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Kawasaki KX100 - Service Manual

Other manuals for KX100 -: Service Manual, Brochure, Service Manual, Owner's Manual

Summary of KX100 -

  • Page 1

    Kx85 kx85-ii kx100 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: Kx85

    Kx85 kx85-ii kx100 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 assu...

  • Page 6

    List of abbreviations a ampere(s) kips kawasaki integrated powervalve system abdc after bottom dead center km/h kilometers per hour ac alternating current l liter(s) ah ampere hour lb pound(s) atdc after top dead center m meter(s) bbdc before bottom dead center min minute(s) bdc bottom dead center m...

  • Page 7: 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 9: General Information

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

  • Page 10

    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 11

    General information 1-3 before servicing storage of removed parts after all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspectio...

  • Page 12

    1-4 general information before servicing tightening torque incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tighten...

  • Page 13

    General information 1-5 before servicing ball bearing and needle bearing do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressu...

  • Page 14

    1-6 general information before servicing direction of engine rotation when rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical leads a two-color lead is i...

  • Page 15

    General information 1-7 model identification kx85ce left side view kx85ce right side view.

  • Page 16

    1-8 general information model identification kx85de left side view kx85de right side view.

  • Page 17

    General information 1-9 model identification kx100fe left side view kx100fe right side view frame number engine number.

  • Page 18

    1-10 general information general specifications items kx85ce kx85de dimensions overall length 1 830 mm (72.04 in.) 1 920 mm (75.59 in.) overall width 765 mm (30.1 in.) ← overall height 1 100 mm (43.31 in.) 1 150 mm (45.28 in.) wheelbase 1 265 mm (49.80 in.) 1 310 mm (51.57 in.) road clearance 290 mm...

  • Page 19

    General information 1-11 general specifications items kx85ce kx85de duration 158° (low speed) ← 187.2° (high speed) ← lubrication system petrol mix (32 : 1) ← drive train primary reduction system: type gear ← reduction ratio 3.400 (68/20) ← clutch type wet, multi disc ← transmission: type 6-speed, c...

  • Page 20

    1-12 general information general specifications items kx85ce kx85de rear suspension: type swing arm (uni-trak) ← wheel travel 275 mm (10.8 in.) ← brake type: front and rear single disc ← effective disc diameter: front 202 mm (7.95 in.) ← rear 150 mm (5.91 in.) ← specifications are subject to change ...

  • Page 21

    General information 1-13 general specifications items kx100fe dimmensions overall length 1 920 mm (75.59 in.) overall width 765 mm (30.1 in.) overall height 1 150 mm (45.28 in.) wheelbase 1 310 mm (51.57 in.) road clearance 330 mm (13.0 in.) seat height 870 mm (34.3 in.) curb mass: 77 kg (169 lb) fr...

  • Page 22

    1-14 general information general specifications items kx100fe drive train primary reduction system: type gear reduction ratio 3.400 (68/20) clutch type wet, multi disc transmission: type 6-speed, constant mesh, return shift gear tatios 1st 2.538 (33/13) 2nd 1.875 (30/16) 3rd 1.500 (27/18) 4th 1.250 ...

  • Page 23

    General information 1-15 general specifications items kx100fe effective disc diameter: front 202 mm (7.95 in.) rear 150 mm (5.97 in.) specifications are subject to change without notice, and may not apply to every country..

  • Page 24

    1-16 general information 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 25: Periodic Maintenance

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

  • Page 26

    2-2 periodic maintenance brake fluid level inspection............................................................................................. 2-32 brake fluid change .......................................................................................................... 2-35 brake pad wear in...

  • Page 27

    Periodic maintenance 2-3 periodic maintenance chart the maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Frequency operation each race (2.5 hr) every 3 races (7.5 hr) every 5 races (12.5 hr) every 10 races (25 hr) as re- quired see page engine ...

  • Page 28

    2-4 periodic maintenance periodic maintenance chart frequency operation each race (2.5 hr) every 3 races (7.5 hr) every 5 races (12.5 hr) every 10 races (25 hr) as re- quired see page drive chain wear - inspect † • 2-28 chain slipper and guide - replace when damaged 2-31 front fork - inspect/clean •...

  • Page 29

    Periodic maintenance 2-5 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 torque for ...

  • Page 30

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks kick ratchet guide bolt 9.4 1.0 83 in·lb kick ratchet guide screw 5.2 0.53 46 in·lb primary gear nut 49 5.0 36 lh engine removal/installation engine bracket mounting nuts 29 3.0 21 r engine mounting nuts 29 3.0...

  • Page 31

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks suspension air pressure relief screws 1.3 0.13 12 in·lb front fork top plugs 28 2.9 21 front fork clamp bolts (upper) 20 2.0 15 front fork clamp bolts (lower) 20 2.0 15 al front fork push rod nuts 15 1.5 11 com...

  • Page 32

    2-8 periodic maintenance specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – air cleaner element polyurethane foam – – – air cleaner element oil high-quality foam air filter oil – – – red warp – – – 0.2 mm (0.008 in.) cooling system coolant...

  • Page 33

    Periodic maintenance 2-9 specifications item standard service limit standard tire: front: size: kx85c 70/100-17 40m – – – kx85d/kx100f 70/100-19 42m – – – make dunlop – – – type mx51f – – – rear: size: kx85c 90/100-14 49m – – – kx85d/kx100f 90/100-16 52m – – – make dunlop – – – type mx51 – – – final...

  • Page 34

    2-10 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 fork spring holder: 57001-1286 fork oil level gauge: 57001-1290 fork piston rod puller, m10 × 1.0: 57001-1298 jack attachment: 57001-1608.

  • Page 35

    Periodic maintenance 2-11 periodic maintenance procedures fuel system fuel hose and connection inspection ○ if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [a]. • check the fuel hose. Replace the fuel hose if any fraying, cracks [b], bulges [c] or ozone cra...

  • Page 36

    2-12 periodic maintenance periodic maintenance procedures if the throttle cable free play cannot be adjusted with the upper end of the throttle cable, use the cable adjuster [a] at the carburetor. • pull the rubber boot [b] of the carburetor. • loosen the locknuts [c] at the carburetor. • turn the t...

  • Page 37

    Periodic maintenance 2-13 periodic maintenance procedures air cleaner element cleaning and inspection note ○ in dusty areas, the element should be cleaned more frequently than recommended interval. ○ after riding through rain or on muddy roads, the element should be cleaned immediately. ○ since repe...

  • Page 38

    2-14 periodic maintenance periodic maintenance procedures • clean the element [a] in a bath of a high flash-point sol- vent using a soft bristle brush. • squeeze it dry in a clean towel [a]. Do not wring the ele- ment [b] or blow it dry; the element can be damaged. • check all parts of the element f...

  • Page 39

    Periodic maintenance 2-15 periodic maintenance procedures fuel system clean 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 includ...

  • Page 40

    2-16 periodic maintenance periodic maintenance procedures reed valve inspection • remove the reed valve (see reed valve removal in the fuel system chapter). • inspect the reeds for cracks, folds, or other visible dam- age. If there is any doubt as to the condition of a reed, replace the reed valve p...

  • Page 41

    Periodic maintenance 2-17 periodic maintenance procedures • check the coolant level. The coolant level [a] should be at the bottom of the radiator filler neck [b]. If the coolant level is low, add coolant through the radiator filler opening to the bottom of the radiator filler neck. Recommended cool...

  • Page 42

    2-18 periodic maintenance periodic maintenance procedures water hoses and connections inspection • remove the right radiator shroud (see radiator removal in the cooling system chapter). ○ the high pressure inside the water hoses [a] can cause coolant to leak [b] or the hose to burst if the line is n...

  • Page 43

    Periodic maintenance 2-19 periodic maintenance procedures cylinder wear inspection note ○ measure the cylinder inside diameter when the cylinder is cold (at room temperature). • visually inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly worn, rep...

  • Page 44

    2-20 periodic maintenance periodic maintenance procedures piston/cylinder clearance inspection 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 onl...

  • Page 45

    Periodic maintenance 2-21 periodic maintenance procedures expansion chamber o-rings replacement • remove the expansion chamber (see expansion cham- ber removal in the engine top end chapter). • replace the exhaust gasket and exhaust o-rings [a]. • apply molybdenum disulfide grease around the exhaust...

  • Page 46

    2-22 periodic maintenance periodic maintenance procedures • replace the silencer wool and o-ring with new ones. • install: silencer wool o-ring • using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • apply liquid gas...

  • Page 47

    Periodic maintenance 2-23 periodic maintenance procedures • loosen the locknut [a] at the clutch cable, and turn the adjusting nut [b] so that clutch lever has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. • tighten the locknut, and start the engine and check that the clutch does not slip and that it release p...

  • Page 48

    2-24 periodic maintenance periodic maintenance procedures transmission oil change • warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Then stop the engine. • place an oil pan beneath the engine. • remove the oil filler cap [a]. • remove the transmission oil dr...

  • Page 49

    Periodic maintenance 2-25 periodic maintenance procedures breather hoses inspection • be certain that the breather hoses [a] are routed without being flattened or kinked and is connected correctly. If it is not, correct it. • inspect the breather hoses for damage or sings of deteri- oration. ○ this ...

  • Page 50

    2-26 periodic maintenance periodic maintenance procedures wheels/tires air pressure inspection/adjustment • using a tire pressure gauge [a], measure the air pressure when the tires are cold. • adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from t...

  • Page 51

    Periodic maintenance 2-27 periodic maintenance procedures spoke tightness inspection • check that all the spokes are adjusted evenly. If spoke tightness is uneven or loose, tighten the spoke nipples [a] to the specified torque. Torque - spoke nipples: 4.0 n·m (0.41 kgf·m, 35 in·lb) • check the rim r...

  • Page 52

    2-28 periodic maintenance periodic maintenance procedures wheel bearing inspection • raise the front/rear wheel off the ground using the jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • rotate [a] the wheel lightly, and check for roughness, binding or noise. If any damage is foun...

  • Page 53

    Periodic maintenance 2-29 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 54

    2-30 periodic maintenance periodic maintenance procedures • tighten both chain adjuster locknuts securely. • replace the rear axle nut with a new one. • tighten: torque - rear axle nut: 78 n·m (8.0 kgf·m, 58 ft·lb) • rotate the wheel, measure the chain slack again at the tightest position, and readj...

  • Page 55

    Periodic maintenance 2-31 periodic maintenance procedures rear sprocket warp (runout) inspection • using the jack, raise the rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • set a dial gauge [a] against the rear sprocket [b] near the teeth as shown. • rotate ...

  • Page 56

    2-32 periodic maintenance periodic maintenance procedures brakes brake lever and pedal adjustment • slide the dust cover [a]. • adjust the brake lever [b] to suit the rider’s preference. ○ loosen the locknut [c] and turn the adjuster [d] to either side. • after adjustment, tighten the locknut. Warni...

  • Page 57

    Periodic maintenance 2-33 periodic maintenance procedures ○ remove: screws [a] brake reservoir cap [b] diaphragm ○ inside the reservoir [a] is stopped end showing the upper level line [b]. Warning mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an ac- cid...

  • Page 58

    2-34 periodic maintenance periodic maintenance procedures rear brake reservoir • check the brake fluid level in the rear brake reservoir [a] and the rear reservoir must always be kept the upper level line [b]. Note ○ hold the reservoir horizontal when checking brake fluid level. If the brake fluid i...

  • Page 59

    Periodic maintenance 2-35 periodic maintenance procedures brake fluid change warning when working with the disc brake, observe the pre- cautions listed below. • never reuse old brake fluid. • do not use fluid from a container that has been left unsealed or that has been open for a long time. • do no...

  • Page 60

    2-36 periodic maintenance periodic maintenance procedures front brake reservoir • remove: screws [a] brake reservoir cap [b] diaphragm rear brake reservoir • remove: rear brake reservoir mounting bolt and washer [a] brake reservoir [b] brake reservoir cap [c] note ○ the procedure to change the front...

  • Page 61

    Periodic maintenance 2-37 periodic maintenance procedures • change the brake fluid as follows: ○ repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [a]. 2. Apply the brake and hold it [b]. 3. Close the bleed valve ...

  • Page 62

    2-38 periodic maintenance periodic maintenance procedures brake pad wear inspection • check the lining thickness [a] and condition of the brake pads in each caliper. Note ○ it is able to check with the pads installed. If either pad is damaged, replace both pads in the caliper as a set. Brake pad lin...

  • Page 63

    Periodic maintenance 2-39 periodic maintenance procedures rear master cylinder disassembly note ○ do not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi- tion adjustment. • remove: rear master cylinder (see rear master cylinder re- moval in the brak...

  • Page 64

    2-40 periodic maintenance periodic maintenance procedures master cylinder assembly • before assembly, clean all parts including the master cylinder with brake fluid or alcohol. Notice except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of th...

  • Page 65

    Periodic maintenance 2-41 periodic maintenance procedures • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ cover the caliper opening with a clean heavy cloth [a]. ○ remove the pistons by lightly applying compressed air [b] to the hose joint opening. Warning ...

  • Page 66

    2-42 periodic maintenance periodic maintenance procedures • pull out the piston [a] by hand. • remove the dust seal [b] and fluid seal [c]. • remove the bleed valve and rubber cap. Caliper assembly • clean the caliper parts except for the pads. Notice for cleaning of the parts, use only disc brake f...

  • Page 67

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

  • Page 68

    2-44 periodic maintenance periodic maintenance procedures brake hoses and connections inspection • 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 properl...

  • Page 69

    Periodic maintenance 2-45 periodic maintenance procedures • remove the front/rear brake hose banjo bolts [a] and washers [b]. • replace the washers with new ones. ○ when removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. ○ when removing the brake hose, t...

  • Page 70

    2-46 periodic maintenance periodic maintenance procedures • take the top plug [a] with the push rod off. • compress the outer tube [b]. • press [a] the fork spring [b] away from the top plug and slip the fork spring holder [c] on top of the spring seat and under the push rod nut [d]. Special tool - ...

  • Page 71

    Periodic maintenance 2-47 periodic maintenance procedures note ○ while doing this, take care to keep the oil level topped off that it stays above the two large holes [a] near the top of the inner tube [b]. • screw the fork piston rod puller [a] onto the end of the rod. Special tool - fork piston rod...

  • Page 72

    2-48 periodic maintenance periodic maintenance procedures rear shock absorber oil change the oil should be changed in the rear shock absorber in accordance with the periodic maintenance chart. The frequency for best performance must be based upon riding conditions and rider ability. The disassembly ...

  • Page 73

    Periodic maintenance 2-49 periodic maintenance procedures • slide up the stopper of the piston rod, then push the oil seal [a] to remove the circlip [b]. • remove the circlip. • wrap a heavy cloth around the rear shock body [a] and piston rod to prevent the oil diffusion. • lightly move the piston r...

  • Page 74

    2-50 periodic maintenance periodic maintenance procedures assembly for oil change • check that the bladder [a] on the gas reservoir cap [b] is not partially collapsed. If it is, push down the valve core with a standard tip screw- driver. • check the bladder for sign of damage or crack. If necessary,...

  • Page 75

    Periodic maintenance 2-51 periodic maintenance procedures • push the oil seal assembly into the rear shock body until it just clears the circlip groove. • replace the circlip [a] with a new one. • fit the circlip into the groove in the rear shock body [b]. • pull up [c] the piston rod assembly [d] a...

  • Page 76

    2-52 periodic maintenance periodic maintenance procedures • purge the air from between the gas reservoir [a] and rear shock body [b] by slowly pumping the piston rod [c] in and out. • replace the o-ring [a] with a new one and apply shock absorber oil. • install the compression damping adjuster [b] s...

  • Page 77

    Periodic maintenance 2-53 periodic maintenance procedures • pump the seat down and up [a] 4 or 5 times, and inspect the smooth stroke. If the uni-trak linkage does not smooth stroke or noise is found, inspect the uni-trak linkage bearings. • push and pull on the swingarm [a] to check for wear. A sma...

  • Page 78

    2-54 periodic maintenance periodic maintenance procedures • remove: number plate (see number plate removal in the frame chapter) handlebars (see handlebar removal in the steering chapter) • loosen the front fork clamp bolts (upper) on both sides. • loosen the steering stem head nut [a]. • turn the s...

  • Page 79

    Periodic maintenance 2-55 periodic maintenance procedures electrical system spark plug cleaning and inspection • clean the cylinder head around the spark plug before re- moving the spark plug. • remove the spark plug cap [a]. • remove the spark plug [b]. • clean the spark plug, preferably in a sandb...

  • Page 80

    2-56 periodic maintenance periodic maintenance procedures points: lubricate with grease. Clutch inner cable upper and lower ends [a] throttle inner cable upper end brake lever pivot bolt clutch lever pivot bolt brake pedal bolt cables: lubricate with rust inhibitor. Throttle inner cable clutch inner...

  • Page 81

    Periodic maintenance 2-57 periodic maintenance procedures if there are loose fasteners, retighten them to the spec- ified torque following the specified tightening sequence. Refer to the torque and locking agent section in this chapter for torque specifications. For each fastener, first loosen it by...

  • Page 83: Fuel System

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

  • Page 84

    3-2 fuel system exploded view.

  • Page 85

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 reed valve screws 1.0 0.10 8.9 in·lb 2 carburetor holder mounting bolts 9.4 1.0 83 in·lb 3 carburetor mounting clamp screw 1.5 0.15 13 in·lb cl: apply cable lubricant. G: apply grease. R: replacement parts.

  • Page 86

    3-4 fuel system exploded view.

  • Page 87

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel tank screws 5.0 0.51 44 in·lb ad: apply adhesive. G: apply grease. O: apply high-quality foam air filter oil. R: replacement parts.

  • Page 88

    3-6 fuel system specifications item standard service limit throttle grip and cables throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – carburetor make/type keihin pwk28 – – – main jet #140 – – – main air jet #60 – – – throttle valve cutaway #3.5 – – – jet needle: kx85c/d nrjc – – – kx100f nrkc...

  • Page 89

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

  • Page 90

    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 91

    Fuel system 3-9 throttle grip and cable • remove: screws [a] carburetor cap [b] with throttle valve assembly • free the lower end [a] of the throttle cable from the throttle valve assembly. • loosen the locknut [b] and adjuster [c] and remove the throttle cable [d]. • lubricate the throttle cable (s...

  • Page 92

    3-10 fuel system carburetor idle speed adjustment • refer to the idle speed adjustment in the periodic main- tenance chapter. Main jet replacement notes warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the are...

  • Page 93

    Fuel system 3-11 carburetor • remove the drain plug from the bottom of the float bowl, and screw a fuel level gauge [a] into the plug hole. Special tool - fuel level gauge, m18 × 1.0: 57001-122 • hold the gauge vertically against the side of the carbure- tor body so that the “zero” line [c] is sever...

  • Page 94

    3-12 fuel system carburetor • drive out the pivot pin [a] and remove the float [b] with float valve needle [c]. • bend the tang [a] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Floa...

  • Page 95

    Fuel system 3-13 carburetor • turn the fuel tap lever to the “off” position. • free the carburetor overflow hose [a] from the clamp [b] on the magnet cover. • slide out the clamp [c] and disconnect the fuel hose [d]. • remove the upper end of the throttle cable (see throttle cable replacement). • lo...

  • Page 96

    3-14 fuel system carburetor • install the clamps [a]. • tighten: torque - carburetor mounting clamp screw [b]: 1.5 n·m (0.15 kgf·m, 13 in·lb) • route the air vent and overflow hoses through the clamp on the crankcase (see cable, wire and hose routing section in the appendix chapter). Notice always k...

  • Page 97

    Fuel system 3-15 carburetor ○ slide the jet needle [a] out of the throttle valve. ○ pull out the snap ring [b], and remove the throttle cable from the carburetor cap [c]. • remove the following parts from the carburetor body. Choke plunger assembly [d] idle adjusting screw and spring [e] air screw a...

  • Page 98

    3-16 fuel system carburetor carburetor cleaning warning gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this in- cludes any ...

  • Page 99

    Fuel system 3-17 carburetor • remove the carburetor (see carburetor removal). • before disassembling the carburetor, check the fuel level (see fuel level inspection). If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. • pull the carburetor cable to check that ...

  • Page 100

    3-18 fuel system air cleaner air cleaner case removal • remove: seat (see seat removal in the frame chapter) rear fender (see rear fender removal/installation in the frame chapter) rear frap (see rear flap removal/installation in the frame chapter) rear frame pipe (see rear frame pipe removal in the...

  • Page 101

    Fuel system 3-19 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 102

    3-20 fuel system fuel tank fuel tap removal • remove the fuel tank (see fuel tank removal). • drain the fuel. • remove the bolts [a] and take off the fuel tap [b]. Fuel tap installation • replace the gasket [a] with a new one. • install the fuel tap. ○ turn the fuel tap lever to the “off” position. ...

  • Page 103

    Fuel system 3-21 reed valve reed valve removal • remove: carburetor (see carburetor removal) carburetor holder mounting bolts [a] clamp [b] carburetor holder [c] reed valve assembly [d] reed valve installation • installation is the reverse of removal. • tighten: torque - carburetor holder mounting b...

  • Page 104

    3-22 fuel system fuel hose fuel hoses and connections inspection ○ check the fuel hose periodically in accordance with the periodic maintenance chart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [a] or the hose to burst. Remove the fuel tank and che...

  • Page 105: Cooling System

    Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 106

    4-2 cooling system exploded view.

  • Page 107

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water hose clamp screws 3.0 0.31 27 in·lb 2 coolant drain bolt (cylinder) 8.8 0.90 78 in·lb 3 air bleeder bolt 9.4 1.0 83 in·lb 4 water pump cover bolts 9.4 1.0 83 in·lb 5 water pump impeller bolt 8.3 0.85 73 in·lb 6 cool...

  • Page 108

    4-4 cooling system specifications item standard recommended 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 am...

  • Page 109

    Cooling system 4-5 coolant coolant level inspection • refer to the coolant level inspection in the periodic main- tenance chapter. Coolant deterioration inspection • refer to the coolant deterioration inspection in the peri- odic maintenance chapter. Coolant draining warning coolant can be extremely...

  • Page 110

    4-6 cooling system coolant coolant filling notice use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the coo...

  • Page 111

    Cooling system 4-7 coolant • tap the water hoses to force out any air bubbles [a] caught inside. • check the coolant level (see coolant level inspection in the periodic maintenance chapter). If the coolant level is low, add coolant up to the bottom of the radiator filler neck. • install the radiator...

  • Page 112

    4-8 cooling system coolant cooling system flushing over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water...

  • Page 113

    Cooling system 4-9 water pump water pump cover removal • drain the coolant (see coolant draining). • loosen the water hose clamp screws [a], and disconnect the water hoses [b]. • remove the water pump cover bolts [c] and water pump cover [d]. Water pump cover installation • replace the water pump co...

  • Page 114

    4-10 cooling system water pump water pump inspection • visually check the impeller [a]. If the surface is corroded, or if the blades [b] are dam- aged, replace the impeller. Water pump gear removal • remove the primary gear (see primary gear removal in the engine right side chapter). • pull out the ...

  • Page 115

    Cooling system 4-11 radiator radiator removal • drain the coolant (see coolant draining). • remove: right shroud (see shroud removal/installation in the frame chapter) • remove the radiator screen bolt [a]. • clear the hook [b] and remove the radiator screen [c]. • disconnect the overflow hose [a]. ...

  • Page 116

    4-12 cooling system radiator radiator inspection • check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [a] are deformed, carefully straighten them with the standard tip screwdriver. Notice do not tear the radiator tubes while straightening the fins. If...

  • Page 117

    Cooling system 4-13 radiator filler neck inspection • check the radiator filler neck for signs of damage. • check the condition of the top and bottom sealing seats [a] in the filler neck. They must be smooth and clean for the radiator cap to function properly. Water hoses and overflow hose inspectio...

  • Page 119: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-2 specifications ................................................................................................

  • Page 120

    5-2 engine top end exploded view.

  • Page 121

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head nuts 25 2.5 18 s 2 exhaust valve cover screws 3.0 0.31 27 in·lb 3 kips cover bolts 5.2 0.53 46 in·lb 4 exhaust valve lever mounting bolt 3.9 0.40 35 in·lb l 5 exhaust valve plate bolts 5.9 0.60 52 in·lb 6 cy...

  • Page 122

    5-4 engine top end specifications item standard service limit cylinder head cylinder compression (usable range) – – – 826 ∼ 1 278 kpa (8.4 ∼ 13 kgf/cm², 120 ∼ 185 psi) at 5 times cylinder head warp – – – 0.03 mm (0.001 in.) cylinder, piston cylinder inside diameter: kx85c/d 48.505 ∼ 48.520 mm (1.909...

  • Page 123

    Engine top end 5-5 special tools compression gauge, 20 kgf/cm²: 57001-221 piston pin puller assembly: 57001-910 compression gauge adapter, m14 × 1.25: 57001-1159.

  • Page 124

    5-6 engine top end cylinder head compression pressure 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 the spark plug (see spark plu...

  • Page 125

    Engine top end 5-7 cylinder head cylinder head installation • replace the cylinder head gasket with a new one. • check the head water jacket for a crust of minerals and rust and remove them if necessary. • install the dowel pins [a]. • install a new cylinder head gasket with the side marked up [b] f...

  • Page 126

    5-8 engine top end cylinder cylinder removal • remove the fuel tank mounting bolt [a] • drain the coolant (see coolant draining in the cooling system chapter). • remove the radiator (see radiator removal in the cool- ing system chapter). • loosen the water hose clamp screws [a]. • remove: water hose...

  • Page 127

    Engine top end 5-9 cylinder cylinder installation • scrape any carbon out of the exhaust port. • check on a crust of minerals and rust in the cylinder water jacket, and remove them if necessary. • replace the cylinder base gasket with a new one. • apply 2-stroke engine oil to the piston surface, pis...

  • Page 128

    5-10 engine top end cylinder piston installation • stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase. • scrape off any carbon of the piston, then lightly polish the piston with fine emery cloth. • clean carbon and dirt out of the p...

  • Page 129

    Engine top end 5-11 cylinder cylinder wear inspection • refer to the cylinder wear inspection in the periodic maintenance chapter. Piston diameter measurement • measure the outside diameter of the piston 17 mm (0.67 in.) [a] up from the bottom of the piston at a right angle to the direction of the p...

  • Page 130

    5-12 engine top end cylinder piston ring groove width inspection • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: kx85c/d 1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.) kx100f 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) service limit: kx85c/d 1...

  • Page 131

    Engine top end 5-13 cylinder piston, piston pin, and connecting rod wear inspection • visually inspect the snap rings [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the diameter o...

  • Page 132

    5-14 engine top end exhaust valve (kips) exhaust valve removal • remove: cylinder (see cylinder removal) exhaust valve cover screws [a] exhaust valve cover [b] exhaust valve cover gasket • remove: exhaust valve lever mounting bolt [a] operating rod [b] exhaust valve lever [c] exhaust valve plate bol...

  • Page 133

    Engine top end 5-15 muffler muffler removal/installation • remove: left side cover (see side cover removal/installation in the frame chapter) bolt [a] bolt [b] and washers • remove the muffler [c] from the rubber [d]. • installation is the reverse of removal. Expansion chamber removal • remove: muff...

  • Page 134

    5-16 engine top end muffler • install the expansion chamber mounting springs [a] as shown. Cylinder side [b] expansion chamber side [c] silencer wool change • refer to the silencer wool replacement in the periodic maintenance chapter..

  • Page 135: Engine Right Side

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

  • Page 136

    6-2 engine right side exploded view.

  • Page 137

    Engine right side 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts 9.4 1.0 83 in·lb 2 clutch spring bolts 9.3 0.95 82 in·lb 3 clutch hub nut 88 9.0 65 r cl: apply cable lubricant. Eo: apply engine oil. G: apply grease. M: apply molybdenum disulfide grease. Mo: apply...

  • Page 138

    6-4 engine right side exploded view.

  • Page 139

    Engine right side 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 lever shaft assembly mounting screw 6.4 0.65 57 in·lb l 2 kick pedal bolt 9.4 1.0 83 in·lb 3 lever shaft retaining bolt 5.2 0.53 46 in·lb 4 oil filler cap – – – hand -tighten 5 right engine cover bolts 9.4 1.0 83 in·lb...

  • Page 140

    6-6 engine right side specifications item standard service limit clutch lever clutch lever free play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.8 mm (0.11 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) steel plate war...

  • Page 141

    Engine right side 6-7 special tools outside circlip pliers: 57001-144 bearing puller: 57001-158 bearing driver set: 57001-1129 clutch holder: 57001-1243 bearing puller adapter: 57001-1526 gear holder: 57001-1602 flywheel & pulley holder: 57001-1605.

  • Page 142

    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 143

    Engine right side 6-9 clutch lever and cable • take the clutch cable off the cable holder [a]. • take the clutch cable lower end [b] off the clutch release lever [c]. Notice do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced ...

  • Page 144

    6-10 engine right side clutch cover and right engine cover clutch cover removal • drain the transmission oil (see transmission oil change in the periodic maintenance chapter). • remove: clutch cable lower end [a] (see clutch cable removal) clutch cover bolts [b] • turn the release lever counterclock...

  • Page 145

    Engine right side 6-11 clutch cover and right engine cover clutch cover disassembly • remove: clutch cover (see clutch cover removal) release shaft (see release shaft removal) oil seal [a] • remove the needle bearings [a]. Clutch cover assembly • replace the needle bearings and oil seal with new one...

  • Page 146

    6-12 engine right side clutch cover and right engine cover • remove: kips cover bolts [a] kips cover [b] kips cover gasket • remove the circlip [a]. • push [b] the shaft lever, and disconnect the link lever [c] from the operating rod [d]. • remove: impeller (see impeller removal in the cooling syste...

  • Page 147

    Engine right side 6-13 clutch cover and right engine cover • replace the circlip [a] and kips cover gasket with new ones. • install the boot [b] to the cylinder. • push [c] the shaft lever, and connect the link lever [d] to the operating rod [e]. • install: circlip kips cover gasket kips cover • tig...

  • Page 148

    6-14 engine right side clutch cover and right engine cover • remove: oil filler cap [a] oil seals [b] • remove the bearings [a]. Right engine cover assembly • replace the oil seals and bearings with new ones. • press the oil level inspection window [a] to the right cover until it is bottomed. Specia...

  • Page 149

    Engine right side 6-15 clutch cover and right engine cover • apply grease to the oil seal [b] lips. • apply molybdenum disulfide grease to the oil seal [c] lips. • when assembly the lever shaft as follows. • fit the spring lower end [a] to the groove [b] of the lever shaft. ○ install the spring so t...

  • Page 150

    6-16 engine right side clutch cover and right engine cover • fit the advancer [a] to the lever shaft [b] as shown. • align [a] the mark [b] on the lever shaft with the mark [c] on the right engine cover and insert the shaft into the cover. • tighten: torque - lever shaft retaining bolt [d]: 5.2 n·m ...

  • Page 151

    Engine right side 6-17 clutch cover and right engine cover advancer assembly • press the gear [a] on the shaft so that the gear contacts the step on the shaft. • install the parts in due order and press fit the guide [b] to set the distance [c] of 44.65 ∼ 44.75 mm (1.7579 ∼ 1.7618 in.)..

  • Page 152

    6-18 engine right side clutch clutch removal • drain the transmission oil (see transmission oil change in the periodic maintenance chapter). • remove: magneto cover (see magneto cover removal in the electrical system chapter) clutch cover (see clutch cover removal) • holding the flywheel [a] with th...

  • Page 153

    Engine right side 6-19 clutch • remove: needle bearings [a] sleeve [b] thrust washer [c] clutch installation • install the thrust washer. • apply molybdenum disulfide oil solution to the inside of the sleeve. • apply engine oil to the needle bearings. • install: sleeve needle bearings clutch housing...

  • Page 154

    6-20 engine right side clutch • install the clutch pressure plate and clutch springs. • holding the flywheel [a] with the flywheel & pulley holder [b]. Special tool - flywheel & pulley holder: 57001-1605 • tighten: torque - clutch spring bolts: 9.3 n·m (0.95 kgf·m, 82 in·lb) • install: clutch cover ...

  • Page 155

    Engine right side 6-21 clutch clutch spring free length inspection • measure the free length of the clutch springs [a]. If any clutch spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 35.0 mm (1.38 in.) service limit: 34.0 mm (1.34 in.) clutch housing...

  • Page 156

    6-22 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 [c]. Special tool - gear holder: 57001-1602 • remove: ...

  • Page 157

    Engine right side 6-23 kickstarter kick pedal removal • remove: kick pedal bolt [a] kick pedal assy [b] kick pedal installation • install the kick pedal assy. ○ put the pedal end [a] near the “s” mark [b]. • tighten: torque - kick pedal bolt: 9.4 n·m (1.0 kgf·m, 83 ft·lb) kick pedal disassembly • re...

  • Page 158

    6-24 engine right side kickstarter • when removing the kickstarter idle gear [a], remove the circlip [b]. Special tool - outside circlip pliers: 57001-144 kick shaft installation • apply molybdenum disulfide grease [a] to the kick shaft. • insert the kick shaft assembly [a] into the crankcase. • ins...

  • Page 159

    Engine right side 6-25 kickstarter kick shaft assembly disassembly/assembly • the kick shaft assembly consists of the following parts. Circlips [a] washer [b] spring [c] ratchet gear [d] kick gear [e] kick shaft [f] kick spring [g] spring guide [h] • check the kick shaft assembly parts for damage. A...

  • Page 161: Engine Removal/installation

    Engine removal/installation 7-1 7 engine removal/installation table of contents exploded view........................................................................................................................ 7-2 special tools .......................................................................

  • Page 162

    7-2 engine removal/installation exploded view.

  • Page 163

    Engine removal/installation 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine bracket mounting nuts 29 3.0 21 r 2 engine mounting nuts 29 3.0 21 r 3 swingarm pivot shaft nut 69 7.0 51 r r: replacement parts.

  • Page 164

    7-4 engine removal/installation special tools jack: 57001-1238 jack attachment: 57001-1608.

  • Page 165

    Engine removal/installation 7-5 engine removal/installation engine removal • place the jack under the frame to support the motorcycle. Special tools - jack: 57001-1238 jack attachment: 57001-1608 warning when the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detach...

  • Page 166

    7-6 engine removal/installation engine removal/installation • remove the bolt [a] to disconnect the ground terminal. • remove the bands [a]. • disconnect: ignition coil primary lead connector [b] crankshaft sensor lead connector [c] cdi unit lead connector [d] • remove: engine bracket mounting nuts ...

  • Page 167

    Engine removal/installation 7-7 engine removal/installation • install the removed parts (see appropriate chapters). • run the cables, hoses, and leads according to the cable, wire, and hose routing section in the appendix chapter. • pour: transmission oil (see transmission oil change in the periodic...

  • Page 169: Table Of Contents

    Engine bottom end/transmission 8-1 8 engine bottom end/transmission table of contents exploded view........................................................................................................................ 8-2 specifications ................................................................

  • Page 170

    8-2 engine bottom end/transmission exploded view.

  • Page 171

    Engine bottom end/transmission 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 drive shaft bearing retainer bolts 9.4 1.0 83 in·lb 2 shift drum bearing retainer bolts 9.4 1.0 83 in·lb 3 transmission oil drain bolt 20 2.0 15 4 crankshaft cover bolts 9.8 1.0 87 in·lb l 5 crankcase bolt...

  • Page 172

    8-4 engine bottom end/transmission exploded view.

  • Page 173

    Engine bottom end/transmission 8-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 shift drum cam bolt 23 2.3 17 2 gear positioning lever bolt 9.4 1.0 78 in·lb 3 shift shaft return spring pin 22 2.2 16 l 4 shift pedal bolt 9.8 1.0 87 in·lb eo: apply engine oil. G: apply grease. L: apply ...

  • Page 174

    8-6 engine bottom end/transmission specifications item standard service limit transmission oil type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 – – – viscosity sae10w-40 – – – amount 0.7 l (0.2 us qt) – – – oil level in middle of oil level inspection window – – – crankshaft, connecting rod con...

  • Page 175

    Engine bottom end/transmission 8-7 special tools and sealant bearing puller: 57001-135 bearing puller adapter: 57001-136 outside circlip pliers: 57001-144 crankcase splitting tool assembly: 57001-1098 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 liquid gasket, tb1215: 92104-1065.

  • Page 176

    8-8 engine bottom end/transmission transmission oil in order for the transmission and clutch to function prop- erly, always maintain the transmission oil at the proper level and change the oil periodically. Warning vehicle operation with insufficient, deteriorated, or contaminated transmission oil w...

  • Page 177

    Engine bottom end/transmission 8-9 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: piston (see piston removal in the engine top end chap- t...

  • Page 178

    8-10 engine bottom end/transmission crankcase • attach the crankcase splitting tool [a] to the left crankcase. ○ use the bearing puller adapter [b] of the crankcase split- ting tool attached. Special tool - crankcase splitting tool assembly: 57001 -1098 bearing puller adapter: 57001-136 • tighten th...

  • Page 179

    Engine bottom end/transmission 8-11 crankcase • support the crankcase bearing boss with a suitable re- tainer [a]. • install the new bearing [b] with a press and the bearing driver set [c]. Special tool - bearing driver set: 57001-1129 notice support the crankcase bearing boss when the bear- ing is ...

  • Page 180

    8-12 engine bottom end/transmission crankcase right crankcase • press the new crankshaft oil seal [a] so that the flat sur- face [b] faces outside of the engine, and until it is bot- tomed. • press the new crankshaft bearing [c] until it is bottomed. Special tool - bearing driver set: 57001-1129 • p...

  • Page 181

    Engine bottom end/transmission 8-13 crankcase • install: crankshaft (see crankshaft installation) transmission shafts (see transmission shaft installa- tion) shift drum (see transmission shaft installation) shift fork and shift rod • position the connecting rod in bdc. • install the crankshaft jig [...

  • Page 182

    8-14 engine bottom end/transmission crankcase • install the gear positioning lever and shift drum cam (see external shift mechanism installation). • check to see that gears shift smoothly from 1st to 6th gear, and 6th to 1st while spinning the output shaft. • set the shift drum in the neutral positi...

  • Page 183

    Engine bottom end/transmission 8-15 crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • remove the transmission shafts and shift drum (see transmission shaft removal). • using a press, remove the crankshaft [a] from the right crankcase. If the bearing stay on t...

  • Page 184

    8-16 engine bottom end/transmission crankshaft crankshaft inspection connecting rod big end radial clearance inspection • 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 dire...

  • Page 185

    Engine bottom end/transmission 8-17 crankshaft • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vise, depending on the nature of the misalign- ment. Notice do not hammer the crank half at the point [b]. If flywheel misalign...

  • Page 186

    8-18 engine bottom end/transmission crankshaft connecting rod twist inspection • with the big-end arbor [a] still on the v block [b], hold the connecting rod horizontally and measure the amount that the arbor [c] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of th...

  • Page 187

    Engine bottom end/transmission 8-19 transmission transmission shaft removal • disassemble the crankcase (see crankcase disassem- bly). • remove: shift rods [a] shift forks [b] shift drum [c] • remove the drive shaft [d] and output shaft [e] together. Transmission shaft installation • apply engine oi...

  • Page 188

    8-20 engine bottom end/transmission transmission • install the shift drum [a]. • fit the output shaft shift forks [b] into the proper gear grooves. • insert the shift rod [c] temporary. • fit the shift fork guide pin into the proper shift drum grooves. • install the shift rod securely. • fit the dri...

  • Page 189

    Engine bottom end/transmission 8-21 transmission • the drive shaft gears can be identified by size; the small- est diameter gear is 1st gear, and the largest is 6th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and washer are properl...

  • Page 190

    8-22 engine bottom end/transmission transmission shift fork/gear groove wear inspection • 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: 3.9 ∼ 4.0 mm (0.15 ∼ 0.16 in.) service limit: ...

  • Page 191

    Engine bottom end/transmission 8-23 external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • install the shift pedal so that the punch mark [a] on the pedal aligns with the punch mark [b] on the shift shaft. • tighten the shift pedal bolt...

  • Page 192

    8-24 engine bottom end/transmission external shift mechanism • install the gear positioning lever [a] as shown. Collar [b] gear positioning lever bolt [c] spring [d] • tighten: torque - gear positioning lever bolt: 9.4 n·m (1.0 kgf·m, 83 in·lb) • insert the shift shaft assembly [a]. ○ take care not ...

  • Page 193

    Engine bottom end/transmission 8-25 bearings/oil seals bearing replacement notice do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the absence of the above mentioned tools, ...

  • Page 194

    8-26 engine bottom end/transmission bearings/oil seals • inspect the needle bearings. ○ 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 ...

  • Page 195: Wheels/tires

    Wheels/tires 9-1 9 wheels/tires table of contents exploded view........................................................................................................................ 9-2 specifications ....................................................................................................

  • Page 196

    9-2 wheels/tires exploded view.

  • Page 197

    Wheels/tires 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples 4.0 0.41 35 in·lb 2 front axle nut 78 8.0 58 r 3 rear axle nut 78 8.0 58 r hg: apply high-temperature grease. R: replacement parts wl: apply soap and water solution or rubber lubricant..

  • Page 198

    9-4 wheels/tires specifications item standard service limit wheels (rims) rim runout (with tire installed): axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) axle runout/100 mm (3.94 in.): front tir 0.1 mm (0.004 in.) or less tir 0.2...

  • Page 199

    Wheels/tires 9-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 10 × 12: 57001-1266 bearing remover head, 15 × 17: 57001-1267 jack attachment: 57001-1608.

  • Page 200

    9-6 wheels/tires wheels (rims) front wheel removal • remove: cotter pin [a] front axle nut [b] • raise the front wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • pull out the axle and remove the wheel. • remove the collars [a] on both sides. Notice do no...

  • Page 201

    Wheels/tires 9-7 wheels (rims) • replace the cotter pin [a] with a new one. • insert a new cotter pin. • bend the cotter pin over the axle. Warning a loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...

  • Page 202

    9-8 wheels/tires wheels (rims) • remove the collars [a] on both sides. 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. • insert a wood wedge between the brake pads. ○ this preve...

  • Page 203

    Wheels/tires 9-9 wheels (rims) • replace the cotter pin [a] with a new one. • insert a new cotter pin. • bend the cotter pin over the axle. Warning a loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...

  • Page 204

    9-10 wheels/tires wheels (rims) ○ install the rear rim so that the marked side faces left. ○ the distance [a] from the brake disc seating surface [b] of the rear hub [c] to right end of the rear rim [d] should be as follows. [e] view from rear distance: 30.25 ±0.5 mm (1.191 ±0.02 in.) • check the ri...

  • Page 205

    Wheels/tires 9-11 tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire removal • remove the wheel (see front/rear wheel removal). Notice do not lay the wheel directly on the ground with the disc facing down. This can d...

  • Page 206

    9-12 wheels/tires tires • lubricate a commercially available tire irons [a] and rim protectors [b] with soap and water solution or rubber lu- bricant. Special tool - rim protector: 57001-1063 • step on the side of the tire opposite air valve, and pry the tire off the rim with the tire irons protecti...

  • Page 207

    Wheels/tires 9-13 tires • tighten the bead protector nut [a] (rear wheel only), air valve nut [b] and air valve cap [c]. • adjust the tire air pressure to the specified pressure (see air pressure inspection/adjustment in the periodic main- tenance chapter)..

  • Page 208

    9-14 wheels/tires hub bearing front hub bearing removal • remove: front wheel (see front wheel removal) grease seals [a] circlip [b] special tool - inside circlip pliers: 57001-143 • use the bearing remover to remove the hub bearings [a]. Notice do not lay the wheel on the ground with the disc facin...

  • Page 209

    Wheels/tires 9-15 hub bearing • install the bearings [a] by using the bearing driver set [b]. Special tool - bearing driver set: 57001-1129 hub bearing inspection since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. Note ○ do not remove any bear...

  • Page 211: Final Drive

    Final drive 10-1 10 final drive table of contents exploded view........................................................................................................................ 10-2 specifications ...................................................................................................

  • Page 212

    10-2 final drive exploded view.

  • Page 213

    Final drive 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 r, s ho: apply heavy oil. L: apply a non-permanent locking agent. R: replacement parts s: follow the specified tightening sequence..

  • Page 214

    10-4 final drive specifications item standard service limit drive chain drive chain slack 54 ∼ 64 mm (2.1 ∼ 2.5 in.) – – – drive chain 20-link length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 259 mm (10.2 in.) standard chain: make daido – – – type did 420ds2 – – – link: kx85c 120 links – – – kx85d/kx100f...

  • Page 215

    Final drive 10-5 special tool outside circlip pliers: 57001-144.

  • Page 216

    10-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection • check that the notch [...

  • Page 217

    Final drive 10-7 drive chain drive chain installation • fit the drive chain onto the engine and rear sprockets. ○ place the drive chain [a] ends on the rear sprocket [b]. • install the master link [c] from the wheel side. • install the link plate [a] so that the mark [b] faces out. • install the cli...

  • Page 218

    10-8 final drive sprockets engine sprocket removal • remove the magneto cover (see magneto cover re- moval in the electrical system chapter). • remove the circlip [a] from the output shaft. Special tool - outside circlip pliers: 57001-144 • remove the engine sprocket [b] from the drive chain [c]. En...

  • Page 219

    Final drive 10-9 sprockets rear sprocket installation • replace the rear sprocket nuts with new ones. • install the rear sprocket [a] so that the marked side [b] faces out. • install the rear sprocket nuts and washers. • install the rear wheel (see rear wheel installation in the wheels/tires chapter...

  • Page 221: Brakes

    Brakes 11-1 11 brakes table of contents exploded view........................................................................................................................ 11-2 specifications .............................................................................................................

  • Page 222

    11-2 brakes exploded view.

  • Page 223

    Brakes 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 front brake reservoir cap screws 1.5 0.15 13 in·lb 3 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 4 brake lever pivot bolt 5.9 0.60 52 in·lb si 5 brake lever pivot bolt locknut 5.9 0.6...

  • Page 224

    11-4 brakes exploded view.

  • Page 225

    Brakes 11-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 9.8 1.0 87 in·lb 3 rear master cylinder push rod locknut 17.5 1.78 12.9 4 brake pedal bolt 25 2.5 18 g 5 rear caliper mounting bolts 25 2.5 18 6 rear caliper...

  • Page 226

    11-6 brakes specifications item standard service limit brake lever brake lever free play adjustable (to suit rider) – – – brake fluid grade: front dot3 or dot4 – – – rear dot4 – – – brake pads lining thickness: front 4.0 mm (0.16 in.) 1 mm (0.04 in.) rear 4.0 mm (0.16 in.) 1 mm (0.04 in.) brake disc...

  • Page 227

    Brakes 11-7 special tools jack: 57001-1238 jack attachment: 57001-1608.

  • Page 228

    11-8 brakes brake lever, brake pedal brake lever play adjustment • refer to the brake lever and pedal adjustment in the periodic maintenance chapter. Brake pedal position adjustment • refer to the brake lever and pedal adjustment in the periodic maintenance chapter. Brake pedal removal • remove: cot...

  • Page 229

    Brakes 11-9 brake lever, brake pedal • replace the cotter pin with a new one. • install the joint pin, washer and new cotter pin. • bend the ends [a] of the cotter pin. • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter)..

  • Page 230

    11-10 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. • never reuse old brake fluid. • do not use fluid from a container that has been left unsealed or that has been open for a long time. • do not mix two types and brands of fluid for use in the b...

  • Page 231

    Brakes 11-11 brake fluid brake line bleeding the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever ...

  • Page 232

    11-12 brakes brake fluid • remove the rubber cap [a] from the bleed valve on the caliper. • attach a clear plastic hose [b] to the bleed valve on the caliper, and run the other end of the hose into a container. • bleed the brake line and caliper as follows: ○ repeat this operation until no more air ...

  • Page 233

    Brakes 11-13 brake fluid • 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 increased stopping distance...

  • Page 234

    11-14 brakes caliper caliper removal front brake loosen the brake pad pin [a] before the caliper [b] re- moval if the caliper is to be disassembled. • loosen the banjo bolt [c] so as not to spill brake fluid. • remove: caliper mounting bolts [d] banjo bolt caliper notice immediately wipe up any brak...

  • Page 235

    Brakes 11-15 caliper • install the brake hose lower end. • replace the washers [a] on each side of hose fitting [b] with new ones. • tighten: torque - brake hose banjo bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the removed parts (see appropriate chapters). • bleed the brake line (see brake line bl...

  • Page 236

    11-16 brakes caliper caliper dust boot and friction boot damage inspection • check that the dust boot [a] and friction boot [b] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. [c] front caliper [d] rear caliper caliper piston and cylinder damage inspection ...

  • Page 237

    Brakes 11-17 caliper caliper holder shaft wear inspection the caliper body must slide smoothly on the caliper holder shaft(s) [a]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temper...

  • Page 238

    11-18 brakes brake pad brake pad removal front brake • loosen the pad pin [a]. • remove the front caliper [b] with the hose installed (see caliper removal). • remove: pad pin [a] piston side pad [b] • push the caliper holder [c] toward the piston, and then remove the pad [d] from the caliper holder ...

  • Page 239

    Brakes 11-19 brake pad brake pad installation • push the caliper piston(s) in by hand as far as they will go. • install the piston side pad [a] first, and then another pad [b]. ○ the piston side pad of the calipers has a wear protecting shim. Be careful not to mix it up with the other pad. [c] front...

  • Page 240

    11-20 brakes master cylinder notice brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely washed up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose upper end [b] from the master cylinder [c]. ○ when removin...

  • Page 241

    Brakes 11-21 master cylinder • install the brake hose (see brake hose replacement in the periodic maintenance chapter). • replace the washers [a] on each side of hose fitting [b] with new ones. • tighten: torque - brake hose banjo bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • bleed the brake line (see brake ...

  • Page 242

    11-22 brakes master cylinder • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter). • bleed the brake line (see brake line bleeding). • check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it takes...

  • Page 243

    Brakes 11-23 brake disc brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • remove the mounting bolts [a], and take off the disc [b]. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-pe...

  • Page 244

    11-24 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hoses and connections inspection in the periodic maintenance chapter..

  • Page 245: Suspension

    Suspension 12-1 12 suspension table of contents exploded view................................... 12-2 specifications .................................... 12-6 special tools ..................................... 12-7 front fork .......................................... 12-9 air pressure adjustment ....

  • Page 246

    12-2 suspension exploded view.

  • Page 247

    Suspension 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 air pressure relief screws 1.3 0.13 12 in·lb 2 front fork top plugs 28 2.9 21 3 front fork clamp bolts (upper) 20 2.0 15 4 front fork clamp bolts (lower) 20 2.0 15 al 5 front fork push rod nuts 15 1.5 11 6 compression valve ...

  • Page 248

    12-4 suspension exploded view.

  • Page 249

    Suspension 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rocker arm bracket bolts 83 8.5 61 2t 2 rocker arm pivot nut 83 8.5 61 r 3 tie-rod mounting nuts 59 6.0 44 r 4 compression damping adjuster 17.5 1.78 12.9 5 rear shock absorber mounting bolt (upper) 39 4.0 29 6 rear shock ab...

  • Page 250

    12-6 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – compression damper setting: kx85c 10 clicks counterclockwise (adjustable range) 20 clicks kx85d/kx100f 14 clicks counterclockwise (adjustable range) 20 clicks suspension oil: kawasaki khl15-...

  • Page 251

    Suspension 12-7 special tools spring compressor: 57001-1087 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, 36: 57001-1352 fork cylinder holder: 57001-1413 hook wre...

  • Page 252

    12-8 suspension special tools fork oil seal driver weight, 48 ∼ 54: 57001-1796 fork oil seal driver attachment, 36 ∼ 46: 57001-1798.

  • Page 253

    Suspension 12-9 front fork air pressure adjustment the standard air pressure in the front fork legs is atmo- spheric (0 kpa, 0 kgf/cm², 0 psi). Air pressure in the fork legs increase with normal use, so the fork action stiffens during operation. Release air pressure from the fork legs prior to each ...

  • Page 254

    12-10 suspension front fork seated position [a]: adjuster turned fully clockwise. Compression damper settings standard: kx85c 10 clicks counterclockwise [b] kx85d/kx100f 14 clicks counterclockwise [c] softer (counterclockwise) [d] harder (clockwise) [e] *: although you can turn the adjuster beyond t...

  • Page 255

    Suspension 12-11 front fork • loosen the upper [a] and lower [b] front fork clamp bolts. • pull out the front fork downward with a twisting motion [a]. Front fork installation • install the front fork. ○ the height [a] between the top end of the outer tube [b] and upper surface of the steering stem ...

  • Page 256

    12-12 suspension front fork front fork disassembly • drain the fork oil (see front fork oil change in the peri- odic maintenance chapter). • hold the fork leg horizontally in a vise. • compress the outer tube. • remove the cap on the bottom of the front fork tube. • stop the cylinder unit [a] from t...

  • Page 257

    Suspension 12-13 front fork ○ remove the retaining ring [a] from the outer tube [b]. ○ grasp the tubes and stroke the inner tube [a] up and down [b] several times. The shock to fork seal separates the inner tube from the outer tube [c]. • remove: bushings [a] washer [b] oil seal [c] retaining ring [...

  • Page 258

    12-14 suspension front fork • when assembling the new outer tube bushings, washer and new oil seal [a], hold the oil seal against the new one, and tap the oil seal with the fork oil seal driver [b] until it stops. Special tools - fork oil seal driver, 36:57001-1352 or fork oil seal driver weight, 48...

  • Page 259

    Suspension 12-15 front fork compression valve assembly inspection • inspect the threads portion [a] of the compression valve assembly [b] for damage. If they are damaged, replace the compression valve as- sembly with a new one. • replace the o-rings [c] with new ones. Cylinder unit inspection • insp...

  • Page 260

    12-16 suspension front fork dust seal inspection • inspect the dust seal [a] for any signs of deterioration or damage. Replace it if necessary. Front fork spring tension inspection • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring is ...

  • Page 261

    Suspension 12-17 rear shock absorber rear shock absorber adjustment to suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. ...

  • Page 262

    12-18 suspension rear shock absorber seated position [a]: adjuster turned fully clockwise. Compression damper settings standard: kx85c 10 clicks counterclockwise [b] kx85d/kx100f 14 clicks counterclockwise [c] softer (counterclockwise) [d] harder (clockwise) [e] *: although you can turn the adjuster...

  • Page 263

    Suspension 12-19 rear shock absorber • using the hook wrench (r37.5) [a], turn the spring preload adjusting nut [b] as required. Turning the adjusting nut downward makes the spring action harder and upward softer. Special tool - hook wrench r37.5, r42: 57001-1101 spring preload setting position (the...

  • Page 264

    12-20 suspension rear shock absorber • remove: rear tie-rod mounting bolt and nut [a] rear master cylinder mounting bolts [b] ○ support the rocker arm [c] to slide out the tie-rod bolts. Notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could dama...

  • Page 265

    Suspension 12-21 rear shock absorber • hold the upper end of the rear shock absorber in a vise with soft jaws [a] or a heavy cloth. • using the hook wrenches (r35, r37.5), loosen the lock- nut and turn the adjusting nut all way up. Special tools - hook wrench r=35: 57001-1580 hook wrench r37.5, r42:...

  • Page 266

    12-22 suspension rear shock absorber rear shock absorber bearing removal • remove: oil seals [a] needle bearing [b] sleeve [c] rear shock absorber bearing installation • replace the needle bearing [a] and the oil seals [b] with new ones. • apply plenty of grease [c] to the inside of the needle bear-...

  • Page 267

    Suspension 12-23 swingarm swingarm removal • remove: rear tie-rod mounting bolt and nut (see tie-rod re- moval) bolts [a] screws [b] chain guide plate [c] • remove: screws [a] and brake hose clamps [b] rear wheel (see rear wheel removal in the wheels/tires chapter) rear caliper (see caliper removal ...

  • Page 268

    12-24 suspension swingarm swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • apply a non-permanent locking agent to the chain slipper screws. • install the chain slipper, and tighten the screws. • replace with new ones: swingarm pivot ...

  • Page 269

    Suspension 12-25 swingarm swingarm bearing, sleeve inspection notice do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings [a] installed in the swingarm. ○ the rollers in a bearings normally wear very little, and wear is difficult to measure. Instead of ...

  • Page 270

    12-26 suspension tie-rod, rocker arm tie-rod removal • pull the hoses [a] upward not to be damaged by tie-rod removing. • place the jack under the frame so that the rear wheel is raised off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • squeeze the brake lever slowly and ...

  • Page 271

    Suspension 12-27 tie-rod, rocker arm • squeeze the brake lever slowly and hold it with a band [a]. • remove: tie-rod [a] (see tie-rod removal) rear shock absorber mounting bolt (lower) [b] notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could da...

  • Page 272

    12-28 suspension tie-rod, rocker arm rocker arm installation • replace with new ones: rocker arm pivot nut tie-rod mounting nuts • apply plenty of grease to the inside of needle bearings and sleeves. Rocker arm needle bearings tie-rod needle bearings • tighten: torque - rear shock absorber mounting ...

  • Page 273

    Suspension 12-29 tie-rod, rocker arm • install the needle bearings [a] [b], oil seals [c] and grease seals [d] so that their positions are as shown. ○ the other side is also the same procedures. Front [e] right side [f] left side [g] rear shock absorber [h] tie-rod [i] rocker arm [j] 5.5 mm (0.2 in....

  • Page 274

    12-30 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 inspection • pull out the sleeves [a] of the rocker arm and the tie-rod. • measure the outside diameter of...

  • Page 275: Steering

    Steering 13-1 13 steering table of contents exploded view........................................................................................................................ 13-2 special tools ..........................................................................................................

  • Page 276

    13-2 steering exploded view.

  • Page 277

    Steering 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 25 2.5 18 2t, s 2 front fork clamp bolts (upper) 20 2.0 15 3 steering stem head nut 64 6.5 47 4 handlebar holder nuts 34 3.5 25 r 5 steering stem nut 4.9 0.50 43 in·lb 6 front fork clamp bolts (lower) 20...

  • Page 278

    13-4 steering special tools bearing puller: 57001-135 bearing driver, 32: 57001-382 head pipe outer race press shaft: 57001-1075 steering stem bearing driver adapter, 29.7: 57001-1092 steering stem nut wrench: 57001-1100 head pipe outer race driver, 46.5: 57001-1106 head pipe outer race remover id >...

  • Page 279

    Steering 13-5 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: number plate (see number plate removal in t...

  • Page 280

    13-6 steering steering • remove the upper stem bearing inner race (tapered roller bearing) [a]. • drive out the bearing outer races from the head pipe. ○ remove the outer races pressed into the head pipe, using the head pipe outer race remover [a], and hammer the head pipe outer race remover to driv...

  • Page 281

    Steering 13-7 steering steering stem, stem bearing installation • replace the bearing outer races with new ones. • apply grease to the outer races. • drive the outer races into the head pipe at the same time with the special tools. Special tools - head pipe outer race press shaft [a]: 57001-1075 hea...

  • Page 282

    13-8 steering steering • tighten the stem head nut temporarily. • install the front forks (see front fork installation in the suspension chapter). • tighten: torque - front fork clamp bolts (upper): 20 n·m (2.0 kgf·m, 15 ft·lb) steering stem head nut: 64 n·m (6.5 kgf·m, 47 ft·lb) front fork clamp bo...

  • Page 283

    Steering 13-9 steering stem warp inspection • whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem shaft [a] for straightness. If the steering stem shaft is bent, replace the steering stem..

  • Page 284

    13-10 steering handlebars handlebar removal • remove: number plate (see number plate removal in the frame chapter) clutch lever assembly [a] engine stop switch [b] (see engine stop switch re- moval in the electrical system chapter) bands [c] left handlebar grip [d] • remove: throttle grip assembly [...

  • Page 285

    Steering 13-11 handlebars • apply grease to the throttle cable upper end and clutch cable upper end. • apply 2-stroke oil to the edge (slash area [a]) of the han- dlebars. • install the throttle grip assembly so that the grip [a] is in as far as it will go. ○ position the throttle grip assembly [b] ...

  • Page 286

    13-12 steering handlebars • remove: handlebars (see handlebar removal) handlebar holder nuts [a] and washers handlebar holders [b] • select the handlebar height as follows. [a] 5 mm (0.2 in.) higher than standard setting [b] 10 mm (0.4 in.) higher than standard setting ○ install the collars [c] betw...

  • Page 287: Frame

    Frame 14-1 14 frame table of contents exploded view........................................................................................................................ 14-2 frame ........................................................................................................................

  • Page 288

    14-2 frame exploded view.

  • Page 289

    Frame 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame pipe nuts 34 3.5 25 r g: apply grease. R: replacement parts.

  • Page 290

    14-4 frame frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Rear frame pipe removal • remove: right side cover (see side cover removal/installation) bolt [a] rear frame pipe bolts [b] and nuts rear frame pipe [c] rear frame pipe installation • installatio...

  • Page 291

    Frame 14-5 seat seat removal • remove the seat bolt [a] on both sides. • remove the seat [b] rearward [c]. Seat installation • install the seat. ○ insert the hooks [a] of the seat [b] under the flange collar [c] and bracket [d]. ○ take care not to damage the side covers with the bracket of seat. • i...

  • Page 292

    14-6 frame side covers side cover removal/installation • remove: seat bolt [a] side cover bolt [b] side cover [c] • installation is the reverse of removal..

  • Page 293

    Frame 14-7 shroud shroud removal/installation • remove: bolts [a] shroud [b] • installation is the reverse of removal..

  • Page 294

    14-8 frame number plate number plate removal • unlock the clamp [a] of the number plate [b]. • remove the number plate mounting bolt [c]. • clear the projections [d] and remove the number plate. Number plate installation • install the number plate [a] so that the projections [b] on the front fender ...

  • Page 295

    Frame 14-9 fender front fender removal/installation • remove the number plate (see number plate removal). • remove the bolts [a] and the front fender [b]. • installation is the reverse of removal. ○ install the number plate (see number plate installation). Rear fender removal/installation • remove t...

  • Page 296

    14-10 frame footpegs footpeg removal • remove: cotter pin [a] washer [b] pivot pin [c] spring [d] footpeg [e] footpeg installation • replace the cotter pin with a new one. • apply grease to the pivot pin. • install the footpeg, spring and pivot pin. ○ insert the pivot pin from upper side. • install ...

  • Page 297: Electrical System

    Electrical system 15-1 15 electrical system table of contents exploded view........................................................................................................................ 15-2 specifications .......................................................................................

  • Page 298

    15-2 electrical system exploded view.

  • Page 299

    Electrical system 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spark plug 25.5 2.60 18.8 in·lb 2 stator coil plate mounting screws 5.2 0.53 46 in·lb 3 flywheel nut 29 3.0 21 r: replacement parts.

  • Page 300

    15-4 electrical system specifications item standard flywheel magneto magneto output voltage 65 v or more at 4 000 r/min (rpm) stator coil resistance 282 ∼ 423 Ω at 20°c (68°f) ignition system ignition coil: 3 needle arcing distance 7 mm (0.28 in.) or more primary winding resistance 0.36 ∼ 0.48 Ω at ...

  • Page 301

    Electrical system 15-5 special tools and sealant flywheel puller, m27 × 1.0: lh: 57001-252 peak voltage adapter: 57001-1415 needle adapter set: 57001-1457 flywheel & pulley holder: 57001-1605 liquid gasket, tb1211: 56019-120

  • Page 302

    15-6 electrical system wiring diagram.

  • Page 303

    Electrical system 15-7 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 304

    15-8 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the stator coil. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it...

  • Page 305

    Electrical system 15-9 flywheel magneto magneto cover removal • free the carburetor overflow hose [a] from the clamp [b] on the magneto cover. • remove: magneto cover bolts [c] magneto cover [d] gasket magneto cover installation • replace the gasket with a new one. • install: magneto cover [a] magne...

  • Page 306

    15-10 electrical system flywheel magneto • remove the magneto cover (see magneto cover re- moval) • holding the flywheel with the flywheel & pulley holder [a] and remove the flywheel nut [b]. Special tool - flywheel & pulley holder: 57001-1605 • screw the flywheel puller [a] into the flywheel by tur...

  • Page 307

    Electrical system 15-11 flywheel magneto • using a high flash-point solvent, clean off any oil or dirt that may be on the crankshaft taper [a] and the flywheel taper [b]. Dry them with a clean cloth. • fit the woodruff key [c] securely in the slot in the crank- shaft, and install the flywheel. • hol...

  • Page 308

    15-12 electrical system flywheel magneto stator coil check • check the stator coil resistance as follows. ○ disconnect the cdi unit lead connector [a]. ○ connect the digital meter [b] as shown in the table. Stator coil resistance at 20 °c (68 °f) connections meter (+) meter (–) to reading bk/w bk/r ...

  • Page 309

    Electrical system 15-13 ignition timing ignition timing adjustment • remove the magneto cover (see magneto cover re- moval). • check to see if the middle mark [a] of the three-marks on the stator coil plate [b] is aligned with the straight surface [c] of the projection on the crankcase. If the marks...

  • Page 310

    15-14 electrical system ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Crankshaft sensor removal/install...

  • Page 311

    Electrical system 15-15 ignition system crankshaft sensor peak voltage inspection • remove the left shroud (see shroud removal/installation in the frame chapter). • disconnect the cdi unit lead connector [a]. • connect the peak voltage adapter [b] to the digital meter [c]. • connect the black lead o...

  • Page 312

    15-16 electrical system ignition system ignition coil installation • install the ignition coil [a]. • tighten the bolts [b] together with the ignition coil ground terminal [c] and cdi unit ground terminal [d]. ○ run the leads correctly (see cable, wire, and hose rout- ing section in the appendix cha...

  • Page 313

    Electrical system 15-17 ignition system measuring coil resistance if the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with a digital meter. However, the digital meter cannot detect layer shorts and shorts resulting from insulation breakdown under high...

  • Page 314

    15-18 electrical system ignition system ignition coil primary peak voltage check • remove the spark plug cap from the spark plug, but do not remove the spark plug. • install the good spark plug [a] to the spark plug cap, then touch the frame with it. Note ○ measure the voltage with each lead connect...

  • Page 315

    Electrical system 15-19 ignition system.

  • Page 316

    15-20 electrical system switches engine stop switch inspection • using a tester, check to see that the connections shown in the table have continuity (about zero ohms). If the switch has an open or short, replace it with a new one. Engine stop switch connection.

  • Page 317: Appendix

    Appendix 16-1 16 appendix table of contents cable, wire, and hose routing .............................................................................................. 16-2 troubleshooting guide ...........................................................................................................

  • Page 318

    16-2 appendix cable, wire, and hose routing 1. Throttle cable 2. Clutch cable 3. Engine stop switch 4. Engine stop switch lead 5. Bands (hold the engine stop switch lead.) 6. Steering stem head bracket 7. Run the engine stop switch lead to the left side of the steering stem head bracket. 8. Clamp 9....

  • Page 319

    Appendix 16-3 cable, wire, and hose routing 1. Band (hold the throttle cable to the lower side of the frame, and front side of the damper.) 2. Damper 3. Throttle cable 4. Engine stop switch lead 5. Clamp (hold the throttle cable and engine stop switch lead.) 6. Radiator mounting bolts 7. Clamp (hold...

  • Page 320

    16-4 appendix cable, wire, and hose routing.

  • Page 321

    Appendix 16-5 cable, wire, and hose routing 1. Cdi unit 2. Band (hold the throttle cable to the lower side of the frame, and front side of the damper.) 3. Engine stop switch lead connector 4. Radiator overflow hose 5. Primary lead connector 6. Band (hold the primary lead to the lower side of the fra...

  • Page 322

    16-6 appendix cable, wire, and hose routing.

  • Page 323

    Appendix 16-7 cable, wire, and hose routing 1. Air vent hose 2. Do not cross the air vent hose and magneto lead. 3. Magneto lead 4. Install the fuel hose so that paint mark faces right side. 5. Fuel hose 6. Run the fuel hose to the outside of the air vent hose. 7. Viewed a 8. Clamp (hold the magneto...

  • Page 324

    16-8 appendix cable, wire, and hose routing.

  • Page 325

    Appendix 16-9 cable, wire, and hose routing 1. Radiator overflow hose 2. Run the radiator overflow hose and breather hose between the engine brackets. 3. Band (hold the radiator overflow hose and breather hose to the frame.) 4. Frame 5. Breather hose 6. Run the radiator overflow hose between the eng...

  • Page 326

    16-10 appendix cable, wire, and hose routing 1. Touch the front brake hose fitting to the stopper. 2. Brake hose 3. Clamp 4. Clamps 5. Viewed a.

  • Page 327

    Appendix 16-11 cable, wire, and hose routing 1. Touch the rear brake hose fitting to the stopper. 2. Brake hose 3. Clamps 4. Cotter pin.

  • Page 328

    16-12 appendix troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: engine won’t turn ov...

  • Page 329

    Appendix 16-13 troubleshooting guide other: cdi unit trouble transmission oil viscosity too high brake dragging drive train trouble engine overheating clutch slipping poor running or no power at high speed: firing incorrect: spark plug dirty, broken, or gap malad- justed spark plug cap or ignition c...

  • Page 330

    16-14 appendix troubleshooting guide water pump not rotating water pump impeller damaged clutch operation faulty: clutch slipping: no clutch lever play clutch cable maladjusted clutch inner cable catching friction plate worn or warped steel plate worn or warped clutch spring broken or weak clutch re...

  • Page 331

    Appendix 16-15 troubleshooting guide disc brake noise: pad installed incorrectly pad surface glazed disc warped caliper trouble master cylinder damaged other noise bracket, nut, bolt, etc. Not properly mounted or tightened exhaust smoke: excessive white smoke: throttle cable maladjusted crankshaft o...

  • Page 332

    Model application year model beginning frame no. 2014 kx85ce jkbkxfcc □ ea000001 jkbkx085cca000001 2014 kx85de jkbkxfdc □ ea000001 jkbkx085dda000001 2014 kx100fe jkakxtfc □ ea000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1470-01 printed in japan.