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Kawasaki KX450F - Service Manual

Manual is about: Motorcycle

Summary of KX450F -

  • Page 1

    Kx450f 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: Kx450F

    Kx450f 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) in. Inch(s) abdc after bottom dead center kds kawasaki diagnostic system ac alternating current km/h kilometers per hour ah ampere hour l liter(s) atdc after top dead center lb pound(s) bbdc before bottom dead center led light emitting diode bdc bottom dead center m...

  • Page 7: Foreword

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

  • Page 9: General Information

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

  • Page 10

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

  • Page 11

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

    General information 1-7 model identification kx450fc left side view kx450fc right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kx450fc ∼ fe dimensions overall length 2 180 mm (85.83 in.) overall width 820 mm (32.3 in.) overall height 1 275 mm (50.20 in.) wheelbase 1 480 mm (58.27 in.) road clearance 330 mm (13.0 in.) seat height 955 mm (37.6 in.) curb mass: kx450fc 113 kg...

  • Page 17

    General information 1-9 general specifications items kx450fc ∼ fe lubrication system forced lubrication (semi-dry sump) engine oil: type api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-40 capacity 1.2 l (1.3 us qt) drive train primary reduction system: type gear reduction ratio 2...

  • Page 18

    1-10 general information general specifications items kx450fc ∼ fe effective disc diameter: front 225 mm (8.86 in.) rear 215 mm (8.46 in.) specifications are subject to change without notice, and may not apply to every country..

  • Page 19

    General information 1-11 technical information - dfi setting data selection overview the dfi setting can be easily selected among three op- tions to suit various track conditions without using the kx fi calibration kit. • the setting can be switched by changing the connector [a] on the right side of...

  • Page 20

    1-12 general information technical information - dfi setting data selection connector circuit 1. Ecu 2. White connector 3. Frame ground 1 4. Green connector 5. Black connector dfi setting map image a. Correction value b. Throttle opening c. Engine speed d. Ignition timing (soft) e. Ignition timing (...

  • Page 21

    General information 1-13 technical information - launch control mode overview • the launch control mode can be used to adjust ignition timing to reduce rear wheel spin at start-up and help riders get better starts on slippery terrain. • when the launch control mode is activated, the ignition timing ...

  • Page 22

    1-14 general information technical information - launch control mode launch control mode circuit 1. Ecu 2. Launch control mode button 3. Orange launch control mode indicator light (led) 4. Capacitor 5. Frame ground 1.

  • Page 23

    General information 1-15 technical information - psf (pneumatic spring fork) front fork (kx450fd ∼ ) 1) overview this model has adopted pneumatic spring fork (psf) system. Unlike conventional front forks, psf does not have a main spring in each leg and uses air pressure as a spring force. [a] air va...

  • Page 24

    1-16 general information technical information - psf (pneumatic spring fork) front fork (kx450fd ∼ ) spring characteristics adjustment • previously, changing to an optional spring needed complicated disassembly. As for psf, spring characteristics can be changed by simply changing air pressure. • com...

  • Page 25

    General information 1-17 technical information - psf (pneumatic spring fork) front fork (kx450fd ∼ ) 1. Air pressure adjustment part 2. New oil (khl15-11) 3. New oil seal 4. Compression damping force adjustment part 5. Air chamber 6. Rebound damping force adjustment part 7. Elimination of pressure s...

  • Page 26

    1-18 general information technical information - psf (pneumatic spring fork) front fork (kx450fd ∼ ) easy-to-do adjustment adjustable range of stroke conventional type (with main spring) oil level adjustment latter half of stroke psf type air pressure adjustment + oil level adjustment whole stroke a...

  • Page 27

    General information 1-19 technical information - psf (pneumatic spring fork) front fork (kx450fd ∼ ) • be sure to remove the air valve adapter (p/no. 57001 -0725) before running. Warning when riding and transporting the motorcycle, make sure that the air pressure is within the adjustable range. If u...

  • Page 28

    1-20 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 29: Periodic Maintenance

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

  • Page 30

    2-2 periodic maintenance brakes.................................................................................................................................. 2-37 brake lever and pedal adjustment .................................................................................. 2-37 brake fluid ...

  • Page 31

    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 32

    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 • 2-32 rear sprocket - inspect † • 2-36 front fork - clean and inspect • 2-48 front fork oil - change • 2...

  • Page 33

    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 34

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks throttle body assy holder screws 9.8 1.0 87 in·lb l cylinder bolt 12 1.2 106 in·lb s camshaft chain tensioner cap bolt 5.0 0.51 44 in·lb camshaft chain tensioner mounting bolts 9.8 1.0 87 in·lb oil pump (scaven...

  • Page 35

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks kick pedal bolt 25 2.5 18 l ratchet guide bolt 8.8 0.90 78 in·lb ratchet plate bolt 9.8 1.0 87 in·lb s ratchet plate screw 15 1.5 11 l, s shift drum cam bolt 24 2.4 18 l gear positioning lever nut 8.8 0.90 78 i...

  • Page 36

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks front fork top plugs (kx450fd ∼ ) 45 4.6 33 swingarm pivot shaft nut 98 10 72 r rocker arm pivot nut 59 6.0 44 r tie-rod mounting nuts 59 6.0 44 r rear shock absorber nut (upper) 39 4.0 29 r rear shock absorber...

  • Page 37

    Periodic maintenance 2-9 torque and locking agent basic torque for general fasteners threads diameter torque (mm) n·m kgf·m ft·lb 5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14...

  • Page 38

    2-10 periodic maintenance specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 2 000 ±50 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – cooling system coolant: type (recommended) permanent type an...

  • Page 39

    Periodic maintenance 2-11 specifications item standard service limit wheels/tires rim runout (with tire installed): axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) tires air pressure (front/rear) 100 kpa (1.00 kgf/cm², 14 psi) – – ...

  • Page 40

    2-12 periodic maintenance specifications item standard service limit amount: cylinder unit 343 ml (11.6 us oz.) – – – outer tube 235 ml (7.95 us oz.) (adjustable range) 190 ∼ 265 ml (6.42 ∼ 8.96 us oz.) rear shock absorber suspension oil kawasaki khv10-k2c or equivalent – – – amount approximately 41...

  • Page 41

    Periodic maintenance 2-13 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 filler cap driver: 57001-1454 jack attachment: 57001-1608 top plug wrench, 49 mm: 57001-1653 top plug wrench, 36 mm: 57001-1705 top plu...

  • Page 42

    2-14 periodic maintenance periodic maintenance procedures fuel system (dfi) fuel hose and connections inspection ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [a] or the hose burst. Remove the fuel tank (see fuel tank re- moval in the fu...

  • Page 43

    Periodic maintenance 2-15 periodic maintenance procedures kx450fd ∼ • loosen the locknut [a] at the upper end of the throttle cable. • screw the throttle cable adjuster [b] to give the throttle grip plenty of play. • tighten the locknut. If the throttle grip free play cannot be adjusted with the adj...

  • Page 44

    2-16 periodic maintenance periodic maintenance procedures when removing with standard tip screwdriver: • insert the standard tip screwdriver [a] into the slit [b] on the joint lock [c]. • turn the driver to disconnect the joint lock. When removing with fingers: • open and push up [a] the joint lock ...

  • Page 45

    Periodic maintenance 2-17 periodic maintenance procedures • apply engine oil to the fuel outlet pipe [a] lightly. • insert the fuel hose [a] joint straight onto the delivery pipe until the hose joint clicks. • push the joint lock [b]. • push and pull [c] the fuel hose joint back and forth more than ...

  • Page 46

    2-18 periodic maintenance periodic maintenance procedures • start the engine and warm it up thoroughly. • with the engine idling, turn the handlebar to both sides [a]. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be da...

  • Page 47

    Periodic maintenance 2-19 periodic maintenance procedures • remove: seat (see seat removal in the frame chapter) wing bolt [a] air cleaner element [b] • stuff a clean, lint-free towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy. • wipe out the inside of the air cl...

  • Page 48

    2-20 periodic maintenance periodic maintenance procedures • apply grease to all connections and screw holes in the air cleaner housing and intake tract. • install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete seal. • i...

  • Page 49

    Periodic maintenance 2-21 periodic maintenance procedures coolant level inspection note ○ check the level when the engine is cold (room or ambi- ent temperature). • lean the motorcycle slightly until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to ex...

  • Page 50

    2-22 periodic maintenance periodic maintenance procedures water hoses and connections inspection • remove the radiator shrouds (see radiator shroud re- moval in the frame chapter). ○ the high pressure inside the water hoses [a] can cause coolant to leak [b] or the hose to burst if the line is not pr...

  • Page 51

    Periodic maintenance 2-23 periodic maintenance procedures • using a thickness gauge [a], measure the clearance be- tween each cam lobe and valve lifter for all 4 valves. ○ for the purpose of adjusting the valve clearances, record the measured values. Valve clearance standard: exhaust 0.17 ∼ 0.22 mm ...

  • Page 52

    2-24 periodic maintenance periodic maintenance procedures adjustment shims thick- ness p/no. Mark thick- ness p/no. Mark 2.00 92025-1870 0 2.55 92025-1881 55 2.05 92025-1871 5 2.575 92025-1985 58 2.10 92025-1872 10 2.60 92025-1882 60 2.15 92025-1873 15 2.625 92180-1059 63 2.20 92025-1874 20 2.65 920...

  • Page 53

    Periodic maintenance 2-25 periodic maintenance procedures cylinder head warp inspection • remove the cylinder head (see cylinder head removal in the engine top end chapter). • lay a straightedge [a] across the lower surface of the head at several different points, and measure warp by inserting a thi...

  • Page 54

    2-26 periodic maintenance periodic maintenance procedures piston/cylinder clearance inspection the piston/cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston/cylinder clearance must be adhered to whenever the cylinder is replaced. If only a pi...

  • Page 55

    Periodic maintenance 2-27 periodic maintenance procedures • insert the new silencer wool [a] and muffler cover [b]. ○ fit the pipe end [c] and the exhaust hole of the baffle. • apply a non-permanent locking agent to the threads of the muffler cover bolts, and tighten them. • tighten: torque - muffle...

  • Page 56

    2-28 periodic maintenance periodic maintenance procedures • remove the number plate (see number plate removal in the frame chapter). • slide the dust cover [a]. • loosen the locknut [b] at the clutch cable, and turn the adjusting nut [c] so that clutch lever has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. • ...

  • Page 57

    Periodic maintenance 2-29 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 58

    2-30 periodic maintenance periodic maintenance procedures oil filter change • drain: engine oil (see engine oil change) • remove: oil filter cap bolts [a] oil filter cap [b] • remove the oil filter [a]. • install the spring [a]. • replace the oil filter with a new one. • apply grease to the grommet ...

  • Page 59

    Periodic maintenance 2-31 periodic maintenance procedures breather hose inspection • be certain that the breather hose [a] are routed without being flattened or kinked and is connected correctly. If it is not, correct it. • inspect the breather hose for damage or signs of deteri- oration. ○ this hos...

  • Page 60

    2-32 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 61

    Periodic maintenance 2-33 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 62

    2-34 periodic maintenance periodic maintenance procedures • stretch the chain taut by hanging a 98 n (10 kg, 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 chai...

  • Page 63

    Periodic maintenance 2-35 periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster locknuts [a]. • remove the cotter pin [b] and loosen the rear axle nut [c]. If the chain is too tight, back out the left and right chain adjusting bolts [d] evenly, and p...

  • Page 64

    2-36 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 65

    Periodic maintenance 2-37 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 66

    2-38 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 67

    Periodic maintenance 2-39 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 68

    2-40 periodic maintenance periodic maintenance procedures note ○ the procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • level the brake fluid reservoir. • remove: screws [a] reservoir cap [b] diaphragm [c] • remove the rubbe...

  • Page 69

    Periodic maintenance 2-41 periodic maintenance procedures • remove the clear plastic hose. • install the diaphragm and reservoir cap. • tighten: torque - front brake reservoir cap screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) • tighten the bleed valve, and install the rubber cap. Torque - caliper bleed val...

  • Page 70

    2-42 periodic maintenance periodic maintenance procedures kx450fc • pull the dust cover [a] out of place, and remove the circlip [b]. Special tool - inside circlip pliers: 57001-143 • remove the washer [c]. • remove the piston assy [d] (include primary and sec- ondary cups). Kx450fd ∼ • pull the pus...

  • Page 71

    Periodic maintenance 2-43 periodic maintenance procedures • apply brake fluid to the removed parts and to the inner wall of the cylinder. • take care not to scratch the piston assy and the inner wall of the cylinder. • apply silicone grease (ex. Pbc grease) to the following parts. Brake lever pivot ...

  • Page 72

    2-44 periodic maintenance periodic maintenance procedures • pull out the pistons [a] by hand. • remove the dust seal [b] and fluid seal [c] on each cylin- der. Note ○ if compressed air is not available, with the brake hose connected to the caliper. ○ prepare a container for brake fluid, and perform ...

  • Page 73

    Periodic maintenance 2-45 periodic maintenance procedures caliper assembly • clean the caliper parts except for the pads. Notice for cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. If you removed the bleed valve, install the bleed valve and rubber cap. Torque -...

  • Page 74

    2-46 periodic maintenance periodic maintenance procedures • replace the friction boot [a] and dust boot [b] if they are damaged. • apply a thin coat of pbc (poly butyl cuprysil) grease to the caliper holder shafts [c] and holder holes (pbc is a special high-temperature, water-resistance grease). • a...

  • Page 75

    Periodic maintenance 2-47 periodic maintenance procedures front brake hose • remove: brake hose clamp bolts [a] brake hose clamps [b] rear brake hose • remove: brake hose clamps [a] • remove: bolts [a] rear caliper guard [b] • remove: rear master cylinder mounting bolts [a] • remove the front/rear b...

  • Page 76

    2-48 periodic maintenance periodic maintenance procedures • when installing the hoses, avoid sharp bending, kink- ing, flattening or twisting, and run the hoses according to cable, wire, and hose routing section in the appendix chapter. • tighten: torque - brake hose banjo bolts: 25 n·m (2.5 kgf·m, ...

  • Page 77

    Periodic maintenance 2-49 periodic maintenance procedures note ○ set rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging. Record the setting before turning the adjuster. • thoroughly clean the fork before disassembly. ...

  • Page 78

    2-50 periodic maintenance periodic maintenance procedures • hold the axle holder [a] with a vise. ○ protect the axle holder with a soft jaw or heavy cloth when using a vise. • loosen the adjuster assembly [b] completely. Warning clamping the axle holder too tight can damage it which will affect ridi...

  • Page 79

    Periodic maintenance 2-51 periodic maintenance procedures • with the outer tube compressed by hands, remove the top plug wrench [a]. Notice removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. • remove ...

  • Page 80

    2-52 periodic maintenance periodic maintenance procedures • drain the fork oil [a] from the cylinder unit [b] by pumping the piston rod several times. • hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain. • clean the threads [a] of cylinder uni...

  • Page 81

    Periodic maintenance 2-53 periodic maintenance procedures • pump [a] the piston rod [b] slowly several times to expel air. • with the piston rod held immovable in fully compressed position [a], gently install the base valve assembly [b] to the cylinder unit. • screw in the base valve assembly in the...

  • Page 82

    2-54 periodic maintenance periodic maintenance procedures • drain the extra oil from the cylinder unit oil holes [a]. • with the cylinder unit in horizontal position, slide [a] the piston rod [b] by hand to inspect it if operating smoothly. ○ if the piston rod is not extend, remove the base valve as...

  • Page 83

    Periodic maintenance 2-55 periodic maintenance procedures • hold the axle holder with a vise. ○ protect the axle holder with a soft jaw or heavy cloth when using a vise. Warning clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tigh...

  • Page 84

    2-56 periodic maintenance periodic maintenance procedures • turn the locknut [a] counterclockwise until it contacts the adjuster assembly [b]. • with the locknut held immovable using a wrench, tighten the adjuster assembly to the specified torque. Torque - adjuster assembly locknut: 28 n·m (2.9 kgf·...

  • Page 85

    Periodic maintenance 2-57 periodic maintenance procedures • install the front forks to the motorcycle (see front fork installation in the suspension chapter). • loosen the front fork mounting bolts (upper). • after installing the front fork, tighten the top plug [a]. Special tool - top plug wrench, ...

  • Page 86

    2-58 periodic maintenance periodic maintenance procedures • turn the handlebar to one side, and loosen the fork top plug [a]. Special tool - top plug wrench, 49 mm [b]: 57001-1653 note ○ do not remove the top plug. • remove: front fork (see front fork removal in the suspension chapter) • thoroughly ...

  • Page 87

    Periodic maintenance 2-59 periodic maintenance procedures • hold the axle holder [a] with a vise. ○ protect the axle holder with a soft jaw or heavy cloth when using a vise. Warning clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too ...

  • Page 88

    2-60 periodic maintenance periodic maintenance procedures • remove the cylinder unit [a] from the outer tube [b]. Notice disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit. • holding the top plug wrench (57001-1653) [a] with a vise, loosen the base valve assemb...

  • Page 89

    Periodic maintenance 2-61 periodic maintenance procedures • clean the threads [a] of cylinder unit and base valve as- sembly. • replace the o-rings [a] on the base valve assembly and cylinder unit with new ones. • apply specified fork oil to the o-rings on the base valve assembly. • with the piston ...

  • Page 90

    2-62 periodic maintenance periodic maintenance procedures • with the piston rod held immovable in fully compressed position [a], gently install the base valve assembly [b] to the cylinder unit. Note ○ plug the two oil holes on the cylinder unit with fingers until the base valve assembly is installed...

  • Page 91

    Periodic maintenance 2-63 periodic maintenance procedures • drain the extra oil from the cylinder unit oil holes [a]. • with the cylinder unit in horizontal position, slide [a] the piston rod [b] by hand to inspect it if operating smoothly. Notice be careful not to bend or damage the piston rod when...

  • Page 92

    2-64 periodic maintenance periodic maintenance procedures • hold the axle holder with a vise. ○ protect the axle holder with a soft jaw or heavy cloth when using a vise. Warning clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tigh...

  • Page 93

    Periodic maintenance 2-65 periodic maintenance procedures • tighten the adjuster assembly [a]. Torque - adjuster assembly: 55 n·m (5.6 kgf·m, 41 ft·lb) • remove the fork leg from the vise. • using the top plug wrench, remove the fork top plug from the outer tube and slowly slide down the outer tube ...

  • Page 94

    2-66 periodic maintenance periodic maintenance procedures • apply grease to the o-ring on the air valve adapter. Note ○ when using the air valve adapter, make sure that there is no dust or foreign material on the threads and o-ring. • install the air valve adapter [a]. • adjust the air pressure in e...

  • Page 95

    Periodic maintenance 2-67 periodic maintenance procedures the torque of fork top plug is specified to 45 n·m (4.6 kgf·m, 33 ft·lb) however, when you use the top plug wrench (special tool) [a], reduce the torque to 90% of the spec- ified value [41 n·m (4.2 kgf·m, 30 ft·lb)] due to the dis- tance [b] ...

  • Page 96

    2-68 periodic maintenance periodic maintenance procedures • insert a suitable tool to center [a] of the reservoir cap, and release the nitrogen gas completely (keep the suitable tool inserted). ○ for instructions on how to use the tool, follow the opera- tion manual provided by the manufacturer. War...

  • Page 97

    Periodic maintenance 2-69 periodic maintenance procedures • remove the suitable tool from the reservoir cap. • using a suitable tool [a] and press, push the reservoir cap [b] in 10 mm (0.39 in.). • remove the circlip [c] from the gas reservoir. • pour the suspension oil into the rear shock body to 3...

  • Page 98

    2-70 periodic maintenance periodic maintenance procedures • replace the bladder [a] with a new one. Notice the bladder is damaged and its performance is re- duced noticeably if the bladder is damaged or de- formed during reuse. • apply grease to the lip [b] of the bladder and install the reservoir c...

  • Page 99

    Periodic maintenance 2-71 periodic maintenance procedures • pour the suspension oil into the rear shock body to 50 mm (2.0 in.) [a] from the lower end of the rear shock body [b]. Suspension oil - khv10-k2c (1l): 45024-0002 • adjust the gas reservoir damping adjusters [a] to the hard- est position. •...

  • Page 100

    2-72 periodic maintenance periodic maintenance procedures • insert the suitable tool to center of the reservoir cap, and operate the piston rod assembly after pour 98 kpa (1.0 kgf/cm², 14 psi) nitrogen gas, and then push out to the place where the reservoir cap hits the circlip. Now, check that the ...

  • Page 101

    Periodic maintenance 2-73 periodic maintenance procedures • check the rear shock body and gas reservoir for oil and gas leaks. If there are no leaks, inject the nitrogen gas up to the 1 000 kpa (10.2 kgf/cm², 145 psi) pressure. Warning high pressure gas is dangerous and can explode, causing serious ...

  • Page 102

    2-74 periodic maintenance periodic maintenance procedures • pump the seat down and up [a] 4 or 5 times, and inspect the smooth stroke. If the uni-trak linkage does not smooth stroke or noise is found, inspect the uni-trak linkage bearings. • push and pull on the swingarm [a] to check for wear. A sma...

  • Page 103

    Periodic maintenance 2-75 periodic maintenance procedures • remove: number plate (see number plate removal in the frame chapter) handlebar pad [a] • remove: handlebar clamp bolts [a] handlebar clamps [b] handlebar [c] • loosen the front fork clamp bolts (upper) [a] on both sides. • remove the steeri...

  • Page 104

    2-76 periodic maintenance periodic maintenance procedures steering stem bearing lubrication • remove the steering stem (see steering stem, stem bearing removal in the steering chapter). • using a high flash-point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and ...

  • Page 105

    Periodic maintenance 2-77 periodic maintenance procedures • measure the gap [a] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [b] with a suitable tool to obtain the correct gap. Spark plug gap standard: 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) • install the spark...

  • Page 106

    2-78 periodic maintenance periodic maintenance procedures cables: lubricate with rust inhibitor. Throttle inner cables clutch inner cable pivots: lubricate with engine oil. Rear master cylinder joint pin cable inspection • with the cable disconnected at the both ends, the cable should move freely [a...

  • Page 107

    Periodic maintenance 2-79 periodic maintenance procedures if there are loose fasteners, retighten them to the spec- ified torque following the specified tightening sequence. Refer to the torque and locking agent section in this chapter for torque specifications. For each fastener, first loosen it by...

  • Page 109: Fuel System (Dfi)

    Fuel system (dfi) 3-1 3 fuel system (dfi) table of contents exploded view........................................................................................................................ 3-4 specifications ..........................................................................................

  • Page 110

    3-2 fuel system (dfi) fuel injector removal ....................................................................................................... 3-55 fuel injector installation .................................................................................................... 3-55 fuel injector ...

  • Page 111

    Fuel system (dfi) 3-3 this page intentionally left blank..

  • Page 112

    3-4 fuel system (dfi) exploded view.

  • Page 113

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolts 3.4 0.35 30 in·lb 2 throttle cable mounting bolts 3.5 0.36 31 in·lb 3 air cleaner duct mounting bolt 3.0 0.31 27 in·lb 4 air cleaner duct mounting nuts 3.0 0.31 27 in·lb 5 air cleaner housin...

  • Page 114

    3-6 fuel system (dfi) exploded view.

  • Page 115

    Fuel system (dfi) 3-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fuel pump bolts 9.8 1.0 87 in·lb l, s 2 water temperature sensor 12 1.2 106 in·lb 3 gear position switch screws 2.9 0.30 26 in·lb l 4. Ecu 5. Vehicle-down sensor 6. Ignition coil 7. Capacitor 8. Crankshaft sensor ad: a...

  • Page 116

    3-8 fuel system (dfi) specifications item standard digital fuel injection system idle speed 2 000 ±50 r/min (rpm) throttle body assy: throttle valve single throttle valve bore 43 mm (1.69 in.) ecu: make keihin type digital memory type, with built in ic igniter, sealed with resin fuel pressure 294 kp...

  • Page 117

    Fuel system (dfi) 3-9 special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 filler cap driver: 57001-1454 needle adapter set: 57001-1457 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 measuring adapter: 57001-1700 ...

  • Page 118

    3-10 fuel system (dfi) dfi system dfi system 1. Fuel tank 2. Pressure regulator 3. Fuel pump 4. Intake air pressure sensor 5. Fuel injector 6. Intake air temperature sensor 7. Air cleaner housing 8. Ignition coil 9. Vehicle-down sensor 10. Crankshaft sensor 11. Water temperature sensor 12. Throttle ...

  • Page 119

    Fuel system (dfi) 3-11 dfi system dfi system wiring diagram part names 1. Ecu 2. Self-diagnosis terminal 3. Throttle sensor 4. Intake air pressure sensor 5. Fuel injector 6. Intake air temperature sensor 7. Water temperature sensor 8. Frame ground 1 9. Spark plug 10. Ignition coil 11. Frame ground 2...

  • Page 120

    3-12 fuel system (dfi) dfi system terminal numbers of ecu connectors terminal names 1. Power supply to ecu 2. Vehicle-down sensor 3. Crankshaft sensor (+) 4. Gear position switch 5. Throttle sensor 6. Intake air pressure sensor 7. Unused 8. Ground for control system 9. Crankshaft sensor (–) 10. Exte...

  • Page 121

    Fuel system (dfi) 3-13 dfi parts location kawasaki diagnostic system connector [1] ecu [2] self-diagnosis terminal [3] orange launch control mode/fi warning indicator light (led) [4] water temperature sensor [5] crankshaft sensor [6] capacitor [7] vehicle-down sensor [8] ignition coil [9] intake air...

  • Page 122

    3-14 fuel system (dfi) dfi parts location fuel injector [12] throttle sensor [13] throttle body assy [14] intake air temperature sensor [15].

  • Page 123

    Fuel system (dfi) 3-15 dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ connect these connectors until they click [a]. ○ never any of the dfi electrical connectors are discon- nected. The ecu memorizes...

  • Page 124

    3-16 fuel system (dfi) troubleshooting the dfi system outline when an abnormality in the system occurs, the orange fi warning indicator light (led) goes on to alert the rider. In addition, the condition of the problem is stored in the mem- ory of the ecu (electronic control unit). With the engine st...

  • Page 125

    Fuel system (dfi) 3-17 troubleshooting the dfi system • when checking the dfi parts, use a digital meter which can be read two decimal place voltage or resistance. ○ the dfi part connectors [a] have seals [b], including the ecu. When measuring the input or output voltage with the connector joined, u...

  • Page 126

    3-18 fuel system (dfi) troubleshooting the dfi system • pull each connectors [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect them securely. • check the wiring for continuity. ○ use the wiring d...

  • Page 127

    Fuel system (dfi) 3-19 troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 128

    3-20 fuel system (dfi) troubleshooting the dfi system sample diagnosis sheet rider name model engine no. Frame no. Date problem occurred environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: temperature □ hot, □ warm, □ cold, □ very cold, □ always problem fr...

  • Page 129

    Fuel system (dfi) 3-21 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 130

    3-22 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Unstable (rough) idling: fue...

  • Page 131

    Fuel system (dfi) 3-23 dfi system troubleshooting guide symptoms or possible causes actions (chapter) surge: unstable fuel pressure fuel pressure regulator trouble (inspect and replace fuel pump) or kinked fuel line (inspect and replace fuel pump) (see chapter 3). Fuel injector trouble inspect (see ...

  • Page 132

    3-24 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Intake air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Knocking: fuel poor quality ...

  • Page 133

    Fuel system (dfi) 3-25 self-diagnosis self-diagnosis outline the self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu connected orange fi warning indicator light (led) goes on when dfi system and ignition system parts a...

  • Page 134

    3-26 fuel system (dfi) self-diagnosis • disconnect the self-diagnosis terminal [a] from the cover [b]. • connect an auxiliary lead [c] for grounding to the self -diagnosis terminal. Note ○ keep the self-diagnosis terminal grounded during self -diagnosis. • to enter the self-diagnosis dealer mode 1, ...

  • Page 135

    Fuel system (dfi) 3-27 self-diagnosis self-diagnosis flow chart.

  • Page 136

    3-28 fuel system (dfi) self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the orange fi warning indicator light (led) as shown below. ○ read 10th digit and unit digit as the orange fi warning indicator light (led) blinks. ○ when there are a num...

  • Page 137

    Fuel system (dfi) 3-29 self-diagnosis service code table service codes orange fi warning indicator light (led) problems 11 throttle sensor malfunction, wiring open or short 12 intake air pressure sensor malfunction, wiring open or short 13 intake air temperature sensor malfunction, wiring open or sh...

  • Page 138

    3-30 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 throttle sensor throttle sensor output voltage 0.391 ∼ 4...

  • Page 139

    Fuel system (dfi) 3-31 throttle sensor (service code 11) the throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttl...

  • Page 140

    3-32 fuel system (dfi) throttle sensor (service code 11) • replace: throttle sensor screw [a] throttle sensor [b] o-ring [c] • apply engine oil to the new o-ring, and install it to the new throttle sensor. • engage the inner rotor groove [a] with the throttle shaft [b]. • insert the throttle sensor ...

  • Page 141

    Fuel system (dfi) 3-33 throttle sensor (service code 11) • adjust the sensor position so that the output voltage is within the specified voltage range. Throttle sensor output voltage standard: dc 0.58 ∼ 0.62 v if the input voltage reading shows other than 5 v, calculate a valid output voltage range ...

  • Page 142

    3-34 fuel system (dfi) throttle sensor (service code 11) • measure the input voltage with the engine stopped and with the connector joined. Input voltage standard: dc 4.75 ∼ 5.25 v • disconnect the power supply harness. If the reading is within the standard, check the output volt- age (see throttle ...

  • Page 143

    Fuel system (dfi) 3-35 throttle sensor (service code 11) • measure the output voltage with the engine stopped, and with the connector joined. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. Output voltage standard: dc 0.58 ∼ 0.62 v at idle throttle opening dc ...

  • Page 144

    3-36 fuel system (dfi) throttle sensor (service code 11) throttle sensor circuit 1. Ecu 2. Throttle sensor.

  • Page 145

    Fuel system (dfi) 3-37 intake air pressure sensor (service code 12) intake air pressure sensor removal notice never drop the intake air pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose repl...

  • Page 146

    3-38 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor input voltage inspection note ○ be sure the battery is fully charged. • disconnect the intake air pressure sensor connector and connect the measuring adapter [a] between these con- nectors. Main harness [b...

  • Page 147

    Fuel system (dfi) 3-39 intake air pressure sensor (service code 12) intake air pressure sensor output voltage inspection • measure the intake air pressure sensor output voltage in the same way as input voltage inspection. Note the fol- lowing. ○ disconnect the intake air pressure sensor connector an...

  • Page 148

    3-40 fuel system (dfi) intake air pressure sensor (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the intake air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the intake air pressure sensor. • temporarily...

  • Page 149

    Fuel system (dfi) 3-41 intake air pressure sensor (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: intake air pressure s...

  • Page 150

    3-42 fuel system (dfi) intake air pressure sensor (service code 12) intake air pressure sensor circuit 1. Ecu 2. Intake air pressure sensor.

  • Page 151

    Fuel system (dfi) 3-43 intake air temperature sensor (service code 13) intake air temperature sensor removal/instal- lation notice never drop the intake air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the seat (see seat removal in the frame ...

  • Page 152

    3-44 fuel system (dfi) intake air temperature sensor (service code 13) • measure the output voltage with the engine stopped and the connector joined. Output voltage standard: about dc 2.28 ∼ 3.43 v at intake air temperature 20°c (68°f) note ○ the output voltage changes according to the intake air te...

  • Page 153

    Fuel system (dfi) 3-45 intake air temperature sensor (service code 13) intake air temperature sensor circuit 1. Ecu 2. Intake air temperature sensor.

  • Page 154

    3-46 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant draining in the cooling system ch...

  • Page 155

    Fuel system (dfi) 3-47 water temperature sensor (service code 14) • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • measure the output voltage with the engine stopped and the connector joined. Output voltage standard: about dc 2.80 ∼ 2.97 v at water temperatur...

  • Page 156

    3-48 fuel system (dfi) water temperature sensor (service code 14) water temperature sensor resistance inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion and ...

  • Page 157

    Fuel system (dfi) 3-49 crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the stator coil removal/installation in the elec- trical system chapter. Cr...

  • Page 158

    3-50 fuel system (dfi) gear position switch (service code 25) gear position switch removal • remove: shift pedal (external shift mechanism removal in the crankshaft/transmission chapter) gear position switch connector [a] (gray, 2-pin) • open the clamps [a]. • remove: screws [a] gear position switch...

  • Page 159

    Fuel system (dfi) 3-51 gear position switch (service code 25) gear position switch inspection note ○ be sure the transmission mechanism is good condition. • disconnect the gear position switch lead connector [a] (gray, 2-pin). • set a digital meter [a] and connect it to the terminals in the gear pos...

  • Page 160

    3-52 fuel system (dfi) vehicle-down sensor (service code 31) when the motorcycle overturned, the engine stops after 6 seconds if the engine speed is 1 300 r/min (rpm) or more. Vehicle-down sensor removal notice never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sen...

  • Page 161

    Fuel system (dfi) 3-53 vehicle-down sensor (service code 31) • measure the input voltage with the engine stopped and with the connector joined. Input voltage standard: dc 4.75 ∼ 5.25 v if the reading is within the standard, check the output volt- age (see vehicle-down sensor output voltage inspec- t...

  • Page 162

    3-54 fuel system (dfi) vehicle-down sensor (service code 31) • hold the vehicle-down sensor vertically. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • measure the output voltage with the engine stopped, and with the connector joined. ○ tilt the sensor 55 ∼ ...

  • Page 163

    Fuel system (dfi) 3-55 fuel injector (service code 41) notice never drop the fuel injector, especially on a hard surface. Such a shock to the injector can damage it. Fuel injector removal • remove: rear frame (see rear frame removal in the frame chapter) fuel tank (see fuel tank removal) fuel hose (...

  • Page 164

    3-56 fuel system (dfi) fuel injector (service code 41) • assemble the delivery pipe [a] and the fuel injector [b]. • fit the projections [a] on the delivery pipe to the hollows [b] of the throttle body assy. • tighten the delivery pipe mounting screw [a]. • connect the fuel injector connector. • ins...

  • Page 165

    Fuel system (dfi) 3-57 fuel injector (service code 41) fuel injector resistance inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) fuel injector connector [a] • connect a digital meter [a] to the injector terminals. • meas...

  • Page 166

    3-58 fuel system (dfi) fuel injector (service code 41) fuel injector output voltage inspection note ○ be sure the battery is fully charged. • remove the ecu (see ecu removal). ○ do not disconnect the ecu connector. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harnes...

  • Page 167

    Fuel system (dfi) 3-59 fuel injector (service code 41) • check the injector fuel line for leakage as follows: ○ connect a commercially available vacuum/pressure pump [a] to the delivery pipe [b] with the fuel hose [c]. ○ hold both ends with the clamps [d]. • apply a soap and water solution to the ar...

  • Page 168

    3-60 fuel system (dfi) fuel pump (service code 46) fuel pump 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 ...

  • Page 169

    Fuel system (dfi) 3-61 fuel pump (service code 46) • install the fuel pump [a] to the fuel tank. • apply a non-permanent locking agent to the threads of the fuel pump bolts. • gradually tighten the fuel pump bolts evenly following the specified tightening sequence [1 ∼ 6]. Torque - fuel pump bolts: ...

  • Page 170

    3-62 fuel system (dfi) fuel pump (service code 46) • measure the operating voltage with engine stopped and with the connector joined. Operating voltage standard: battery voltage if the reading is not battery voltage, check the wiring for continuity (see fuel pump circuit). If the wiring is good, che...

  • Page 171

    Fuel system (dfi) 3-63 ignition coil (service code 51) ignition coil removal/installation • refer to the ignition coil removal/installation in the elec- trical system chapter. Ignition coil primary peak voltage inspection • refer to the ignition coil primary peak voltage check in the electrical syst...

  • Page 172

    3-64 fuel system (dfi) orange fi warning indicator light (led) orange fi warning indicator light (led) inspection note ○ be sure the battery is fully charged. • refer to the self-diagnosis procedures, connect the 12 v battery to the main harness. • confirm that the orange fi warning indicator light ...

  • Page 173

    Fuel system (dfi) 3-65 orange fi warning indicator light (led) orange fi warning indicator light (led) circuit 1. Ecu 2. Orange fi warning indicator light (led) 3. Capacitor 4. Frame ground 1.

  • Page 174

    3-66 fuel system (dfi) ecu ecu identification ○ most countries have their own regulations, so each ecu has different characteristic. So, do not confuse ecu with each other and use only the ecu for your model. Other- wise, the motorcycle cannot clear the regulation. Ecu identification (kx450fc) part ...

  • Page 175

    Fuel system (dfi) 3-67 ecu • insert the slits [a] of the rubber protector to the ecu bracket. • connect the ecu connector [b]. Ecu power supply inspection • remove the number plate (see number plate removal in the frame chapter). • visually inspect the ecu connector. If the connector is clogged with...

  • Page 176

    3-68 fuel system (dfi) ecu • connect a digital meter [a] to the ecu connector [b] with the needle adapter set. Special tool - needle adapter set: 57001-1457 ecu power supply inspection connections: digital meter (+) → r/w lead (ecu terminal 1) digital meter (–) → battery (–) terminal standard: when ...

  • Page 177

    Fuel system (dfi) 3-69 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: radiator shroud (see radiator shroud removal in the frame chapter) fuel tank (see fuel tank removal) fuel hose (see fuel hose replacement in the periodic maintenance chapter) ○ be sure to...

  • Page 178

    3-70 fuel system (dfi) fuel line • start the engine, and let it idle. • measure the fuel pressure with the engine idling. Fuel pressure standard: 294 kpa (3.00 kgf/cm², 43 psi) at engine idling note ○ the gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indica...

  • Page 179

    Fuel system (dfi) 3-71 fuel line • open the fuel tank cap [a] to lower the pressure in the tank. • disconnect the fuel hose from the fuel pump (see fuel tank removal). ○ be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. Warning fuel is flammable and explosive under cert...

  • Page 180

    3-72 fuel system (dfi) 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 thro...

  • Page 181

    Fuel system (dfi) 3-73 throttle grip and cable • loosen the throttle cable mounting bolts [a]. • take the cables [b] off the throttle body assy. • free the throttle cable tips [c] from the pulley. • remove the throttle cables. • lubricate the throttle cables (see lubrication in the peri- odic mainte...

  • Page 182

    3-74 fuel system (dfi) throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Throttle bore cleaning • refer to the throttle body cleaning in the periodic main- tenance chapter. Throttle body assy removal warning gasoline is extremely fla...

  • Page 183

    Fuel system (dfi) 3-75 throttle body assy • disconnect the throttle sensor connector [a]. Kx450fd ∼ • disconnect: intake air pressure sensor connector [a] throttle sensor connector [b] fuel injector connector [c] • loosen the clamp screw [a]. • take the throttle body assy [a] off the engine as shown...

  • Page 184

    3-76 fuel system (dfi) throttle body assy throttle body assy disassembly • remove: throttle body assy (see throttle body assy removal) plate mounting screws [a] plate [b] intake air pressure sensor [c] • remove: delivery pipe mounting screw [a] delivery pipe [b] with fuel injector [c] note ○ do not ...

  • Page 185

    Fuel system (dfi) 3-77 throttle body assy • remove: idle adjusting screw assy [a] note ○ if necessary, refer to the throttle sensor replacement and remove the throttle sensor [b]. Throttle body assy assembly note ○ if necessary, refer to the throttle sensor replacement and install the throttle senso...

  • Page 186

    3-78 fuel system (dfi) throttle body assy • fit the delivery pipe projections [a] to the throttle body hollows [b]. • tighten the delivery pipe mounting screw securely. • install the plate [a]. • fit the hole [b] and the projection [c]. • install the vacuum hose to the fitting [d]. • tighten the pla...

  • Page 187

    Fuel system (dfi) 3-79 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 • when assembling the air cleaner hous...

  • Page 188

    3-80 fuel system (dfi) 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 p...

  • Page 189

    Fuel system (dfi) 3-81 fuel tank when removing with standard tip screwdriver: • insert the standard tip screwdriver [a] into the slit [b] on the joint lock [c]. • turn the driver to disconnect the joint lock. When removing with fingers: • open and push up [a] the joint lock [b] with your fingers. No...

  • Page 190

    3-82 fuel system (dfi) fuel tank • clean the pipe [a]. • cover the pipe and hose joint [b] with the vinyl bags [c] to keep them clean. Fuel tank installation • note the above warning (see fuel tank removal). • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapt...

  • Page 191

    Fuel system (dfi) 3-83 fuel tank • insert the fuel hose joint [a] straight onto the fuel outlet pipe until the hose joint clicks. • push the joint lock [b]. • push and pull [c] the fuel hose joint back and forth more than two times, and make sure it is locked and does not come off. Warning leaking f...

  • Page 193: Cooling System

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

  • Page 194

    4-2 cooling system exploded view.

  • Page 195

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator mounting bolts 9.8 1.0 87 in·lb 2 radiator screen bolts 9.8 1.0 87 in·lb 3 water hose clamp screws 3.0 0.31 27 in·lb 4 water pump cover bolts 9.8 1.0 87 in·lb 5 coolant drain bolt 7.0 0.71 62 in·lb 6 water pump i...

  • Page 196

    4-4 cooling system specifications item standard recommended coolant type permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) color green mixed ratio soft water 50%, coolant 50% freezing point –35°c (–31°f) total am...

  • Page 197

    Cooling system 4-5 special tools outside circlip pliers: 57001-144 bearing driver set: 57001-1129.

  • Page 198

    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 199

    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 200

    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 201

    Cooling system 4-9 water pump water pump cover removal • drain the coolant (see coolant draining). • loosen the clamp screw [a], and disconnect the water hose [b] from the water pump cover. • remove the cover bolts [c]. • using the pry points [a], remove the pump cover [b]. Water pump cover installa...

  • Page 202

    4-10 cooling system water pump impeller removal • remove: water pump cover (see water pump cover removal) impeller bolt [a] impeller [b] impeller installation • install: impeller [a] • tighten: torque - water pump impeller bolt [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install: water pump cover (see wate...

  • Page 203

    Cooling system 4-11 water pump • insert a bar [a] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [b] by tapping [c] evenly around the bearing in- ner race. • remove the spacer [d]. • remove the ball bearing [e] and oil seal [f] from the right e...

  • Page 204

    4-12 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: radiator shrouds (see radiator shroud removal in the frame chapter) • loosen: clamp screws [a] • remove: clamp [b] water hoses [c] bolt [d] left radiator screen [e] • remove: radiator mounting bolts [...

  • Page 205

    Cooling system 4-13 radiator radiator installation • install: radiators washers clutch cable clamps [a] (left side) • tighten: torque - radiator mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • run the hoses correctly (see cable, wire, and hose rout- ing section in the appendix chapter). • tighten: t...

  • Page 206

    4-14 cooling system radiator radiator cap inspection • check the condition of the valve spring [a], and the top and bottom valve seals [b] of the radiator cap. If any one of them shows visible damage, replace the cap. • wet the top and bottom valve seals with water or coolant to prevent pressure lea...

  • Page 207: 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 208

    5-2 engine top end exploded view.

  • Page 209

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 9.8 1.0 87 in·lb 2 cylinder head bolts (m10) 59 6.0 44 mo, s 3 camshaft cap bolts 9.8 1.0 87 in·lb mo, s 4 camshaft sprocket bolts 12 1.2 106 in·lb l 5 plug 20 2.0 15 l 6 oil line plug 3.0 0.31 2...

  • Page 210

    5-4 engine top end exploded view.

  • Page 211

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe holder nuts 20 2.0 15 s 2 exhaust pipe cover bolts 12 1.2 106 in·lb 3 muffler clamp bolt 16.5 1.68 12.2 s 4 muffler mounting bolts 20 2.0 15 s g: apply grease. L: apply a non-permanent locking agent. R: repla...

  • Page 212

    5-6 engine top end specifications item standard service limit camshafts cam height: exhaust 36.943 ∼ 37.057 mm (1.4544 ∼ 1.4589 in.) 36.84 mm (1.450 in.) intake: kx450fc 38.143 ∼ 38.257 mm (1.5017 ∼ 1.5062 in.) 38.04 mm (1.498 in.) kx450fd ∼ 37.743 ∼ 37.857 mm (1.4859 ∼ 1.4904 in.) 37.64 mm (1.482 i...

  • Page 213

    Engine top end 5-7 specifications item standard service limit valve seat surface: outside diameter: exhaust 30.4 ∼ 30.6 mm (1.197 ∼ 1.205 in.) – – – intake 35.4 ∼ 35.6 mm (1.394 ∼ 1.402 in.) – – – width: exhaust 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) – – – intake 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) – – – valve s...

  • Page 214

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

  • Page 215

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

  • Page 216

    5-10 engine top end special tools and sealant valve seat cutter, 55° - 35: 57001-1247 compression gauge adapter, m10 × 1.0: 57001-1317 piston ring compressor belt, 95 ∼ 108: 57001-1358 filler cap driver: 57001-1454 valve seat cutter, 45° - 40: 57001-1496 valve seat cutter, 55° - 38.5: 57001-1497 val...

  • Page 217

    Engine top end 5-11 special tools and sealant valve guide driver attachment, g: 57001-1728 liquid gasket, tb1216b: 92104-1064.

  • Page 218

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) fuel hose (see fuel hose replacement in the periodic maintenance chapter) spark plug cap [a] cylinder head cover bolts [b] and washers cylinder head cover ...

  • Page 219

    Engine top end 5-13 cylinder head cover • install the cylinder head cover bolt washers with the metal side [a] upwards. • tighten: torque - cylinder head cover bolts [b]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the spark plug cap [a] so that it is aligned with the line [b] on the cylinder head cover...

  • Page 220

    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 221

    Engine top end 5-15 camshaft chain tensioner • replace the chain tensioner gasket with a new one. • install the chain tensioner body. • tighten: torque - camshaft chain tensioner mounting bolts [a]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • take out the holder plate [b]. • replace the o-ring with a new one. •...

  • Page 222

    5-16 engine top end 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 the compression stroke. ○ place a wrench over the flywheel nut...

  • Page 223

    Engine top end 5-17 camshafts • while holding the exhaust camshaft with a vise, remove the camshaft sprocket bolts [a]. • remove: auto-decompressor [b] (with sprocket) • remove: circlips [a] camshaft installation • assemble the auto-decompressor weights [a] and spring [b] to install it to the sprock...

  • Page 224

    5-18 engine top end camshafts • engage the camshaft chain with the camshaft sprockets. ○ align the timing mark on the sprocket with the cylinder head upper surface as shown in the figure. ○ starting with the timing mark on the front of the exhaust sprocket, count to the 1st pin. Feed the exhaust cam...

  • Page 225

    Engine top end 5-19 camshafts • apply grease to the rubber portions of the oil pipes [a]. • assemble: camshaft caps [b] oil pipes • while keeping the camshaft caps in parallel, install them to the cylinder head. • apply molybdenum disulfide oil to the threads of the camshaft cap bolts. • tighten all...

  • Page 226

    5-20 engine top end camshafts camshaft chain removal • remove: camshafts (see camshaft removal) flywheel (see flywheel removal in the electrical sys- tem chapter) oil pump (scavenge) cover bolts [a] lower camshaft chain guide [b] • disengage the camshaft chain from the crankshaft. Camshaft chain ins...

  • Page 227

    Engine top end 5-21 camshafts camshaft runout inspection • remove the camshafts (see camshaft removal). • set the camshaft in a camshaft alignment jig or on v blocks. • measure the runout with a dial gauge [a] at the specified place as shown in the figure. If the runout exceeds the service limit, re...

  • Page 228

    5-22 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 (dfi) chapter) spark plug (see spark plug cleaning and inspection in the periodic maintenance chapter) • attach the com...

  • Page 229

    Engine top end 5-23 cylinder head cylinder head removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) cylinder head cover (see cylinder head cover re- moval) camshafts (see camshaft removal) exhaust pipe (see exhaust pipe removal) ignition coil (see ignition coil remov...

  • Page 230

    5-24 engine top end cylinder head ○ take care not to damage the chain guides [a]. Notice do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • remove the cylinder head gasket [b]. Cylinder head installation • fit the projections [a] of the ...

  • Page 231

    Engine top end 5-25 cylinder head • tighten: torque - cylinder bolt [a]: 12 n·m (1.2 kgf·m, 106 in·lb) cylinder head bolts (m6) [b]: 12 n·m (1.2 kgf·m, 106 in·lb) • install the removed parts (see appropriate chapters). Cylinder head cleaning • refer to the cylinder head warp inspection in the peri- ...

  • Page 232

    5-26 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 233

    Engine top end 5-27 valves valve installation notice do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. • visually inspect the valve surface. If the surface is damaged, replace the valve. • replace the oil seal [a] with a ne...

  • Page 234

    5-28 engine top end valves • hammer lightly on the valve guide arbor [a] to remove the guide. Special tool - valve guide arbor, 5.5: 57001-1021 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 235

    Engine top end 5-29 valves valve/valve guide clearance measurement (wobble method) if a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the guide [b] and set a dial g...

  • Page 236

    5-30 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, 5.5 [b]: 57001 -1125 valve seat cutter holder bar: 57001-1128 exhaust: valve seat cu...

  • Page 237

    Engine top end 5-31 valves repair operating procedures • clean the seat area carefully. • coat the seat with machinist’s dye. • fit a 45° cutter into the holder and slide it into the valve guide. • press down lightly on the handle and turn it right or left. Grind the seating surface only until it is...

  • Page 238

    5-32 engine top end valves notice the 32° cutter removes material very quickly. Check the seat outside diameter frequently to pre- vent overgrinding. ○ after making the 32° grind, return to the seat outside di- ameter measurement step above. • to measure the seat width, use a vernier caliper to mea-...

  • Page 239

    Engine top end 5-33 valves valve seat repair.

  • Page 240

    5-34 engine top end cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] water temperature sensor connector [c] (disconnect) • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remo...

  • Page 241

    Engine top end 5-35 cylinder and piston note ○ the oil ring rails have no “top” or “bottom”. • install the oil ring expander [a] in the bottom piston ring groove so the ends [b] butt together. • install the oil ring steel rails, one above the expander and one below it. ○ spread the rail with your th...

  • Page 242

    5-36 engine top end cylinder and piston • the piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 20° [a] of angle from the opening of the oil ring expander. Circle mark [b] top ring [c] upper oil ring steel rail [d] oil ring expande...

  • Page 243

    Engine top end 5-37 cylinder and piston piston ring/ring groove clearance inspection • check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. • with the piston rings in their groo...

  • Page 244

    5-38 engine top end cylinder and piston piston ring end gap measurement • place the piston ring [a] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. • measure the gap [b] between the ends of the ring...

  • Page 245

    Engine top end 5-39 throttle body holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) throttle body assy clamp [a] throttle body assy holder screws [b] clamp [c] (kx450fd ∼ ) throttle body assy holder [d] throttle bo...

  • Page 246

    5-40 engine top end muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler body removal • remove the right side cover (see side cover removal in the frame chapter). • loosen the muffler clamp bolt [a...

  • Page 247: Clutch

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

  • Page 248

    6-2 clutch exploded view.

  • Page 249

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch hub nut 98 10 72 r 2 clutch spring bolts 8.8 0.90 78 in·lb 3 right engine cover bolts 9.8 1.0 87 in·lb 4 oil filter cap bolt 9.8 1.0 87 in·lb 5 clutch cover bolts 9.8 1.0 87 in·lb 6 oil filler plug 3.5 0.36 31 in·lb cl: ap...

  • Page 250

    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 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.7 mm (0.11 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) steel plate warp 0.20 mm ...

  • Page 251

    Clutch 6-5 special tools inside circlip pliers: 57001-143 bearing driver set: 57001-1129 clutch holder: 57001-1243.

  • Page 252

    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 253

    Clutch 6-7 clutch lever and cable • align the slit [a] of the adjusting nut to the slit [b] of the clutch lever. • free the clutch cable upper end from the clutch lever. • loosen the adjusting nuts [a] fully. • free the clutch cable lower end [b] from the clutch release lever [c]. Notice do not remo...

  • Page 254

    6-8 clutch clutch lever and cable • install the clutch cable with the threads width as shown in the figure. 5 ±2 mm (0.2 ±0.08 in.) [a] • run the clutch cable correctly (see cable, wire, and hose routing section in the appendix chapter). • adjust the clutch cable (see clutch lever free play ad- just...

  • Page 255

    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: rear master cylinder mounting bolts [a] brake pedal bolt [b] brake pedal return spring [c] • remove: clutch cover bolts [a] clutch cover...

  • Page 256

    6-10 clutch clutch cover and right engine cover • remove: kick pedal (see kick pedal removal in the crank- shaft/transmission chapter) rear master cylinder mounting bolts [a] brake pedal bolt [b] brake pedal return spring [c] • remove: bolt [a] right engine guard [b] • remove: water pump cover (see ...

  • Page 257

    Clutch 6-11 clutch cover and right engine cover • remove the vinyl tape from the kick shaft. • install: water pump cover (see water pump cover installation in the cooling system chapter) right engine guard (see engine guard installation in the frame chapter) rear master cylinder (see rear master cyl...

  • Page 258

    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] clutch springs clutch spring plate [b] • remove: washer [a] needle bearing [b] push rod holder [c] push ro...

  • Page 259

    Clutch 6-13 clutch • remove: toothed washer [a] clutch housing [b] clutch installation • check the clutch plate assembly free play (see clutch plate assembly free play inspection/adjustment). • apply molybdenum disulfide oil to the inside [a] of the clutch housing. • install: clutch housing [b] toot...

  • Page 260

    6-14 clutch clutch • apply molybdenum disulfide grease to the push rod end [a] sliding portion [b] of the push rod holder. Note ○ do not close the oil passage hole on the push rod holder with the molybdenum disulfide grease. • install the push rod and push rod holder. • apply molybdenum disulfide gr...

  • Page 261

    Clutch 6-15 clutch • check the release shaft lever position. • pushing [a] the release shaft lever [b] lightly forward, measure the distance [c] between the release shaft lever and bracket [d]. Release shaft lever position standard: 68.6 ∼ 76.4 mm (2.70 ∼ 3.01 in.) if the lever position is not withi...

  • Page 262

    6-16 clutch clutch clutch plate assembly free play inspection/ad- justment • assemble the following parts. Clutch hub [a] friction plates [b] steel plates [c] friction plates [d] spring plate [e] spring [f] bolts [g] note ○ install the both ends of friction plates, which are marked when disassembled...

  • Page 263

    Clutch 6-17 clutch clutch plates wear, damage inspection • refer to the clutch plates inspection in the periodic main- tenance chapter. Clutch plates warp inspection • refer to the clutch plates inspection in the periodic main- tenance chapter. Clutch spring free length inspection • measure the free...

  • Page 265: Engine Lubrication System

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

  • Page 266

    7-2 engine lubrication system exploded view.

  • Page 267

    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 (feed) cover bolts 9.8 1.0 87 in·lb 3 oil pressure relief valve 15 1.5 11 l 4 piston oil nozzle 3.0 0.31 27 in·lb 5 piston oil nozzle bolt 7.0 0.71 62 in·lb l 6 oil pump ...

  • Page 268

    7-4 engine lubrication system lubrication system chart.

  • Page 269

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

  • Page 270

    7-6 engine lubrication system specifications item standard engine oil type castrol “power1 racing 4t” 5w-40 or api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, or 10w-50 capacity 0.96 l (1.01 us qt) (when filter is not removed) 0.98 l (1.04 us qt) (when filter is remov...

  • Page 271

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

  • Page 272

    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 273

    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 (scavenge) removal • remove: oil pump (scavenge) cover (see oil pump (scavenge) removal) oil screen [a] oil screen (scavenge) install...

  • Page 274

    7-10 engine lubrication system engine oil and oil filter • install the oil screen [a], and tighten the bolts [b]. Torque - oil screen (feed) mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) oil screen (scavenge) cleaning • remove the oil screen (see oil screen (scavenge) re- moval). • clean the oil scr...

  • Page 275

    Engine lubrication system 7-11 engine oil and oil filter oil screen (feed) cleaning • remove the oil screen (see oil screen (feed) removal). • clean the oil screen with a high flash-point solvent and remove the particles stuck. • blow away the particles by applying compressed air [a] from the inside...

  • Page 276

    7-12 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: right engine cover (see right engine cover removal in the clutch chapter) oil pressure relief valve [a] oil pressure relief valve installation • apply a non-permanent locking agent to the threads of ...

  • Page 277

    Engine lubrication system 7-13 oil pump oil pump (scavenge) removal • remove: flywheel (see flywheel removal in the electrical sys- tem chapter) oil pump (scavenge) cover bolts [a] lower camshaft chain guide [b] oil pump cover [c] • remove: oil pump shaft [a] with inner rotor [b] outer rotor [c] oil...

  • Page 278

    7-14 engine lubrication system oil pump oil pump (feed) removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) circlip [a] oil pump driven gear [b] shaft [c] oil pump idle gear [d] special tool - outside circlip p...

  • Page 279

    Engine lubrication system 7-15 oil pump • apply molybdenum disulfide grease to the shaft of the oil pump idle gear. • install the oil pump idle gear [a] facing the stepped side [b] to the outside. • install the shaft [c] and oil pump driven gear [d]. • turn the oil pump driven gear to check that the...

  • Page 280

    7-16 engine lubrication system oil pressure oil pressure measurement • remove: oil filter cap bolts [a] oil filter cap [b] • install the o-rings of the oil filter cap to the oil pressure cap [a]. Special tool - oil pressure cap: 57001-1656 • install the oil pressure cap, and tighten the oil filter c...

  • Page 281: Engine Removal/installation

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

  • Page 282

    8-2 engine removal/installation exploded view.

  • Page 283

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

  • Page 284

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

  • Page 285

    Engine removal/installation 8-5 engine removal/installation engine removal • place the jack under the frame to support the motorcycle. Special tools - jack: 57001-1238 jack attachment: 57001-1608 warning when the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detach...

  • Page 286

    8-6 engine removal/installation engine removal/installation • disconnect: water temperature sensor connector (see water tem- perature sensor removal/installation in the fuel system (dfi) chapter) gear position switch lead connector [a] magneto lead connector [b] • remove: water hoses [a] • remove th...

  • Page 287

    Engine removal/installation 8-7 engine removal/installation engine installation • replace with new ones: upper engine mounting nuts middle engine mounting nut middle engine bracket nuts lower engine mounting nut swingarm pivot shaft nut • install the engine. ○ first, insert the front portion of the ...

  • Page 288

    8-8 engine removal/installation engine removal/installation • install the removed parts (see appropriate chapters). • run the cables, hoses, and leads according to the cable, wire and hose routing section in the appendix chapter. • pour: engine oil (see engine oil change in the periodic main- tenanc...

  • Page 289: Crankshaft/transmission

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

  • Page 290

    9-2 crankshaft/transmission exploded view.

  • Page 291

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 piston oil nozzle bolt 7.0 0.71 62 in·lb l 2 crankcase bearing retainer screws 15 1.5 11 l 3 primary gear nut 98 10 72 lh 4 balancer weight mounting nut 52 5.3 38 5 crankcase bolts (m7) 15 1.5 11 s 6 piston oil n...

  • Page 292

    9-4 crankshaft/transmission exploded view.

  • Page 293

    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 ratchet guide bolt 8.8 0.90 78 in·lb 3 ratchet plate bolt 9.8 1.0 87 in·lb s 4 shift drum cam bolt 24 2.4 18 l 5 gear positioning lever nut 8.8 0.90 78 in·lb 6 ratchet plate screw 15...

  • Page 294

    9-6 crankshaft/transmission specifications item standard service limit crankshaft, connection 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 295

    Crankshaft/transmission 9-7 special tools and sealant inside circlip pliers: 57001-143 outside circlip pliers: 57001-144 bearing driver set: 57001-1129 crankshaft jig: 57001-1174 crankcase splitting tool assembly: 57001-1362 gear holder, m2.0: 57001-1557 grip: 57001-1591 rotor holder: 57001-1730 liq...

  • Page 296

    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: piston (see piston removal in the engine top end chap- ter) rig...

  • Page 297

    Crankshaft/transmission 9-9 crankcase • remove: circlip [a] balancer drive gear [b] special tool - outside circlip pliers: 57001-144 • remove the crankcase bolts [a]. • insert a suitable tool to the pry point [a], and split the crankcase. If the crankcase cannot be split easily, split the crankcase ...

  • Page 298

    9-10 crankshaft/transmission crankcase notice do not remove the bearings and the oil seals unless it is necessary. Removal may damage them. Crankcase assembly notice right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set. • ...

  • Page 299

    Crankshaft/transmission 9-11 crankcase • press the new drive shaft bearing [a] in the right crankcase half [b] so that the stepped side [c] faces inside of the engine. Special tool - bearing driver set: 57001-1129 • press the new crankshaft bearings [a] in the left and right crankcase halves [b] so ...

  • Page 300

    9-12 crankshaft/transmission crankcase • next, press the new outside release shaft needle bear- ing [a] until the surface of the bearing is even with the crankcase surface [b]. Special tool - bearing driver set: 57001-1129 • replace the oil seals, if removed. • press the release shaft oil seal [a] s...

  • Page 301

    Crankshaft/transmission 9-13 crankcase • when installing the piston oil nozzle [a], note the follow- ing. ○ replace the o-ring [b] with a new one. ○ install the o-ring to the piston oil nozzle. ○ apply a non-parmanent locking agent to the threads of the piston oil nozzle bolt [a]. ○ tighten: torque ...

  • Page 302

    9-14 crankshaft/transmission crankcase • using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • apply liquid gasket to the mating surface [a] of the left crankcase half. Sealant - liquid gasket, tb1216: 92104-1063 not...

  • Page 303

    Crankshaft/transmission 9-15 crankcase • replace the washers [a] with a new one. • tighten the crankcase bolts, starting with the periphery of the crankshaft, then outward. Torque - crankcase bolts (m6): 12 n·m (1.2 kgf·m, 106 in·lb) crankcase bolts (m7): 15 n·m (1.5 kgf·m, 11 ft·lb) note ○ after ti...

  • Page 304

    9-16 crankshaft/transmission crankcase • replace the circlip [a] with a new one, and install it to the output shaft. Special tool - outside circlip pliers: 57001-144 • install the removed parts (see appropriate chapters)..

  • Page 305

    Crankshaft/transmission 9-17 crankshaft crankshaft removal • split the crankcase (see crankcase disassembly). • remove the crankshaft [a] from the right crankcase half [b]. Crankshaft installation • install the crankshaft to the right crankcase half. • apply engine oil to the connecting rod big end ...

  • Page 306

    9-18 crankshaft/transmission crankshaft crankshaft inspection connecting rod big end radial clearance inspection • set the crankshaft on v blocks, and place a dial gauge [a] against the connecting rod big end. • push [b] the connecting rod first towards the gauge and then in the opposite direction. ...

  • Page 307

    Crankshaft/transmission 9-19 crankshaft • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vise, depending on the nature of the misalign- ment. Notice do not hammer the crank half at the point [b]. If flywheel misalignment ca...

  • Page 308

    9-20 crankshaft/transmission crankshaft connecting rod twist inspection • with the big-end arbor [a] still on the v block [c], hold the connecting rod horizontally and measure the amount that the arbor [b] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor...

  • Page 309

    Crankshaft/transmission 9-21 transmission transmission shaft removal • split the crankcase (see crankcase disassembly). • pull out the shift rods [a] allowing the shift fork guide pins to free from the shift drum [b]. • remove: shift drum shift forks [c] • pull out the drive shaft [d] and output sha...

  • Page 310

    9-22 crankshaft/transmission transmission transmission shaft assembly • apply engine oil liberally to the transmission shaft, gears and bearings. • replace any circlips that were removed with new ones. ○ always install the circlips [a] so that the opening [b] is aligned with a spline groove [c], and...

  • Page 311

    Crankshaft/transmission 9-23 transmission 1. 2nd gear (17t) 2. Circlip 3. Toothed washer 4. Bushing 5. 4th gear (19t) 6. 3rd gear (16t) 7. 5th gear (24t) 8. 1st gear (16t) 9. Drive shaft 10. Output shaft 11. 1st gear (28t) 12. 5th gear (21t) 13. 3rd gear (19t) 14. 4th gear (19t) 15. 2nd gear (24t) 1...

  • Page 312

    9-24 crankshaft/transmission transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear inspectio...

  • Page 313

    Crankshaft/transmission 9-25 balancer balancer removal • remove: magneto cover (see magneto cover removal in the electrical system chapter) • hold the flywheel [a] steady with the rotor holder [b], and loosen the balancer weight mounting nut [c]. Special tools - grip [d]: 57001-1591 rotor holder: 57...

  • Page 314

    9-26 crankshaft/transmission 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) oil pump idle gear (see oil pump (feed) removal in the engine lubrication system chapter) • temporarily...

  • Page 315

    Crankshaft/transmission 9-27 external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • install the shift pedal so that the slit [a] on the pedal aligns with the punch mark [b] on the shift shaft. • tighten: torque - shift pedal bolt: 9.8 n...

  • Page 316

    9-28 crankshaft/transmission external shift mechanism external shift mechanism installation • install the spring [a], collar and gear positioning lever [b]. ○ fit each end of the spring to the original positions. • install the washer [c]. • tighten: torque - gear positioning lever nut [d]: 8.8 n·m (...

  • Page 317

    Crankshaft/transmission 9-29 external shift mechanism • before installing the shift shaft, apply grease to the oil seal lips and shift shaft splines. • insert the shift shaft [a]. ○ take care not to damage the oil seal when inserting the shift shaft. • install the removed parts (see appropriate chap...

  • Page 318

    9-30 crankshaft/transmission kickstarter kick pedal assy removal • remove: kick pedal bolt [a] and washer kick pedal assy [b] kick pedal assy 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 ...

  • Page 319

    Crankshaft/transmission 9-31 kickstarter idle gear removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) circlip [a] idle gear [b] special tool - outside circlip pliers: 57001-144 idle gear installation • make su...

  • Page 320

    9-32 crankshaft/transmission kickstarter kickshaft installation • install the ratchet guide [a] pushing it to counterclockwise. • tighten: torque - ratchet guide bolt [b]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • apply molybdenum disulfide grease to the end [c] of the kick shaft. • insert the kick shaft ass...

  • Page 321

    Crankshaft/transmission 9-33 kickstarter • apply grease to the inside of the spring guide [a]. • fit the spring end [b] and hollow [c] on the spring guide..

  • Page 322

    9-34 crankshaft/transmission bearings/oil seals bearing replacement notice do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • using a press or puller, remove the ball bearing and/or needle bearings. Note ○ in the absence of the above mentioned tools, satisfa...

  • Page 323

    Crankshaft/transmission 9-35 bearings/oil seals • inspect the needle bearings. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the conditi...

  • Page 325: Wheels/tires

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

  • Page 326

    10-2 wheels/tires exploded view.

  • Page 327

    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 clamp bolts 20 2.0 15 al, s 3 front axle nut 78 8.0 58 s 4 rear axle nut 108 11.0 79.7 al: tighten the two clamp bolts alternately two ...

  • Page 328

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim size: front 21 × 1.60 – – – rear 19 × 2.15 – – – rim runout: axial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) radial tir 1.0 mm (0.04 in.) or less tir 2.0 mm (0.08 in.) axle runout/100 mm (3.94 in.) tir 0.03 mm (...

  • Page 329

    Wheels/tires 10-5 special tools inside circlip pliers: 57001-143 rim protector: 57001-1063 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover head, 25 × 28: 57001-1346 bearing remover shaft, 13: 57001-1377 jack attachment: 57001-1608.

  • Page 330

    10-6 wheels/tires wheels (rims) front wheel removal • remove the axle nut [a]. • loosen the axle clamp bolts [b] on both sides. • raise the front wheel off the ground with jack. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • pull out the axle and remove the wheel. • remove the collar...

  • Page 331

    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 332

    10-8 wheels/tires wheels (rims) • remove the collars [a] with caps [b] on both sides. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • insert a wood wedge between the brake pad...

  • Page 333

    Wheels/tires 10-9 wheels (rims) • insert a new cotter pin [a]. Note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [b] up to next alignment. ○ it should be within 30°. ○ loosen once and tighten again when the slot...

  • Page 334

    10-10 wheels/tires wheels (rims) rim installation position • when installing the rim, set the rim following position. ○ the distance [a] from the brake disc seating surface [b] of the front hub [c] to left end of the front rim [d] should be as follows. View from front [e] distance: 26.5 ±0.5 mm (1.0...

  • Page 335

    Wheels/tires 10-11 tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire removal • remove the wheel (see front/rear wheel removal). Notice do not lay the front wheel on the ground with the disc facing down. This can dam...

  • Page 336

    10-12 wheels/tires tires • break the beads away from both sides of the rim with a suitable bead breaker. • lubricate the suitable tire irons [a] and rim protectors [b] with soap and water solution or rubber lubricant. Special tool - rim protector: 57001-1063 • step on the side of the tire opposite a...

  • Page 337

    Wheels/tires 10-13 tires • tighten the bead protector nut [a], air valve nut [b] and air valve cap [c]. • adjust the tire air pressure to the specified pressure (see air pressure inspection/adjustment in the periodic main- tenance chapter)..

  • Page 338

    10-14 wheels/tires 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 bloc...

  • Page 339

    Wheels/tires 10-15 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 340

    10-16 wheels/tires 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 341: Final Drive

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

  • Page 342

    11-2 final drive exploded view.

  • Page 343

    Final drive 11-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 r 2 engine sprocket nut 70 7.1 52 3 engine sprocket cover bolts 9.8 1.0 87 in·lb 4. Kx450fc ho: apply heavy oil. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 344

    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 114 links – – – sprocket rear sprocket warp ti...

  • Page 345

    Final drive 11-5 drive chain drive chain slack inspection • refer to the drive chain slack inspection in the periodic maintenance chapter. Drive chain slack adjustment • refer to the drive chain slack adjustment in the periodic maintenance chapter. Wheel alignment inspection • check that the notch [...

  • Page 346

    11-6 final drive 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 347

    Final drive 11-7 sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • flatten the bended sprocket washer [a]. • remove: engine sprocket nut [b] washer • remove the engine sprocket [c] from the drive chain [d]. Engine sprocket i...

  • Page 348

    11-8 final drive sprockets rear sprocket installation • replace the rear sprocket nuts with new ones. • install the rear sprocket [a] so that the marked side [b] faces out. • install the rear sprocket bolts and washers. • tighten: torque - rear sprocket nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) sprocket we...

  • Page 349: Brakes

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

  • Page 350

    12-2 brakes exploded view.

  • Page 351

    Brakes 12-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 brake lever pivot bolt 5.9 0.60 52 in·lb si 2 brake lever pivot bolt locknut 5.9 0.60 52 in·lb 3 front master cylinder clamp bolts 8.8 0.90 78 in·lb s 4 brake reservoir cap screws 1.5 0.15 13 in·lb 5 brake hose banjo bolts 25 2....

  • Page 352

    12-4 brakes exploded view.

  • Page 353

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear master cylinder mounting bolts 9.8 1.0 87 in·lb 2 brake reservoir cap screws 1.5 0.15 13 in·lb 3 brake hose banjo bolts 25 2.5 18 4 rear master cylinder push rod locknut 17 1.7 13 5 brake pad pin plug 2.5 0.25 22 in·lb 6 br...

  • Page 354

    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 355

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

  • Page 356

    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 357

    Brakes 12-9 brake lever, brake pedal • replace the cotter pin with a new one. • install the joint pin, washer and new cotter pin. ○ bend the ends [a] of the cotter pin as shown in the figure. • check the brake pedal position (see brake lever and pedal adjustment in the periodic maintenance chapter)..

  • Page 358

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

  • Page 359

    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 360

    12-12 brakes brake fluid • bleed the brake line and caliper as follows: ○ repeat this operation until no more air can be seen com- ing out into the clear 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 wh...

  • Page 361

    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 362

    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 363

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

  • Page 364

    12-16 brakes caliper caliper piston and cylinder damage inspection • visually inspect the piston(s) [a] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front caliper [b] rear caliper [c] caliper holder shaft wear inspection the caliper body must slide...

  • Page 365

    Brakes 12-17 brake pad brake pad removal front brake • loosen the pad pin [a]. • remove the bolts [b]. • remove the caliper with the hose installed. • remove: pad pin [a] brake pads [b] rear brake • remove: pad pin plug [a] • remove the pad pin [a]. • remove the piston side pad [b]. • push the calip...

  • Page 366

    12-18 brakes brake pad brake pad installation • push the caliper piston(s) in by hand as far as they will go. • install the piston side pad first, and then another pad. ○ fit the pad end into the groove [a] of the anti-rattle spring securely. Front brake [b] rear brake [c] • install the front calipe...

  • Page 367

    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 368

    12-20 brakes master cylinder kx450fd ∼ • install the master cylinder [a]. 176.95 mm (6.967 in.) [b] horizontal line of frame [c] handlebars [d] horizontal line of cap surface [e] • the master cylinder clamp must be installed with the ar- row mark [a] upward. • tighten the upper clamp bolt [b] first,...

  • Page 369

    Brakes 12-21 master cylinder rear master cylinder removal • remove: cotter pin [a] joint pin [b] washer [c] note ○ pull off the joint pin while pressing down the brake pedal. • remove the master cylinder mounting bolts [a], and re- move the master cylinder [b] backward. • remove the brake hose banjo...

  • Page 370

    12-22 brakes master cylinder front master cylinder disassembly • refer to the brake master cylinder cup and dust cover replacement in the periodic maintenance chapter. Rear master cylinder disassembly • refer to the brake master cylinder cup and dust cover replacement in the periodic maintenance cha...

  • Page 371

    Brakes 12-23 brake disk brake disc removal • remove the wheels (see front/rear wheel removal in the wheels/tires chapter). • remove 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. Front brake disk [b] rea...

  • Page 372

    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 373: Suspension

    Suspension 13-1 13 suspension table of contents exploded view................................... 13-2 specifications .................................... 13-8 special tools ..................................... 13-10 front fork .......................................... 13-11 air pressure (kx450fc) ...

  • Page 374

    13-2 suspension exploded view kx450fc.

  • Page 375

    Suspension 13-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 20 2.0 15 al 2 brake hose clamp bolt 2.0 0.20 18 in·lb 3 pressure relief screws 1.2 0.12 11 in·lb 4 base valve assemblies 30 3.1 22 5 front fork clamp bolts (lower) 20 2.0 15 al 6 front fork to...

  • Page 376

    13-4 suspension exploded view kx450fd ∼.

  • Page 377

    Suspension 13-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 front fork clamp bolts (upper) 20 2.0 15 al 2 brake hose clamp bolt 2.0 0.20 18 in·lb 3 air valve plug 0.2 0.020 1.8 in·lb 4 base valve assemblies 30 3.1 22 5 front fork clamp bolts (lower) 20 2.0 15 al 6 front fork top plug...

  • Page 378

    13-6 suspension exploded view.

  • Page 379

    Suspension 13-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear shock absorber nut (upper) 39 4.0 29 r 2 rear shock absorber nut (lower) 34 3.5 25 r 3 tie-rod mounting nuts 59 6.0 44 r 4 rocker arm pivot nut 59 6.0 44 r 5 swingarm pivot shaft nut 98 10 72 r 6 piston rod locknut 28 2...

  • Page 380

    13-8 suspension specifications item standard service limit front fork kx450fc: air pressure atmospheric pressure – – – rebound damping adjustment (from the seated position adjuster turned fully clockwise) 10 clicks counterclockwise (adjustable range) 20 clicks compression damping adjustment (from th...

  • Page 381

    Suspension 13-9 specifications item standard service limit rear shock spring free length 255 mm (10.0 in.) 250 mm (9.84 in.) suspension oil kawasaki khv10-k2c or equivalent – – – amount: approx. 417 ml (14.1 us oz.) – – – gas reservoir high speed compression damping adjustment (from the seated posit...

  • Page 382

    13-10 suspension special tools oil seal & bearing remover: 57001-1058 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 fork oil seal driver, 48: 57001-1509 jack attachment: 57001-1608.

  • Page 383

    Suspension 13-11 front fork air pressure (kx450fc) if you felt that a front fork is strong during a driving, place the jack under the frame so that the front wheel off the ground, and remove the screw [a] at the top of the front fork top plugs to let the air pressure equalize. Special tools - jack: ...

  • Page 384

    13-12 suspension front fork note ○ when using the air valve adapter, make sure that there is no dust or foreign material on the threads and o-ring. ○ when the handlebar clamps are in the front position in the steering stem head, the air valve adapter cannot be installed. • adjust the air pressure in...

  • Page 385

    Suspension 13-13 front fork seated position [a]: adjuster turned fully clockwise. Notice do not force the compression damping adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. Compression damping adjuster setting standard: 10 clicks [b] (kx450fc) (eur, br) 13 clic...

  • Page 386

    13-14 suspension front fork front fork removal • remove: number plate (see number plate removal in the frame chapter) bolts [a] brake hose clamps [b] • remove: front caliper mounting bolts [a] • remove the caliper [b] from the fork leg to be removed, and rest the caliper on some kind of stand so tha...

  • Page 387

    Suspension 13-15 front fork front fork installation • install the fork so that the distance [a] between the top end of the outer tube and the upper surface of the steering stem head is specified dimension. Kx450fc (other than eur, br): 10 mm (0.39 in.) kx450fc (eur, br): 5 mm (0.2 in.) kx450fd ∼ : 5...

  • Page 388

    13-16 suspension front fork • remove the following parts from the inner tube. Guide bushes [a] washer [b] collar [c] oil seal [d] retaining ring [e] dust seal [f] front fork assembly • when the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the for...

  • Page 389

    Suspension 13-17 front fork • install the retaining ring to the outer tube. • push the dust seal into the outer tube, and put the spring band on the dust seal. • pour the fork oil (see front fork oil change in the periodic maintenance chapter). Adjuster assembly inspection • inspect the adjuster ass...

  • Page 390

    13-18 suspension front fork inner tube inspection • visually inspect the inner tube [a]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced. Notice if the inner tube...

  • Page 391

    Suspension 13-19 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 392

    13-20 suspension rear shock absorber • adjust the high speed compression damping, turn the high speed compression damping adjuster with a 14 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 393

    Suspension 13-21 rear shock absorber • using the jack under the frame, raise the rear wheel off the ground. Special tools - jack: 57001-1238 jack attachment: 57001-1608 • using the hook wrenches [a] (r42, 57001-1103 × 2), loosen the locknut [b]. ○ the hook wrench (r42, 57001-1103) is in the hook wre...

  • Page 394

    13-22 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 395

    Suspension 13-23 rear shock absorber • hold the lower end of the rear shock absorber in a vise with soft jaws or a heavy cloth. • using the hook wrenches [a] (r42, 57001-1103 × 2), loosen the locknut [b] and turn the adjusting nut [c] all way up. ○ the hook wrench (r42, 57001-1103) is in the hook wr...

  • Page 396

    13-24 suspension rear shock absorber • hold the lower of the piston rod assembly in a vise with soft jaws or a heavy cloth. • remove the piston rod locknut [a] and washers for the threads length adjustment. • discard the piston rod locknut. • remove the piston assembly [a] as it is. ○ be careful not...

  • Page 397

    Suspension 13-25 rear shock absorber • make the threads of the piston rod end using the die [a]. Die: 12 × 1.5 mm • clean all parts with solvent and dry them with compressed air. Rear shock absorber assembly • install: damper holder [a] damper [b] stopper [c] • wrap the threads of the piston rod wit...

  • Page 398

    13-26 suspension rear shock absorber rear shock absorber oil change • refer to the rear shock absorber oil change in the pe- riodic maintenance chapter. Rear shock absorber inspection • remove the rear shock absorber (see rear shock ab- sorber removal). • visually inspect the following items. Oil le...

  • Page 399

    Suspension 13-27 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 hose clamps [a] • remove: bolts [a] and nuts [b] chain guide plate [c] chain guide [d] • remove the rocker arm pivot nut...

  • Page 400

    13-28 suspension swingarm • remove the screws [a]. • remove the chain slipper [b] from the swingarm. Swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • apply a non-permanent locking agent to the chain slipper mounting screws. • install...

  • Page 401

    Suspension 13-29 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 upper and lower chain guide rollers [a] and replace them if excessively worn or damaged. • visua...

  • Page 402

    13-30 suspension 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: 57001-1608 • remove: nut [a] lower chain guide roller [b] • remove: rear tie-rod mounting bolt and nut [a] front tie-rod mount...

  • Page 403

    Suspension 13-31 tie-rod, rocker arm 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 the needle bearings and grease seals. • check that collars are in place on the rocker arm. • install th...

  • Page 404

    13-32 suspension tie-rod, rocker arm • install the needle bearings [a] [b], oil seals [c] and grease seals [d] so that their positions are as shown in the figure. ○ the other side is also the same procedures. Front [e] right side [f] left side [g] rear shock absorber [h] tie-rod [i] rocker arm [j] d...

  • Page 405

    Suspension 13-33 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 407: Steering

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

  • Page 408

    14-2 steering exploded view.

  • Page 409

    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 front fork clamp bolts (upper) 20 2.0 15 al 4 steering stem nut 4.9 0.50 43 in·lb t 5 handle holder nuts 34 3.5 25 r 6 brake hose clamp bolt 2.0 0.20 18 in...

  • Page 410

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

  • Page 411

    Steering 14-5 steering steering inspection • refer to the steering inspection in the periodic mainte- nance chapter. Steering adjustment • refer to the steering adjustment in the periodic mainte- nance chapter. Steering stem, stem bearing removal • remove: number plate (see number plate removal in t...

  • Page 412

    14-6 steering steering • remove the upper stem bearing inner race (tapered roller bearing) [a]. • drive out the bearing outer races from the head pipe. ○ remove the outer races pressed into the head pipe, using the head pipe outer race remover [a], and hammer the head pipe outer race remover to driv...

  • Page 413

    Steering 14-7 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 414

    14-8 steering 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 415

    Steering 14-9 handlebar handlebar removal • remove: number plate (see number plate removal in the frame chapter) handlebar pad [a] fuel tank breather hose [b] • remove: clutch lever holder assembly [a] engine stop switch [b] launch control mode button [c] band(s) [d] left handlebar grip [e] kx450fc ...

  • Page 416

    14-10 steering handlebar handlebar installation • apply adhesive cement to the innermost area of the left handlebar grip and all-around inner surface of the left han- dlebar grip hole entrance and also apply it to the roulette area on the handlebars. • the left handlebar grip must be installed with ...

  • Page 417

    Steering 14-11 handlebar • install the throttle grip assembly so that the grip [a] is in as far as it will go. ○ position the throttle grip assembly so that the cable gate- way [b] of the throttle case is above the handlebar. • install the front master cylinder (see front master cylinder installatio...

  • Page 418

    14-12 steering handlebar • remove the handlebar pad. • remove the handlebar clamp bolts [a], handlebar clamps [b] and handlebar [c]. • check the handlebar for damage or cracks. If the handlebar is damage or cracks, replace it with a new one. • remove: handlebar holder nuts [a] flat washers [b] round...

  • Page 419: Frame

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

  • Page 420

    15-2 frame exploded view.

  • Page 421

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 radiator shroud bolts 9.8 1.0 87 in·lb s 2 footpeg bracket bolts (upper) 34 3.5 25 l 3 footpeg bracket bolts (lower) 16.5 1.68 12.2 l 4 rear frame mounting bolts 34 3.5 25 5. Kx450fc 6. Other than kx450fc and kx450fd ∼ us, ca mod...

  • Page 422

    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 423

    Frame 15-5 frame engine guards removal • remove the engine guards as shown in the figure. Right engine guard [a] lower engine guard [b] bolts [c] collars [d] engine guards installation • installation is the reverse of removal. Note the following. ○ fit the projection [a] of the right engine guard to...

  • Page 424

    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 425

    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 426

    15-8 frame radiator shroud radiator shroud removal • remove: bolts [a] radiator shroud [b] ○ clear the radiator shroud tabs [c] from the air cleaner housing. Radiator shroud installation • install the radiator shrouds. ○ insert the tabs [a] of the radiator shroud into the slots [b] of the air cleane...

  • Page 427

    Frame 15-9 number plate number plate removal • unlock the band [a] of the number plate [b]. • remove the bolt [c]. • clear the projections [d] and remove the number plate. Number plate installation kx450fc • insert the projections [a] of the number plate into the holes [b] of the steering stem base....

  • Page 428

    15-10 frame fender front fender removal/installation • remove the bolts [a] and take off the front fender. • installation is the reverse of removal. Rear fender removal/installation • remove the side covers (see side cover removal). • remove the bolts [a]. • remove the bolt [a] on both sides, and ta...

  • Page 429

    Frame 15-11 footpegs footpeg removal • for the right footpeg removal, remove the brake pedal assy (see right engine cover removal in the clutch chapter). • remove: cotter pin [a] washer [b] pivot pin [c] spring [d] footpeg [e] footpeg bracket bolt [f] footpeg bracket [g] footpeg installation note ○ ...

  • Page 430

    15-12 frame footpegs footpeg height adjustment ○ the footpeg can be adjusted in two positions. Footpeg bracket [a] bolts [b] bolt holes [c] upper position [d] lower position [e] • remove: footpegs (see footpeg removal) • adjust the footpeg height. Note ○ install the footpegs with same height on both...

  • Page 431: Electrical System

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

  • Page 432

    16-2 electrical system exploded view.

  • Page 433

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 regulator/rectifier nuts 10 1.0 89 in·lb r 2 ignition coil bolts 9.8 1.0 87 in·lb 3 spark plug 13 1.3 115 in·lb 4 breather fitting 15 1.5 11 l 5 magneto cover bolts 9.8 1.0 87 in·lb 6 timing inspection cap 3.5 0.36 31...

  • Page 434

    16-4 electrical system specifications item standard flywheel magneto magneto output voltage 37 v or more at 4 000 r/min (rpm) stator coil resistance 0.4 ∼ 1.1 Ω at 20°c (68°f) charging system charging voltage (regulator/rectifier output voltage) 14.0 ∼ 14.5 v capacitor internal resistance see text i...

  • Page 435

    Electrical system 16-5 special tools and sealant bearing driver set: 57001-1129 rotor puller, m16/m18/m20/m22 × 1.5: 57001-1216 timing light: 57001-1241 hand tester: 57001-1394 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 flywheel puller, m28 × 1.0: 5...

  • Page 436

    16-6 electrical system special tools and sealant liquid gasket, tb1211f: 92104-0004.

  • Page 437

    Electrical system 16-7 special tools and sealant this page intentionally left blank..

  • Page 438

    16-8 electrical system wiring diagram.

  • Page 439

    Electrical system 16-9 wiring diagram.

  • Page 440

    16-10 electrical system precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the...

  • Page 441

    Electrical system 16-11 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 442

    16-12 electrical system 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 shroud removal in the frame chapter) shift pedal (see shift pedal removal in the crank- shaft/transmission...

  • Page 443

    Electrical system 16-13 flywheel magneto • when installing the breather fitting [a], note the following. ○ apply a non-permanent locking agent to the threads of the breather fitting. ○ tighten: torque - breather fitting: 15 n·m (1.5 kgf·m, 11 ft·lb) • install: magneto cover [a] holder [b] clamps [c]...

  • Page 444

    16-14 electrical system flywheel magneto flywheel installation • using a high flash-point solvent, clean off any oil or dirt on the following portions and dry them with a clean cloth. Crankshaft tapered portion [a] flywheel tapered portion [b] • fit the woodruff key [c] securely in the slot of the c...

  • Page 445

    Electrical system 16-15 flywheel magneto stator coil installation • apply a non-permanent locking agent to the threads of the stator coil bolts. • install the stator coil and crankshaft sensor as a set. • tighten: torque - stator coil bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the holder [a] and...

  • Page 446

    16-16 electrical system flywheel magneto flywheel magneto inspection there are three types of magneto problems: short, open (lead burned out), or loss in flywheel magnetism. A short or open in one of the coil leads will result in either a low output, or no output at all. A loss in flywheel magnetism...

  • Page 447

    Electrical system 16-17 flywheel magneto if there is more resistance than shown in the table, or no tester reading (infinity), the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • using the highest resistance range of t...

  • Page 448

    16-18 electrical system charging system regulator/rectifier removal • remove: fuel tank (see fuel tank removal in the fuel system (dfi) chapter) • open the clamp [a], and free the leads. • disconnect the regulator/rectifier lead connector [b]. • remove: regulator/rectifier bracket bolts [a] regulato...

  • Page 449

    Electrical system 16-19 charging system • connect the 12 v battery to the main harness (see self -diagnosis procedures in the fuel system (dfi) chapter). • connect a tester [a] to the battery terminals [b]. • start the engine, and note the voltage readings at various engine speeds. But they must be ...

  • Page 450

    16-20 electrical system charging system charging system troubleshooting note ○ be sure the prepared battery is fully charged..

  • Page 451

    Electrical system 16-21 charging system capacitor removal • disconnect the connector [a], and pull the capacitor [b] upward. Capacitor installation • face the lead of the capacitor downward, and insert the capacitor to the bracket. • connect the connector. Capacitor inspection • remove: capacitor (s...

  • Page 452

    16-22 electrical system ignition timing ignition timing inspection • remove the timing inspection cap [a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • star...

  • Page 453

    Electrical system 16-23 ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Ignition coil removal • remove: f...

  • Page 454

    16-24 electrical system ignition system • install the spark plug cap [a] so that it is aligned with the line [b] on the cylinder head cover. • pull up the spark plug cap lightly to make sure of the in- stallation of the spark plug cap. Ignition coil inspection measuring arcing distance the most accu...

  • Page 455

    Electrical system 16-25 ignition system measuring coil resistance if the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with a digital meter. However, the digital meter cannot detect layer shorts and shorts resulting from insulation breakdown under high...

  • Page 456

    16-26 electrical system ignition system ignition coil primary peak voltage check • remove the spark plug cap from the spark plug, but do not remove the spark plug. • install the good spark plug [a] to the spark plug cap, then touch the frame with it. Note ○ measure the voltage with each lead connect...

  • Page 457

    Electrical system 16-27 ignition system.

  • Page 458

    16-28 electrical system ignition system crankshaft sensor peak voltage check • disconnect the magneto lead connector (see magneto cover removal). Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if disconnected. ○ maintain the correct value of co...

  • Page 459

    Electrical system 16-29 ignition system engine stop switch system check • start the engine. • push the engine stop switch [a], stop the engine. If the engine does not stop, check the engine stop switch for continuity (see engine stop switch inspection). If the engine stop switch is good, check the w...

  • Page 460

    16-30 electrical system ignition system • check the wiring for continuity between the terminals of each connector referring the connector circuit. White connector [a] green connector [b] black connector [c] if a digital meter [d] does not read 0 Ω, the connector is defective. Replace the connector w...

  • Page 461

    Electrical system 16-31 switches engine stop switch inspection • using a digital meter, check to see that the connections shown in the table have continuity (about zero ohms). If the switch has an open or short, replace it with a new one. Engine stop switch connection launch control mode button insp...

  • Page 463: Appendix

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

  • Page 464

    17-2 appendix cable, wire, and hose routing kx450fc 1. Throttle cable (accelerator) 2. Throttle cable (decelerator) 3. Bands (hold the engine stop switch lead and launch control mode button lead. Cut the excess of the bands into 15 mm length or shorter.) 4. Launch control mode button 5. Engine stop ...

  • Page 465

    Appendix 17-3 cable, wire, and hose routing this page intentionally left blank..

  • Page 466

    17-4 appendix cable, wire, and hose routing kx450fd ∼.

  • Page 467

    Appendix 17-5 cable, wire, and hose routing 1. Front brake hose 2. Run the throttle cables inside of the number plate. 3. Clutch cable 4. Run the clutch cable inside of the number plate. 5. Run the front brake hose outside of the number plate. 6. Throttle cable (accelerator) 7. Throttle cable (decel...

  • Page 468

    17-6 appendix cable, wire, and hose routing kx450fc 1. Launch control mode button lead 2. Engine stop switch lead 3. Main harness 4. Run the clutch cable outside of the main harness. 5. Clutch cable 6. Clamp 7. Clamp (wind the clamp on the cable.) 8. Run the clutch cable outside of the mag- neto lea...

  • Page 469

    Appendix 17-7 cable, wire, and hose routing kx450fd ∼ 1. Launch control mode button lead 2. Clutch cable 3. Launch control mode button connector 4. Run the clutch cable outside of the main harness. 5. Main harness 6. Engine stop switch lead 7. Clamps (wind the clamps on the cable.) 8. Gear position ...

  • Page 470

    17-8 appendix cable, wire, and hose routing kx450fc 1. Launch control mode button lead 2. Engine stop switch lead 3. Clamp 4. Hold the engine stop switch lead and the main harness. 5. Water hoses 6. Fuel pump lead connector 7. Gear position switch lead connector 8. Capacitor lead connector 9. Magnet...

  • Page 471

    Appendix 17-9 cable, wire, and hose routing kx450fd ∼ 1. Launch control mode button lead 2. Engine stop switch lead 3. Position the self-diagnosis terminal out- side of the main harness. 4. Clamp 5. Run the main harness over the water hose. 6. Gear position switch lead connector 7. Fuel pump lead co...

  • Page 472

    17-10 appendix cable, wire, and hose routing kx450fc.

  • Page 473

    Appendix 17-11 cable, wire, and hose routing 1. Viewed a 2. Frame pipe 3. Upper side 4. Regulator/rectifier lead 5. Main harness 6. Clamp (hold the pvc tube of the regulator/rectifier lead and main harness. Do not hold the regulator/rectifier leads.) 7. Front side 8. Viewed b 9. Do not touch the reg...

  • Page 474

    17-12 appendix cable, wire, and hose routing kx450fd ∼.

  • Page 475

    Appendix 17-13 cable, wire, and hose routing 1. Water hoses 2. Clamp 3. Regulator/rectifier 4. Regulator/rectifier lead 5. Kx fi calibration kit lead connector 6. Ignition coil 7. Capacitor 8. Ignition coil lead connector 9. Fuel pump lead connector 10. Position the engine stop switch lead connector...

  • Page 476

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

  • Page 477

    Appendix 17-15 cable, wire, and hose routing 1. Frame ground 2 lead 2. Tighten the ignition coil mounting bolt together with the frame ground 2 and ignition coil ground. 3. Ignition coil ground lead 4. Capacitor (do not touch the radiator.) 5. Ignition coil 6. Vehicle-down sensor 7. Do not touch the...

  • Page 478

    17-16 appendix cable, wire, and hose routing kx450fc 1. Hold the harness at the blue tape por- tions. 2. Intake air temperature sensor connector 3. Throttle sensor connector 4. Intake air pressure sensor connector 5. Fuel injector connector 6. Water temperature sensor connector.

  • Page 479

    Appendix 17-17 cable, wire, and hose routing kx450fd ∼ 1. Intake air pressure sensor connector 2. Main harness 3. Intake air temperature sensor connector 4. Fuel injector connector 5. Throttle sensor connector 6. Water temperature sensor connector.

  • Page 480

    17-18 appendix cable, wire, and hose routing kx450fd ∼.

  • Page 481

    Appendix 17-19 cable, wire, and hose routing 1. Clamp (run the throttle sensor lead inside of the clamp.) 2. Intake air pressure sensor 3. Throttle sensor connector 4. Fuel injector connector 5. Intake air temperature sensor lead 6. Intake air temperature sensor 7. Throttle sensor 8. Run the throttl...

  • Page 482

    17-20 appendix cable, wire, and hose routing 1. Intake air temperature sensor lead 2. Run the intake air temperature sensor lead through the hole of the guide as shown in the figure. 3. Bracket 4. Do not show up the intake air temperature sensor lead above the bracket as shown in the figure. 5. Do n...

  • Page 483

    Appendix 17-21 cable, wire, and hose routing 1. Viewed a 2. Viewed b 3. Clamp (face the claw portion leftward.) 4. Face the white mark of the hoses upward. 5. Clamp (face the claw portion forward and downward.) 6. Left radiator 7. Right radiator 8. Align the rib of the joint pipe to the white mark o...

  • Page 484

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

  • Page 485

    Appendix 17-23 cable, wire, and hose routing 1. Viewed a 2. 45° 3. Spark plug cap 4. Viewed b 5. Run the magneto lead under the claw of the holder. 6. Magneto lead 7. Viewed c 8. Radiator overflow hose 9. Run the fuel pump lead over the fuel hose and between the fuel hose and frame. 10. Paint mark 1...

  • Page 486

    17-24 appendix cable, wire, and hose routing 1. Touch the front brake hose fitting to the stopper. 2. Brake hose 3. Clamp 4. Viewed a 5. Clamps.

  • Page 487

    Appendix 17-25 cable, wire, and hose routing 1. Brake hose 2. Clamps 3. Cotter pin 4. Touch the rear brake hose fitting to the stopper. 5. Viewed a.

  • Page 488

    17-26 appendix troubleshooting guide note ○ refer to the fuel system (dfi) chapter for most of dfi trouble shooting 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 com...

  • Page 489

    Appendix 17-27 troubleshooting guide spark plug cap or spark plug lead trouble spark plug cap shorted or not in good con- tact spark plug incorrect heat value ecu trouble crankshaft sensor trouble flywheel damage ignition coil trouble wiring connector not in good contact fuel/air mixture incorrect: ...

  • Page 490

    17-28 appendix troubleshooting guide gear seized gear positioning lever operation trouble shift drum broken jumps out of gear: shift fork ear worn, bent gear groove worn gear dogs and/or dog holes worn shift drum groove worn gear positioning lever spring weak or bro- ken shift fork guide pin worn dr...

  • Page 491

    Appendix 17-29 troubleshooting guide steering stem bearing damaged steering stem bearing lubrication inade- quate steering stem bent tire air pressure too low handlebar shakes or excessively vibrates: tire worn swingarm pivot bearings worn rim warped, or not balanced spokes loose wheel bearing worn ...

  • Page 492

    Model application year model beginning frame no. 2012 kx450fc jkakxgfc □ ca000001 jkakx450ffa000001 2013 kx450fd jkakxgfc □ da012001 jkakx450ffa012001 2014 kx450fe jkakxgfc □ ea022001 jkakx450ffa022001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1448-03 print...