carbon accumulation on piston and in cylinder head (combustion chamber) is suspected due to damaged valve stem or piston oil rings. Remove the carbon deposits and replace damaged parts if necessary. The cylinder compression is highe...

  • Page 160

    5-24 engine top end cylinder head • remove the vacuum switch valve hose [a] and vacuum hose [b] from the cylinder head (equipped models). • remove the 10 mm cylinder head bolts following the tight- ening sequence [1 ∼ 4] as shown. • tap lightly up with a plastic mallet [a] to separate the cylin- der...

  • Page 161

    Engine top end 5-25 cylinder head • tighten the 10 mm cylinder head bolts in the numbered sequence [1 ∼ 4]. Torque - cylinder head bolts (m10): 59 n·m (6.0 kgf·m, 44 ft·lb) • tighten: torque - cylinder bolt [a]: 12 n·m (1.2 kgf·m, 106 in·lb) cylinder head bolts (m6) [b]: 12 n·m (1.2 kgf·m, 106 in·lb...

  • Page 162

    5-26 engine top end 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 163

    Engine top end 5-27 valves valve guide removal • remove: valve (see valve removal) oil seal spring seat • heat the area around the valve guide up to 120 ∼ 150°c (248 ∼ 302°f). Notice do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil...

  • Page 164

    5-28 engine top end valves • ream the valve guide with valve guide reamer [a], even if the old guide is reused. Special tool - valve guide reamer, 5.5: 57001-1079 valve/valve guide clearance measurement (wobble method) ○ if a small bore gauge is not available, inspect the valve guide wear by measuri...

  • Page 165

    Engine top end 5-29 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. • measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 166

    5-30 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the vale for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fail...

  • Page 167

    Engine top end 5-31 valves • measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Original seating surface [b] ○ remove all pittings of flaws f...

  • Page 168

    5-32 engine top end valves • the seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. • when the engine is assembled, be s...

  • Page 169

    Engine top end 5-33 valves valve seat repair.

  • Page 170

    5-34 engine top end cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remove the cylinder base gasket. Piston removal • remove...

  • Page 171

    Engine top end 5-35 cylinder and piston • install the top ring [a] so that the "r" mark [b] faces up. Note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston rings. • apply engine oil to the inside wall of the small end of ...

  • Page 172

    5-36 engine top end cylinder and piston • apply engine oil to the cylinder bore. • determine the position of the piston ring ends. • install the cylinder while compressing the piston rings with your fingers or the special tool [a]. Special tools - piston ring compressor grip: 57001-1095 piston ring ...

  • Page 173

    Engine top end 5-37 cylinder and piston piston ring groove width • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: top 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) service limit: top 1.13 mm (0.0445 in.) if any of the groove widths exce...

  • Page 174

    5-38 engine top end cylinder and piston piston, piston pin, connecting rod wear inspection • visually inspect the snap rings [a] still fitted in place. If the rings show weakness or deformation, replace the rings. Also if the pin hole groove shows excessive wear, replace the piston. • measure the di...

  • Page 175

    Engine top end 5-39 carburetor holder carburetor holder installation • install the carburetor holder [a] with the marked [b] side facing toward the cylinder head outside. ○ install the holder clamp [c] with its screw head [d] facing left side. Torque - carburetor holder clamp screws: 2.0 n·m (0.20 k...

  • Page 176

    5-40 engine top end muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler removal • loosen the muffler clamp bolt [a]. • remove the exhaust pip holder nuts [b]. • remove the exhaust pipe [c] and muf...

  • Page 177

    Engine top end 5-41 muffler exhaust system inspection • the exhaust system, in particular the silencer, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If car- bon has built up inside the silencer, exhaust efficiency is reduced, caus...

  • Page 179: Engine Right Side

    Engine right side 6-1 6 engine right side table of contents exploded view........................................................................................................................ 6-2 specifications ..........................................................................................

  • Page 180

    6-2 engine right side exploded view.

  • Page 181

    Engine right side 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 primary gear nut 98 10 72 lh,r 2 clutch cover bolts 9.8 1.0 87 in·lb 3 right engine cover bolts 9.8 1.0 87 in·lb 4 clutch spring bolts 8.8 0.90 78 in·lb 5 clutch hub nut 98 10 72 r 6. Primary gear 7. Push rod holder 8....

  • Page 182

    6-4 engine right side exploded view.

  • Page 183

    Engine right side 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 ratchet guide bolt 8.8 0.90 78 in·lb 2 kick pedal bolt 25 2.5 18 l 3 ratchet plate mounting bolt 9.8 1.0 87 in·lb s 4 ratchet plate mounting screw 6.4 0.65 56 in·lb l,s 5 gear set lever nut 8.8 0.90 78 in·lb 6 shift dr...

  • Page 184

    6-6 engine right side specifications item standard service limit clutch lever clutch lever free play (lever pointed end) 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 ...

  • Page 185

    Engine right side 6-7 special tools outside circlip pliers: 57001-144 clutch holder: 57001-1243 gear holder, m2.0: 57001-1557.

  • Page 186

    6-8 engine right side clutch lever and cable due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the periodic maintenance chart. Warning the engine and exhaust system get extremely hot during normal operation and can cause s...

  • Page 187

    Engine right side 6-9 clutch lever and cable • free the clutch inner cable tip [a] from the pull rod [b]. Notice do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with a new one. • pull the clutch cable out of the frame. Clu...

  • Page 188

    6-10 engine right side clutch cover and right engine cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the brake pedal (see brake pedal removal in the brakes chapter). • remove the clutch cover bolts [a] and right engine cover b...

  • Page 189

    Engine right side 6-11 clutch cover and right engine cover right engine cover installation • three dowel pins [a] are installed at the mating surface between the crankcase and the right engine cover. • apply grease to the o-rings [b], and install them to the crankcase. ○ install the lower o-ring so ...

  • Page 190

    6-12 engine right side clutch cover and right engine cover • turn the release lever shaft [a] and remove the short ca- ble [b] from the lever. • pull the lever and shaft assembly [c] out of the crankcase. Release shaft installation • apply grease to the oil seal lips. • apply engine oil to the beari...

  • Page 191

    Engine right side 6-13 clutch clutch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the clutch cover (see clutch cover removal). • remove: clutch spring bolts [a] clutch springs clutch spring plate [b] • remove: adjusting washer [a] needle bear...

  • Page 192

    6-14 engine right side clutch • install the washer so that stamp mark [a] facing the out- side. • tighten the clutch hub nut [a] with the clutch holder [b]. Special tool - clutch holder: 57001-1243 torque - clutch hub nut: 98 n·m (10 kgf·m, 72 ft·lb) • install the friction plates and steel plates, s...

  • Page 193

    Engine right side 6-15 clutch • tighten: torque - clutch spring bolts [a]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install the clutch cover (see clutch cover installation). • check the pull rod positions [a]. ○ pulling [b] the pull rod [c] lightly upward by hand and measure the portion of the pull rod comi...

  • Page 194

    6-16 engine right side clutch clutch plate assembly free play inspection/ad- justment • assemble the following parts. Clutch hub [a] friction plates [b] steel plates [c] friction plates [d] spring plate [e] spring [f] bolts [g] ○ friction plates [b] have lining blocks that are wider than other plate...

  • Page 195

    Engine right side 6-17 clutch clutch housing finger damage • visually inspect the clutch housing fingers [a] that come in contact with the friction plate tangs. If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction...

  • Page 196

    6-18 engine right side primary gear primary gear removal • remove: right engine cover (see right engine cover removal) clutch (see clutch removal) • temporarily install the clutch housing [a]. • using the gear holder [b], secure the primary gear and loosen the primary gear nut. Special tool - gear h...

  • Page 197

    Engine right side 6-19 external shift mechanism external shift mechanism removal • remove: shift pedal bolt [a] shift pedal [b] • remove: right engine cover (see right engine cover removal) clutch housing (see clutch removal) circlip [a] oil pump driven gear [b] • pull out the shift shaft [c]. • rem...

  • Page 198

    6-20 engine right side external shift mechanism • set up the shift ratchet assembly as shown in the figure. Ratchet [a] pawls [b] pins [c] springs [d] ○ assembly the shift ratchet so that groove [e] of the pawl facing the crankcase side [f]. • then install the ratchet assembly [a] to the ratchet pla...

  • Page 199

    Engine right side 6-21 external shift mechanism • check the ratchet assembly for damage. If ratchet [a], pawls [b], pins [c] or springs [d] are dam- aged in any way, replace them. • check the gear set lever [a] and its spring [b] for cracks or distortion. If the lever or spring is damaged in any way...

  • Page 200

    6-22 engine right side kickstarter kick pedal assy removal • remove: mounting bolt [a] kick pedal assy [b] kick pedal assy installation • install the kick pedal assy [a] at the angle shown. 17 ∼ 27 mm (0.67 ∼ 1.1 in.) [b] • apply a non-permanent locking agent to the kick pedal bolt. • tighten: torqu...

  • Page 201

    Engine right side 6-23 kickstarter idle gear installation • apply engine oil to the inside of the idle gear. • replace the circlip [a] with a new one. • install the idle gear [b] facing embossed letter [c] to the outside. • install the circlip. Kickshaft removal • remove: right engine cover (see rig...

  • Page 202

    6-24 engine right side kickstarter kick shaft assembly disassembly/assembly • the kick shaft assembly consists of the following parts. [a] kick gear [b] circlip [c] washer [d] spring [e] ratchet gear [f] kick shaft [g] kick spring [h] spring guide • check the kick shaft assembly parts for damage. An...

  • Page 203: Engine Lubrication System

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

  • Page 204

    7-2 engine lubrication system exploded view.

  • Page 205

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain plug (m10) (main) 20 2.0 15 2 engine oil drain plug (m6) (sub) 7.0 0.71 62 in·lb 3 oil pump (scavenge) cover bolts 9.8 1.0 87 in·lb 4 oil pump (feed) cover bolts 9.8 1.0 87 in·lb 5 right engine...

  • Page 206

    7-4 engine lubrication system lubrication system chart.

  • Page 207

    Engine lubrication system 7-5 lubrication system chart 1. Oil screen (feed) 2. Oil pump (feed) 3. Oil pressure relief valve 4. Right engine cover oil passage (from feed oil pump to oil filter) 5. Oil filter 6. Right engine cover oil passage (from oil filter to crankshaft) 7. Crankshaft 8. Piston oil...

  • Page 208

    7-6 engine lubrication system specifications item standard engine oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity oil change - when filter is not removed 1.06 l (1.12 us qt) oil change - when filter is removed 1.08 l (1.14 us qt) when engine is completely dry...

  • Page 209

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm²: 57001-125 outside circlip pliers: 57001-144 oil pressure gauge adapter, m10 × 1.25: 57001-1182 oil pressure cap: 57001-1656.

  • Page 210

    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 211

    Engine lubrication system 7-9 engine oil and oil filter oil filter change • refer to the oil filter change in the periodic maintenance chapter..

  • Page 212

    7-10 engine lubrication system oil screen oil screen (scavenge) removal • remove the oil pump (scavenge) cover (see oil pump (scavenge) removal). • pull out the oil screen [a] from the crankcase. Oil screen (scavenge) installation • clean the oil screens thoroughly whenever it is removed for any rea...

  • Page 213

    Engine lubrication system 7-11 oil screen oil screen (feed) removal • split the crankcase (see crankcase disassembly in the crankshaft/transmission chapter). • remove: bolts [a] oil screen [b] oil screen (feed) installation • replace the o-ring [a] with a new one. • apply grease to the o-ring, and i...

  • Page 214

    7-12 engine lubrication system oil screen • check the screen [a] carefully for any damage, holes, broken wires gasket pulling off. If the screen is damaged, replace it. • install the oil screen (see oil screen (scavenge) installa- tion). Oil screen (feed) cleaning • remove the oil screen (see oil sc...

  • Page 215

    Engine lubrication system 7-13 oil pressure relief valve oil pressure relief valve removal • remove: right engine cover (see right engine cover removal in the engine right side chapter) clutch (see clutch removal in the engine right side chapter) • remove the oil pressure relief valve [a]. Oil press...

  • Page 216

    7-14 engine lubrication system oil pump oil pump (scavenge) removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant draining in the coolant system chapter) • remove: shift pedal (see external shift mechanism in the engine right side chapter) fly...

  • Page 217

    Engine lubrication system 7-15 oil pump oil pump (feed) removal • remove: right engine cover (right engine cover removal in the engine right side chapter) clutch (clutch removal in the engine right side chap- ter) circlip [a] oil pump driven gear [b] shaft [c] oil pump idle gear [d] • remove: oil pu...

  • Page 218

    7-16 engine lubrication system oil pump • apply molybdenum disulfide grease to the oil pump idle gear shaft [a]. • install the oil pump idle gear [b] facing the stepped side [c] to the outside. • replace the circlip [d] with a new one. • install the oil pump driven gear [e] and circlip. Oil pump ins...

  • Page 219

    Engine lubrication system 7-17 oil pressure oil pressure measurement • remove: exhaust pipe (see muffler removal in the engine top end chapter) right engine cover bolt [a] oil filter cover bolt [b] oil filter cover [c] • install the o-rings to the oil pressure cap. Special tool - oil pressure cap: 5...

  • Page 221: Engine Removal/installation

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

  • Page 222

    8-2 engine removal/installation exploded view.

  • Page 223

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine mounting bolts (m10) 49 5.0 36 2 middle engine mounting nut (m10) 49 5.0 36 r 3 lower engine mounting nut (m10) 49 5.0 36 r 4 upper engine bracket bolts (m8) 29 3.0 21 5 middle engine bracket nut...

  • Page 224

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

  • Page 225

    Engine removal/installation 8-5 engine removal/installation engine removal • place the jack [a] under the frame to support the motor- cycle. 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 frame ...

  • Page 226

    8-6 engine removal/installation engine removal/installation • remove: radiator (see radiator removal in the cooling system chapter) muffler (see muffler removal in the engine top end chapter) air cleaner housing with rear frame (see air cleaner housing removal in the fuel system chapter) starter mot...

  • Page 227

    Engine removal/installation 8-7 engine removal/installation • remove the swingarm pivot shaft nut [a] to pull out the swingarm pivot shaft [b]. ○ pull out the swingarm pivot shaft half way from right side to free the engine. • remove the engine from the vehicle to right side. ○ clear the engine rear...

  • Page 228

    8-8 engine removal/installation engine removal/installation engine installation • install the engine. ○ first, insert the front portion of the engine, and then install the rear portion. • install the swingarm pivot shaft, all engine bracket and mounting bolts temporarily. ○ swingarm pivot shaft inse...

  • Page 229

    Engine removal/installation 8-9 engine removal/installation warning after servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride t...

  • Page 231: Crankshaft/transmission

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

  • Page 232

    9-2 crankshaft/transmission exploded view.

  • Page 233

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 crankcase bolts (m6) 12 1.2 106 in·lb s 2 crankcase bolts (m7) 15 1.5 11 s 3 gear set lever nut 8.8 0.90 78 in·lb 4 engine oil drain plug (m6)(sub) 7.0 0.71 62 in·lb 5 engine oil drain plug (m10)(main) 20 2.0 1...

  • Page 234

    9-4 crankshaft/transmission specifications item standard service limit connecting rods connecting rod big end radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.0006 in.) 0.06 mm (0.002 in.) connecting rod big end side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) 0.6 mm (0.02 in.) crankshaft runout tir...

  • Page 235

    Crankshaft/transmission 9-5 special tools and sealant outside circlip pliers: 57001-144 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 liquid gasket, tb1216: 92104-1063.

  • Page 236

    9-6 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: magneto cover (see magneto cover removal in the electrical syst...

  • Page 237

    Crankshaft/transmission 9-7 crankcase • remove: gear position switch finger [a] spring [b] • remove: circlip [a] balancer drive gear [b] special tool - outside circlip pliers: 57001-144 • remove: circlip [a] special tool - outside circlip pliers: 57001-144 • remove the crankcase bolts [a]. • pry the...

  • Page 238

    9-8 crankshaft/transmission crankcase ○ the crankcase may also be split, using the crankcase splitting tool assembly. ○ install the jig [a] between the crankshaft flywheels. Special tool - crankshaft jig: 57001-1174 ○ attach the crankcase splitting tool [a] to the left crankcase. Special tool - cran...

  • Page 239

    Crankshaft/transmission 9-9 crankcase • support the crankcase bearing boss with a suitable re- tainer [a]. • using a press and the bearing driver set [c], install a new bearing [b] until it bottoms out. Special tool - bearing driver set: 57001-1129 notice support the crankcase bearing boss when the ...

  • Page 240

    9-10 crankshaft/transmission crankcase • first, press the inside release shaft needle bearing [a] until its top comes 19.5 mm [b] from the surface using the bearing driver set. • next, press the oil seal [c] until it reach to the inside nee- dle bearing with the bearing driver set. Special tool - be...

  • Page 241

    Crankshaft/transmission 9-11 crankcase • apply engine oil to the transmission gears, bearings, shift forks, shift drum and crankshaft bearing. • install the drive shaft [a] and output shaft [b] in the right crankcase [c] as a set. • install: shift drum [a] (see transmission shaft installation) shift...

  • Page 242

    9-12 crankshaft/transmission crankcase • apply liquid gasket to the mating surface [a] of the left crankshaft half. Sealant - liquid gasket, tb1216: 92104-1063 note ○ make the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied. ○ m...

  • Page 243

    Crankshaft/transmission 9-13 crankcase • install the gear set lever [a]. ○ fit each end [b] of the spring or original positions. ○ do not forget to install the collar and washer [c]. • tighten the gear set lever nut [d]. Torque - gear set lever nut: 8.8 n·m (0.90 kgf·m, 78 in·lb) • to install the sh...

  • Page 244

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

  • Page 245

    Crankshaft/transmission 9-15 crankshaft/connecting rod crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • using the hand pull out the crankshaft [a] from the right crankcase [b]. Crankshaft installation • apply high-temperature grease to the outer side of the crankshaft ...

  • Page 246

    9-16 crankshaft/transmission crankshaft/connecting rod 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 directi...

  • Page 247

    Crankshaft/transmission 9-17 crankshaft/connecting rod • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. Notice do not hammer the crank half at the point [b]. If flywheel ...

  • Page 248

    9-18 crankshaft/transmission crankshaft/connecting rod connecting rod twist • with the big-end arbor [a] still on the v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being parallel with the surface plate over a 100 mm length of the arbor to det...

  • Page 249

    Crankshaft/transmission 9-19 torque limiter torque limiter removal/installation • remove: torque limiter cover bolts [a] torque limiter cover [b] torque limiter [c] notice do not disassemble the torque limiter. The torque limiter will not function if this is done. • install the torque limiter cover ...

  • Page 250

    9-20 crankshaft/transmission 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 251

    Crankshaft/transmission 9-21 transmission transmission shaft assembly • apply engine oil liberally to the transmission shaft, gears and bearings. • replace any circlips that were removed with new ones. ○ always install the circlips [a] so that the opening [b] is aligned with a spline groove [c], and...

  • Page 252

    9-22 crankshaft/transmission transmission 1. Circlip 2. Toothed washer 3. 2nd gear (15 t) 4. Bushing 5. 4th gear (20 t) 6. 3rd gear (16 t) 7. 5th gear (21 t) 8. 1st gear (12 t) 9. Drive shaft 10. Output shaft 11. Collar 12. 2nd gear (23 t) 13. 4th gear (19 t) 14. 3rd gear (19 t) 15. 5th gear (17 t) ...

  • Page 253

    Crankshaft/transmission 9-23 transmission shift fork/gear groove wear • measure the thickness [a] of the shift fork ears, and mea- sure the width [b] of the gear grooves (with which the fork engages). Shift fork ear thickness standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) service limit: 4.8 mm (0.19 in....

  • Page 254

    9-24 crankshaft/transmission balancer balancer removal • remove: right engine cover (see right engine cover removal in the engine right side chapter) magneto cover (see magneto cover removal in the electrical system chapter) flywheel (see flywheel removal in the electrical sys- tem chapter) • instal...

  • Page 255

    Crankshaft/transmission 9-25 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 256

    9-26 crankshaft/transmission 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 257: Wheels/tires

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

  • Page 258

    10-2 wheels/tires exploded view.

  • Page 259

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples 2.2 0.22 19 in·lb 2 front axle nut 79 8.0 58 3 front axle clamp bolts 20 2.0 15 al 4 rear axle nut 110 11.2 81.1 5. Spokes 6. Front tire 7. Rims 8. Front axle 9. Rear tire 10. Rear axle al: tighten the two cl...

  • Page 260

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout: axial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) radial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) axle runout/100 mm (3.94 in.) 0.1 mm (0.004 in.) or less 0.2 mm (0.008 in.) rim size: front 21 × 1...

  • Page 261

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bead breaker assembly: 57001-1072 bearing driver set: 57001-1129 jack: 57001-1238.

  • Page 262

    10-6 wheels/tires wheels (rims) front wheel removal • using the jack [a] under the frame, and stabilize the mo- torcycle. Special tool - jack: 57001-1238 • apply the rear brake to rear wheel does not turn. • unscrew the axle nut [a]. • loosen the left and right axle clamp bolts [b]. • place a commer...

  • Page 263

    Wheels/tires 10-7 wheels (rims) • install the speedometer gear housing so that the projec- tions [a] fit in the drive notches [b]. • fit the collar on the right side of the hub. • fit the speedometer gear housing stop [a] on the fork leg clamp flat face [b]. • insert the axle [a] from right side. • ...

  • Page 264

    10-8 wheels/tires wheels (rims) • remove the jack. • before tightening the right clamp bolts on the right fork leg, pump the forks up and down [a] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle. Note ○ do not apply the front brake during this process to stop th...

  • Page 265

    Wheels/tires 10-9 wheels (rims) rear wheel installation • install the groove [a] of the brake holder [b] onto the pro- jection [c] of the swingarm. • install the rear wheel while holding the disc cover [d]. • fit the projection on the cap to the groove on the collar. • install the collars [a] on the...

  • Page 266

    10-10 wheels/tires wheels (rims) wheels inspection • place the jack under the frame so that the front/rear wheel is raised off the ground. Special tool - jack: 57001-1238 • spin the wheel lightly, and check for roughness or binding. If the roughness or binding is found, replace the hub bear- ings. •...

  • Page 267

    Wheels/tires 10-11 tires tire removal notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • remove the wheel from the motorcycle (see wheels re- moval). • to maintain front wheel ba...

  • Page 268

    10-12 wheels/tires tires • step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [a] of the bead breaker protecting the rim with rim protectors [b]. Special tools - rim protector: 57001-1063 bead breaker assembly: 57001-1072 notice take care not to inset the t...

  • Page 269

    Wheels/tires 10-13 tires • tighten the bead protector nut [a] and valve stem nut [b], and put on the valve cap [c]. • check and adjust the air pressure after installing. Air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter..

  • Page 270

    10-14 wheels/tires hub bearings hub bearing removal • remove the wheel (see wheel removal). Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. • remove the oil seals and circl...

  • Page 271

    Wheels/tires 10-15 hub bearings hub bearing lubrication note ○ since the hub bearings are packed with grease and sealed, lubrication is not required..

  • Page 273: Final Drive

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

  • Page 274

    11-2 final drive exploded view.

  • Page 275

    Final drive 11-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 r 2 engine sprocket nut 127 13.0 93.7 3. Engine sprocket cover 4. Engine sprocket 5. Output shaft 6. Chain slipper 7. Swingarm 8. Chain guide 9. Locknut 10. Adjusting bolt 11. Chain adjuster 12. ...

  • Page 276

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make daido – – – type d.I.D. 520mxv – – – length 114 links – – – link pin outside diameter ...

  • Page 277

    Final drive 11-5 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 • check that the rear en...

  • Page 278

    11-6 final drive drive chain • grind [a] the heads of the link pin to make it flat. • set the cutting and riveting pin [c] in the pin holder [b] as shown in the figure. • set the “u” holder and body, align the positioning pin [a] with the “a mark” [b]. • turn the pin holder [c] clockwise until the c...

  • Page 279

    Final drive 11-7 drive chain • 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 another wrench and press in the link plate on the link pin. • remove the “u” holder and body. • set the cutting...

  • Page 280

    11-8 final drive 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: 5.5 ∼ 5.8 mm (0.22 ∼ 0.23 in.) link plate outside width standard: 16.50 ∼ 16.70 mm (0...

  • Page 281

    Final drive 11-9 sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • remove: drive chain [b] (free of engine sprocket) • flatten the bended sprocket washer [a]. • remove the engine sprocket nut [c] and sprocket washer, and pul...

  • Page 282

    11-10 final drive sprockets rear sprocket installation • install the rear sprocket [a] so that the marked side [b] faces out. • replace the rear sproket nuts with new ones. • install the rear sprocket bolts and tighten the nuts. Torque - rear sprocket nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) sprocket wear...

  • Page 283: Brakes

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

  • Page 284

    12-2 brakes exploded view.

  • Page 285

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 2 brake hose banjo bolts 25 2.5 18 3 brake pad bolt 17 1.7 13 4 caliper bleed valve 7.8 0.80 69 in·lb 5 caliper mounting bolts 25 2.5 18 6 front brake disc mounting bolts 10 ...

  • Page 286

    12-4 brakes exploded view.

  • Page 287

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 10 1.0 89 in·lb 3 rear master cylinder push rod locknut 17 1.7 13 4 caliper bleed valve 7.8 0.80 69 in·lb 5 brake pad bolt 17 1.7 13 6 rear brake pad bolt ...

  • Page 288

    12-6 brakes specifications item standard service limit brake adjustment lever play adjustable (to suit rider) – – – brake fluid recommended disc brake fluid: – – – type front dot3 or dot4 – – – rear dot4 brake pads lining thickness: front 3.8 mm (0.15 in.) 1 mm (0.04 in.) rear 6.4 mm (0.25 in.) 1 mm...

  • Page 289

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

  • Page 290

    12-8 brakes brake lever, brake pedal brake lever adjustment • refer to the brake lever and pedal position adjustment in the periodic maintenance chapter. Brake pedal position adjustment • refer to the brake lever and pedal position adjustment in the periodic maintenance chapter. Brake pedal removal ...

  • Page 291

    Brakes 12-9 brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the...

  • Page 292

    12-10 brakes brake fluid bleeding the brake line the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake le...

  • Page 293

    Brakes 12-11 brake fluid • check the fluid level. • after bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in in...

  • Page 294

    12-12 brakes caliper caliper removal front brake • loosen the banjo bolt [a] so as not to spill brake fluid. • remove the caliper mounting bolts [b]. • remove the banjo bolt and take off the brake hose from the caliper [c]. • if the caliper is to be disassembled after removal and if compressed air i...

  • Page 295

    Brakes 12-13 caliper • bleed the brake line (see bleeding the brake line). • check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in i...

  • Page 296

    12-14 brakes caliper brake pad removal front brake pad • unscrew the pad bolt [a]. • take the piston side pad [b]. • push the caliper holder toward the piston, and then re- move another pad [c] from the caliper holder. Rear brake pad • remove: plug [a] • unscrew the pad bolt [a]. • take the piston s...

  • Page 297

    Brakes 12-15 master cylinder notice brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the upper brake hose [b] from the master cylinder [c]. • when removing the...

  • Page 298

    12-16 brakes master cylinder rear master cylinder removal • remove the cotter pin [a]. • pull off the joint pin [b] with washer. Note ○ pull off the joint pin while pressing down the brake pedal. • unscrew the master cylinder mounting bolts [c], and re- move the master cylinder [d]. • unscrew the br...

  • Page 299

    Brakes 12-17 master cylinder master cylinder inspection (visual inspection) • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall of each master cylinder [a] and on the outside of each piston [b]. If a master cylinder or piston show...

  • Page 300

    12-18 brakes brake disk 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 [b]. Brake disc installation • install the disc on the wheel so that the marked side [a] faces out. • apply a non-permanen...

  • Page 301

    Brakes 12-19 brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hose and connection check in the periodic maintenance chapter..

  • Page 303: Suspension

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

  • Page 304

    13-2 suspension exploded view.

  • Page 305

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 base valve assembly 28 2.9 21 2 front fork top plug 30 3.1 22 3 front fork clamp bolts (upper) 20 2.0 15 al 4 front fork clamp bolts (lower) 20 2.0 15 al 5 steering stem head nut 98 10 72 6 locknut/adjuster assembly 29 3.0 2...

  • Page 306

    13-4 suspension exploded view.

  • Page 307

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 98 10 72 r 2 rocker arm pivot nut 59 6.0 44 r 3 tie-rod mounting nut (front, rear) 59 6.0 44 r 4 rear shock absorber mounting nut (upper) 39 4.0 29 r 5 rear shock absorber mounting nut (lower) 34 3.5...

  • Page 308

    13-6 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – rebound damping adjustment (adjustable range) (from the seated position adjuster turned fully clockwise) 9 clicks counterclockwise 18 clicks compression damping adjustment (adjustable range)...

  • Page 309

    Suspension 13-7 special tools oil seal & bearing remover: 57001-1058 steering stem nut wrench: 57001-1100 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 15 × 17: 57001-1267 fork oil seal driver, 48: 57001-...

  • Page 310

    13-8 suspension front fork air pressure the standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race through the pressure ...

  • Page 311

    Suspension 13-9 front fork compression damping adjustment • place the jack under the frame so that the front wheel off the ground. Special tool - jack: 57001-1238 • to adjust compression damping, turn the adjuster [a] on the front fork top plugs with the blade of a screwdriver until you feel a click...

  • Page 312

    13-10 suspension front fork • loosen the upper [a], and lower [b] fork clamp bolts. • remove the front fork. ○ with a twisting motion [a], work the fork leg [b] down and out. Front fork installation • install the fork so that the distance between the top end of the outer tube and the upper surface o...

  • Page 313

    Suspension 13-11 front fork front fork disassembly (each fork leg) • loosen the front fork upper clamp bolts [a]. • loosen the fork top plug (subtank) [a] with the top plug wrench [b]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] • remove the front fork (see front fork removal). Note ○ set ...

  • Page 314

    13-12 suspension front fork • place a drain pan under the front fork and drain fork oil [a]. Note ○ pump the fork tube several times to discharge the fork oil. • raise the outer tube and temporarily install the fork top plug [a] (subtank) to the outer tube [b] with the top plug wrench [c]. Special t...

  • Page 315

    Suspension 13-13 front fork • hold the locknut [a] with a wrench [b] and remove the adjuster assembly [c]. • remove the push rod [a]. • with the outer tube compressed by hands, remove the top plug wrench [a]. Notice removing the locknut and pushing the piston rod thread into the cylinder unit will d...

  • Page 316

    13-14 suspension front fork • remove the dust seal [a] and the retaining ring [b]. Notice be careful not to scratch the inner tube. • grasp the outer tube and stroke [a] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • remove the following parts fr...

  • Page 317

    Suspension 13-15 front fork • drain the fork oil [a] from the cylinder unit [b] by pumping the piston rod several times. Front fork assembly • when the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain. • replace the follow...

  • Page 318

    13-16 suspension front fork • clean the threads [a] of subtank and base valve assem- bly. • with the piston rod in fully compressed position, pour the specified amount of fork oil [a]. Recommended oil: khl15-10 (kayaba01) or equivalent recommended quantity: 189 ml (6.4 us oz.) note ○ plug the two oi...

  • Page 319

    Suspension 13-17 front fork • with the piston rod held immorable in fully compressed position [a], gently install the base valve assembly [b] to the subtank. • screw in the base valve assembly in the subtank when the piston rod extends. Note ○ when it is hard to screw in the base valve assembly, pul...

  • Page 320

    13-18 suspension front fork • drain the extra oil from the subtank oil hole [a]. • with the cylinder unit in horizontal position, move [a] the piston rod [b] by hand to inspect it if operating smoothly. ○ if the piston rod is not extend, remove the base valve assembly and perform the air bleeding (p...

  • Page 321

    Suspension 13-19 front fork • compress the outer tube by hands and install the top plug wrench [a] between the axle holder bottom and locknut. Special tool - top plug wrench, 49 mm: 57001-1653 warning the fork spring applies pressure to the adjuster as- sembly and can eject the special tool with sub...

  • Page 322

    13-20 suspension front fork • loosen and remove the fork top plug (subtank) form the outer tube and slowly slide down the outer tube. Special tool - top plug wrench, 49 mm: 57001-1653 • pour [a] the specified amount of fork oil into the outer tube. Recommended oil: khl15-10 (kayaba01) or equivalent ...

  • Page 323

    Suspension 13-21 front fork cylinder unit inspection • inspect the piston rod [b] of cylinder unit [a] for scratches or bending. If it has scratches or is bent, replace cylinder unit with a new one. Inner tube inspection • visually inspect the inner tube [a], repair any damage. • nick or rust damage...

  • Page 324

    13-22 suspension front fork spring tension • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining sp...

  • Page 325

    Suspension 13-23 rear suspension (uni-trak) rear shock absorber: the rear suspension system of this motorcycle is new uni-trak. It consists of a rear shock absorber, swing arm, tie-rod and rocker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or t...

  • Page 326

    13-24 suspension rear suspension (uni-trak) • adjust the high speed compression damping, turn the high speed compression damping adjuster with a 17 mm wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. High speed compression damping standard: 1 1/...

  • Page 327

    Suspension 13-25 rear suspension (uni-trak) • using the hook wrenches [a], loosen the locknut [b] on the rear shock absorber. Special tool - hook wrench r37.5, r42: 57001-1101 • using the stem nut wrench [a], turn the adjusting nut [b] as required. Turning the adjusting nut downward marks the spring...

  • Page 328

    13-26 suspension rear suspension (uni-trak) rear shock absorber removal • remove: seat (see seat removal in the frame chapter) side covers (see side cover removal in the frame chapter) muffler (see muffler removal in the engine top end chapter) rear frame with air cleaner housing • using the jack un...

  • Page 329

    Suspension 13-27 rear suspension (uni-trak) • using the hook wrenches [c], loosen the locknut [b] and turn the adjusting nut [a] all way up. Special tool - hook wrench r37.5, r42: 57001-1101 • remove the rear shock absorber from the vise. • slide down the rubber bumper [a]. • remove the spring guide...

  • Page 330

    13-28 suspension swingarm swingarm removal • place the jack [a] under the frame so that the rear wheel is off the ground. Special tool - jack: 57001-1238 • remove rear wheel (see rear wheel removal in the wheels/tires chapter) clamps [b] brake pedal [c] (see brake pedal removal in the brakes chapter...

  • Page 331

    Suspension 13-29 swingarm • unscrew the screws [a] • separate the chain slipper [b] from the swingarm. Swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • replace the swingarm pivot shaft nut with a new one. • tighten the following: torque...

  • Page 332

    13-30 suspension swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings installed in the swingarm. ○ the rollers in a bearing normally wear very little, and wear is difficult to measure. Instead of measu...

  • Page 333

    Suspension 13-31 tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • unscrew the nut [a] and remove the guide roller [b]. Notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapp...

  • Page 334

    13-32 suspension tie-rod, rocker arm rocker arm installation • apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve. • apply plenty of 2-stroke oil to the threads of the tie-rod rear mounting bolts. • tighten: torque - rear shock a...

  • Page 335

    Suspension 13-33 tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearing, grease seals and oil seals with new ones. • apply plenty of grease to the oil seal and needle bearings [a]. Note ○ install the grease seals so that the deep groove side of the rip out-ward....

  • Page 336

    13-34 suspension uni-trak maintenance uni-trak linkage inspection • refer to the swingarm and uni-trak linkage inspection in the periodic maintenance chapter. Tie-rod and rocker arm sleeve wear • pull out the sleeves [a] of the tie-rod and rocker arm. • measure the outside diameter of the sleeve. If...

  • 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 handlebar clamp bolts 25 2.5 18 2t 2 steering stem head nut 98 10 72 3 steering stem nut 4.9 0.50 43 in·lb t 4 front fork clamp bolts (upper) 20 2.0 15 al 5 front fork clamp bolts (lower) 20 2.0 15 al 6. Handlebar clamp 7. Han...

  • 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 inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter. Steering stem, stem bearing removal • remove: front wheel (see front wheel removal in the...

  • Page 342

    14-6 steering steering • remove: front fork lower clamp bolts [a] front forks [b] • pushing up on the stem base [a], and remove the steering stem nut [b], with the steering stem nut wrench [c], then remove the steering stem [d] and stem base. Special tool - steering stem nut wrench: 57001-1100 • tak...

  • Page 343

    Steering 14-7 steering steering stem, stem bearing installation • replace the bearing outer race with new ones. ○ apply grease to the outer races, and drive them into the head pipe at the same time using the head pipe outer race press shaft [a] and the head pipe outer race drivers. Special tools - h...

  • Page 344

    14-8 steering steering • install the front fork (see front fork installation in the sus- pension chapter). Note ○ tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolt. • tighten: torque - steering stem head nut: 98 n·m (10 kgf·m, 72 ft·lb) front fork clamp...

  • Page 345

    Steering 14-9 handlebar handlebar removal • remove: clutch holder [a] engine stop switch [b] clamps [c] left handlebar grip [d] • remove: throttle grip assy [a] (see throttle cable replacement in the fuel system chapter) master cylinder [b] (see front master cylinder removal in the brakes chapter) c...

  • Page 346

    14-10 steering handlebar • apply grease to the throttle cable upper end and clutch cable upper end. • apply a 2-stroke oil to the throttle grip inner wall [a]. • install the throttle grip assy so that the grip [a] is in as far as it will go. • position the throttle grip assy so that the parting line...

  • Page 347: Frame

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

  • Page 348

    15-2 frame exploded view.

  • Page 349

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolt 34 3.5 25 2 upper footpeg bracket bolts 54 5.5 40 l 3 sidestand nut 29 3.0 21 r g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 350

    15-4 frame exploded view 1. Ca model r: replacement parts.

  • Page 351

    Frame 15-5 frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Rear frame removal • remove: seat (see seat removal) right and left side cover (see side cover removal) battery cables [a] and holder [b] (see battery removal in the electrical system chapter) st...

  • Page 352

    15-6 frame frame engine guard installation • install the engine guard as shown. Engine guards [a] collar [b] bolts [c] engine guard [d] bolts [e].

  • Page 353

    Frame 15-7 seat seat removal • remove the bolts [a]. • pull the seat [b] out from the back. Seat installation • stick the pad on the inside of the seat. • fit the hooks [a] of the seat under the flange collar [b] and brackets [c]. ○ install the brackets [a] of the seat to inside [b] of side cover. •...

  • Page 354

    15-8 frame side cover right side cover removal • remove: bolts [a] side cover [b] right side cover installation • stick the pad [a] on the inside of the right side cover [b]. • insert the inside rib [c] between rear fender and rear frame. • insert the tab [a] of the right side cover into the air cle...

  • Page 355

    Frame 15-9 side cover left side cover installation • install: left side cover washer bolts air cleaner cover [a] quick fastener.

  • Page 356

    15-10 frame fender front fender removal • unscrew the bolts [a] and remove the front fender [b]. Rear fender removal • remove: seat (see seat removal) reserve tank (see reserve tank removal in the cool- ing system chapter) regulator/rectifier (see regulator/rectifier inspection in the electrical sys...

  • Page 357

    Frame 15-11 footpegs and brackets footpeg removal • remove: cotter pin [a] washer [b] pin [c] spring [d] footpeg [e] upper bolt [f] lower bolt [g] footpeg bracket [h] footpegs installation • apply a non-permanent locking agent to the bracket lower bolts. • tighten the upper bracket bolt [a]. Torque ...

  • Page 359: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view................................... 16-2 specifications .................................... 16-8 special tools and sealant ................. 16-9 wiring diagram (other than australia models) ....................................

  • Page 360

    16-2 electrical system exploded view.

  • Page 361

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spark plug 13 1.3 115 in·lb 2. Ignition coil 3. Spark plug cap 4. Starter button 5. Engine stop switch 6. Starter lockout switch 7. Battery 8. Main relay 9. Igniter 10. Main harness 11. Regulator/rectifier.

  • Page 362

    16-4 electrical system exploded view.

  • Page 363

    Electrical system 16-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor terminal nut 5.9 0.60 52 in·lb 2 starter motor mounting bolts 9.8 1.0 87 in·lb 3 crankshaft sensor bolts 7.0 0.71 62 in·lb 4 stator bolts 4.0 0.41 35 in·lb l 5 flywheel nut 98 10 72 6 magneto cover bolts...

  • Page 364

    16-6 electrical system exploded view.

  • Page 365

    Electrical system 16-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 head light bracket screws 1.4 0.14 12 in·lb 2 gear position switch screws 2.9 0.30 26 in·lb l 3. Meter unit 4. Headlight 5. Speed sensor 6. Tail light 7. Gear position switch 8. Australia models hg: apply high-temprer...

  • Page 366

    16-8 electrical system specifications item standard service limit battery type sealed battery (wet) – – – model ytz7s (f) – – – capacity 12 v 6 ah – – – magneto crankshaft sensor resistance 190 ∼ 290 Ω (at 20°c (68°f)) – – – magneto output voltage in the text – – – stator coil resistance in the text...

  • Page 367

    Electrical system 16-9 special tools and sealant inside circlip pliers: 57001-143 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 timing light: 57001-1241 spark plug wrench, hex 16: 57001-1262 flywheel holder: 57001-1313 hand tester: 57001-1394 throttle position sensor setting adapter #1: 57001-1400...

  • Page 368

    16-10 electrical system special tools and sealant flywheel puller, m28 × 1.0: 57001-1471 liquid gasket, tb1211f: 92104-0004.

  • Page 369

    Electrical system 16-11 wiring diagram (other than australia models).

  • Page 370

    16-12 electrical system precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the...

  • Page 371

    Electrical system 16-13 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 372

    16-14 electrical system battery battery removal • remove the seat (see seat removal in the frame chap- ter). • disconnect the negative (–) cable [a] and then positive (+) cable [b]. Notice be sure to disconnect the negative (–) cable first. • remove the battery holder bolts [c] and holder [d]. • rem...

  • Page 373

    Electrical system 16-15 battery danger batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before tu...

  • Page 374

    16-16 electrical system battery refreshing charge • remove the battery (see battery removal). • do refresh charge by following method according to the battery terminal voltage. Warning this battery is sealed type. Charge with current and time as stated below. Terminal voltage: 12 ∼ less than 12.4 v ...

  • Page 375

    Electrical system 16-17 flywheel magneto magneto cover removal • remove: left radiator shroud bolt [a] left radiator screen [b] left radiator mounting bolts [c] • push the left radiator backward [d]. • pry open the clamps [a]. • drain the engine oil from the crank room oil sump (see engine oil chang...

  • Page 376

    16-18 electrical system flywheel magneto magneto cover installation • replace the gasket [a] with a new one. • be sure to install the dowel pins [b]. • apply silicone sealant to the area [a] to the magneto lead grommet. Sealant - liquid gasket, tb1211f: 92104-0004 • tighten: torque - magneto cover b...

  • Page 377

    Electrical system 16-19 flywheel magneto • screw the rotor pullers [a] onto the flywheel. • remove the flywheel from the crankshaft by turning in the puller and tapping the head of the bolt lightly with a hammer, while holding the puller body steady. There is a woodruff key in the crankshaft tapered...

  • Page 378

    16-20 electrical system flywheel magneto stator removal • remove: magneto cover (see magneto cover removal) stator bolts [a] crankshaft sensor bolts [b] wiring holder [c] wiring grommet [d] • remove the stator [e] and crankshaft sensor [f] as a set. Stator installation • route the wires according to...

  • Page 379

    Electrical system 16-21 flywheel magneto ○ connect the hand tester [a] to the connector [b] as shown in the table 1, using the needle adapter set [c]. ○ start the engine. ○ run it at the rpm given in the table 1. ○ note the voltage readings (total 2 measurements). Special tools - hand tester: 57001-...

  • Page 380

    16-22 electrical system flywheel magneto charging voltage inspection • check the battery condition (see charging condition in- spection). • warm up the engine to obtain actual magneto operating conditions. • remove the seat (see seat removal in the frame chap- ter). • connect the hand tester [a] as ...

  • Page 381

    Electrical system 16-23 flywheel magneto • with the kawasaki hand tester, measure the internal re- sistance in both directions between the terminals. Special tool - hand tester: 57001-1394 if the reading is not the specified value, replace the reg- ulator/rectifier. Internal resistance (20°c) unit: ...

  • Page 382

    16-24 electrical system starter motor clutch starter motor clutch removal/installation • refer to the flywheel removal/installation. Starter motor clutch inspection • remove: torque limiter (see torque limiter removal/installation in the crankshaft/transmission chapter) magneto cover (see magneto co...

  • Page 383

    Electrical system 16-25 ignition timing ignition timing inspection • remove the timing inspection cap [a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • star...

  • Page 384

    16-26 electrical system ignition system crankshaft sensor removal • refer to the stator removal. Crankshaft sensor installation • refer to the stator installation. Safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or high te...

  • Page 385

    Electrical system 16-27 ignition system ignition coil inspection measuring arcing distance the most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3-needle method. • remove the ignition coil. • connect the ignition ...

  • Page 386

    16-28 electrical system ignition system spark plug gap inspection • refer to the spark plug cleaning and inspection in the periodic maintenance chapter. Igniter removal • remove the right side cover (see side cover removal in the frame chapter). • disconnect the main harness connector [a]. • pull ou...

  • Page 387

    Electrical system 16-29 ignition system • shift the gear to the neutral position. • crank the engine by kicking the kick pedal and by push- ing the starter button several times to measure the peak voltage of the primary ignition coil. Ignition coil primary peak voltage standard: 128 v or above (kick...

  • Page 388

    16-30 electrical system ignition system.

  • Page 389

    Electrical system 16-31 ignition system crankshaft sensor peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained...

  • Page 390

    16-32 electrical system ignition system exciter coil peak voltage check • disconnect the magneto lead connector from the main harness. • to check the peak voltage, do the following procedures. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if d...

  • Page 391

    Electrical system 16-33 ignition system • connect the throttle position sensor setting adapter [a] between throttle position sensor lead connector [b] and main harness connector [c]. Special tools - hand tester: 57001-1394 throttle position sensor setting adapter #1: 57001-1400 • set the hand tester...

  • Page 392

    16-34 electrical system ignition system throttle position sensor position adjustment • check the idle speed, using the engine revolution tester for high accuracy and adjust the idle speed specified (see idle speed inspection in the periodic maintenance chap- ter). • disconnect the throttle position ...

  • Page 393

    Electrical system 16-35 ignition system ignition system circuit (other than australia models) 1. Frame ground 2. Ignition coil 3. Spark plug 4. Frame ground 5. Gear position switch 6. Flywheel magneto 7. Crankshaft sensor 8. Throttle position sensor 9. Starter relay 10. Main fuse 20 a 11. Battery 12...

  • Page 394

    16-36 electrical system electrical starter system starter motor removal • remove: exhaust pipe (see muffler removal in the engine top end chapter) starter motor terminal nut [a] starter motor mounting bolts [b] • pull out the starter motor to right side. Starter motor installation notice do not tap ...

  • Page 395

    Electrical system 16-37 electrical starter system starter motor assembly • replace the o-ring with a new one. • apply a thin coat of high-temperature grease to the oil seal [a] and the needle bearing [b]. • fit the toothed washer [c] into the end cover. Thin washer [d] thick washer [e] • install the...

  • Page 396

    16-38 electrical system electrical starter system commutator inspection, cleaning • smooth the commutator surface [a] if necessary with fine emery cloth [b], and clean out the grooves. • measure the outer diameter [a] of the commutator [b]. Replace the starter motor with a new one if the commu- tato...

  • Page 397

    Electrical system 16-39 electrical starter system terminal bolt inspection • using the highest hand tester range, measure the resis- tance as shown. Terminal bolt and brush plate [a] terminal bolt and negative brush holder [b] terminal bolt and end cover [c] if there is any reading, the brush holder...

  • Page 398

    16-40 electrical system electrical starter system electric starter circuit (other than australia models) 1. Frame ground 2. Starter motor 3. Starter relay 4. Main fuse 20 a 5. Battery 12 v 6 ah 6. Ic igniter 7. Engine starter button 8. Engine stop switch 9. Starter lockout switch.

  • Page 399

    Electrical system 16-41 lighting system headlight aiming inspection • inspect the headlight beam for aiming. If the headlight beam points too low or high, adjust the vertical beam. Headlight beam vertical adjustment • turn the vertical adjuster [a] on the headlight with the screwdriver in or out to ...

  • Page 400

    16-42 electrical system lighting system • replace the headlight bulb. • fit the projections [a] of the bulb in the hollow [b] of the headlight. • install the hook [c]. • fit the dust cover [a] firmly so that the headlight lead [b] faces downward [c] as shown. • after installation, adjust the headlig...

  • Page 401

    Electrical system 16-43 lighting system tail light removal • remove the seat (see seat removal in the frame chap- ter). • disconnect the tail light lead connector [a]. • unhook the tail light lead [a] from the clamps [b]. • unscrew the bolts [c] and remove the tail light [d]. Tail light installation...

  • Page 402

    16-44 electrical system lighting system headlight/tail light circuit (other than australia models) 1. Headlight 2. Frame ground 3. Flywheel magneto 4. Regulator/rectifier 5. Starter relay 6. Main fuse 20 a 7. Battery 12 v 6 ah 8. Tail light 9. Main relay 10. Ic igniter.

  • Page 403

    Electrical system 16-45 meter gauge meter unit removal/installation • remove the headlight assy (see headlight removal/in- stallation). • remove the mounting nuts [a]. • slide the boots [b] and disconnect the meter connector [c]. • installation is reverse of removal. Meter unit disassembly/assembly ...

  • Page 404

    16-46 electrical system meter gauge • check that the display [a] shifts between odo and clock each time the odo/clock button [b] is pushed. If the display does not shift, replace the meter unit. • check that the display [a] shifts between trip-a and trip-b each time the trip a/b button [b] is pushed...

  • Page 405

    Electrical system 16-47 meter gauge ○ in the hour/minute setting mode, the numbers that rep- resent the hours and the minutes flash. In the hour set- ting mode, the numbers that represent the hours flash [a]. And in the minute setting mode, the numbers that repre- sent the minutes flash [b]. • in th...

  • Page 406

    16-48 electrical system meter gauge meter circuit (other than australia models) 1. Speed sensor 2. Meter unit 3. Frame ground 4. Starter relay 5. Main fuse 20 a 6. Battery 12 v 6 a 7. Ic igniter 8. Main relay 9. Engine starter button 10. Starter lockout switch.

  • Page 407

    Electrical system 16-49 switches and sensors speed sensor removal • disconnect the speed sensor connector [a] and remove the sensor lead from the clamp. • remove the bolts [a] and open the clamps [b], take off the sensor lead. • remove the front wheel with the speed sensor (see front wheel removal i...

  • Page 408

    16-50 electrical system switches and sensors • turn [a] the rotor of the speed sensor. ○ then the tester indicator should flick [b]. If the tester indicator does not flick, replace the speed sensor. Throttle position sensor removal/installation • refer to the carburetor disassembly/assembly in the f...

  • Page 409

    Electrical system 16-51 switches and sensors • pry open the clamps [a]. • disconnect the gear position switch connector. • remove: shift pedal (external shift mechanism removal in the engine right side chapter) screws [a] gear position switch [b] • remove: o-ring [a] gear position switch finger [b] ...

  • Page 410

    16-52 electrical system switches and sensors gear position switch inspection note ○ be sure the transmission mechanism is good condition. • remove the left radiator shroud. • disconnect the gear position switch lead connector [a]. • set the hand tester [a] to the ×1 k Ω or ×100 Ω range and connect i...

  • Page 411

    Electrical system 16-53 main relay main relay inspection • remove the seat (see seat removal in the frame chap- ter). • remove the main relay [a]. • check conductivity of the following numbered terminals by connecting the hand tester and one 12 v battery to the main relay as shown. If the tester doe...

  • Page 412

    16-54 electrical system fuses main fuse 20 a removal • remove the seat (see seat removal in the frame chap- ter). • disconnect the starter relay connector [a]. • remove the main fuse [b] from the starter relay. Main fuse 20 a inspection • remove the fuse (see main fuse 20 a removal) and in- spect th...

  • Page 413: Appendix

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

  • Page 414

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

  • Page 415

    Appendix 17-3 cable, wire, and hose routing 1. Starter button lead 2. Throttle cables 3. Marked (aaa) cable is accelerator side. 4. Bands 5. Brake hose 6. Engine stop switch lead 7. Starter lockout switch lead 8. Hot starter cable 9. Clutch cable 10. Harness/cable guide 11. Starter lockout switch co...

  • Page 416

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

  • Page 417

    Appendix 17-5 cable, wire, and hose routing 1. Hot starter cable 2. Main harness 3. Clamps 4. Run the throttle cables over the main harness. 5. White tape 6. Throttle cables 7. Blue tape 8. Clamps 9. Band 10. Clutch cable 11. Run the clutch cable outside of the fuel hose. 12. Fuel hose 13. Clamp (fa...

  • Page 418

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

  • Page 419

    Appendix 17-7 cable, wire, and hose routing 1. Throttle cables 2. Clamp 3. Harness/cable guide 4. Speed sensor lead connector (gray) 5. Fix the connector on the bracket. 6. Clamp (put the sensor grommet into the clamp, and then fix it by crushing the clamp.) 7. Speed sensor lead 8. Run the harnesses...

  • Page 420

    17-8 appendix cable, wire, and hose routing.

  • Page 421

    Appendix 17-9 cable, wire, and hose routing 1. Headlight connector (black) 2. Speed sensor lead connector (gray) 3. Meter unit connector (black cap) 4. Starter lockout switch connector (green) 5. Engine stop switch connector (white) 6. Starter button lead connector (black) 7. Clamps 8. White tape 9....

  • Page 422

    17-10 appendix cable, wire, and hose routing.

  • Page 423

    Appendix 17-11 cable, wire, and hose routing 1. Battery negative (–) cable (black) 2. Starter relay connector (red) 3. Starter relay 4. Black cap 5. Battery positive (+) cable (red) 6. Starter motor cable (white) 7. Tail light lead 8. Clamps (fix the tail light lead by twisting the clamps.) 9. Tail ...

  • Page 424

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

  • Page 425

    Appendix 17-13 cable, wire, and hose routing 1. Starter motor cable (white) 2. Run the starter motor cable over the harness. 3. Tighten together the battery negative (–) cable and starter mounting bolt. 4. Connect the starter motor cable to the starter motor terminal bolt. 5. Meter unit connector (b...

  • Page 426

    17-14 appendix cable, wire, and hose routing.

  • Page 427

    Appendix 17-15 cable, wire, and hose routing 1. Brake lever 2. Front brake master cylinder 3. Front brake hose 4. Clamp 5. View from a-a 6. Clamps 7. Front brake caliper 8. Front brake disc 9. Brake pedal 10. Rear brake master cylinder 11. Rear brake hose 12. Clamps 13. Rear brake caliper 14. Rear b...

  • Page 428

    17-16 appendix cable, wire, and hose routing.

  • Page 429

    Appendix 17-17 cable, wire, and hose routing 1. Breather hose 2. Fuel hoses 3. Run the breather hose over the fuel hoses. 4. Clamp 5. Stretch to the arrow mark without loosing the hose when mounting the fuel tank. (keep the gap of the chain guide roller and hoses) 6. Breather hose 7. Face the painte...

  • Page 430

    17-18 appendix cable, wire, and hose routing.

  • Page 431

    Appendix 17-19 cable, wire, and hose routing 1. Reserve tank hose 2. Hot starter cable 3. Clutch cable 4. Clamp 5. Clamps 6. Run the reserve tank hose under the throttle cables and main harness. 7. Regulator/rectifier lead connector (green) 8. Starter motor cable (white) 9. Main harness 10. Clamp 11...

  • Page 432

    17-20 appendix cable, wire, and hose routing u.S.A., california and canada models.

  • Page 433

    Appendix 17-21 cable, wire, and hose routing 1. Vacuum switch valve hose 2. Cylinder head cover 3. Front of the engine 4. White paint 5. Insert the vacuum switch valve hose to the white painted portion of the pipe. 6. Clamps (face the tabs to the upper of the engine.) 7. Clamp (face the tab to the u...

  • Page 434

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

  • Page 435

    Appendix 17-23 cable, wire, and hose routing 1. Radiator hose 2. Clamps (install the clamp as shown in the figure.) 3. Radiator hose 4. Clamps (install the clamp as shown in the figure.) 5. Face the white painted portion to the right side of the engine. 6. Water hose 7. Face the white painted portio...

  • Page 436

    17-24 appendix cable, wire, and hose routing 1. Clamp (install the clamp as shown in the figure.) 2. Fuel hose 3. Carburetor 4. Clamp (install the clamp as shown in the figure.) 5. Clamp (run the vent hoses through the clamp on the backward of the crankcase.) 6. Vent hoses.

  • Page 437

    Appendix 17-25 troubleshooting guide this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: starter motor not rotating:...

  • Page 438

    17-26 appendix 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 gasket damaged cylinder head warped val...

  • Page 439

    Appendix 17-27 troubleshooting guide brake dragging drive train trouble lubrication inadequate: engine oil level too low engine oil poor quality or incorrect coolant incorrect: coolant level too low coolant deteriorated cooling system component incorrect: radiator clogged radiator cap trouble water ...

  • Page 440

    17-28 appendix troubleshooting guide drive chain noise: drive chain maladjusted drive chain worn rear and/or engine sprocket worn drive chain lubrication insufficient rear wheel misaligned abnormal frame noise: front fork noise: oil insufficient or too thin spring weak or broken front fork air press...

  • Page 441

    Model application year model beginning frame no. 2008 klx450a8f jkalxga1 □ 8a000001 or jkalx450aaa000001 2009 klx450a9f jkalxga1 □ 9a010001 or jkalx450aaa010001 2010 klx450aaf jkalxga1 □ aa013001 or jkalx450aaa013001 2011 klx450abf □ :this digit in the frame number changes from one machine to anothe...