1. DL manuals
  2. Kawasaki
  3. Other
  4. KX250F -
  5. Service Manual

Kawasaki KX250F - Service Manual

Manual is about: Motorcycle

Summary of KX250F -

  • Page 3: Quick Reference Guide

    This quick refernce guide will assist you in locating a desired topic or procedure. •bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •refer to the sectional table of contents for the exact pages to locate the s...

  • Page 5: Kx250F

    Kx250f all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assurance department/consumer products & m...

  • Page 6

    List of abbreviations a ampere(s) lb pound(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inch...

  • Page 7: 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 8

    Note ○ this note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • indicates a procedural step or work to be done. ○ indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a note. Indicates...

  • 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 arrangement and cleaning of removed parts disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of removed parts after all the parts including subas...

  • Page 12

    1-4 general information before servicing tightening sequence bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating dia...

  • Page 13

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

  • Page 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 wires a two-color wire is i...

  • Page 15

    General information 1-7 model identification kx250–n1 left side view kx250–n1 right side view.

  • Page 16

    1-8 general information general specifications items kx250–n1 dimensions: overall length 2 170 mm (85.43 in.) overall width 840 mm (33.1 in.) overall height 1 270 mm (50 in.) wheelbase 1 475 mm (8.07 in.) road clearance 340 mm (13.4 in.) seat height 960 mm (37.8 in.) dry mass 92.5 kg (204 lb) curb m...

  • Page 17

    General information 1-9 general specifications items kx250–n1 transmission: type 5-speed, constant mesh, return shift gear ratios: 1st 2.142 (30/14) 2nd 1.785 (25/14) 3rd 1.444 (26/18) 4th 1.200 (24/20) 5th 1.052 (20/19) final drive system: type chain drive reduction ratio 3.692 (48/13) overall driv...

  • Page 18

    1-10 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 19: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-2 torque and locking agent................. 2-4 specifications .................................... 2-8 special tools ..................................... 2-10 periodic maintenance procedur...

  • Page 20

    2-2 periodic maintenance periodic maintenance chart the maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Frequency each every 3 every 6 every 12 see operation race races races races page spark plug – clean, gap † • 2-54 clutch – adjust • 2-22 c...

  • Page 21

    Periodic maintenance 2-3 periodic maintenance chart frequency each every 3 every 6 every 12 see operation race races races races page front fork – inspect and clean • 2-44 front fork oil – change • 2-44 rear shock oil – replace • 2-46 cable – inspect • 2-55 fuel hose – replace every 4 years 2-11 fue...

  • Page 22

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

  • Page 23

    Periodic maintenance 2-5 torque and locking agent torque fastener n·m kgf·m ft·lb remarks exhaust pipe holder nuts 21 2.1 15 s muffler mounting bolts 21 2.1 15 s engine right side: primary gear nut 98 10 72 shift drum cam bolt 24 2.4 17 l clutch spring bolts 9.8 1.0 87 in·lb clutch hub nut 98 10 72 ...

  • Page 24

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine oil drain plug (for crank room oil sump) 7.0 0.7 61 in·lb (for transmission room oil sump) 15 1.5 11 output shaft bearing retaining screw 6.4 0.65 56 in·lb l drive shaft bearing retaining screw 6.4 0.65 ...

  • Page 25

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks rear shock absorber mounting nuts: (upper) 39 4.0 29 (lower) 34 3.5 25 air bleed bolt 6.4 0.65 56 in·lb tie-rod mounting nut (front, rear) 83 8.5 61 rocker arm pivot nut 83 8.5 61 steering: steering stem head n...

  • Page 26

    2-8 periodic maintenance specifications item standard service limit fuel system: throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) - - - hot start lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) - - - air cleaner element oil high quality foam air filter oil - - - cooling system: coolant: type (recom...

  • Page 27

    Periodic maintenance 2-9 specifications item standard service limit wheels/tires: rim runout: axial under 1.0 mm (0.039 in.) 2 mm (0.08 in.) radial under 1.0 mm (0.039 in.) 2 mm (0.08 in.) front and rear tires air pressure 100 kpa (1.0 kgf/cm², 14 psi) standard tire: front: size 80/100-21 51m - - - ...

  • Page 28

    2-10 periodic maintenance special tools valve spring compressor assembly : 57001–241 steering stem nut wrench : 57001–1100 valve spring compressor adapter, 20 : 57001–1154 jack : 57001–1238 spark plug wrench, m16 : 57001–1262 fork oil level gauge : 57001–1290 pilot screw adjuster, c : 57001–1292.

  • Page 29

    Periodic maintenance 2-11 periodic maintenance procedures fuel system fuel hose and connection inspection ○ the fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to ...

  • Page 30

    2-12 periodic maintenance periodic maintenance procedures if the throttle grip free play cannot be adjusted with the adjusters at the upper end of the throttle cables, use the cable adjusters [a] at the carburetor. • make the necessary free play adjustment at the lower ca- ble adjusters, tighten the...

  • Page 31

    Periodic maintenance 2-13 periodic maintenance procedures • check the idle speed, using the engine revolution tester [a] for high accuracy. If the idle speed is out of specified range, adjust it. Idle speed: standard: 2 000 ± 50 r/min (rpm) idle speed adjustment • first, turn in the air screw [a] us...

  • Page 32

    2-14 periodic maintenance periodic maintenance procedures • remove: seat (see frame chapter) wing bolt [a] air cleaner element [b] • stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor. • wipe out the inside of the air cleaner housing with a clean damp to...

  • Page 33

    Periodic maintenance 2-15 periodic maintenance procedures • install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a compete seal. • install the air cleaner element so that its tab faces [a] upward and its projections [b] align wi...

  • Page 34

    2-16 periodic maintenance periodic maintenance procedures • check the coolant level. The coolant level [a] should be at the bottom of the filler neck [b]. If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap. Recommended coolant: perma...

  • Page 35

    Periodic maintenance 2-17 periodic maintenance procedures engine top end valve clearance inspection note ○ valve clearance must be checked and adjusted when the engine is cold (at room temperature). • remove: cylinder head cover (see engine top end chapter) timing inspection cap [a] flywheel cap [b]...

  • Page 36

    2-18 periodic maintenance periodic maintenance procedures note ○ mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions. • clean the shim to remove any dust or oil. • measure the thickness of the removed shim [a]. • select a new shim ...

  • Page 37

    Periodic maintenance 2-19 periodic maintenance procedures caution be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ if there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valv...

  • Page 38

    2-20 periodic maintenance periodic maintenance procedures cylinder wear inspection note ○ measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • visually inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly w...

  • Page 39

    Periodic maintenance 2-21 periodic maintenance procedures exhaust system • the exhaust system, in particular the silencer, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If car- bon has built up inside the silencer, exhaust efficien...

  • Page 40

    2-22 periodic maintenance periodic maintenance procedures • apply silicone sealant to the circumference [a] of the si- lencer pipe. • install the muffler (see engine top end chapter). Engine right side warning to avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjus...

  • Page 41

    Periodic maintenance 2-23 periodic maintenance procedures • slide the adjuster cover [a] back. • if it cannot be done, loosen the locknut [b] at the middle of the clutch cable, and turn the adjusting nut [c] so that clutch lever has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play. • after the adjustment is made,...

  • Page 42

    2-24 periodic maintenance periodic maintenance procedures • remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely. Drain plug (for crank room oil sump) [a] drain plug (for transmission oil sump) [b] note ○ hold the motorcycle upright so that the oil may drai...

  • Page 43

    Periodic maintenance 2-25 periodic maintenance procedures • using the pry point [a], remove the water pump cover [b]. • remove the oil filter [a]. • replace the oil filter with a new one. • apply grease to the grommet. • be sure to install the filter with the grommet [a] facing inside as shown. Caut...

  • Page 44

    2-26 periodic maintenance periodic maintenance procedures oil screen cleaning • split the crankcase (see crankshaft/transmission chap- ter). • remove the oil screen [a]. • clean the oil screens with a high-flash point solvent and remove any particles stuck to them. Warning clean the screen in a well...

  • Page 45

    Periodic maintenance 2-27 periodic maintenance procedures connecting rod big end side clearance • measure the connecting rod big end side clearance [a]. Connecting rod big end side clearance standard: 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) service limit: 0.55 mm (0.0217 in.) if the clearance exceeds t...

  • Page 46

    2-28 periodic maintenance periodic maintenance procedures • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. Caution do not hammer the crank half at the point [b]. If flywh...

  • Page 47

    Periodic maintenance 2-29 periodic maintenance procedures tires inspection as the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • remove any imbedded stones or other foreign particles from the tread. • visually inspect the tire for cracks and cuts, replacing th...

  • Page 48

    2-30 periodic maintenance periodic maintenance procedures rim runout inspection • place the jack under the frame so that the front/rear wheel off the ground. Special tool - jack: 57001–1238 • inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must b...

  • Page 49

    Periodic maintenance 2-31 periodic maintenance procedures final drive drive chain wear inspection • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. [a...

  • Page 50

    2-32 periodic maintenance periodic maintenance procedures • if a special lubricant is not available, a heavy oil such as sae90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • apply oil to the sides of the rollers so that oil will penetrate to ...

  • Page 51

    Periodic maintenance 2-33 periodic maintenance procedures brakes brake lever and pedal adjustment warning always maintain proper brake adjustment. If ad- justment is improper, the brake could drag and overheat. This could damage the brake assembly and possibly lock the wheel resulting in loss of con...

  • Page 52

    2-34 periodic maintenance periodic maintenance procedures brake fluid level inspection • check the brake fluid level in the front or rear brake reser- voir [a]. Note ○ hold the reservoir horizontal when checking brake fluid level. • the front or rear reservoir must be kept above the lower level line...

  • Page 53

    Periodic maintenance 2-35 periodic maintenance procedures brake fluid change in accordance with the periodic maintenance chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the ai...

  • Page 54

    2-36 periodic maintenance periodic maintenance procedures note ○ the procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove the screw [a], reservoir cap [b] and diaphragm [c]. • remove the rubber cap ...

  • Page 55

    Periodic maintenance 2-37 periodic maintenance procedures • remove the clear plastic hose. • tighten the bleed valves, and install the rubber caps. Torque - caliper bleed valve: 7.8 n·m (0.8 kgf·m, 69 in·lb) brake reservoir cap screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) • after changing the fluid, check...

  • Page 56

    2-38 periodic maintenance periodic maintenance procedures brake master cylinder cup and dust seal replacement • remove the front master cylinder (see brake chapter). • remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • unscrew the locknut and pivot bolt, and remove ...

  • Page 57

    Periodic maintenance 2-39 periodic maintenance procedures • apply brake fluid to the removed parts and to the inner wall of the cylinder. • take care not to scratch the piston or the inner wall of the cylinder. • apply silicone grease (ex. Pbc grease). Brake lever pivot bolt brake lever pivot contac...

  • Page 58

    2-40 periodic maintenance periodic maintenance procedures ○ pull out the piston [a] by hand. • remove the dust seals [b] and fluid seals [c]. Note ○ if compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ prepare a container...

  • Page 59

    Periodic maintenance 2-41 periodic maintenance procedures • replace the fluid seal(s) [a] with new ones. ○ apply brake fluid to the fluid seal(s), and install them into the cylinders by hand. • replace the dust seal(s) [b] with new ones. ○ apply brake fluid to the dust seal(s), and install them into...

  • Page 60

    2-42 periodic maintenance periodic maintenance procedures • replace the shaft rubber friction boot [a] and dust boot [b] if they are damaged. • apply a thin coat of pbc (poly butyl cuprysil) grease to the caliper holder shafts [c] and holder holes (pbc is a special high temperature, water-resistance...

  • Page 61

    Periodic maintenance 2-43 periodic maintenance procedures • remove each banjo bolts [a] and washers [b]. • replace the washers with new ones. For front brake • remove bolts [a] brake hose clamps [b] for rear brake • remove: master cylinder [a] hose clamps [b] caliper cover [c] • when installing the ...

  • Page 62

    2-44 periodic maintenance periodic maintenance procedures suspension front fork inspection • holding the brake lever, pump the front fork back and forth manually to check for smooth operation. • visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner t...

  • Page 63

    Periodic maintenance 2-45 periodic maintenance procedures • use wrenches [a] on the rod nut [b] and the top plug [c] to loosen the top plug. • remove the top plug from the push rod. • lift the fork spring [d] and its top spring seat [e] out of the outer tube. • take the rebound damping adjuster rod ...

  • Page 64

    2-46 periodic maintenance periodic maintenance procedures • purge the air from the fork cylinder by gently moving the piston rod [a] up and down ten times. • purge the air from between the inner and outer tubes by pumping the outer tube [a] up and down. • after purging the air from the assembly, let...

  • Page 65

    Periodic maintenance 2-47 periodic maintenance procedures warning do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure. An oil mist is often released with the nitrogen. Always release nitrogen gas pressure before disassem- bling the rear shock absorber to...

  • Page 66

    2-48 periodic maintenance periodic maintenance procedures • slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm (0.39 in.) down. • remove the circlip [a]. • lightly move the piston rod back and forth, and pull ...

  • Page 67

    Periodic maintenance 2-49 periodic maintenance procedures • push the bladder into the gas reservoir slowly until it just clears the circlip groove. Wipe out any spilled oil. Caution ensure that no air remains in the system. • check the circlip for weakening, deformity and flaws. If necessary, replac...

  • Page 68

    2-50 periodic maintenance periodic maintenance procedures • pour kyb k2-c (sae 5w or bel-ray se2 #40) oil into the rear shock body to 55 mm (1.77 in.) [a] from the lower end [b] of the rear shock body. • insert the piston end [a] of the piston rod assembly into the rear shock body [c] slowly. Do not...

  • Page 69

    Periodic maintenance 2-51 periodic maintenance procedures • install the suitable oil cup [a] to the air bleeder bolt hole, and fill the specified oil into the cup. • purge the air from between the gas reservoir [b] and rear shock body [c] by slowly pumping the push rod [d] in and out. • install the ...

  • Page 70

    2-52 periodic maintenance periodic maintenance procedures steering steering inspection • using the jack, raise the front wheel off the ground. Special tool - jack : 57001–1238 • with the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing fu...

  • Page 71

    Periodic maintenance 2-53 periodic maintenance procedures • loosen the front fork upper clamp bolts [a], and remove the steering stem head nut [b] and steering stem head [c]. • turn the steering stem locknut [a] with the steering stem nut wrench [b] to obtain the proper adjustment. If the steering i...

  • Page 72

    2-54 periodic maintenance periodic maintenance procedures • install the handlebar clamp [a] together with the handle- bar so that the cut side [b] on the clamp points at the front. • tighten the handlebar clamp bolts [c]. Torque - handlebar clamp bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) ○ tighten the cla...

  • Page 73

    Periodic maintenance 2-55 periodic maintenance procedures • remove the spark plug [a], using the spark plug wrench [b]. Special tool - spark plug wrench: 57001–1262 owner’s tool - spark plug wrench, 16 mm: 57001–1262 • clean the spark plug, preferably in a sandblasting device, and then clean off any...

  • Page 74

    2-56 periodic maintenance periodic maintenance procedures points: lubricate with grease. Clutch inner cable upper and lower ends [a] hot start inner cable upper end throttle inner cable upper end cables: lubricate with rust inhibitor. Throttle cables clutch cable hot start cable • with the cable dis...

  • Page 75

    Periodic maintenance 2-57 periodic maintenance procedures nut, bolt, and fastener tightness inspection tightness inspection • check the tightness of the bolts and nuts listed here in accordance with the periodic maintenance chart. Also, check to see that each cotter pin is in place and in good condi...

  • Page 77: Fuel System

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

  • Page 78

    3-2 fuel system exploded view.

  • Page 79

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolt 3.4 0.3 30 in·lb 2 throttle cable locknut 7.0 0.7 61 in·lb 3. Throttle cables 4. Throttle grip 5. Carburetor cap 6. Throttle valve plate 7. Throttle valve 8. Jet needle 9. Throttle pulley shaft 10....

  • Page 80

    3-4 fuel system exploded view.

  • Page 81

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolts 34 3.5 25 2 air cleaner duct clamp screw 2.0 0.2 17 in·lb 3 fuel tap plate mounting screws 0.8 0.08 7 in·lb 4. Fuel tank cap 5. Fuel tank 6. Fuel tap 7. Element 8. Frame 9. Holder 10. Air cleaner du...

  • Page 82

    3-6 fuel system specifications standard item kx250-n1 service limit carburetor: make/type keihin fcr37 - - - starter jet #68 - - - leak jet #60 - - - main jet #165 - - - throttle valve cutaway #1.5 - - - jet needle 0bekr - - - jet needle clip position 4th groove from the top - - - slow jet #40 - - -...

  • Page 83

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

  • Page 84

    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 85

    Fuel system 3-9 throttle grip and cable • remove the rear frame assy (see frame chapter). • remove the carburetor and move it to the right side of the frame. • unscrew the bolt [a]. • remove the throttle pulley cover [b]. • loosen the locknuts [a]. • remove the cables [b] from the carburetor. • free...

  • Page 86

    3-10 fuel system throttle grip and cable hot start cable removal • remove: dust cover [a] (slide out) locknut [b] (loosen) • turn in the adjuster [c] fully. • remove the cable end [d] from the hot start lever [e]. • remove: carburetor (inlet side out ) • unscrew the plunger cap bolt [a] and remove t...

  • Page 87

    Fuel system 3-11 throttle grip and cable hot start lever free play adjustment • refer to the hot start lever free play inspection in peri- odic maintenance hot start cable lubrication • whenever the hot start cable is removed or in accordance with the periodic maintenance chart, lubricate the these ...

  • Page 88

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

  • Page 89

    Fuel system 3-13 carburetor • hold the gauge vertically against the side of the carbure- tor body so that the "zero" line [c] is several millimeters higher than the bottom edge [d] of the carburetor body. • turn the fuel tap to the on position to feed fuel to the carburetor. • wait until the fuel le...

  • Page 90

    3-14 fuel system carburetor • bend the tang [a] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float height standard: 6.5 ± 1 mm (0.256 ± 0.039 in.) note ○ float height [a] is the dis...

  • Page 91

    Fuel system 3-15 carburetor • disconnect the throttle sensor connector [a]. • loosen the clamp screws [a], and remove the carburetor from the carburetor holder [b] and then pull it out of the end of the air cleaner duct [c]. If necessary, do the following procedure. • remove: seat side covers silenc...

  • Page 92

    3-16 fuel system carburetor • loosen the locknut [a]. • pull out the end of the throttle cables [b]. • free the tips [c]. • remove the carburetor right side of the frame. • after removing the carburetor, push a clean, lint-free towel into the carburetor holder and the air cleaner duct to keep dirt o...

  • Page 93

    Fuel system 3-17 carburetor fuel inspection 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 li...

  • Page 94

    3-18 fuel system carburetor • unscrew the throttle rink screw [a]. • pull out the throttle valve assembly [b]. • disassemble the throttle valve assembly; jet needle holder [a] (unscrew), spring [b], retainer [c], jet needle with circlip [d], o-ring with throttle valve plate [e] and throttle valve [f...

  • Page 95

    Fuel system 3-19 carburetor • turn in the pilot air screw [a] fully but not tightly and count the number of turns. ○ record this number as the manufacture-set number of turns out. • unscrew the pilot air screw. • unscrew the screws [a]. • remove the acceleration pump cover [b] from the carbu- retor....

  • Page 96

    3-20 fuel system carburetor • pull out the push rod [a] of the acceleration pump. • unscrew the leak jet [a]. • remove: c-clip [a] washer [b] • pull out the acceleration pump lever assembly [c] as a set. • remove the throttle sensor mounting bolt [a]. • before removing the throttle sensor [b], mark ...

  • Page 97

    Fuel system 3-21 carburetor carburetor cleaning warning clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline...

  • Page 98

    3-22 fuel system carburetor • remove the carburetor. • 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. • turn the throttle pulley to check that the throttle valve [a] mov...

  • Page 99

    Fuel system 3-23 carburetor carburetor assembly • clean the disassembly parts before assembling. ○ clean the fuel and air passages with a high flash-point solvent and compressed air [a]. • set up the acceleration pump lever assembly as shown. Acceleration pump lever [a] spring [b] push rod holder [c...

  • Page 100

    3-24 fuel system carburetor • apply thin coat silicone grease to the shaft. • fit the hook [a] of the return spring onto the stopper [b] of the throttle cable pulley. • insert the throttle cable pulley shaft [a] and install the steel washer [d], nylon washer [c] and valve rink [b]. ○ fit the end [a]...

  • Page 101

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

  • Page 102

    3-26 fuel system carburetor • replace the o-ring with new one. • install: pilot air screw [a] spring [b] washer [c] o-ring [d] ○ turn in the pilot air screw fully but not tightly, and the back it out the counted number of turn (see carburetor disassembly). • hanging the needle valve [a] on the tang ...

  • Page 103

    Fuel system 3-27 carburetor • install the choke knob/starter plunger [a]. • replace the o-rings [a] with the new ones. • install the fuel hose fitting [b]. • tighten the screws. • install all hoses [a]. • install the carburetor (see carburetor installation). • if turn the adjusting screw of the acce...

  • Page 104

    3-28 fuel system air cleaner air cleaner housing removal • remove: side covers (see frame chapter) seat (see frame chapter) silencer (see engine top end chapter) bolts and rear fender [a] (see frame chapter) screws and rear flap [b] (see frame chapter) rear frame bolts [c] rear frame • loosen the ai...

  • Page 105

    Fuel system 3-29 air cleaner • install the element so that its tab [a] faces upward and fit the element projections [b] to the holes of the housing [c]. • tighten the wing bolt [d]. • install the seat (see frame chapter). Element cleaning and inspection • refer to the air cleaner element cleaning an...

  • Page 106

    3-30 fuel system fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot l...

  • Page 107

    Fuel system 3-31 fuel tank fuel tap removal • remove the fuel tank and drain it. • remove the mounting bolts [a] and take out the fuel tap [b]. Fuel tap installation • be sure the o-ring is in good condition to prevent leaks. • be sure to clamp the fuel hose to the tap to prevent leaks. Fuel tank an...

  • Page 109: Cooling System

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

  • Page 110

    4-2 cooling system exploded view.

  • Page 111

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump cover bolts 9.8 1.0 87 in·lb 2 water pump cover bolt (with washer) 7.0 0.7 61 in·lb 3 coolant drain plug 7.0 0.7 61 in·lb 4 water pump impeller bolt 7.0 0.7 61 in·lb 5 right engine cover bolts 9.8 1.0 87 in·lb ...

  • Page 112

    4-4 cooling system specifications item service limit coolant type permanent type antifreeze for aluminum engines and radiators color green mixed ratio soft water 50%, antifreeze 50% total amount: 1.2 l (1.27 us qt.) radiator cap relief pressure 93 ∼ 123 kpa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi).

  • Page 113

    Cooling system 4-5 special tool bearing driver set : 57001–1129.

  • Page 114

    4-6 cooling system coolant check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the periodic maintenance chart (see periodic maintenance chapter). Warning to avoid burns, do not remove the radiator cap or tr...

  • Page 115

    Cooling system 4-7 coolant coolant filling caution 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 co...

  • Page 116

    4-8 cooling system coolant cooling system pressure testing caution during pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kpa (1.25 kgf/cm², 18 psi). • remove the radiator cap, and install a cooling system pressure tester [a] and a...

  • Page 117

    Cooling system 4-9 water pump water pump cover removal • drain the engine oil from the oil filter oil chamber. ○ unscrew the drain plug [a] • drain the coolant (see coolant draining). ○ unscrew the drain bolt [b]. • unscrew the water pipe bolt [a], and disconnect the water pipe [b]. • unscrew the co...

  • Page 118

    4-10 cooling system water pump • fill the cooling system (see coolant filling). • bleed the air from the cooling system. • check the engine oil level and add the engine oil. Impeller removal • drain: coolant (see coolant draining) engine oil (see above) water pump cover • remove the impeller bolt [a...

  • Page 119

    Cooling system 4-11 water pump water pump gear installation • to prevent the oil seal lips from peeling, apply thin coat of high-temperature grease [a] to the water pump gear shaft [b] and insert it into the oil seals [c] from the inside of the right engine cover [d]. Caution be sure to apply a moly...

  • Page 120

    4-12 cooling system water pump • apply plenty of high temperature grease to the oil seal lips. • press in the oil seals direction as shown. ○ press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the right engine cover. Flat side [a] water p...

  • Page 121

    Cooling system 4-13 radiator radiator removal • drain the coolant (see coolant draining) • drain the engine oil from the oil filter oil chamber (see water pump removal) • remove: radiator shrouds (see fuel system chapter) fuel tank (see fuel system chapter) • loosen: clamp screws [a] • remove: radia...

  • Page 122

    4-14 cooling system radiator • remove: bolts with clamps [a] left radiator with hoses [b] radiator installation • hold the clutch cable with clamps. • fit the projections [a] of the screen in the holl [b] of the radiator. Torque - radiator hose clamp screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) radiator m...

  • Page 123

    Cooling system 4-15 radiator radiator cap inspection • check the condition of the valve seals [a], and the top and bottom valve spring [b] of the radiator cap. If any one of them shows visible damage, replace the cap. • wet the top and bottom valve seals with water or coolant to prevent pressure lea...

  • Page 125: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools & sealants ................... 5-9 cylinder head cover ......................... 5-11 cylinder head cover removal .... 5-11...

  • Page 126

    5-2 engine top end exploded view.

  • Page 127

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 auto decompressor bolt 12 1.2 104 in·lb 2 cylinder head cover bolts 9.8 1.0 87 in·lb 3 cylinder head bolts m6 12 1.2 104 in·lb s 4 camshaft cap bolts 12 1.2 104 in·lb s 5 carburetor holder clamp screws 2.0 0.2 17 in·lb 6 ...

  • Page 128

    5-4 engine top end exploded view.

  • Page 129

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 chain tensioner mounting bolts 9.8 1.0 87 in·lb 2 chain tensioner cap 20 2.0 14.5 3 cylinder head bolts m6 12 1.2 104 in·lb s 4 cylinder bolt m6 12 1.2 104 in·lb s 5 exhaust pipe cover screws 12 1.2 104 in·lb 6 exhaust pi...

  • Page 130

    5-6 engine top end specifications item standard service limit camshafts: cam height: exhaust 33.941 ∼ 34.057 mm 33.84 mm (1.3363 ∼ 1.3408 in.) (1.3322 in.) inlet 36.642 ∼ 34.758 mm 34.54 mm (1.3639 ∼ 1.3684 in.) (1.3598 in.) camshaft journal clearance 0.020 ∼ 0.062 mm 0.15 mm (0.0008 ∼ 0.0024 in.) (...

  • Page 131

    Engine top end 5-7 specifications item standard service limit valve seat surface outside diameter: exhaust 4.62 ∼ 4.82 mm - - - (0.9693 ∼ 0.9772 in.) inlet 30.62 ∼ 30.82 mm - - - (1.2055 ∼ 1.2134 in.) valve seat surface width: exhaust 0.5 ∼ 1.0 mm - - - (0.0197 ∼ 0.0394 in.) inlet 0.5 ∼ 1.0 mm - - -...

  • Page 132

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

  • Page 133

    Engine top end 5-9 special tools & sealants compression gauge, 20 kgf/cm² : 57001–221 valve spring compressor assembly : 57001–241 piston ring compressor grip : 57001–1095 piston ring compressor belt, 67 ∼ 79 : 57001–1097 valve seat cutter, 45° – 24.5 : 57001–1113 (or 45° – 27.5 : 57001–1114) valve ...

  • Page 134

    5-10 engine top end special tools & sealants valve seat cutter, 45° – 30 : 57001–1187 valve seat cutter, 67.5° – 22 : 57001–1207 spark plug wrench, hex 16 : 57001–1262 compression gauge adapter, m10 × 1.0 : 57001–1317 valve seat cutter holder, 4.5 : 57001–1330 valve guide arbor, 4.5 : 57001–1331 val...

  • Page 135

    Engine top end 5-11 cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel system chapter) spark plug cap [a] • remove the cylinder head cover bolts [b] and remove the cylinder head cover [c]. Cylinder head cover installation • apply silicon sealant [a] to the cylinder head as...

  • Page 136

    5-12 engine top end camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the ten...

  • Page 137

    Engine top end 5-13 camshaft camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] flywheel cap [b] • first, bring the piston to the tdc (of either the compres- sion or exhaust stroke). ○ place a wrench over the flywheel nut and turn it counter-...

  • Page 138

    5-14 engine top end camshaft • remove: bolt [a] auto decompressor [b] spring camshaft installation • install: spring [a] auto decompressor [b] bolt [c] torque - auto decompressor bolt: 12 n·m (1.2 kgf·m, 104 in·lb) • apply molybdenum disulfide oil to the ball bearing, all cam and journal surfaces of...

  • Page 139

    Engine top end 5-15 camshaft 1st pin [a] punch marks (exhaust) [d] 2nd pin [b] punch marks (inlet) [e] 28th pin [c] upper cylinder head surface [f] • be sure to install the positioning rings [a] and dowel pins [b]. • install the camshaft caps in their original positions by fac- ing their triangle ma...

  • Page 140

    5-16 engine top end camshaft • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ bolts [a] are long. ○ following the sequence numbers on the camshaft caps, tighten the cap bolts [1 ∼ 4]. Torque - camshaft cap bolts: 12 n·m (1.2 kgf·m, 104 in·lb) • i...

  • Page 141

    Engine top end 5-17 camshaft camshaft chain removal • remove: camshaft (see camshaft removal) camshaft chain tensioner (see camshaft chain ten- sioner removal) magneto flywheel (see electrical system) lower camshaft chain guide bolt [a] lower chain guide [b] • remove the camshaft chain [c] from the ...

  • Page 142

    5-18 engine top end cylinder head cylinder compression measurement • start the engine. • thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • stop the engine. • remove: fuel tank (see fuel system ...

  • Page 143

    Engine top end 5-19 cylinder head cylinder head removal • remove: fuel tank (see fuel system chapter) camshaft chain tensioner (see camshaft chain ten- sioner removal) cylinder head cover (see cylinder head cover re- moval) camshaft (see camshaft removal) nut [a] bolt [b] (loosen) exhaust pipe [c] c...

  • Page 144

    5-20 engine top end cylinder head • remove the 10 mm cylinder head bolts [a]. • tap lightly up with a plastic mallet [a] to separate the cylin- der head [b] from the cylinder. • move back the carburetor [a] and hold it. • pull the cylinder head upward [b]. ○ do not damage the radiator core. ○ clear ...

  • Page 145

    Engine top end 5-21 cylinder head • replace all the 10 mm cylinder head bolt washers with new ones. ○ the 10 mm cylinder head bolt washers are copper-plated, and they could leak oil if reused. • apply molybdenum disulfide oil to the following areas. 10 mm cylinder head bolt washer, both sides [a] • ...

  • Page 146

    5-22 engine top end valves valve clearance inspection ○ refer to the engine top end in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and the shim from the valve. Note ○ use the valve spring compressor assembly and th...

  • Page 147

    Engine top end 5-23 valves • hammer lightly on the valve guide arbor [a] to remove the guide. Special tools - valve guide arbor, 4.5: 57001–1331 valve guide installation • apply a thin coat of oil to the outer surface of the valve guide. • heat the area around the valve guide up to 120 ∼ 150 °c (248...

  • Page 148

    5-24 engine top end valves • repeat the measurement in a direction at a 90° angle to the first measurement. If the reading exceeds the service limit, replace the guide. Note ○ the reading is greater than the actual valve/valve guide clearance because the measurement is taken outside of the guide. Va...

  • Page 149

    Engine top end 5-25 valves exhaust: valve seat cutter, 45° - 24.5 : 57001-1113 (or 1114) valve seat cutter, 32° - 25 : 57001-1118 (or 1119) valve seat cutter, 67.5° - 22 : 57001-1207 inlet: valve seat cutter, 45° - 30 : 57001-1187 valve seat cutter, 32° - 38.5 : 57001-1120 valve seat cutter, 60° - 3...

  • Page 150

    5-26 engine top end valves repair operating procedures: • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter into the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it i...

  • Page 151

    Engine top end 5-27 valves caution the 32° cutter removes material very quickly. Check the seat outside diameter frequently to pre- vent overgrinding. ○ after making the 32° grind, return to the seat o.D. Mea- surement step above. • to measure the seat width, use a vernier caliper to mea- sure the w...

  • Page 152

    5-28 engine top end valves valve seat repair.

  • Page 153

    Engine top end 5-29 cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remove the cylinder base gasket. Piston removal • remove...

  • Page 154

    5-30 engine top end cylinder and piston • install the top ring [a] so that the "r" mark [b] faces up. Note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston rings. • apply engine oil to the inside wall of the small end of ...

  • Page 155

    Engine top end 5-31 cylinder and piston • apply engine oil to the cylinder bore. • determine the position of the piston ring ends. • install the cylinder while compressing the piston rings with your fingers or the special tool [a]. Special tool - piston ring compressor grip: 57001–1095 piston ring c...

  • Page 156

    5-32 engine top end cylinder and piston piston ring thickness • measure the thickness at several points around ring with a micrometer. Piston ring thickness (top) standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) service limit: 0.70 mm (0.0276 in.) if any of the measurements is less than the service li...

  • Page 157

    Engine top end 5-33 carburetor holder carburetor holder installation • install the carburetor holder [a] with the marked [b] side facing toward the cylinder head outside. ○ install the holder clamp [c] with its screw head [d] facing left side. Torque - carburetor holder clamp screw: 2.0 n·m (0.2 kgf...

  • Page 158

    5-34 engine top end muffler warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler removal • loosen the muffler clamp bolt [a]. • remove the exhaust pip holder nut [b]. • remove the exhaust pipe [c]. • remove seat (see fram...

  • Page 159: Engine Right Side

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

  • Page 160

    6-2 engine right side exploded view.

  • Page 161

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

  • Page 162

    6-4 engine right side exploded view.

  • Page 163

    Engine right side 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 ratchet guide bolt 8.8 0.9 78 in·lb l 2 kick pedal bolt 25 2.5 18 l 3 shift pedal bolt 9.8 1.0 87 in·lb 4 ratchet plate mounting bolt 9.8 1.0 87 in·lb 5 ratchet plate mounting screw 6.4 0.65 56 in·lb l 6 gear set lever...

  • Page 164

    6-6 engine right side specifications item standard service limit clutch lever clutch lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) - - - clutch: friction plate thickness 2.72 ∼ 2.88 mm 2.62 mm (0.1031 in.) (0.107 ∼ 0.113 in.) steel plate thickness 15 ∼ 1.7 mm 1.4 mm (0.055 in.) (0.059 ∼ 0.067 in.) fric...

  • Page 165

    Engine right side 6-7 special tool clutch holder : 57001–1243 gear holder : 57001–1557.

  • Page 166

    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 to avoid a serious burn, never touch the hot engine or exhaust chamber during clutch ad...

  • Page 167

    Engine right side 6-9 clutch lever and cable • free the cable from the cable holder [a]. • free the clutch inner cable tip [b] from the clutch release lever [c]. Caution do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with...

  • Page 168

    6-10 engine right side clutch cover and right engine cover clutch cover removal • drain the engine oil (see periodic maintenance chapter). • set the stand attached. • remove the brake pedal (see brakes chapter). • remove the clutch cover bolts [a] and remove the clutch cover [b]. Clutch cover instal...

  • Page 169

    Engine right side 6-11 clutch cover and right engine cover • when installing the cover doesn’t go well, the cover is installed according to the following procedures. ○ the cover is installed while turning [a] the impeller [b]. • install: water pump cover (see cooling system chapter) torque - right e...

  • Page 170

    6-12 engine right side clutch clutch removal • drain the engine oil (see periodic maintenance chapter). • remove the clutch cover (see clutch cover removal). • remove the clutch spring bolts [a], spring, and clutch pressure plate [b]. • remove the push rod holder assy [a], friction plates [b] and st...

  • Page 171

    Engine right side 6-13 clutch • install the toothed washer [a]. • tighten the clutch hub nut [b]. Torque - clutch hub nut: 98 n·m (10 kgf·m, 72 ft·lb) note ○ use the clutch holder [c] to prevent the clutch hub from rotating. Special tool - clutch holder: 57001–1243 • install the friction plates and ...

  • Page 172

    6-14 engine right side clutch clutch spring free length inspection • measure the free length [a] of the clutch springs. If any clutch spring is shorter than the service limit, it must be replaced. Clutch spring free length standard: 46.8 mm (1.843 in.) service limit: 44.9 mm (1.768 in.) clutch housi...

  • Page 173

    Engine right side 6-15 primary gear primary gear removal • remove the clutch (see clutch removal). • temporarily install the clutch housing [a]. • using the gear holder [b], secure the primary gear. Special tool - gear holder: 57001–1557 • remove the primary gear nut [c], washer, and the primary gea...

  • Page 174

    6-16 engine right side external shift mechanism external shift mechanism removal • remove: shift pedal bolt [a] shift pedal [b] • remove: right engine cover (see this chapter) clutch housing (see this chapter) • pull out the shift shaft [a]. • remove the screw [b] and bolt [c], take off the shift ra...

  • Page 175

    Engine right side 6-17 external shift mechanism • set up the shift ratchet assembly as shown in the figure. Ratchet [a] pawls [b] pins [c] springs [d] crankcase side [e] • then install the ratchet assembly [a] to the ratchet plate [b] as shown in the figure. • install the ratchet assembly to the shi...

  • Page 176

    6-18 engine right side external shift mechanism • check the ratchet assembly for damage. If ratchet [a], pawls [b], pins [c] or springs [d] are dam- aged in any way, replace them. • check the gear set lever [a] and its spring [b] for cracks or distortion. If the lever or spring is damaged in any way...

  • Page 177

    Engine right side 6-19 kickstarter kick pedal assy removal • remove: mounting bolt [a] kick pedal assy [b] kick pedal assy installation • install the kick pedal assy [a] at the angle shown. 14 ∼ 24 mm [b] • apply a non-permanent locking agent to the mounting bolt. • tighten the mounting bolt. Torque...

  • Page 178

    6-20 engine right side kickstarter idle gear installation • apply molybdenum disulfide grease to the inside of the idle gear. • install the washer [a]. • fit the idle gear [b] with the boss [c] facing toward the engine side. Kickshaft removal • remove: right engine cover (see right engine cover remo...

  • Page 179

    Engine right side 6-21 kickstarter kickstarter assembly disassembly/assembly • the kickstarter assembly consists of the following parts. • check the kickstarter assembly parts for damage. Any damaged parts should be replaced with new ones. A. Idle gear f. Kick gear b. Circlip g. Kick shaft c. Washer...

  • Page 181: Engine Lubrication System

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

  • Page 182

    7-2 engine lubrication system exploded view.

  • Page 183

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain plug m10 (for transmission room oil sump) 15 1.5 11 2 engine oil drain plug m6 (for crank room oil sump) 7.0 0.7 61 in·lb 3 engine oil drain plug m6 (for oil filter oil chamber) 7.0 0.7 61 in·l...

  • Page 184

    7-4 engine lubrication system lubrication system chart.

  • Page 185

    Engine lubrication system 7-5 lubrication system chart 1. Oil screen (scavenging) 2. Oil screen (feed) 3. Oil pump (scavenging) 4. Oil pump (feed) 5. Right crankcase oil passage (from scavenging oil pump to transmission oil shower passage) 6. Right engine cover oil passage (from feed oil pump to oil...

  • Page 186

    7-6 engine lubrication system specifications item standard engine oil: grade castrol “r4 superbike” 5w-40 api sh or sj with jaso ma viscosity sae 10w-30, 10w-40, or 10w-50 capacity oil change – when filter is not removed 1.3 l (1.4 us qt) oil change – when filter is removed 1.35 l (1.43 us qt) when ...

  • Page 187

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm² : 57001–125 outside circlip pliers : 57001–144 gear holder : 57001–1557 oil pressure gauge adapter, m6 × 1.0 : 57001–1579.

  • Page 188

    7-8 engine lubrication system engine oil and oil filter warning motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Engine oil level inspection • situate the motorcycl...

  • Page 189

    Engine lubrication system 7-9 engine oil and oil filter oil screen removal • separate the crankcase (see crankshaft/transmission chapter). • remove the oil screens [a] from the crankcase. Oil screen installation • clean the oil screens thoroughly whenever it is removed for any reason. • clean the oi...

  • Page 190

    7-10 engine lubrication system oil pump oil pump removal • drain: engine oil (see periodic maintenance chapter) coolant (see periodic maintenance chapter) • remove: brake pedal (see brakes chapter) kick pedal (see engine right side chapter) water pipe bolt [a] water pipe [b] (pull out) water pump co...

  • Page 191

    Engine lubrication system 7-11 oil pump • remove the inner [a] and outer [b] rotors of the scaveng- ing oil pump. • disassembly the feed oil pump assembly. Oil pump cover [a] inner rotor [b] outer rotor [c] pin [d] oil pump body [e] oil pump gear [f] oil pump installation • apply engine oil to the s...

  • Page 192

    7-12 engine lubrication system oil pump • install the outer rotor [a]. • install the dowel pin [b] and dowel pin [c]. • install the scavenging and feed oil pump assemblies [d]. • tighten the oil pump mounting bolts. Torque - oil pump mounting bolts: 7.0 n·m (0.7 kgf·m, 61 in·lb) • apply engine oil t...

  • Page 193

    Engine lubrication system 7-13 oil pressure oil pressure measurement • remove the oil drain plug (for oil filter oil chamber) [a]. • attach the oil pressure gauge adapter [a]. • attach the oil pressure gauge [b]. Special tools - oil pressure gauge adapter: 57001–1579 oil pressure gauge: 57001–125 • ...

  • Page 195: Engine Removal/installation

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

  • Page 196

    8-2 engine removal/installation exploded view.

  • Page 197

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper engine mounting bolt, nut (m10) 49 5.0 36 2 middle engine mounting bolt, nut (m10) 49 5.0 36 3 lower engine mounting bolt, nut (m10) 49 5.0 36 4 upper engine bracket bolts, nuts (m8) 29 3.0 22 5 middle ...

  • Page 198

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

  • Page 199

    Engine removal/installation 8-5 engine removal/installation engine removal • place the jack [a] under the frame to support the motor- cycle. Special tool - jack: 57001–1238 warning for engine removal, the swingarm pivot shaft must be pulled out, causing the swingarm and rear wheel assembly to become...

  • Page 200

    8-6 engine removal/installation engine removal/installation • loosen: carburetor clamp bolts [a] • remove: inlet duct [b] with rear frame (see frame chapter) carburetor [c] (hanging it) clutch cable lower end [d] (see clutch chapter) drive chain [e] (cut out) • remove: bolts [a] rear brake pedal [b]...

  • Page 201

    Engine removal/installation 8-7 engine removal/installation • pull out the carburetor hoses [a] and breather hose [b] from the clamp [c]. • remove the swing arm pivot shaft [d]. ○ pull out the swing arm pivot shaft half way from right side to free the engine. • remove the engine from the vehicle to ...

  • Page 202

    8-8 engine removal/installation engine removal/installation • install the removed parts (see appropriate chapter). • run the cables, hoses, and leads according to the cable, wire and hose routing section of the appendix chapter. • fill: engine oil (see periodic maintenance chapter) coolant (see peri...

  • Page 203: Crankshaft/transmission

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

  • Page 204

    9-2 crankshaft/transmission exploded view.

  • Page 205

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase bolts 9.8 1.0 87 in·lb s 2 gear set lever nut 8.8 0.9 78 in·lb 3 neutral switch 12 1.2 104 in·lb 4 engine oil drain plug (for crank room oil sump) 7.0 0.7 61 in·lb 5 engine oil drain plug (for transmiss...

  • Page 206

    9-4 crankshaft/transmission specifications item standard service limit connecting rods: connecting rod big end radial clearance 0.002 ∼ 0.014 mm 0.06 mm (0.0024 in.) (0.00008 ∼ 0.0006 in.) connecting rod big end side clearance 0.25 ∼ 0.35 mm 0.55 mm (0.0217 in.) (0.0098 ∼ 0.0138 in.) crankshaft runo...

  • Page 207

    Crankshaft/transmission 9-5 special tools bearing puller : 57001–135 outside circlip pliers : 57001–144 bearing driver set : 57001–1129 crankshaft jig : 57001–1174 crankcase splitting tool assembly : 57001–1362 kawasaki bond (liquid gasket – black) : 92104–1064.

  • Page 208

    9-6 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine re- moval/installation chapter) • set the engine on clean surface while parts are being re- moved. • remove: magneto cover (see electrical system chapter) cylinder head cover (see engine top en...

  • Page 209

    Crankshaft/transmission 9-7 crankcase • remove the crankcase bolts [a]. • install the jig [a] between the crankshaft flywheels [b]. Special tool - crankshaft jig: 57001–1174 • attach the crankcase splitting tool [a] to the left crankcase. Special tool - crankcase splitting tool assembly: 57001–1362 ...

  • Page 210

    9-8 crankshaft/transmission crankcase crankcase assembly caution right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set. • remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high...

  • Page 211

    Crankshaft/transmission 9-9 crankcase • press the new drive shaft bearing [a] in the left and right crankcase half, so that the sealed side [b] faces outside of the engine. • press the new output shaft bearings [a] in the left and right crankcase half [b], so that the stepped side [c] faces inside o...

  • Page 212

    9-10 crankshaft/transmission crankcase • apply engine oil to the transmission gears, bearings, shift forks, shift drum and crankshaft bearing. • install the drive shaft [a] and output shaft [b] in the right crankcase [c] as a set [a]. • install: shift drum [a] (see transmission installation) shift f...

  • Page 213

    Crankshaft/transmission 9-11 crankcase • using a plastic hammer [a], press [b] the rear portion of the crankcase, and tap [c] the area around the crank- shaft of the left crankcase. While maintaining the mating surfaces of the right and left crankcase halves constantly parallel, mate the crankcase h...

  • Page 214

    9-12 crankshaft/transmission crankcase • to install the shift drum cam [a], use the driver [b] to bring the gear set lever [c] to the bottom of the crankcase. • mate the shift drum pin [d] into the shift drum hole. ○ fit the groove [e] of the shift drum cam on the shift drum pin. • apply non-permane...

  • Page 215

    Crankshaft/transmission 9-13 crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • remove the transmission shaft (see this chapter). • using the hand press [a], remove the crankshaft [b] from the right crankcase [c]. If the bearing stay on the crankshaft when spl...

  • Page 216

    9-14 crankshaft/transmission crankshaft crankshaft assembly since the assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crank- shaft can only be done by a shop having the necessary tools and equipment. • reassemble the crankshaft according to the standard ...

  • Page 217

    Crankshaft/transmission 9-15 transmission transmission shaft removal • disassemble the crankcase halves (see crankcase dis- assembly). • pull out the oil screens. Crank room side oil screen [a] transmission room side oil screen [b] • pull out the shift rods [a] allowing the shift fork guide pins to ...

  • Page 218

    9-16 crankshaft/transmission transmission • apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear. • the shift forks can be identified by their shape or mark. Install them noting the direction shown. ○ the drive shaft fork [a] is the ...

  • Page 219

    Crankshaft/transmission 9-17 transmission • the output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 5th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and washers are properly in pl...

  • Page 220

    9-18 crankshaft/transmission transmission • check each gear spins or slides freely on the transmission shaft without binding after assembly. Shift fork bending • visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmissi...

  • Page 221

    Crankshaft/transmission 9-19 bearings/oil seals bearing replacement caution do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • remove the ball bearing and/or needle bearing outer race using a press or puller. Note ○ in the absence of the above mentioned tools, sati...

  • Page 222

    9-20 crankshaft/transmission bearings/oil seals • check the needle bearing. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition ...

  • Page 223: Wheels/tires

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

  • Page 224

    10-2 wheels/tires exploded view.

  • Page 225

    Wheels/tires 10-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 spoke nipple 2.2 0.22 19 in·lb 2 front axle 79 8.0 58 3 front axle clamp bolts 20 2.0 14.5 al 4 rear axle nut 110 11.0 80 5. Spokes 6. Front tire 7. Rims 8. Front axle 9. Swingarm 10. Rear tire 11. Rear axle al: tighten the...

  • Page 226

    10-4 wheels/tires specifications item standard service limit wheels (rims): rim runout: axial 1.0 mm (0.039 in.) or less 2 mm (0.08 in.) radial 1.0 mm (0.039 in.) or less 2 mm (0.08 in.) axle runout/ 100 mm 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) tires air pressure: front and rear 100 kpa (1.0 kgf/cm²...

  • Page 227

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

  • Page 228

    10-6 wheels/tires wheels (rims) front wheel removal • using the jack [a] under the frame, and stabilize the mo- torcycle. Special tools - jack: 57001–1238 • loosen the left and right axle clamp bolts [a]. • unscrew the axle nut [b]. • place a stand under the engine to raise the front wheel off the g...

  • Page 229

    Wheels/tires 10-7 wheels (rims) • remove the jack. • before tightening the clamp bolts on the right fork leg, pump the forks up and down [a] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle. Note ○ do not apply the front brake during this process to stop the moto...

  • Page 230

    10-8 wheels/tires wheels (rims) • remove cotter pin [a] axle nut [b] • pull out the axle [c]. • move the rear wheel back with the rear caliper installed. • take off the collar and cap from the each side of the rear hub. Caution do not lay the wheel on the ground with the disc facing down. This can d...

  • Page 231

    Wheels/tires 10-9 wheels (rims) • check the drive chain slack (see final drive chapter). • tighten the axle nut. Torque - rear axle nut: 110 n·m (11 kg·m, 80 ft·lb) • install the new cotter pin [a] and spread its end. Note ○ when inserting the cotter pin, if the slots in the nut do not align with th...

  • Page 232

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

  • Page 233

    Wheels/tires 10-11 tires • step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [a] of the bead breaker protecting the rim with rim protectors [b]. Special tools - rim protector: 57001–1063 bead breaker assembly: 57001–1072 caution take care not to inset the ...

  • Page 234

    10-12 wheels/tires hub bearings hub bearing removal • remove the wheel (see wheel removal). Caution do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. • remove the oil seals and circ...

  • Page 235: Final Drive

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

  • Page 236

    11-2 final drive exploded view.

  • Page 237

    Final drive 11-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 2 engine sprocket cover bolts 9.8 1.0 87 in·lb 3. Engine sprocket 4. Output shaft 5. Chain slipper 6. Swingarm 7. Chain guide 8. Locknut 9. Adjusting bolt 10. Chain adjuster 11. Drive chain 12. R...

  • Page 238

    11-4 final drive specifications item standard service limit drive chain: chain slack 52 ∼ 62 mm (2.05 ∼ 2.44 in.) - - - chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.72 in.) standard chain: make: daido - - - type: d.I.D 520dma2 - - - length: 114 links - - - sprocket engine spr...

  • Page 239

    Final drive 11-5 special tools outside circlip pliers : 57001–144 jack : 57001–1238.

  • Page 240

    11-6 final drive drive chain drive chain slack inspection • raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • check the wheel alignment (see wheel alignment inspec- tion in the final drive chapter), and adjust it i...

  • Page 241

    Final drive 11-7 drive chain note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [a] up to next alignment. ○ it should be within 30 degree. ○ loosen one and tighten again when the slot goes past the nearest ...

  • Page 242

    11-8 final drive drive chain drive chain removal • remove the clip [a] from the master link using pliers, and free the drive chain from the rear sprocket. • remove the drive chain from the chassis. Drive chain installation • fit the drive chain back onto the sprockets with the ends at the rear sproc...

  • Page 243

    Final drive 11-9 sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • remove: drive chain [a] (free of engine sprocket) • remove the circlip [b], and pull off the engine sprocket [c]. Special tools - outside circlip pliers: 570...

  • Page 244

    11-10 final drive sprockets rear sprocket warp inspection • refer to the rear sprocket wrap inspection in periodic maintenance chapter..

  • Page 245: Brakes

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

  • Page 246

    12-2 brakes exploded view.

  • Page 247

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front master cylinder clamp bolts 8.8 0.9 78 in·lb 2 brake hose banjo bolts 25 2.5 18 3 brake pad bolt 18 1.8 13 4 caliper bleed valve 7.8 0.8 69 in·lb 5 caliper mounting bolts 25 2.5 18 6 brake disc mounting bolts 9.8 1.0 87 in...

  • Page 248

    12-4 brakes exploded view.

  • Page 249

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 9.8 1.0 87 in·lb 3 rear master cylinder push rod locknut 18 1.8 13 4 caliper bleed valve 7.8 0.8 69 in·lb 5 brake pad bolt 18 1.8 13 6 rear brake pad bolt pl...

  • Page 250

    12-6 brakes specifications item standard service limit brake adjustment: lever play adjustable (to suit rider) - - - brake fluid: recommended disc brake fluid: - - - type front dot3 or dot4 - - - rear dot4 brake pads: lining thickness: front 3.8 mm (0.150 in.) 1 mm (0.04 in.) rear 6.4 mm (0.252 in.)...

  • Page 251

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

  • Page 252

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

  • Page 253

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

  • Page 254

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

  • Page 255

    Brakes 12-11 brake fluid • check the fluid level. • after bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. Warning do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are...

  • Page 256

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

  • Page 257

    Brakes 12-13 caliper caliper installation • tighten the brake pad bolts if it was removed. Torque - brake pad bolts: 18 n·m (1.8 kgf·m, 13 ft·lb) front brake: • install the caliper and tighten the bolts. Torque - caliper mounting bolts: 25 n·m (2.5 kgf·m, 18.0 ft·lb) rear brake: • before install the...

  • Page 258

    12-14 brakes caliper caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shafts. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature. • chec...

  • Page 259

    Brakes 12-15 caliper brake pad installation • push the caliper pistons in by hand as far as they will go. • install the piston side pad first, and then another pad. ○ fit the pad end [a] into the groove [b] of the anti-rattle spring securely. • tighten the brake pad bolt. Torque - brake pad bolt: 18...

  • Page 260

    12-16 brakes master cylinder caution brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wished up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the upper brake hose [b] from the master cylinder [c]. • when removing t...

  • Page 261

    Brakes 12-17 master cylinder rear master cylinder removal • remove the cotter pin [a]. • pull off the joint pin [b] with washer. Note ○ pull off the joint pin while pressing down the brake pedal. • unscrew the master cylinder mounting bolts [c], and re- move the master cylinder [d]. • unscrew the br...

  • Page 262

    12-18 brakes master cylinder master cylinder inspection (visual inspection) • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall of each master cylinder [a] and on the outside of each piston [b]. If a master cylinder or piston show...

  • Page 263

    Brakes 12-19 brake disk brake disc inspection • visually inspect the disc [a]. If it is scratched or damaged, replace the disc. • measure the thickness of each disc at the point [b] where it has worn the most. Replace the disc if it has worn past the service limit. Thickness front rear standard: 2.8...

  • Page 264

    12-20 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in periodic main- tenance chapter. Brake hose inspection • refer to the brake hose and connection check in peri- odic maintenance chapter..

  • Page 265: Suspension

    Suspension 13-1 13 suspension table of contents exploded view................................... 13-2 specifications .................................... 13-6 special tools ..................................... 13-7 front fork .......................................... 13-9 air pressure ...............

  • Page 266

    13-2 suspension exploded view.

  • Page 267

    Suspension 13-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 front fork top plug 29 3.0 22 2 lower front fork clamp bolts 20 2.0 14.5 al 3 upper front fork bolts 20 2.0 14.5 al 4 steering stem head nut 79 8.0 58 5 push rod nut 28 2.85 20.6 6 front axle clump bolts 20 2.0 14.5 al 7 fron...

  • Page 268

    13-4 suspension exploded view.

  • Page 269

    Suspension 13-5 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 98 10 72 2 rocker arm pivot nut 83 8.5 61 3 tie-rod mounting nut (front, rear) 83 8.5 61 4 rear shock absorber mounting nut (upper) 39 4.0 29 5 rear shock absorber mounting nut (lower) 34 3.5 25 6 air...

  • Page 270

    13-6 suspension specifications item standard service limit front fork: air pressure atmospheric pressure - – – rebound damping adjustment (adjustable range) 11 clicks counterclockwise 16 clicks (from the seated position adjuster turned fully clockwise) 12 clicks counterclockwise (eu) compression dam...

  • Page 271

    Suspension 13-7 special tools oil seal & bearing remover : 57001–1058 steering stem nut wrench : 57001–1100 hook wrench : 57001–1101 bearing driver set : 57001–1129 fork outer tube weight : 57001–1218 jack : 57001–1238 bearing remover shaft, 9 : 57001–1265 bearing remover head, 15 × 17 : 57001–1267 ...

  • Page 272

    13-8 suspension special tools fork cylinder holder : 57001–1573.

  • Page 273

    Suspension 13-9 front fork air pressure the standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race through the pressure ...

  • Page 274

    13-10 suspension front fork seated positions adjuster turned fully clockwise [a]. Compression damping adjuster setting standard: 8 clicks [b] 11 clicks (european model) [c] softer (counterclockwise) [d] harder (clockwise) [e] *: number of turns counterclockwise usable range – 16 clicks or more. Coun...

  • Page 275

    Suspension 13-11 front fork • place a stand or other suitable support [a] under the front wheel. • while holding the push rod nut with a 19 mm wrench, loosen the front fork top plug [a] from the top of the push rod. • remove the fork top plug with the fork spring seat [b] and fork spring [c]. • fill...

  • Page 276

    13-12 suspension front fork • hold the push rod with your hand fully up. • insert the fork spring [a] into the fork tube. • install the fork spring seat [a] on the fork spring [b]. • check both top plug o-ring [c] for damage and replace them if necessary. • while holding the push rod nut [a] with a ...

  • Page 277

    Suspension 13-13 front fork • remove: front wheel (see wheels/tires chapter) bolts [a] • remove the caliper [b] from the fork leg to be removed, and rest the caliper on some kind of stand so that it doesn’t dangle. • loosen the upper [a], and lower fork clamp bolts [b]. • remove the front fork. ○ wi...

  • Page 278

    13-14 suspension front fork front fork installation • if the fork leg was disassembled, check the fork oil level. • install the fork so that the distance [b] between the top end [a] of the outer tube and the upper surface [c] of the steering stem head is specified dimension. [b] = 8 mm (0.59 in.) • ...

  • Page 279

    Suspension 13-15 front fork • use wrenches [a] on the rod nut [b] and top plug [c] loosen the push rod nut. • remove the top plug from the push rod. • lift the fork spring [d] and its top spring seat [e] out of the outer tube. • take the rebound damping adjuster rod [a] out of the push rod. • hold t...

  • Page 280

    13-16 suspension front fork • remove: circlip [a] o-ring [b] nut [c] collar [d] holder [e] • clean the bottom of the inner tube. • remove the cap on the bottom of the inner tube. • hold the front fork horizontally in a vise. • stop the cylinder unit [a] from turning by using the fork cylinder holder...

  • Page 281

    Suspension 13-17 front fork • separate the inner tube [a] from the outer tube [b] as follows: ○ slide up the spring band [c]. ○ slide up the dust seal [d]. ○ remove the retaining ring [b] from the outer tube [a]. ○ grasp the outer tube and stroke the inner tube up and down several times. The shock t...

  • Page 282

    13-18 suspension front fork • when assembling the new outer tube guide bush [a], hold the washer against the new one, and tap the washer with the fork oil seal driver [b] until it stops. Special tool - fork oil seal driver, 48: 57001–1509 • after installing the washer, install the oil seal by using ...

  • Page 283

    Suspension 13-19 front fork • fit the circlips [a] onto the groove of the push rod [b]. • install the collar [c], holder [d], and nut [e] • replace the o-ring [f] with a new one. • install the spring guide [a] so that the thinner portion end [b] is down. • screw on the push rod nut [c] fully. • inse...

  • Page 284

    13-20 suspension front fork inner tube inspection • visually inspect the inner tube [a], repair any damage. • nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Sin...

  • Page 285

    Suspension 13-21 rear suspension (uni-trak) rear shock absorber: the rear suspension system of this motorcycle is new uni-trak. It consists of a rear shock absorber, swing arm, tie-rod and rocker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or t...

  • Page 286

    13-22 suspension rear suspension (uni-trak) seated position : adjuster turned fully clockwise [a]. Rebound damping adjuster setting standard: 11 clicks [b] softer (counterclockwise) [c] harder (clockwise) [d] *: number of turns counterclockwise usable range – 16 clicks or more. Counterclockwise from...

  • Page 287

    Suspension 13-23 rear suspension (uni-trak) spring preload adjustment (adjusting nut position at the lower surface [a] from the center of the mounting hole) standard: 113 mm (4.45 in.) adjustable range 109 ∼ 129.5 mm (4.29 ∼ 5.098 in.) • tighten the locknut securely. • after adjusting, move the spri...

  • Page 288

    13-24 suspension rear suspension (uni-trak) spring replacement in addition to the standard spring, heavy and light springs are available. If the standard spring is improper for your purpose, select a proper one according to the rider’s weight or course conditions. • remove side covers seat silencer ...

  • Page 289

    Suspension 13-25 rear suspension (uni-trak) spring tension since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring is shorter than the service limit, it must be replaced. Rear shock absorber spring free length standard: 260 mm (10.24 in.) ser...

  • Page 290

    13-26 suspension swingarm swingarm removal • place the jack [a] under the frame so that the rear wheel is off the ground. Special tool - jack : 57001–1238 • remove rear wheel (see wheels/tires chapter) clamps [b] brake pedal [c] (see brakes chapter) caps [d] disc protector [e] • remove: bolts [a] ch...

  • Page 291

    Suspension 13-27 swingarm swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • tighten the following: torque - swingarm pivot shaft nut: 98 n·m (10.0 kgf·m, 72 ft·lb) rocker arm mounting nut: 83 n·m (8.5 kgf·m, 61 ft·lb) • refer to the whee...

  • Page 292

    13-28 suspension swingarm • visually inspect the chain slipper [a] on the swingarm [b] and replace it if worn or damaged. • visually inspect the upper and lower chain guide rollers [a] and replace them if excessively worn or damaged..

  • Page 293

    Suspension 13-29 tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001–1238 • unscrew the nut [a] and remove the guide roller [b]. Caution when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tap...

  • Page 294

    13-30 suspension tie-rod, rocker arm rocker arm installation • apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve. • be sure seated the washers. • tighten the following: torque - rear shock absorber lower mounting nut: 34 n·m (3....

  • Page 295

    Suspension 13-31 tie-rod, rocker arm • install the needle bearings [a], [b], grease seals [c], and oil seals [d] position as shown. ○ the installation procedure is the same as the counter side. Front [e] rear shock absorber [h] right side [f] tie-rod [i] left side [g] rocker arm [j] needle bearing i...

  • Page 296

    13-32 suspension uni-trak maintenance uni-trak linkage inspection • refer to the uni-trak linkage inspection in periodic main- tenance chapter. Tie-rod and rocker arm sleeve wear • pull out the sleeves [a] of the tie-rod and rocker arm. • measure the outside diameter of the sleeve. If the sleeve is ...

  • Page 297: Steering

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

  • Page 298

    14-2 steering exploded view.

  • Page 299

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18.0 s 2 steering stem head nut 78 8.0 58 3 steering stem locknut 4.9 0.5 43 in·lb t 4 upper front fork clamp bolts 20 2.0 14.5 al 5 lower front fork clamp bolts 20 2.0 14.5 al 6. Handlebar clamp 7...

  • Page 300

    14-4 steering special tools bearing puller : 57001–135 steering stem bearing driver : 57001–137 steering stem bearing driver adapter : 57001–1074 head pipe outer race press shaft : 57001–1075 head pipe outer race driver : 57001–1076 head pipe outer race driver : 57001–1077 steering stem nut wrench :...

  • Page 301

    Steering 14-5 steering steering inspection • refer to the steering inspection in periodic maintenance chapter. Steering adjustment • refer to the steering adjustment in periodic maintenance chapter. Steering stem, stem bearing removal • remove: front wheel (see wheels/tires chapter) front fender bol...

  • Page 302

    14-6 steering steering • take off 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 dr...

  • Page 303

    Steering 14-7 steering • replace the lower inner races with new ones. ○ apply grease to the lower tapered roller bearing [a], and drive it onto the stem using the steering stem bearing driver [b] and adapter [c]. Special tool - steering stem bearing driver : 57001–137 steering stem bearing driver ad...

  • Page 304

    14-8 steering steering • install the parts removed (see the appropriate chapter). Warning do not impede the handlebar turning by routing the cables, wires and hoses improperly (see the gen- eral information chapter). • check and adjust : steering front brake clutch cable throttle cable.

  • Page 305

    Steering 14-9 steering maintenance stem bearing lubrication • refer to the stem bearing lubrication in periodic mainte- nance chapter. Stem bearing wear, damage • using a high flash-point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which ...

  • Page 306

    14-10 steering handlebar handlebar removal • remove : clutch holder [a] (see clutch chapter) engine stop switch [b] clamp [c] (discard) left handlebar grip [d] • remove: throttle grip assy [a] (see fuel system chapter) master cylinder [b] (see brakes chapter) • remove: handlebar clamp bolts [a] hand...

  • Page 307

    Steering 14-11 handlebar • apply grease to the throttle cable upper end and clutch cable upper end. • apply a 2 stroke oil to the throttle grip inner wall [a]. • install the throttle grip assy so that the grip [a] is in as far as it will go. ○ position the throttle grip assy so that the horizontal p...

  • Page 309: Frame

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

  • Page 310

    15-2 frame exploded view.

  • Page 311

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 upper rear frame mounting bolt 34 3.5 25 2 lower rear frame mounting bolts 34 3.5 25 g: apply grease. R: replacement parts.

  • Page 312

    15-4 frame frame frame inspection • refer to the frame inspection in periodic maintenance chapter. Rear frame removal • remove: seat (see seat removal) right & left side cover (see side cover removal) silencer (see engine top end chapter) rear fender (see fender removal) rear flap (see flap removal)...

  • Page 313

    Frame 15-5 seat seat removal • unscrew the bolts [a]. • pull the seat [b] out from the back. Seat installation • fit the hooks [a] of the seat under the flange collar [b] and brackets [c]..

  • Page 314

    15-6 frame side cover side cover removal • unscrew the bolts [a] and remove the side cover. Side cover installation • stick the pads [a] on the inside of the right side cover [b]. ○ bend this parts [c] and stick it to the upper surface of the rib. ○ install the dampers [d]. • insert the tabs [a] of ...

  • Page 315

    Frame 15-7 fender front fender removal • unscrew the bolts [a] and remove the front fender [b]. Rear fender removal • unscrew the bolts [a] and remove the rear fender [b]. Rear flap removal • unscrew the screws [a] and remove the rear flap [b]..

  • Page 317: Electrical System

    Electrical system 16-1 16 electrical system table of contents exploded view........................................................................................................................ 16-2 specifications .......................................................................................

  • Page 318

    16-2 electrical system exploded view.

  • Page 319

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 neutral switch 12 1.2 104 in·lb 2 flywheel nut 49 5.0 36 3 stator bolts 7.0 0.7 61 in·lb 4 spark plug 13 1.3 115 in·lb 5 magneto cover bolts l35 9.8 1.0 87 in·lb l 6 magneto cover bolts l30 9.8 1.0 87 in·lb 7 neutral ...

  • Page 320

    16-4 electrical system specifications item standard magneto: crankshaft sensor resistance: 80 ∼ 120 Ω magneto output voltage: in the text magneto coil resistance: in the text ignition system: ignition timing: (disconnect the throttle sensor lead) 8° btdc @ 2 000r/min (rpm) ignition coil: 3 needle ar...

  • Page 321

    Electrical system 16-5 special tools timing light : 57001–1241 spark plug wrench, hex 16 : 57001–1262 hand tester : 57001–1394 throttle sensor setting adapter : 57001–1400 needle adapter set : 57001–1457 rotor puller : 57001–1565 rotor holder : 57001–1567.

  • Page 322

    16-6 electrical system wiring diagram.

  • Page 323

    Electrical system 16-7 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 324

    16-8 electrical system electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean...

  • Page 325

    Electrical system 16-9 flywheel magneto magneto cover removal • drain the engine oil from the crank room oil sump (see periodic maintenance chapter). • push down the stopper [a]. • remove the magneto lead connector [b]. • disconnect the magneto lead connector with neutral switch lead connector [c] f...

  • Page 326

    16-10 electrical system flywheel magneto • screw the flywheel puller [a] into the flywheel. • remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer, while holding the puller body steady. There is a woodruff key in the cran...

  • Page 327

    Electrical system 16-11 flywheel magneto stator installation • route the wires according to the cable, wiring, and hose routing section in the appendix chapter. • install the stator and tighten it. Torque - stator bolts: 7.0 n·m (0.7 kgf·m, 61 in·lb) • install the crankshaft sensor and wiring holder...

  • Page 328

    16-12 electrical system flywheel magneto table 2 stator coil resistance connections tester range tester (+) to tester (–) to reading black/red lead red/white lead 27.2 ∼ 40.8 Ω × 1Ω yellow/white lead yellow lead 1.76 ∼ 2.64 Ω if there is more resistance than shown in the table, or no hand tester rea...

  • Page 329

    Electrical system 16-13 ignition timing ignition timing inspection • remove the timing inspection cap [a]. • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001–1241 • start the engine and aim the timing light at the ...

  • Page 330

    16-14 electrical system ignition system safety instructions: warning the ignition system produces extremely high volt- age. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. Ignition coil removal • remove: ...

  • Page 331

    Electrical system 16-15 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 an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage....

  • Page 332

    16-16 electrical system ignition system • disconnect the main harness connector [a]. • unscrew the mounting bolt [b] and remove the c.D.I unit [c]. C.D.I unit inspection caution when inspecting the c.D.I. Unit observe the follow- ing to avoid damage to the c.D.I. Unit. Do not disconnect the c.D.I. U...

  • Page 333

    Electrical system 16-17 ignition system • shift the gear to the neutral position, then free the engine stop switch. • crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil. Peak voltage 176 v or above warning do not touch the metal portion of th...

  • Page 334

    16-18 electrical system ignition system.

  • Page 335

    Electrical system 16-19 ignition system crankshaft sensor peak voltage check: • to check the peak voltage, do the following procedures. ○ disconnect the connector of the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value m...

  • Page 336

    16-20 electrical system ignition system exciter coil peak voltage check: • disconnect the connector of the magneto lead connector from the main harness. • to check the peak voltage, do the following procedures. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may no...

  • Page 337

    Electrical system 16-21 ignition system throttle sensor output/input voltage check note ○ if the variable rheostat is available, refer to throttle sen- sor inspection. • remove the carburetor lead connector [a]. • connect the throttle sensor setting adapter [a] between carburetor lead connector [b] ...

  • Page 338

    16-22 electrical system ignition system engine stop switch electric current check: • open the clamp [a]. • disconnect the engine stop switch lead connector [b]. • start the engine. • ground the stop switch black/white lead of the main har- ness side while the engine is running. If does not stop the ...

  • Page 339

    Electrical system 16-23 throttle sensor throttle sensor inspection note ○ if the variable rheostat is not available, refer to throttle sensor output/input voltage check in the c.D.I unit in- spection. ○ when inspecting the throttle sensor the throttle valve of the carburetor shall be completely clos...

  • Page 340

    16-24 electrical system neutral switch neutral switch inspection • slide out the dust cover [a]. • disconnect the connector [b]. ○ unscrew the screw. • using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). If the switch has an open or sho...

  • Page 341: Appendix

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

  • Page 342

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

  • Page 343

    Appendix 17-3 cable, wire, and hose routing 1. Throttle cables 2. Clamp 3. Engine stop switch lead 4. Hot start cable 5. Clutch cable 6. Main harness 7. C.D.I. Unit 8. Throttle cable (accelerator cable) 9. Throttle cable (decelerator cable) 10. Clamp (hold the throttle cable.) 11. C.D.I. Unit bracke...

  • Page 344

    17-4 appendix cable, wire, and hose routing 1. Clutch cable 2. C.D.I. Unit 3. Main harness 4. Clamps (run the clutch cable.) 5. Clamps (run the clutch cable.) 6. Run the clutch cable inside of the mag- neto lead. 7. Hot start cable 8. Engine stop switch lead 9. Clamp (hold the hot start cable, engin...

  • Page 345

    Appendix 17-5 cable, wire, and hose routing 1. Clutch cable 2. C.D.I. Unit 3. Main harness 4. Bolt (together with ground lead terminal) 5. Neutral lead connector 6. Magneto lead 7. Clamp 8. Run the magneto lead outside of the clutch cable. 9. Engine stop switch 10. Clamp (hold the hot start cable, e...

  • Page 346

    17-6 appendix cable, wire, and hose routing 1. Radiator overflow hose 2. Clamp 3. Hot start cable 4. Fuel hose 5. Breather hose 6. Clamp 7. Breather hose 8. Viewed a 9. Left radiator 10. Right radiator 11. Radiator hose (to cylinder head) 12. Radiator hose (to water pump) 13. Radiator hose (to water...

  • Page 347

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

  • Page 348

    17-8 appendix troubleshooting guide this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: engine won’t turn over: valv...

  • Page 349

    Appendix 17-9 troubleshooting guide valve not seating properly (valve bent, de- formed, worn, or carbon accumulation on the seating surface) decompression trouble other: faulty cdi unit engine oil level to high engine oil viscosity too high brake dragging drive train trouble engine overheating clutc...

  • Page 350

    17-10 appendix troubleshooting guide clutch inner cable sticking friction plate worn or warped steel plate worn or warped clutch spring broken or weak clutch release function trouble clutch hub or housing unevenly worn clutch not disengaging properly: clutch lever play excessive clutch spring compre...

  • Page 351

    Appendix 17-11 troubleshooting guide master cylinder damaged other noise: bracket, nut, bolt, etc., not properly mounted or tightened abnormal exhaust color: white smoke: piston oil ring worn cylinder worn valve oil seal damaged valve guide worn engine oil level too high black smoke: air cleaner ele...

  • Page 352

    Model application year model beginning frame no. 2004 kx250–n1 jkakxmnc □ 4a000001 or jkakx250nna000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1324-01 printed in japan.