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Kawasaki KX250F - Service Manual

Manual is about: Motorcycle

Summary of KX250F -

  • Page 1

    Kx250f motorcycle service manual.

  • Page 3: Quick Reference Guide

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

  • Page 5: Kx250F

    Kx250f motorcycle service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of quality assurance divisi...

  • Page 6

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

  • Page 7: Foreword

    Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...

  • Page 9: General Information

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

  • Page 10

    1-2 general information before servicing before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions...

  • Page 11

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

    General information 1-7 model identification kx250xaf left side view kx250xaf right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kx250xaf dimensions overall length 2 170 mm (85.43 in.) overall width 820 mm (32.3 in.) overall height 1 270 mm (50.00 in.) wheelbase 1 470 mm (57.87 in.) road clearance 340 mm (13.4 in.) seat height 955 mm (37.6 in.) curb mass: 105.1 kg (231.7 lb...

  • Page 17

    General information 1-9 general specifications items kx250xaf drive train primary reduction system: type gear reduction ratio 3.350 (67/20) clutch type wet multi disc, manual transmission: type 5-speed, constant mesh, return shift gear ratios: 1st 2.142 (30/14) 2nd 1.769 (23/13) 3rd 1.444 (26/18) 4t...

  • 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 ................................................................................................... 2-3 torque and locking agent..................................................................................

  • Page 20

    2-2 periodic maintenance brake lever and pedal adjustment .................................................................................. 2-35 brake fluid level inspection............................................................................................. 2-36 brake fluid change ...........

  • Page 21

    Periodic maintenance 2-3 periodic maintenance chart the maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page spark plug - clean,...

  • Page 22

    2-4 periodic maintenance periodic maintenance chart frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page wheels/tires - inspect • 2-30 rear sprocket - inspect † • 2-34 front fork - inspect and clean • 2-46 front fork oil - change • 2...

  • Page 23

    Periodic maintenance 2-5 torque and locking agent tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for ...

  • Page 24

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks carburetor clamp screw 2.0 0.20 18 in·lb cylinder bolt 12 1.2 106 in·lb s camshaft chain tensioner cap bolt 20 2.0 15 camshaft chain tensioner mounting bolts 9.8 1.0 87 in·lb lower camshaft chain guide bolt 9.8...

  • Page 25

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks ratchet plate bolt (front) 9.8 1.0 87 in·lb l, s ratchet plate bolt (rear) 15 1.5 11 l, s shift drum cam bolt 24 2.4 18 l gear positioning lever nut 8.8 0.90 78 in·lb shift pedal bolt 9.8 1.0 87 in·lb wheels/ti...

  • Page 26

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks tie-rod mounting nuts 59 6.0 44 r rear shock absorber mounting nut (upper) 39 4.0 29 r rear shock absorber mounting nut (lower) 34 3.5 25 r rear shock absorber spring locknut 45 4.6 33 piston rod locknut 37 3.8...

  • Page 27

    Periodic maintenance 2-9 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – hot starter lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – idle speed 1 950 ±50 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – ...

  • Page 28

    2-10 periodic maintenance specifications item standard service limit wheels/tires rim runout (with tire installed): axial tir 1.0 mm (0.039 in.) or less tir 2.0 mm (0.079 in.) radial tir 1.0 mm (0.039 in.) or less tir 2.0 mm (0.079 in.) tires air pressure (front/rear) 100 kpa (1.00 kgf/cm², 14 psi) ...

  • Page 29

    Periodic maintenance 2-11 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 attachment jack: 57001-1252 spark plug wrench, hex 16: 57001-1262 carburetor drain plug wrench, hex 3: 57001-1269 filler cap driver: 57001-1454 pilot screw adjuster, d: 5700...

  • Page 30

    2-12 periodic maintenance periodic maintenance procedures fuel system fuel hose and connection inspection ○ if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [a]. • check the fuel hose. Replace the fuel hose if any fraying, cracks [b], bulges [c] or ozone cra...

  • Page 31

    Periodic maintenance 2-13 periodic maintenance procedures if the throttle grip free play cannot be adjusted with the adjuster, replace the throttle cables. • turn the handlebar from side to side while idling the en- gine. If idle speed varies, the throttle cable may be poorly routed or it may be dam...

  • Page 32

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

  • Page 33

    Periodic maintenance 2-15 periodic maintenance procedures air cleaner element cleaning and inspection note ○ in dusty areas, the element should be cleaned more frequently than recommended interval. ○ after riding through rain or on muddy roads, the element should be cleaned immediately. ○ since repe...

  • Page 34

    2-16 periodic maintenance periodic maintenance procedures • clean the element [a] in a bath of a high-flash point sol- vent using a soft bristle brush. • squeeze it dry in a clean towel [a]. Do not wring the ele- ment or blow it dry; the element can be damaged. • check all parts of the element for v...

  • Page 35

    Periodic maintenance 2-17 periodic maintenance procedures fuel system clean warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includ...

  • Page 36

    2-18 periodic maintenance periodic maintenance procedures cooling system warning coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spi...

  • Page 37

    Periodic maintenance 2-19 periodic maintenance procedures notice for refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum en- gine parts. In an emergency, soft wat...

  • Page 38

    2-20 periodic maintenance periodic maintenance procedures • place the piston to the tdc (compression stroke) to in- spect the valve clearance. ○ place a wrench over the flywheel nut [a] and turn it coun- terclockwise to align the tdc mark [b] with the center of the groove [c] of the inspection hole....

  • Page 39

    Periodic maintenance 2-21 periodic maintenance procedures • clean the shim to remove any dust or oil. • measure the thickness of the removed shim [a]. • select a new shim thickness calculation as follows. A + b – c = d [a] present shim thickness [b] measured valve clearance [c] specified valve clear...

  • Page 40

    2-22 periodic maintenance periodic maintenance procedures • install the shim. ○ turn the marked side [a] to upside. ○ apply engine oil to the shim or the back of valve lifter [b] to keep the shim in place during camshaft installation. Notice do not put shim stock under the shim. This may cause the s...

  • Page 41

    Periodic maintenance 2-23 periodic maintenance procedures • take a side-to-side and a front-to-back measurement shown in the figure (total 6 measurements). ○ the cylinder wear is uneven in different places. 10 mm (0.39 in.) [a] 25 mm (0.98 in.) [b] 60 mm (2.36 in.) [c] cylinder inside diameter stand...

  • Page 42

    2-24 periodic maintenance periodic maintenance procedures muffler baffle replacement • remove: right side cover (see side covers removal in the frame chapter) muffler body cover bolts [a] muffler mounting bolt [b] • remove the muffler body cover [a]. ○ tap the bracket [b] with a plastic hammer [c] t...

  • Page 43

    Periodic maintenance 2-25 periodic maintenance procedures clutch clutch operation inspection clutch lever (clutch cable) free play inspection • slide the clutch cable adjuster knob [a] out of place. • check that the clutch cable upper end [b] is fully seated in the adjusting bolt [c]. • install the ...

  • Page 44

    2-26 periodic maintenance periodic maintenance procedures • loosen the locknut [a] at the clutch cable, and turn the adjusting nut [b] so that clutch lever has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. • tighten the locknut, and start the engine and check that the clutch does not slip and that it release p...

  • Page 45

    Periodic maintenance 2-27 periodic maintenance procedures engine oil change • warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Then stop the engine. • place an oil pan beneath the engine. • remove the oil filler plug [a]. Special tool - filler cap driver: 570...

  • Page 46

    2-28 periodic maintenance periodic maintenance procedures oil filter change • drain: engine oil (see engine oil change) • remove: oil filter cap bolt [a] oil filter cap [b] • remove the oil filter [a]. • replace the oil filter with a new one. • apply grease to the grommet [a]. • install the oil filt...

  • Page 47

    Periodic maintenance 2-29 periodic maintenance procedures crankshaft/transmission crankshaft inspection • remove: cylinder head (see cylinder head removal in the en- gine top end chapter) cylinder (see cylinder removal in the engine top end chapter) piston (see piston removal in the engine top end c...

  • Page 48

    2-30 periodic maintenance periodic maintenance procedures tires inspection • remove any imbedded stones or other foreign particles from the tread. Repair or replace with a new one if necessary. • visually inspect the tire for cracks and cuts. Replace the tire, if any damage are noticed. ○ swelling o...

  • Page 49

    Periodic maintenance 2-31 periodic maintenance procedures • set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [a]. ○ the difference between the highest and lowest dial read- ings is the amount of runout. • set a dial gauge against the outer circumference of...

  • Page 50

    2-32 periodic maintenance periodic maintenance procedures • stretch the chain taut by hanging a 98 n (10 kgf, 20 lb) weight [a] on the chain. • measure the length of 20 links [b] on the straight part [c] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the cha...

  • Page 51

    Periodic maintenance 2-33 periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster locknuts [a]. • remove the cotter pin [b] and loosen the axle nut [c]. If the chain is too tight, back out the left and right chain adjusting bolts [d] evenly, and push t...

  • Page 52

    2-34 periodic maintenance periodic maintenance procedures drive chain lubrication ○ the chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain. If the chain is especially dirty, it should be...

  • Page 53

    Periodic maintenance 2-35 periodic maintenance procedures brakes brake lever and pedal adjustment • slide the dust cover [a]. • adjust the brake lever to suit you. ○ loosen the adjuster locknut [b] and turn the adjuster [c] to either side. • after adjustment, tighten the locknut. Warning an improper...

  • Page 54

    2-36 periodic maintenance periodic maintenance procedures brake fluid level inspection • check the brake fluid level in the front or rear brake reser- voir [a] and the front or rear reservoir must be kept above the lower level line [b]. Note ○ hold the reservoir horizontal when checking brake fluid ...

  • Page 55

    Periodic maintenance 2-37 periodic maintenance procedures brake fluid change 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...

  • Page 56

    2-38 periodic maintenance periodic maintenance procedures • remove the rubber cap [a] on the bleed valve [b]. • attach a clear plastic hose [a] to the bleed valve on the caliper, and run the other end of the hose into a container. • change the brake fluid as follows: ○ repeat this operation until fr...

  • Page 57

    Periodic maintenance 2-39 periodic maintenance procedures brake pad wear inspection • check the lining thickness and condition of the brake pads in each caliper. Note ○ it is able to check with the pads installed. If either pad is damaged, replace both pads in the caliper as a set. Brake pad lining ...

  • Page 58

    2-40 periodic maintenance periodic maintenance procedures • slide the dust cover [a] on the push rod [b] out of place, and remove the circlip [c]. Special tool - inside circlip pliers: 57001-143 • pull out the push rod with the piston stop [d]. • take off the piston [e], secondary cup [f], primary c...

  • Page 59

    Periodic maintenance 2-41 periodic maintenance procedures caliper rubber parts replacement front caliper disassembly • remove: front caliper (see caliper removal in the brakes chap- ter) brake pads (see brake pad removal in the brakes chapter) • separate the caliper holder [a] from the caliper [b]. ...

  • Page 60

    2-42 periodic maintenance periodic maintenance procedures • separate the caliper holder [a] from the caliper [b]. • remove the anti-rattle springs [c]. • using compressed air, remove the piston. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ remove the piston by lightly applying compre...

  • Page 61

    Periodic maintenance 2-43 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 62

    2-44 periodic maintenance periodic maintenance procedures • replace the shaft rubber 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 grease)....

  • Page 63

    Periodic maintenance 2-45 periodic maintenance procedures front brake hose • remove: brake hose clamp bolts [a] brake hose clamp [b] rear brake hose • remove: brake hose clamps [a] bolts [b] caliper guard [c] • remove: rear master cylinder mounting bolts [a] • remove the front/rear brake hose banjo ...

  • Page 64

    2-46 periodic maintenance periodic maintenance procedures suspension front fork inspection • visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tubes [a]. • holding the brake lever, pump the front fork down and up manually to check for smooth oper...

  • Page 65

    Periodic maintenance 2-47 periodic maintenance procedures ○ rest the caliper [a] on a stand [b] so that it does not dan- gle. • loosen the front fork clamp bolts (lower) [a]. • remove the front fork. ○ with a twisting motion, work the fork leg [b] down and out. • record the position of each damping ...

  • Page 66

    2-48 periodic maintenance periodic maintenance procedures • hold the fork tube [a] upside down over a clean container [b] and drain the oil. Note ○ pump the outer tube up and down to discharge the fork oil. • temporarily install the fork cylinder unit [a] to the outer tube [b]. Special tool - top pl...

  • Page 67

    Periodic maintenance 2-49 periodic maintenance procedures • hold the locknut [a] with a wrench [b] and remove the adjuster assembly [c]. Note ○ do not remove the locknut from the piston rod. The piston rod may slide into the inner tube. • take the rebound damping adjuster rod [a] out of the pis- ton...

  • Page 68

    2-50 periodic maintenance periodic maintenance procedures • holding the top plug wrench [a] with a vise, unscrew the base valve assembly [b] on the fork cylinder unit [c]. ○ use a hexagon box wrench [d]. • pull out the base valve assembly [a] from the fork cylinder unit [b]. ○ slowly compress the pi...

  • Page 69

    Periodic maintenance 2-51 periodic maintenance procedures • clean the threads [a] of the fork cylinder unit and base valve assembly. • hold the fork cylinder unit [a] upright with the piston rod fully stretched. • plug the two oil holes [b] on the cylinder unit with fingers. • pour the specified oil...

  • Page 70

    2-52 periodic maintenance periodic maintenance procedures • stretch the piston rod fully, and gently install the base valve assembly [a] to the fork cylinder unit [b]. Note ○ if there is difficulty in assembling the base valve, it may be because the oil level is too high. Check the oil level in the ...

  • Page 71

    Periodic maintenance 2-53 periodic maintenance procedures • protect the piston rod end with a heavy cloth to prevent damage. • check the piston rod for smooth operation. ○ pump the piston rod [a] to full stroke [b] by pushing down the fork cylinder unit [c]. If the piston rod operation is not smooth...

  • Page 72

    2-54 periodic maintenance periodic maintenance procedures • wipe the fork oil off completely from the spring [a] and fork cylinder unit [b]. • install: spring fork cylinder unit • temporarily tighten the fork cylinder unit using the top plug wrench. Special tool - top plug wrench, 50 mm: 57001-1645 ...

  • Page 73

    Periodic maintenance 2-55 periodic maintenance procedures • replace the adjuster assembly o-ring [a] with a new one and apply specified fork oil to it. • slowly turn the adjuster assembly [b] clockwise until re- sistance is felt. • check the clearance between the locknut [c] and adjuster assembly fo...

  • Page 74

    2-56 periodic maintenance periodic maintenance procedures • temporarily install the cylinder unit [a] to the outer tube [b] using the top plug wrench. Special tool - top plug wrench, 50 mm: 57001-1645 • install the front fork to the motorcycle. • tighten: torque - front fork clamp bolts (lower): 20 ...

  • Page 75

    Periodic maintenance 2-57 periodic maintenance procedures • insert a suitable tool into the gas reservoir cap hole [a] to release the nitrogen gas. • adjust the gas reservoir damping adjusters to the softest position. High speed compression damping adjuster [a] low speed compression damping adjuster...

  • Page 76

    2-58 periodic maintenance periodic maintenance procedures • visually inspect the piston [a], o-ring [b], and oil seal as- sembly [c]. If the piston, o-ring and oil seal assembly are badly scored, rusty or damaged, replace them. • using the grinder, shave off the stake portions [a] of the rod and nut...

  • Page 77

    Periodic maintenance 2-59 periodic maintenance procedures • wrap the threads [a] of the piston rod with tape. • remove the oil seal assembly [b]. • remove the o-ring [a]. • pull out the spring [b]. • remove the rebound rubber [a] out of its groove [b]. • remove: collar [c] spring holder [d] oil seal...

  • Page 78

    2-60 periodic maintenance periodic maintenance procedures • replace the following with new ones. Oil seals rebound rubber (if damaged) o-ring • install each parts direction as shown in the figure. Oil seal [a] oil seal [b] spring holder [c] collar [d] rebound rubber [e] spring [f] o-ring [g] • remov...

  • Page 79

    Periodic maintenance 2-61 periodic maintenance procedures • install: damper holder [a] damper [b] stopper [c] • wrap the threads of the piston rod with tape [a]. • apply thin coat of rear shock oil to the sliding surface of the piston rod. • insert the oil seal assembly [b]. • install: washer [a] st...

  • Page 80

    2-62 periodic maintenance periodic maintenance procedures ○ install the piston direction as shown in the figure. Locknut side face [a] • stake the end of the piston rod with the chisel [a] in three place [b]. • check the oil seal assembly moving smoothly on the rod. • check that the bladder [a] on t...

  • Page 81

    Periodic maintenance 2-63 periodic maintenance procedures • pull up the gas reservoir cap [a] against the circlip as shown in the figure. 2.6 mm (0.1 in.) [b] warning pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly in- stalled, allowing oil and inte...

  • Page 82

    2-64 periodic maintenance periodic maintenance procedures • remount the upper portion of the shock absorber in a vise with soft jaws or a heavy cloth. • fill the specified oil [a] into the damping adjuster assem- bly hole. Recommended oil showa ss-25 or equivalent sae 2.5 w rear shock absorber oil c...

  • Page 83

    Periodic maintenance 2-65 periodic maintenance procedures • inject the nitrogen gas up to the 980 kpa (10 kgf/cm², 142 psi) pressure. Warning high pressure gas is dangerous and can explode, causing serious injury. To avoid injury, have a qual- ified mechanic pressurize the shock reservoir with nitro...

  • Page 84

    2-66 periodic maintenance periodic maintenance procedures steering steering inspection • using the jack, raise the front wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • with the front wheel pointing straight ahead, alternately nudge each end of the...

  • Page 85

    Periodic maintenance 2-67 periodic maintenance procedures • loosen the front fork clamp bolts (upper) [a] on both sides. • remove the steering stem head nut [b] and washer [c]. • take off the steering stem head [d]. • turn the steering stem nut [a] with the steering stem nut wrench [b] to obtain the...

  • Page 86

    2-68 periodic maintenance periodic maintenance procedures • install the handlebar clamps [a]. • tighten the handlebar clamp bolts [b]. ○ equalize the front and rear gaps [c]. Torque - handlebar clamp bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) note ○ tighten the two clamp bolts alternately two times to en- ...

  • Page 87

    Periodic maintenance 2-69 periodic maintenance procedures electrical system spark plug cleaning and inspection • remove the stick coil (see stick coil removal in the elec- trical system chapter). • clean the plug hole, using the compressed air [a]. • remove the spark plug using the spark plug wrench...

  • Page 88

    2-70 periodic maintenance periodic maintenance procedures general lubrication and cable inspection lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubricant. Note ...

  • Page 89

    Periodic maintenance 2-71 periodic maintenance procedures • with the cable disconnected at the both ends, the cable should move freely [a] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [b], or if the cable housing is kinked [c], replace the cable. ...

  • Page 90

    2-72 periodic maintenance periodic maintenance procedures if there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the torque and locking agent section of the general information chapter for torque specifications. For each fastener, fi...

  • Page 91: Fuel System

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

  • Page 92

    3-2 fuel system exploded view.

  • Page 93

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m in·lb remarks 1 throttle pulley cover bolt 3.4 0.35 30 2 throttle cable bolts 3.5 0.36 31 3 hot starter plunger cap bolt 1.0 0.10 9 cl: apply cable lubricant. G: apply grease. L: apply a non-permanent locking agent. R: replacement parts si:...

  • Page 94

    3-4 fuel system exploded view.

  • Page 95

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m in·lb remarks 1 air cleaner element wing bolt – – – hand tighten 2 air cleaner duct nuts 3.0 0.31 27 3 air cleaner duct bolt 7.1 0.72 63 4 air cleaner housing bolts 9.8 1.0 87 ad: apply adhesive cement. G: apply grease. O: apply high-qualit...

  • Page 96

    3-6 fuel system specifications item standard throttle grip and cable throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) hot starter lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) carburetor make/type keihin fcr-mx37 starter jet #68 leak jet #55 main jet #185 throttle valve cutaway 1.5 jet needle nhj...

  • Page 97

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

  • Page 98

    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 99

    Fuel system 3-9 throttle grip and cable • remove the fuel tank (see fuel tank removal). • unscrew the bolt [a]. • remove the throttle pulley cover [b]. • loosen the throttle cable bolts [a]. • remove the throttle cables [b] from the carburetor. • free the tips [c] from the pulley. • remove the throt...

  • Page 100

    3-10 fuel system throttle grip and cable throttle cable lubrication • whenever the throttle cable is removed or in accordance with the periodic maintenance chart, lubricate the these cables (see general lubrication and cable inspection section in the periodic maintenance chapter). ○ apply a thin coa...

  • Page 101

    Fuel system 3-11 throttle grip and cable • install the hot starter cable. ○ run the hot starter cable in accordance with the cable, wire, and hose routing section in the appendix chapter. • tighten: torque - hot starter plunger cap bolt: 1.0 n·m (0.10 kgf·m, 9 in·lb) • install the dust boot. • after...

  • Page 102

    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 103

    Fuel system 3-13 carburetor • remove the drain plug from the bottom of the float bowl, and screw a fuel level gauge [a] into the plug hole. Special tool - fuel level gauge, m18 × 1.0: 57001-122 • hold the gauge vertically against the side of the carbure- tor body so that the “zero” line [b] is sever...

  • Page 104

    3-14 fuel system carburetor • drive out the pivot pin [a] and remove the float [b] with float valve needle [c]. • bend the tang [a] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Floa...

  • Page 105

    Fuel system 3-15 carburetor • disconnect the throttle sensor connector [a]. • loosen the clamp screw [a] and remove the carburetor backward [b]. • loosen the carburetor drain plug [a] to drain the fuel into the suitable container. • tuck up the dust boot [a]. • unscrew the plunger cap bolt [b]. • un...

  • Page 106

    3-16 fuel system carburetor • loosen the throttle cable bolts [a] and take off the cables. • free the tips [b]. • pull out the carburetor tubes from the clamp [a]. • after removing the carburetor, push a clean, lint-free towel into the carburetor holder and the air cleaner duct to keep dirt or other...

  • Page 107

    Fuel system 3-17 carburetor • after installing the carburetor, do the following. ○ turn the fuel tap to the on position, and check for fuel leakage from the carburetor. Warning fuel spilled from the carburetor is hazardous. ○ adjust the following items if necessary: throttle cable idle speed (see id...

  • Page 108

    3-18 fuel system carburetor • unscrew the throttle valve link screw [a]. • pull out the throttle valve assembly [b]. • disassemble the throttle valve assembly. Jet needle holder [a] spring [b] retainer [c] jet needle with circlip [d] o-ring with throttle valve plate [e] throttle valve [f] • remove t...

  • Page 109

    Fuel system 3-19 carburetor • turn in the pilot 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 screw. • unscrew the screws [a]. • remove the acceleration pump cover [b] from the carbu- retor. • remov...

  • Page 110

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

  • Page 111

    Fuel system 3-21 carburetor carburetor cleaning warning gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this in- cludes any ...

  • Page 112

    3-22 fuel system carburetor • remove the carburetor (see carburetor removal). • before disassembling the carburetor, check the fuel level (see service fuel level inspection). If the service fuel level is incorrect, adjust it after the car- buretor inspection. • turn the throttle pulley to check that...

  • Page 113

    Fuel system 3-23 carburetor • check the jet needle for wear. A worn jet needle should be replaced. • inspect the throttle sensor (see throttle sensor inspec- tion in the electrical system chapter). • check the valve seat [a] of the choke plunger [b] for dam- age or stepped wear. Replace the choke kn...

  • Page 114

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

  • Page 115

    Fuel system 3-25 carburetor • replace the o-ring [a] with a new one. • apply grease to the o-ring. • fit the stopper [b] of the throttle sensor onto the projection [c] on the throttle cable pulley shaft. ○ install the throttle sensor and check its position (see throttle sensor inspection in the elec...

  • Page 116

    3-26 fuel system carburetor • install: starter jet [a] pilot jet [b] baffle plate [c] needle jet [d] main jet [e] • replace the o-ring with a new one. • install: pilot screw [a] spring [b] washer [c] o-ring [d] ○ turn in the pilot screw fully but not tightly, and the back it out the counted number o...

  • Page 117

    Fuel system 3-27 carburetor • install the float bowl. • tighten the bolts together with hose clamps [a] and cable holder [b] as shown in the figure. • replace the o-rings [a] with new ones. • install: diaphragm [b] spring [c] acceleration pump cover ○ install the diaphragm so that its mark [d] facin...

  • Page 118

    3-28 fuel system carburetor • install all tubes [a] as shown in the figure. Right side [b] left side [c] • install the carburetor (see carburetor installation). If turn the adjusting screw of the acceleration pump, follow the procedure below. ○ prepare an arbor [a] with the outside diameter of 3.25....

  • Page 119

    Fuel system 3-29 air cleaner air cleaner housing removal • remove the rear frame (see rear frame removal in the frame chapter). • remove the air cleaner housing bolts [a]. • take the air cleaner housing off the rear frame. Air cleaner housing installation • assemble the air cleaner housing (see expl...

  • Page 120

    3-30 fuel system air cleaner air cleaner element installation • coat the lip of the element with a thick layer of all pur- pose grease [a] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. • apply grease to all connections and scre...

  • Page 121

    Fuel system 3-31 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 122

    3-32 fuel system fuel tank fuel tap removal • remove the fuel tank (see fuel tank removal). • drain the fuel. • remove the bolts [a] and take off the fuel tap [b]. Fuel tap installation • replace the gasket [a] with a new one. • install the fuel tap. ○ turn the knob to left side. Fuel tank and tap c...

  • Page 123: Cooling System

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

  • Page 124

    4-2 cooling system exploded view.

  • Page 125

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m in·lb remarks 1 water pump cover bolts (l = 30, 65 mm) 9.8 1.0 87 2 water pump cover bolts (l = 55 mm) 9.8 1.0 87 l 3 coolant drain bolt 7.0 0.71 62 4 water pump impeller bolt 7.0 0.71 62 5 water hose clamp screws 3.0 0.31 27 6 water pip...

  • Page 126

    4-4 cooling system specifications item standard coolant type permanent type antifreeze for aluminum engines and radiators. Color green mixed ratio soft water 50%, antifreeze 50% freezing point –35°c (–31°f) total amount 1.2 l (1.3 us qt.) radiator cap relief pressure 93 ∼ 123 kpa (0.95 ∼ 1.25 kgf/cm...

  • Page 127

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

  • Page 128

    4-6 cooling system coolant coolant level inspection • refer to the coolant level inspection in the periodic main- tenance chapter. Coolant deterioration inspection • refer to the coolant deterioration inspection in the peri- odic maintenance chapter. Coolant draining warning coolant can be extremely...

  • Page 129

    Cooling system 4-7 coolant coolant filling notice use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the coo...

  • Page 130

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

  • Page 131

    Cooling system 4-9 water pump water pump cover removal • remove the oil filter (see oil filter change in the periodic maintenance chapter). ○ drain the engine oil from the water pump cover. • drain the coolant (see coolant draining). • unscrew the water pipe bolt [a], and disconnect the water pipe [...

  • Page 132

    4-10 cooling system water pump impeller removal • remove: water pump cover (see water pump cover removal) • remove the impeller bolt [a] and take out the impeller [b] and washer. Impeller installation • install the washer [a] and impeller [b]. • tighten: torque - water pump impeller bolt: 7.0 n·m (0...

  • Page 133

    Cooling system 4-11 water pump water pump gear installation • press in the water pump gear shaft [a] to the gear [b] until it is bottomed. • apply grease to the water pump gear shaft. • install the gear shaft from bearing side [c]. Notice be sure to apply grease to the water pump shaft when installi...

  • Page 134

    4-12 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: radiator shroud bolts [a] (both sides) radiator shroud [b] (both sides) • loosen: water hose clamp screws [a] • pull the water hoses [b] off the radiator. • remove: radiator screen bolt [c] left radia...

  • Page 135

    Cooling system 4-13 radiator radiator installation • install: radiators water hoses washers clutch cable clamps [a] (left side) • tighten: torque - radiator mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) water hose clamp screws: 3.0 n·m (0.31 kgf·m, 27 in·lb) • run the joint hose, over flow hose and ...

  • Page 136

    4-14 cooling system radiator radiator cap inspection • check the top and bottom valve seals [a] of the radiator cap, and the condition of the valve spring [b]. 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 137: Engine Top End

    Engine top end 5-1 5 engine top end table of contents exploded view................................... 5-2 specifications .................................... 5-6 special tools and sealant ................. 5-9 cylinder head cover ......................... 5-12 cylinder head cover removal .... 5-12 ...

  • Page 138

    5-2 engine top end exploded view.

  • Page 139

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 auto-decompressor bolt 12 1.2 106 in·lb 2 cylinder head cover bolts 9.8 1.0 87 in·lb 3 camshaft cap bolts 9.8 1.0 87 in·lb s, mo 4 cylinder head bolts (m10) 49 5.0 36 s, mo 5 cylinder head bolts (m6) 12 1.2 106 in·lb s 6 ...

  • Page 140

    5-4 engine top end exploded view.

  • Page 141

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover screws 12 1.2 106 in·lb 2 exhaust pipe holder nuts 15 1.5 11 s 3 muffler mounting bolts 21 2.1 15 s 4 muffler clamp bolt 11 1.1 97 in·lb s l: apply a non-permanent locking agent. Lg: apply liquid gasket...

  • Page 142

    5-6 engine top end specifications item standard service limit camshafts cam height: exhaust 33.942 ∼ 34.056 mm (1.3363 ∼ 1.3408 in.) 33.84 mm (1.332 in.) inlet 34.643 ∼ 34.757 mm (1.3639 ∼ 1.3684 in.) 34.54 mm (1.360 in.) camshaft journal/cap clearance 0.020 ∼ 0.062 mm (0.0008 ∼ 0.0024 in.) 0.15 mm ...

  • Page 143

    Engine top end 5-7 specifications item standard service limit valve seat surface: outside diameter: exhaust 24.6 ∼ 24.8 mm (0.969 ∼ 0.976 in.) – – – inlet 30.6 ∼ 30.8 mm (1.205 ∼ 1.213 in.) – – – width: exhaust 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – inlet 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – valve spr...

  • Page 144

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

  • Page 145

    Engine top end 5-9 special tools and sealant compression gauge, 20 kgf/cm²: 57001-221 valve spring compressor assembly: 57001-241 piston ring compressor grip: 57001-1095 piston ring compressor belt, 67 ∼ 79: 57001-1097 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 45° - 32: 57001-1115...

  • Page 146

    5-10 engine top end special tools and sealant compression gauge adapter, m10 × 1.0: 57001-1317 valve seat cutter, 60° - 25: 57001-1328 valve seat cutter holder, 4.5: 57001-1330 valve guide arbor, 4.5: 57001-1331 valve guide reamer, 4.5: 57001-1333 valve seat cutter, 60° - 33: 57001-1334 filler cap d...

  • Page 147

    Engine top end 5-11 special tools and sealant valve guide driver attachment, f: 57001-1722 liquid gasket, tb1211f: 92104-0004.

  • Page 148

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) stick coil (see stick coil removal in the electrical sys- tem chapter) • remove the cylinder head cover bolts [a] and take off the cylinder head cover [b]. • rem...

  • Page 149

    Engine top end 5-13 cylinder head cover • install the cylinder head cover bolt washers [a] with the metal side upwards. • tighten: torque - cylinder head cover bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropriate chapters)..

  • Page 150

    5-14 engine top end camshaft chain tensioner camshaft chain tensioner removal notice this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the tens...

  • Page 151

    Engine top end 5-15 camshafts camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection cap [a] flywheel nut cap [b] special tool - filler cap driver: 57001-1454 • bring the piston to the tdc (of either the compression or exhaust stroke). ○ place a wrench o...

  • Page 152

    5-16 engine top end camshafts • remove: bolt [a] auto-decompressor [b] spring [c] camshaft installation • install: spring [a] auto-decompressor [b] • tighten: torque - auto-decompressor bolt [c]: 12 n·m (1.2 kgf·m, 106 in·lb) • replace the o-ring [a] with a new one, and apply grease it. • fill the o...

  • Page 153

    Engine top end 5-17 camshafts 1st pin [a] punch marks (exhaust) [d] 2nd pin [b] punch marks (inlet) [e] 28th pin [c] cylinder head upper surface [f] • install the dowel pins [a] and positioning rings [b]. • apply molybdenum disulfide oil to the threads and seating surface of the camshaft cap bolts. ...

  • Page 154

    5-18 engine top end camshafts • install the camshaft chain tensioner (see camshaft chain tensioner installation). • check the camshaft chain timing. ○ turn the crankshaft slowly. ○ if the crankshaft does not turn smoothly, the timing is dif- ferent. Stop turning immediately. Notice the improper cams...

  • Page 155

    Engine top end 5-19 camshafts camshaft and camshaft cap wear inspection • measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [a]. ○ tighten the camshaft cap bolts after applying engine oil to the seat and thread of them. Torque - camshaft cap bolts: ...

  • Page 156

    5-20 engine top end cylinder head cylinder compression measurement • warm up the engine thoroughly. • stop the engine. • remove: fuel tank (see fuel tank removal in the fuel system chapter) stick coil (see stick coil removal in the electrical sys- tem chapter) spark plug (see spark plug cleaning and...

  • Page 157

    Engine top end 5-21 cylinder head cylinder head removal • remove: fuel tank (see fuel tank removal in the 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) exhaust pipe (see e...

  • Page 158

    5-22 engine top end cylinder head cylinder head installation • install the front camshaft chain guide. ○ fit the projection [a] in the groove [b] of the cylinder. ○ insert the guide end [c] into the recess of the crankcase securely. ○ in this figure, the magneto cover and flywheel has been removed f...

  • Page 159

    Engine top end 5-23 cylinder head cylinder head warp inspection • refer to the cylinder head warp inspection in the peri- odic maintenance chapter..

  • Page 160

    5-24 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head r...

  • Page 161

    Engine top end 5-25 valves valve installation • visually inspect the valve surface. If the surface is damaged, replace the valve. • replace the oil seal [a] with a new one. • apply a thin coat of molybdenum disulfide grease to the valve stem [b] and install the valve. • check to make sure that the v...

  • Page 162

    5-26 engine top end valves • hammer lightly on the valve guide arbor [a] to remove the guide. Special tool - valve guide arbor, 4.5: 57001-1331 valve guide installation • apply a thin coat of engine oil to the outer surface of the valve guide. • heat the area around the valve guide up to 120 ∼ 150°c...

  • Page 163

    Engine top end 5-27 valves • repeat the measurement in a direction at a 90° angle to the first measurement. Note ○ the reading is greater than the actual valve/valve guide clearance because the measurement is taken outside of the guide. Valve/valve guide clearance (wobble method) standard: exhaust 0...

  • Page 164

    5-28 engine top end valves valve seat repair • for the instructions on how to use the valve seat cutter [a], follow the operation manual provided by the tool man- ufacturer. Special tools - valve seat cutter holder, 4.5 [b]: 57001 -1330 valve seat cutter holder bar: 57001-1128 exhaust: valve seat cu...

  • Page 165

    Engine top end 5-29 valves marks stamped on the cutter: the marks stamped on the back of the cutter [a] represent the following. 60° ........................... Cutter angle [b] 37.5 ....................... Cutter outer diameter [c] repair operating procedures • clean the seat area carefully. • coat...

  • Page 166

    5-30 engine top end valves if the outside diameter [a] of the seating surface is too large, make the 32° [b] grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. • grind the seat at a 32° angle until the sea...

  • Page 167

    Engine top end 5-31 valves valve seat repair.

  • Page 168

    5-32 engine top end cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] • tap lightly up with a plastic hammer to separate the cylin- der from the crankcase. • remove the cylinder base gasket. Piston removal • remo...

  • Page 169

    Engine top end 5-33 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 inspec- tion in the periodic maintenance chapter), and use new piston rings. • apply e...

  • Page 170

    5-34 engine top end cylinder and piston • apply engine oil to the cylinder bore and the piston side wall. • install the cylinder while compressing the piston rings with your fingers or the special tool [a]. ○ upturn the chamfering side of the belt. Special tools - piston ring compressor grip: 57001-...

  • Page 171

    Engine top end 5-35 cylinder and piston piston ring groove width inspection • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: top 0.83 ∼ 0.85 mm (0.0327 ∼ 0.335 in.) service limit: top 0.93 mm (0.037 in.) if any of the groove wi...

  • Page 172

    5-36 engine top end cylinder and piston piston, piston pin, connecting rod wear inspection • visually inspect the snap ring [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the diam...

  • Page 173

    Engine top end 5-37 carburetor holder carburetor holder installation • install: carburetor holder carburetor holder clamp ○ turn the mark [a] to the carburetor. ○ turn the screw head [b] to the engine right side. • fit the projection [a] of the cylinder head and the recess [b] of the holder. Torque ...

  • Page 174

    5-38 engine top end muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler body removal • remove the right side cover (see side cover removal in the frame chapter). • loosen the muffler clamp bolt [a...

  • Page 175: Clutch

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

  • Page 176

    6-2 clutch exploded view.

  • Page 177

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts 9.8 1.0 87 in·lb 2 right engine cover bolts 9.8 1.0 87 in·lb 3 clutch spring bolts 9.8 1.0 87 in·lb 4 clutch hub nut 98 10 72 r 5 oil filler plug 5.0 0.51 44 in·lb cl: apply cable lubricant. Eo: apply engine oi...

  • Page 178

    6-4 clutch specifications item standard service limit clutch lever clutch lever free play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – clutch friction plate thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.5 mm (0.10 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.15 mm ...

  • Page 179

    Clutch 6-5 special tools outside circlip pliers: 57001-144 bearing driver set: 57001-1129 clutch holder: 57001-1243.

  • Page 180

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

  • Page 181

    Clutch 6-7 clutch lever and cable • slide the dust cover [a] and the knob [b] out of place. • align the slit [a] of the adjusting nut to the slit [b] of the lever. • free the clutch cable upper end. • take the cable off the cable holder [a]. • take the cable lower end [b] off the clutch release leve...

  • Page 182

    6-8 clutch clutch lever and cable clutch cable inspection and lubrication • during a periodic inspection or when the cable has been removed, inspect and lubricate the cable (see general lubrication and cable inspection section in the periodic maintenance chapter)..

  • Page 183

    Clutch 6-9 clutch cover and right engine cover clutch cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: brake pedal bolt [a] brake pedal return spring [b] • remove the clutch cover bolts [a] and take off the clutch cover. Clutch cover insta...

  • Page 184

    6-10 clutch clutch cover and right engine cover • remove: bolt [a] right engine guard [b] • remove: water pump cover (see water pump cover removal in the cooling system chapter) clutch cover bolts [a] right engine cover bolts [b] right engine cover [c] right engine cover installation • apply a greas...

  • Page 185

    Clutch 6-11 clutch cover and right engine cover • pour: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant filling in the cooling system chap- ter) • check the rear brake effectiveness (see brakes section in the periodic maintenance chapter). Oil seal insta...

  • Page 186

    6-12 clutch clutch clutch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: clutch cover (see clutch cover removal) clutch spring bolts [a] spring clutch pressure plate [b] • remove: push rod holder assembly [a] friction plates [b] steel plates [...

  • Page 187

    Clutch 6-13 clutch • install the clutch housing [a]. ○ turn the kick idle gear and the oil pump idle gear with suitable tool [b] to fit in the clutch housing. • install: thrust washer [a] clutch hub [b] • hold the clutch hub with the clutch holder [a]. Special tool - clutch holder: 57001-1243 • inst...

  • Page 188

    6-14 clutch clutch • if a clutch part was replaced, install the standard adjusting washer (1.5 mm thickness) [a] of the push rod holder as- sembly, and check the release lever position as explained later procedure. • install the clutch pressure plate and clutch spring. • tighten the clutch spring bo...

  • Page 189

    Clutch 6-15 clutch release shaft removal • remove: clutch (see clutch removal) clutch cable upper end (see clutch cable removal) • remove the tips [a] of the clutch cable. • pull out the release shaft assembly [b]. Release shaft installation • apply engine oil to the bearings [a]. • replace the oil ...

  • Page 190

    6-16 clutch clutch friction plate/clutch housing clearance inspection • measure the clearance between the tangs [a] on the fric- tion plate and the fingers [b] of the clutch housing. ○ if this clearance is excessive, the clutch will be noisy. Friction plate/clutch housing clearance standard: 0.04 ∼ ...

  • Page 191: Engine Lubrication System

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

  • Page 192

    7-2 engine lubrication system exploded view.

  • Page 193

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 breather fitting 15 1.5 11 l 2 oil pump mounting bolts 7.0 0.71 62 in·lb l 3 oil pump idle gear shaft screws 5.9 0.60 52 in·lb l 4 oil filter cap bolts 9.8 1.0 87 in·lb 5 piston oil nozzle 2.9 0.30 26 in·lb 6 e...

  • Page 194

    7-4 engine lubrication system engine oil flow chart.

  • Page 195

    Engine lubrication system 7-5 engine oil flow chart 1. Oil screen (scavenge) 2. Oil screen (feed) 3. Oil pump (scavenge) 4. Oil pump (feed) 5. Oil filter 6. Oil shower to transmission 7. Piston oil nozzle 8. Kick starter idle gear 9. Breather hose a: crank room oil b: transmission room oil c: blowby...

  • Page 196

    7-6 engine lubrication system specifications item standard engine oil grade castrol “power1 r4 racing” 5w-40 or api sg, sh, sj or sl with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, or 10w-50 capacity oil change - when filter is not removed 0.75 l (0.79 us qt) oil change - when filter is remov...

  • Page 197

    Engine lubrication system 7-7 special tools oil pressure gauge, 5 kgf/cm²: 57001-125 outside circlip pliers: 57001-144 oil pressure gauge adapter, m6 × 1.0: 57001-1664.

  • Page 198

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

  • Page 199

    Engine lubrication system 7-9 engine oil and oil filter oil filter replacement • refer to the oil filter replacement in the periodic main- tenance chapter. Oil screen cleaning and inspection oil screen (feed) • remove the engine (see engine removal in the engine removal/installation chapter). • sepa...

  • Page 200

    7-10 engine lubrication system engine oil and oil filter oil screen (scavenge) • remove the magneto cover (see magneto cover re- moval in the electrical system chapter). • remove the oil screen (scavenge) [a]. • clean the oil screen with a high-flash point solvent and remove any particles stuck to i...

  • Page 201

    Engine lubrication system 7-11 oil pump oil pump removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant draining in the cooling system chapter) • remove: brake pedal (see brake pedal removal in the brakes chapter) kick pedal (see kick pedal rem...

  • Page 202

    7-12 engine lubrication system oil pump • disassemble the oil pump assembly. Pins [a] oil pump cover [b] inner [c] and outer [d] rotors (feed) oil pump body [e] oil pump gear [f] oil pump installation • apply molybdenum disulfide grease to the shaft of the oil pump gear. • apply engine oil to the in...

  • Page 203

    Engine lubrication system 7-13 oil pump • apply a non-permanent locking agent to the oil pump mounting bolts. • tighten: torque - oil pump mounting bolts: 7.0 n·m (0.71 kgf·m, 62 in·lb) • apply engine oil to the shaft of the oil pump idle gear. • install the oil pump idle gear. • turn the oil pump i...

  • Page 204

    7-14 engine lubrication system oil pressure oil pressure measurement • remove water pump cover bolt. • install the oil pressure gauge adapter [a] to the water pump cover. Special tool - oil pressure gauge adapter, m6 × 1.0: 57001-1664 • attach the oil pressure gauge [a]. Special tool - oil pressure ...

  • Page 205: Engine Removal/installation

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

  • Page 206

    8-2 engine removal/installation exploded view.

  • Page 207

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

  • Page 208

    8-4 engine removal/installation special tools jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608.

  • Page 209

    Engine removal/installation 8-5 engine removal/installation engine removal • remove the engine guards. • place the jack under the frame to support the motorcycle. Special tools - jack: 57001-1238 jack attachment :57001-1252 or 57001-1608 warning when the swingarm pivot shaft is removed the swingarm ...

  • Page 210

    8-6 engine removal/installation engine removal/installation • remove: rear frame (see rear frame removal in the frame chapter) exhaust pipe (see exhaust pipe removal in the engine top end chapter) fuel tank (see fuel tank removal in the fuel system chapter) radiators and water hoses (see radiator re...

  • Page 211

    Engine removal/installation 8-7 engine removal/installation • remove: middle engine bracket bolts and nuts [a] middle engine mounting bolt and nut [b] middle engine brackets [c] (both sides) lower engine mounting bolt and nut [d] • remove: swingarm pivot shaft nut [a] swingarm pivot shaft • remove t...

  • Page 212

    8-8 engine removal/installation engine removal/installation • tighten: torque - swingarm pivot shaft nut [a]: 98 n·m (10 kgf·m, 72 ft·lb) lower engine mounting nut [b]: 49 n·m (5.0 kgf·m, 36 ft·lb) • tighten the other engine mounting bolts and nut [c]. Torque - middle engine mounting nut: 49 n·m (5....

  • Page 213: Crankshaft/transmission

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

  • Page 214

    9-2 crankshaft/transmission exploded view.

  • Page 215

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase bolts 50 mm (2.0 in.) 9.8 1.0 87 in·lb s 2 crankcase bolts 60 mm (2.4 in.) 9.8 1.0 87 in·lb s 3 crankcase bolts 65 mm (2.6 in.) 9.8 1.0 87 in·lb s 4 crankcase bolts 70 mm (2.8 in.) 9.8 1.0 87 in·lb s 5 ...

  • Page 216

    9-4 crankshaft/transmission exploded view.

  • Page 217

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 kick pedal bolt 25 2.5 18 l 2 kick ratchet guide bolt 8.8 0.90 78 in·lb l 3 ratchet plate bolt (front) 9.8 1.0 87 in·lb l, s 4 ratchet plate bolt (rear) 15 1.5 11 l, s 5 shift drum cam bolt 24 2.4 18 l 6 gear pos...

  • Page 218

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connecting rod connecting rod big end: radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 in.) 0.06 mm (0.0024 in.) side clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) 0.6 mm (0.02 in.) crankshaft runout tir 0.03 mm...

  • Page 219

    Crankshaft/transmission 9-7 special tools & sealant bearing puller: 57001-135 outside circlip pliers: 57001-144 crankcase splitting tool assembly: 57001-1098 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 gear holder, m2.0: 57001-1557 liquid g...

  • Page 220

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

  • Page 221

    Crankshaft/transmission 9-9 crankcase • position the connecting rod in bdc. • install the jig [a] between the crankshaft flywheels. Special tool - crankshaft jig: 57001-1174 • attach the crankcase splitting tool [a] to the left crankcase. ○ adjust the gap with suitable collars or nuts [b] as shown i...

  • Page 222

    9-10 crankshaft/transmission crankcase • remove the reed valve [a] from the left crankcase half. ○ unscrew the screws [b] and remove the guide [c]. Crankcase assembly notice right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a...

  • Page 223

    Crankshaft/transmission 9-11 crankcase • press the new drive shaft bearing [a] so that the sealed side [b] faces outside of the engine. • press the new output shaft bearing [c] so that the stepped side [d] faces inside of the engine. Special tool - bearing driver set: 57001-1129 • install the left c...

  • Page 224

    9-12 crankshaft/transmission crankcase • install the reed valve [a] and guide [b] as shown in the figure. • tighten: torque - reed valve screws [c]: 7.0 n·m (0.71 kgf·m, 62 in·lb) right crankcase • press the new crankshaft bearing [a] and new drive shaft bearing [b] until they bottom out. Special to...

  • Page 225

    Crankshaft/transmission 9-13 crankcase • install the right crankcase bearing retainers [a]. ○ the right crankcase bearing retainers are larger than left ones. • apply a non-permanent locking agent to the crankcase bearing retainer bolts. • tighten: torque - crankcase bearing retainer bolts: 15 n·m (...

  • Page 226

    9-14 crankshaft/transmission crankcase • apply liquid gasket to the mating surface [a] of the left crankshaft half. Sealant - liquid gasket, tb1216: 92104-1063 note ○ make the application finish within 20 minutes when the liquid gasket is applied. ○ moreover fit the case and tighten the case bolts j...

  • Page 227

    Crankshaft/transmission 9-15 crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • remove the transmission shafts (see transmission shaft removal). • using a hand press, remove the crankshaft from the right crankcase. If the bearing stay on the crankshaft when sp...

  • Page 228

    9-16 crankshaft/transmission crankshaft • carefully align the oil passage hole in the right flywheel [a] with the one in the crankpin [b] at rebuilding of the crankshaft as shown in the figure. • reassemble the crankshaft according to the standard tol- erances in specifications. ○ connecting rod ben...

  • Page 229

    Crankshaft/transmission 9-17 crankshaft crankshaft runout inspection • set the crankshaft in a flywheel alignment jig or on v blocks, and place a dial gauge as shown and turn the crankshaft slowly. The maximum difference in gauge reading is the crankshaft runout. 8 mm (0.3 in.) [a] crankshaft runout...

  • Page 230

    9-18 crankshaft/transmission crankshaft connecting rod bend inspection • remove the connecting rod. • select an arbor [a] of the same diameter as the connect- ing rod big end, and insert it through the connecting rod big end. • select an arbor [b] of the same diameter as the piston pin and more than...

  • Page 231

    Crankshaft/transmission 9-19 transmission transmission shaft removal • disassemble the crankcase halves (see crankcase dis- assembly). • pull out the shift rods [a], and take off the shift forks [b]. • remove the shift drum [c]. • pull out the drive shaft [d] and output shaft [e] together. Transmiss...

  • Page 232

    9-20 crankshaft/transmission transmission • install the oil screen [a] as shown in the figure. Longer outcrop of pipe [b] right crankcase [c] • assembly the crankcase (see crankcase assembly). Transmission shaft disassembly • remove the transmission shafts (see transmission shaft removal). • remove ...

  • Page 233

    Crankshaft/transmission 9-21 transmission 1. Circlip (small) 2. Toothed washer 3. Circlip (large) 4. Ball bearing (left crankcase, one side sealed) 5. 2nd gear (13t) 6. Needle bearing 7. 4th gear (20t) 8. 3rd gear (18t) 9. 5th gear (22t) 10. Drive shaft (1st gear, 14t) 11. Ball bearing (right crankc...

  • Page 234

    9-22 crankshaft/transmission transmission shift fork/gear groove wear inspection • measure the thickness [a] of the shift fork ears, and mea- sure the width [b] of the gear grooves (with which the fork engages). Shift fork ear thickness standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) service limit: 4.8 m...

  • Page 235

    Crankshaft/transmission 9-23 bearings/oil seals bearing replacement notice do not remove the ball bearings unless it is neces- sary. Removal may damage them. • remove the ball bearing and/or needle bearing outer race using a press or suitable bearing remover. Note ○ in the absence of the above menti...

  • Page 236

    9-24 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 237

    Crankshaft/transmission 9-25 primary gear primary gear removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) • temporarily install the clutch housing [a], clutch hub [b] and clutch hub nut [c]. • hold the primary...

  • Page 238

    9-26 crankshaft/transmission external shift mechanism external shift mechanism removal • remove: shift pedal bolt [a] shift pedal [b] • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) • pull out the shift shaft [a], ...

  • Page 239

    Crankshaft/transmission 9-27 external shift mechanism external shift mechanism installation • install: pin [a] spring [b] collar [c] gear positioning lever [d] washer [e] • tighten: torque - gear positioning lever nut: 8.8 n·m (0.90 kgf·m, 78 in·lb) • hold the gear positioning lever [a] with the sui...

  • Page 240

    9-28 crankshaft/transmission external shift mechanism • apply grease to the oil seal lips [a] and shift shaft splines [b]. • insert the shift shaft [a] as shown in the figure. ○ take care not to damage the oil seal when inserting the shift shaft. • install: clutch (see clutch removal in the clutch c...

  • Page 241

    Crankshaft/transmission 9-29 external shift mechanism • check the gear positioning lever [a] and its spring [b] for cracks or distortion. If the lever or spring is damaged in any way, replace them. • visually inspect the shift drum cam [a]. If it is badly worn or if it shows any damage, replace it..

  • Page 242

    9-30 crankshaft/transmission kickstarter kick pedal removal • remove: kick pedal bolt [a] kick pedal assy [b] kick pedal installation • install the kick pedal assy. ○ put the pedal end [a] near the cylinder head mating sur- face [b]. • apply a non-permanent locking agent to the kick pedal bolt. • ti...

  • Page 243

    Crankshaft/transmission 9-31 kickstarter • remove the bolts [a], and take off the ratchet guide [b]. Kick shaft installation • apply a non-permanent locking agent to the kick ratchet guide bolt. • install the ratchet guide [a], and tighten the bolt. Torque - kick ratchet guide bolt [b]: 8.8 n·m (0.9...

  • Page 245: Wheels/tires

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

  • Page 246

    10-2 wheels/tires exploded view.

  • Page 247

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples not less than 2.2 not less than 0.22 not less than 19 in·lb 2 front axle nut 78 8.0 58 3 front axle clamp bolts 20 2.0 15 al 4 rear axle nut 108 11.0 80 al: tighten the two clamp bolts alternately two times t...

  • Page 248

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim size: front 21 × 1.60 – – – rear 19 × 1.85 – – – rim runout: axial tir 1.0 mm (0.04 in.) or less tir 2 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2 mm (0.08 in.) axle runout/100 mm (3.94 in.) tir 0.1 mm (0.004...

  • Page 249

    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 attachment jack: 57001-1252 bearing remover head, 20 × 22: 57001-1293 bearing remover head, 25 × 28: 57001-1346 bearing remover...

  • Page 250

    10-6 wheels/tires wheels (rims) front wheel removal • using the jack under the frame, and stabilize the motor- cycle. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • loosen the axle clamp bolts [a] on both sides. • unscrew the axle nut [b]. • using a commercially availa...

  • Page 251

    Wheels/tires 10-7 wheels (rims) • pump the front fork up and down [a] 4 or 5 times to align both fork positions. Note ○ put a block [b] in front of the wheel to stop moving. ○ do not apply the front brake. • tighten: torque - front axle clamp bolts (right): 20 n·m (2.0 kgf·m, 15 ft·lb) note ○ tighte...

  • Page 252

    10-8 wheels/tires wheels (rims) rear wheel installation • fit the groove [a] of the caliper holder and the swingarm rib [b]. • apply high-temperature grease to the oil seal lips. • install the caps and collars to the hub on both sides. ○ fit the projection [a] and the groove [b]. • install the rear ...

  • Page 253

    Wheels/tires 10-9 wheels (rims) • adjust the drive chain slack (see drive chain slack in- spection in the periodic maintenance chapter). • check the rear brake for good braking power and no brake drag. Warning after servicing, it takes several applications of the brake pedal before the brake pads co...

  • Page 254

    10-10 wheels/tires tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire removal notice do not lay the wheel directly on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the whe...

  • Page 255

    Wheels/tires 10-11 tires • break the beads away from both sides of the rim with the bead breaker [a]. Special tool - bead breaker assembly: 57001-1072 • step on the tire opposite valve stem, pry the tire off the rim with the tire iron [a]. ○ protect the rim with rim protectors [b]. Special tools - r...

  • Page 256

    10-12 wheels/tires tires • align the valve stem [a] and the tire balance mark [b] (the chalk mark made during removal; see tire removal). ○ the new tire is no marked. • insert the valve stem into the rim, and screw the nut on loosely. • fit the rim protectors and use tire irons to install the tire b...

  • Page 257

    Wheels/tires 10-13 hub bearing front hub bearing removal • remove front wheel (see front wheel removal) grease seals [a] • use the bearing remover to remove the hub bearings [a]. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place wooden block...

  • Page 258

    10-14 wheels/tires hub bearing • using a suitable bar [a], tap the around of the bearing inner race evenly to remove the bearings [b]. Hub bearing installation • before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the ...

  • Page 259

    Wheels/tires 10-15 hub bearing hub bearing inspection since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. Note ○ do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones. • turn each...

  • Page 261: Final Drive

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

  • Page 262

    11-2 final drive exploded view.

  • Page 263

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 r 2 engine sprocket cover bolts 4.9 0.50 43 in·lb g: apply grease. Ho: apply heavy oil. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 264

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make: daido – – – type: did 520dma4 – – – link: 112 links – – – sprocket rear sprocket warp...

  • Page 265

    Final drive 11-5 special tool outside circlip pliers: 57001-144.

  • Page 266

    11-6 final drive drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection • check that the notch [...

  • Page 267

    Final drive 11-7 drive chain • install the link plate [a] so that the mark faces out. • install the clip [b] so that the closed end [c] of the "u" pointed in the direction of chain rotation [d]. • adjust the drive chain slack (see drive chain slack ad- justment in the periodic maintenance chapter)..

  • Page 268

    11-8 final drive sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • remove the circlip [a], and take off the engine sprocket [b] together with the drive chain. ○ using the thin blade driver [c] as shown in the figure when rem...

  • Page 269

    Final drive 11-9 sprockets rear sprocket removal • remove the rear wheel (see rear wheel removal in the wheels/tires chapter). Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the groun...

  • Page 271: Brakes

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

  • Page 272

    12-2 brakes exploded view.

  • Page 273

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front brake reservoir cap screws 1.5 0.15 13 in·lb 2 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 3 brake lever pivot bolt 5.9 0.60 52 in·lb si 4 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 5 brake hose banjo bolts...

  • Page 274

    12-4 brakes exploded view.

  • Page 275

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear brake reservoir cap screws 1.5 0.15 13 in·lb 2 rear master cylinder mounting bolts 9.8 1.0 87 in·lb 3 brake hose banjo bolts 25 2.5 18 4 rear master cylinder push rod locknut 17 1.7 13 5 brake pedal bolt 25 2.5 18 l, g 6 re...

  • Page 276

    12-6 brakes specifications item standard service limit brake lever lever free play adjustable (to suit rider) – – – brake fluid grade: front dot3 or dot4 – – – rear dot3 or dot4 – – – brake pads lining thickness: front 4.0 mm (0.16 in.) 1 mm (0.04 in.) rear 6.4 mm (0.25 in.) 1 mm (0.04 in.) brake di...

  • Page 277

    Brakes 12-7 special tools jack: 57001-1238 attachment jack: 57001-1252 jack attachment: 57001-1608.

  • Page 278

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

  • Page 279

    Brakes 12-9 brake lever, brake pedal • replace the o-rings [a] with new ones. • apply grease to the o-rings and shaft portion [b] of the brake pedal bolt. • apply a non-premanent locking agent to the thread of the brake pedal bolt. • install the brake pedal [c]. ○ install the washer [d] inside the p...

  • Page 280

    12-10 brakes brake fluid warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in th...

  • Page 281

    Brakes 12-11 brake fluid brake line bleeding the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever ...

  • Page 282

    12-12 brakes brake fluid • bleed the brake line and the caliper as follows: ○ repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close [b] the bleed valve whil...

  • Page 283

    Brakes 12-13 caliper caliper removal front brake • loosen the brake pad pin [a] before the caliper [b] re- moval if the caliper is to be disassembled. • loosen the banjo bolt [c] so as not to spill brake fluid. Note ○ if the caliper is to be disassembled after removal and compressed air is not avail...

  • Page 284

    12-14 brakes caliper caliper installation • install the brake pad if it was removed (see brake pad installation). Front brake • install the caliper and tighten the bolts. Torque - front caliper mounting bolts: 25 n·m (2.5 kgf·m, 18 ft·lb) rear brake • install the rear wheel and caliper (see rear whe...

  • Page 285

    Brakes 12-15 caliper fluid seal damage inspection the fluid seals [a] around the piston maintains the proper pad/disc clearance. If this seal is not in good condition, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. • replace the fluid seals un...

  • Page 286

    12-16 brakes caliper caliper piston and cylinder damage • visually inspect the pistons [a] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. [b] front caliper [c] rear caliper caliper holder shaft wear the caliper body must slide smoothly on the caliper...

  • Page 287

    Brakes 12-17 brake pad brake pad removal front brake • remove the pad pin [a]. • take off the piston side pad [b]. • push the caliper holder toward the piston, and then re- move another pad [c]. Rear brake • remove: pad pin plug [a] • remove the pad pin [a]. • take off the piston side pad [b]. • pus...

  • Page 288

    12-18 brakes brake pad • tighten the brake pad pin. Torque - brake pad pin: 17 n·m (1.7 kgf·m, 13 ft·lb) rear brake pad pin plug: 2.5 n·m (0.25 kgf·m, 22 in·lb) • check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it takes several applications of th...

  • Page 289

    Brakes 12-19 master cylinder notice brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely washed up immediately. Front master cylinder removal • remove the banjo bolt [a] to disconnect the brake hose upper end [b] from the master cylinder [c]. ○ when removin...

  • Page 290

    12-20 brakes master cylinder • the master cylinder clamp must be installed with the ar- row mark [a] upward. • tighten the upper clamp bolt [b] first, and then the lower clamp bolt [c]. ○ there will be a gap at the lower mating surface of the clamp after tightening. Torque - front master cylinder cl...

  • Page 291

    Brakes 12-21 master cylinder rear master cylinder installation • install the brake hose. ○ replace the washers [a] are on each side of hose fitting [b] with new ones. • tighten: torque - brake hose banjo bolt: 25 n·m (2.5 kgf·m, 18 ft·lb) • install the rear master cylinder. • tighten: torque - rear ...

  • Page 292

    12-22 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 293

    Brakes 12-23 brake disk brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts, and take off the disc. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-permanent...

  • Page 294

    12-24 brakes brake hose brake hose removal/installation • refer to the brake hose replacement in the periodic maintenance chapter. Brake hose inspection • refer to the brake hoses and connections inspection in the periodic maintenance chapter..

  • Page 295: Suspension

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

  • Page 296

    13-2 suspension exploded view.

  • Page 297

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork cylinder units 34 3.5 25 2 front fork clamp bolts (lower) 20 2.0 15 al 3 front fork clamp bolts (upper) 20 2.0 15 al, l 4 front fork adjuster assembly locknuts 22 2.2 16 5 front fork base valve assemblies 30 3.1 2...

  • Page 298

    13-4 suspension exploded view.

  • Page 299

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 98 10 72 r 2 rocker arm pivot nut 59 6.0 44 r 3 tie-rod mounting nuts 59 6.0 44 r 4 rear shock absorber mounting nut (upper) 39 4.0 29 r 5 rear shock absorber mounting nut (lower) 34 3.5 25 r 6 rear ...

  • Page 300

    13-6 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – rebound damping adjustment (from the seated position adjuster turned fully clockwise) 9 clicks counterclockwise (eur, br) 8 clicks counterclock- wise (adjustable range) 20 ±4 clicks compress...

  • Page 301

    Suspension 13-7 specifications item standard service limit rocker arm: large 19.987 ∼ 20.000 mm 0.78689 ∼ 0.78740 in.) 19.85 mm (0.7815 in.) small 15.950 ∼ 16.000 mm (0.62795 ∼ 0.62992 in.) 15.92 mm (0.6268 in.) rocker arm mounting bolt runout tir 0.1 mm (0.004 in.) or less tir 0.2 mm (0.008 in.).

  • Page 302

    13-8 suspension special tools oil seal & bearing remover: 57001-1058 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 attachment jack: 57001-1252 bearing remover shaft, 9: 57001-1265 bearing remover head, 15 × 17: 57001-1267 hook wrench t=3.2 r37: 57001-1539 jack at...

  • Page 303

    Suspension 13-9 special tools fork oil seal driver, 47: 57001-1662.

  • Page 304

    13-10 suspension front fork air pressure the standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during operation. Re- lease air pressure prior to each race through the pressure relief screw. • pl...

  • Page 305

    Suspension 13-11 front fork rebound damping adjustment • place the jack under the frame so that the front wheel is raises off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • clean the bottom of the fork tubes. • turn the adjuster [a] on the cylinder valve wi...

  • Page 306

    13-12 suspension front fork • remove: bolt [a] number plate [b] • loosen the front fork clamp bolts (upper [a] and lower [b]). • pull out the front fork downward with a twisting motion [a]. Front fork installation • install the front fork. ○ the length [a] between the upper end [b] of outer tube (ex...

  • Page 307

    Suspension 13-13 front fork front fork disassembly (each fork leg) • drain the fork oil (see front fork oil change (each fork leg) in the periodic maintenance chapter). • unscrew the front fork adjuster assembly locknut [a]. • wrap the piston rod end [b] with a vinyl tape. • push out the piston rod ...

  • Page 308

    13-14 suspension front fork ○ grasp the tubes and stroke the inner tube up and down [a] several times. The shock to fork seal separates the inner tube from the outer tube. • remove: bushings [a] washer [b] oil seal [c] retaining ring [d] dust seal [e] spring band [f] • wipe off the oil from the remo...

  • Page 309

    Suspension 13-15 front fork • insert the piston rod [a] into the fork cylinder [b]. ○ wrap the end of the piston rod with a vinyl tape. ○ push in [a] the piston rod with a suitable tool [b]. • remove a vinyl tape and install the locknut. • fill the fork oil (see front fork oil change (each fork leg)...

  • Page 310

    13-16 suspension front fork slide/guide bushing inspection • visually inspect the guide bushing [a], and replace them if necessary. Dust seal/oil seal inspection • inspect the dust seal [a] for any signs of deterioration or damage. Replace it if necessary. • replace the oil seal [b] with a new one w...

  • Page 311

    Suspension 13-17 rear shock absorber to suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Rebound damping adjustment • tu...

  • Page 312

    13-18 suspension rear shock absorber • adjust the high speed compression damping, turn the high speed compression damping adjuster with a 17 mm wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. Seated position [a]: adjuster turned fully clockwise...

  • Page 313

    Suspension 13-19 rear shock absorber • using the hook wrenches [a], loosen the locknut [b]. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench t=3.2 r37: 57001-1539 • using the hook wrench [a], turn the adjusting nut [b] as required. Turning the adjusting nut downward marks the spring ac...

  • Page 314

    13-20 suspension rear shock absorber rear shock absorber removal • remove: seat (see seat removal in the frame chapter) side covers (see side cover removal in the frame chapter) muffler body (see muffler body removal in the engine top end chapter) rear frame (see rear frame removal in the frame chap...

  • Page 315

    Suspension 13-21 rear shock absorber • hold the upper end of the rear shock absorber in a vise with soft jaws [a] or a heavy cloth. • using the hook wrenches [b], loosen the locknut [c] and turn the adjusting nut all way up. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench t=3.2 r37: 5...

  • Page 316

    13-22 suspension swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear flap (see rear flap removal in the frame chap- ter) brake pedal bolt [a] return spring [b] • remove: bolts [a] chain guide plate [b] chain guide [c] brake hose clamps [d] • put t...

  • Page 317

    Suspension 13-23 swingarm swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • apply a non-permanent locking agent to the chain slipper mounting screws. • install the chain slipper, and tighten the screws. • replace with new ones: swingarm ...

  • Page 318

    13-24 suspension swingarm drive chain guide, guide roller, chain slipper wear inspection • visually inspect the drive chain guide [a] and replace it if excessively worn or damaged. • visually inspect the chain slipper [a] on the swingarm and replace it if excessively worn or damaged. • visually insp...

  • Page 319

    Suspension 13-25 tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1252 or 57001 -1608 • remove: nut [a] lower chain guide roller [b] • remove: tie-rod rear mounting bolt and nut [a] tie-...

  • Page 320

    13-26 suspension tie-rod, rocker arm • remove: rear shock absorber bolt and nut (lower) [a] rocker arm pivot bolt and nut [b] rocker arm [c] rocker arm installation • replace with new ones: rear shock absorber mounting nut (lower) rocker arm pivot nut tie-rod mounting nut • apply plenty of grease to...

  • Page 321

    Suspension 13-27 tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearing, grease seals and oil seals with new ones. • apply plenty of grease to the oil seal and needle bearings. Note ○ install the bearings so that the marked side faces out. ○ install the grease s...

  • Page 322

    13-28 suspension uni-trak maintenance uni-trak linkage inspection • refer to the swingarm and uni-trak linkage inspection in the periodic maintenance chapter. Tie-rod and rocker arm sleeve wear inspection • pull out the sleeves [a] of the tie-rod and rocker arm. • measure the outside diameter of the...

  • Page 323: Steering

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

  • Page 324

    14-2 steering exploded view.

  • Page 325

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar clamp bolts 25 2.5 18 al 2 steering stem head nut 98 10 72 3 steering stem nut 4.9 0.50 43 in·lb 4 front fork clamp bolts (upper ) 20 2.0 15 al, l 5 front fork clamp bolts (lower) 20 2.0 15 al ad: apply adhesive. Al:...

  • Page 326

    14-4 steering special tools bearing puller: 57001-135 steering stem bearing driver: 57001-137 bearing puller adapter: 57001-317 steering stem bearing driver adapter, 34.5: 57001-1074 head pipe outer race press shaft: 57001-1075 head pipe outer race driver, 51.5: 57001-1076 head pipe outer race drive...

  • Page 327

    Steering 14-5 special tools bearing puller: 57001-1575.

  • Page 328

    14-6 steering steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter. Steering stem, stem bearing removal • remove: bolt [a] number plate [b] pad cover [c] and...

  • Page 329

    Steering 14-7 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 330

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

  • Page 331

    Steering 14-9 steering • install the removed parts (see appropriate chapters). Warning if the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar move- ment...

  • Page 332

    14-10 steering handlebar handlebar removal • remove: pad cover [a] and pad • remove: clutch lever holder assembly [a] engine stop switch [b] bands [c] left handlebar grip [d] • remove: throttle grip assy [a] (see throttle cable replacement in the fuel system chapter) front master cylinder [b] (see f...

  • Page 333

    Steering 14-11 handlebar • install the clutch lever holder assembly [a] as shown in the figure. 25° ∼ 35° [b] horizontal line of frame [c] 170 mm (6.69 in.) [d] • install the engine stop switch. • apply grease to the throttle cable upper end and clutch cable upper end. • apply a 2 stroke oil to the ...

  • Page 334

    14-12 steering handlebar • install the clamps [a]. • tighten the handlebar clamp bolts [b]. ○ equalize the front and rear gaps [c]. Note ○ tighten the two clamp bolts alternately two times to en- sure even tightening torque. Torque - handlebar clamp bolts: 25 n·m (2.5 kgf·m, 18 ft·lb).

  • Page 335: Frame

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

  • Page 336

    15-2 frame exploded view.

  • Page 337

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

  • Page 338

    15-4 frame frame frame inspection • refer to the frame inspection in the periodic mainte- nance chapter. Rear frame removal • remove: seat (see seat removal) side covers (see side cover removal) muffler body (see muffler body removal in the engine top end chapter) rear fender (see rear fender remova...

  • Page 339

    Frame 15-5 frame • install the rear frame. ○ insert the duct onto the carburetor. ○ fit the rib [a] and the projections [b]. • tighten: torque - rear frame mounting bolts: 34 n·m (3.5 kgf·m, 25 ft·lb) • tighten the air cleaner duct clamp screw. • install the removed parts (see appropriate chapters)....

  • Page 340

    15-6 frame seat seat removal • remove the side cover bolt [a] on both sides. • spread [a] the side covers lightly. • take off the seat [b] backward [c]. Seat installation • install the seat. ○ insert the hooks [a] of the seat under the flange collar [b] and brackets [c]. ○ take care not to damage th...

  • Page 341

    Frame 15-7 side covers side cover removal • remove the bolts [a] and take off the side cover. ○ clear the side cover tabs [b] from the air cleaner housing. Side cover installation • stick the pad [a] on the inside of the right side cover. • install the damper [b] securely. • install the side covers....

  • Page 342

    15-8 frame fender front fender removal • remove the bolts [a] and take off the front fender. Rear fender removal • remove the side covers (see side cover removal). • remove the bolts [a]. • remove the bolt [a] on both sides, and take off the rear fender [b]. Rear flap removal • remove the screws [a]...

  • Page 343

    Frame 15-9 footpegs and brackets footpeg installation • apply a non-permanent locking agent to the footpeg bracket bolts [a]. • install the footpeg bracket [b], and tighten the bolts. Torque - footpeg bracket bolt (upper): 54 n·m (5.5 kgf·m, 40 ft·lb) • apply grease to the pivot pin [c]. • install t...

  • Page 345: Electrical System

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

  • Page 346

    16-2 electrical system exploded view.

  • Page 347

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 c.D.I. Unit mounting bolts 9.8 1.0 87 in·lb 2 spark plug 13 1.3 115 in·lb 3 timing inspection cap 3.9 0.40 35 in·lb 4 flywheel nut cap 4.9 0.50 43 in·lb 5 magneto cover bolts 9.8 1.0 87 in·lb 6 flywheel nut 49 5.0 36 ...

  • Page 348

    16-4 electrical system specifications item standard magneto crankshaft sensor resistance 80 ∼ 120 Ω at 20°c (68°f) magneto output voltage: bk/r - r/w leads 40 v or more at 4 000 r/min (rpm) w - y leads 15 v or more at 4 000 r/min (rpm) stator coil resistance: bk/r - r/w leads 27.2 ∼ 40.8 Ω at 20°c (...

  • Page 349

    Electrical system 16-5 special tools & sealant timing light: 57001-1241 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 lead wire - peak voltage adapter: 57001-1449 filler cap driver: 57001-1454 needle adapter set: 57001-1457 rotor puller m24 ×...

  • Page 350

    16-6 electrical system wiring diagram.

  • Page 351

    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 352

    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 353

    Electrical system 16-9 flywheel magneto magneto cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove: left radiator shroud (see radiator removal in the cool- ing system chapter) shift pedal (see external shift mechanism removal in the crankshaf...

  • Page 354

    16-10 electrical system flywheel magneto flywheel magneto removal • remove the magneto cover (see magneto cover re- moval). • hold the flywheel with the rotor holder [a], and remove the flywheel nut [b]. Special tool - rotor holder: 57001-1567 • screw the rotor puller [a] into the flywheel. • remove...

  • Page 355

    Electrical system 16-11 flywheel magneto • holding the flywheel steady with the rotor holder, and tighten the flywheel nut. Special tool - rotor holder: 57001-1567 torque - flywheel nut: 49 n·m (5.0 kgf·m, 36 ft·lb) • install the magneto cover (see magneto cover installa- tion). Stator removal • rem...

  • Page 356

    16-12 electrical system flywheel magneto magneto output voltage inspection • check the magneto output voltage with the following pro- cedures. ○ pull the stopper [a] outside and remove the magneto lead connector [b] from the bracket. ○ connect the hand tester [a] to the connector [b] as shown in the...

  • Page 357

    Electrical system 16-13 ignition timing ignition timing inspection • remove the timing inspection cap [a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • start the engine and aim the t...

  • Page 358

    16-14 electrical system ignition system warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Stick coil removal • remove: seat (see seat removal i...

  • Page 359

    Electrical system 16-15 ignition system stick coil inspection • remove the stick coil (see stick coil removal). • measure the primary winding resistance [a] as follows. ○ connect the tester between the coil terminals. ○ set the tester to the × 1 Ω range, and read the value. • measure the secondary w...

  • Page 360

    16-16 electrical system ignition system c.D.I. Unit inspection warning electrical equipment can cause serious electrical shock. To avoid being shocked, do not touch the metal portion of the probe when measuring voltage. Notice do not disconnect the c.D.I. Unit while the engine is running. This may d...

  • Page 361

    Electrical system 16-17 ignition system crankshaft sensor peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained...

  • Page 362

    16-18 electrical system ignition system exciter coil peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if d...

  • Page 363

    Electrical system 16-19 ignition system charge coil peak voltage check • to check the peak voltage, do the following procedures. ○ disconnect the magneto lead connector from the main harness. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if di...

  • Page 364

    16-20 electrical system ignition system • connect the throttle sensor setting adapter [a] between each connectors. Special tools - hand tester [b]: 57001-1394 throttle sensor setting adapter #1: 57001 -1400 • set the tester to the dc 10 v range, and connect it to the adapter leads. Connections: test...

  • Page 365

    Electrical system 16-21 ignition system • start the engine. • ground the black/white lead [b] of the main harness side [a] while the engine is running. If does not stop the engine, replace the c.D.I. Unit. Crankshaft sensor inspection • disconnect the magneto lead connector (see magneto cover remova...

  • Page 366

    16-22 electrical system ignition system ignition system troubleshooting chart.

  • Page 367

    Electrical system 16-23 switch and 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 ...

  • Page 368

    16-24 electrical system switch and sensor throttle sensor position adjustment • remove the carburetor (see carburetor removal in the fuel system chapter). • measure the resistance between the blue and black lead terminals of the sensor side connector. Blue lead terminal [a] black lead terminal [b] y...

  • Page 369

    Electrical system 16-25 switch and sensor neutral switch inspection • slide out the dust cover [a]. • remove the neutral switch lead [b]. • using the 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 short, repair...

  • Page 371: Appendix

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

  • Page 372

    17-2 appendix cable, wire, and hose routing 1. Throttle cable (accelerator) 2. Throttle cable (decelerator) 3. Bands (hold the engine stop switch lead.) 4. Engine stop switch lead 5. Hot starter cable 6. Clutch cable 7. Run the engine stop switch lead, hot starter cable and clutch cable into the gui...

  • Page 373

    Appendix 17-3 cable, wire, and hose routing 1. Joint hose 2. Run the throttle cables between the frame pipe and right radiator. 3. Throttle cables 4. Clutch cable 5. Clamp (roll up the clamp to hold the cable.) 6. Clamp 7. Run the throttle cables over the joint hose. 8. Right radiator.

  • Page 374

    17-4 appendix cable, wire, and hose routing 1. C.D.I. Unit 2. Install the clamp as shown in the figure. 3. Install the carburetor holder clamp as shown in the figure. 4. Install the carburetor clamp as shown in the figure. 5. Run the throttle position sensor lead above the carburetor tubes. 6. Insta...

  • Page 375

    Appendix 17-5 cable, wire, and hose routing 1. Run the engine stop switch lead and the hot starter cable over the joint hose. 2. Clamp (hold the engine stop switch lead, the hot starter cable and the main harness.) 3. Set the white tape in rear of the clamp. 4. Run the neutral switch lead outside of...

  • Page 376

    17-6 appendix cable, wire, and hose routing 1. Viewed rear 2. Viewed a 3. Viewed b 4. Joint hose (turn the blue paint to upside.) 5. Clamps 6. Clamps (turn the screw head to outside.) 7. Right radiator 8. Water pipe 9. Joint pipe 10. Left radiator 11. Radiator overflow hose 12. 45° 13. Bottom engine...

  • Page 377

    Appendix 17-7 cable, wire, and hose routing 1. Clamp (turn the claw to the exhaust pipe side.) 2. Clamp 3. Breather hose 4. Viewed a 5. Viewed front 6. Clamp (turn the screw head to outside.) 7. Turn the green paint to outside. 8. Water pipe 9. Clamp (turn the screw head to front.) 10. Turn the gree...

  • Page 378

    17-8 appendix cable, wire, and hose routing 1. Brake hose 2. Clamp 3. Clamps 4. Viewed a.

  • Page 379

    Appendix 17-9 cable, wire, and hose routing 1. Clamps 2. Brake hose 3. Cotter pin.

  • Page 380

    17-10 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: val...

  • Page 381

    Appendix 17-11 troubleshooting guide brake dragging drive train trouble engine overheating clutch slipping poor running or no power at high speed: firing incorrect: spark plug dirty, broken, or gap malad- justed stick coil not in good contact spark plug incorrect heat value faulty cdi unit crankshaf...

  • Page 382

    17-12 appendix troubleshooting guide engine oil level too high clutch housing seized clutch release function trouble clutch hub nut loose clutch plate warped or rough clutch hub spline damaged gear shifting faulty: doesn’t go into gear; shift pedal doesn’t return: clutch not disengaging shift fork b...

  • Page 383

    Appendix 17-13 troubleshooting guide valve oil seal damaged valve guide worn engine oil level too high black smoke: air cleaner element clogged main jet too large or fallen off choke plunger stuck open fuel level in carburetor float bowl too high brown smoke: main jet too small fuel level in carbure...

  • Page 384

    Model application year model beginning frame no. 2010 kx250xaf jkakxmxc □ aa000001 or jkakx250xxa000001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1428-01 printed in japan.