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

  • Page 7: Foreword

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

  • Page 9: General Information

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

  • Page 10

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

  • Page 11

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

  • Page 12

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

  • Page 13

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

  • Page 14

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

  • Page 15

    General information 1-7 model identification kx450d6f left side view kx450d6f right side view.

  • Page 16

    1-8 general information general specifications items kx450d6f ∼ d8f dimensions overall length 2 185 mm (86.02 in.) overall width 820 mm (32.3 in.) overall height 1 280 mm (50.39 in.) wheelbase 1 485 mm (58.46 in.) road clearance 345 mm (13.6 in.) seat height 965 mm (38.0 in.) dry mass 99.8 kg (220 l...

  • Page 17

    General information 1-9 general specifications items kx450d6f ∼ d8f transmission: type 4-speed, constant wesh, return shift (kx450d6f) 5-speed, constant mesh, return shift (kx450d7f ∼ ) gear ratios: 1st 1.800 (27/15) (kx450d6f), 1.750 (28/16) (kx450d7f ∼ ) 2nd 1.411 (24/17) 3rd 1.187 (19/16) 4th 1.0...

  • Page 18

    1-10 general information unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us)...

  • Page 19: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart .............. 2-3 torque and locking agent................. 2-5 specifications .................................... 2-9 special tools ..................................... 2-11 periodic maintenance procedur...

  • Page 20

    2-2 periodic maintenance steering adjustment .................... 2-68 steering stem bearing lubrication................................. 2-70 frame ............................................. 2-70 frame inspection ......................... 2-70 electrical system ............................ 2-71 ...

  • Page 21

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

  • Page 22

    2-4 periodic maintenance periodic maintenance chart frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page drive chain-lubricate • 2-34 wheels/tires-inspect • 2-29 rear sprocket-inspect † • 2-35 front fork-inspect and clean • 2-45 fron...

  • Page 23

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

  • Page 24

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks cylinder bolt 12 1.2 104 in·lb s exhaust pipe cover screws 12 1.2 104 in·lb exhaust pipe holder nuts 21 2.1 15 muffler mounting bolts 21 2.1 15 muffler pipe mounting bolts – – – l engine right side primary gear...

  • Page 25

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks engine oil drain bolt (m10) (for transmission room oil sump) 20 2.0 15 engine oil drain bolt (m6) (for crank room oil sump) 7.0 0.71 62 in·lb bearing retaining screw 15 1.5 11 l gear set lever nut 8.8 0.90 78 i...

  • Page 26

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks base valve assembly 28 2.9 21 locknut/adjuster assembly 29 3.0 21 swingarm pivot shaft nut 98 10 72 rear shock absorber mounting nuts: (upper) 39 4.0 29 (lower) 34 3.5 25 air bleed bolt 6.4 0.65 56 in·lb tie-ro...

  • Page 27

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

  • Page 28

    2-10 periodic maintenance specifications item standard service limit standard tire: front: size 90/100-21 57m – – – make dunlop type d742f, tube rear: size 120/80-19 63m – – – make dunlop type d756, tube final drive drive chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – drive chain 20 link length 317.5 ...

  • Page 29

    Periodic maintenance 2-11 special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 pilot screw adjuster, c: 57001-1292 pilot screw adjuster adapter, 4: 57001-1371 filler cap driver: 57001-1454 pilot screw adjust, d: 57...

  • Page 30

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

  • Page 31

    Periodic maintenance 2-13 periodic maintenance procedures hot starter lever (hot starter cable) free play inspection • slide the clutch lever dust cover [a] back. • check the hot starter lever play [b] when pulling the start lever [c] lightly. Hot starter lever free play standard: 0.5 ∼ 1.0 mm (0.02...

  • Page 32

    2-14 periodic maintenance periodic maintenance procedures • check the idle speed, using the engine revolution tester [a] for high accuracy. If the idle speed is out of specified range, adjust it. Idle speed: standard: 1 800 ±50 r/min (rpm) idle speed adjustment • first, turn in the air screw using t...

  • Page 33

    Periodic maintenance 2-15 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 carburetor so no dirt is allowed to enter the carburetor. • wipe out the inside of the air cleaner housing ...

  • Page 34

    2-16 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 35

    Periodic maintenance 2-17 periodic maintenance procedures fuel tank, filter and tap cleaning warning clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or...

  • Page 36

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

  • Page 37

    Periodic maintenance 2-19 periodic maintenance procedures coolant deterioration inspection • visually inspect the coolant. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the...

  • Page 38

    2-20 periodic maintenance periodic maintenance procedures • first, bring the piston to the top-dead-center of its com- pression stroke to inspect the valve clearance (the posi- tion at the end of the compression stroke), when the cam lobe faces outside of the camshaft. ○ place a wrench over the bala...

  • Page 39

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

  • Page 40

    2-22 periodic maintenance periodic maintenance procedures • when installing the shim, face the marked side [a] toward the valve lifter [b]. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation. Caution do not put shim stock under the s...

  • Page 41

    Periodic maintenance 2-23 periodic maintenance procedures cylinder wear inspection note ○ measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • visually inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly w...

  • Page 42

    2-24 periodic maintenance periodic maintenance procedures exhaust system inspection • the exhaust system, in particular the muffler body, is de- signed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the muffler bod...

  • Page 43

    Periodic maintenance 2-25 periodic maintenance procedures • apply silicone sealant to the circumference [a] of the inner pipe. • install the muffler (see muffler installation in the engine top end chapter). Engine right side warning to avoid a serious burn, never touch the hot engine or exhaust cham...

  • Page 44

    2-26 periodic maintenance periodic maintenance procedures • if it cannot be done, loosen the locknut [a] at the middle of the clutch cable, and turn the adjusting nut [b] so that the clutch lever has 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. • after the adjustment is made, tighten the locknut, and start th...

  • Page 45

    Periodic maintenance 2-27 periodic maintenance procedures • remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely. Drain plug (for transmissionroom oil sump) [a] drain plug (for crank oil sump) [b] note ○ hold the motorcycle upright so that the oil may drain...

  • Page 46

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

  • Page 47

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

  • Page 48

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

  • Page 49

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

  • Page 50

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

  • Page 51

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

  • Page 52

    2-34 periodic maintenance periodic maintenance procedures warning if the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damag...

  • Page 53

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

  • Page 54

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

  • Page 55

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

  • Page 56

    2-38 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 the screws [a], reservoir cap [b] and diaphragm [c]. • remove t...

  • Page 57

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

  • Page 58

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

  • Page 59

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

  • Page 60

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

  • Page 61

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

  • Page 62

    2-44 periodic maintenance periodic maintenance procedures brake hoses and connections inspection • inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ the high pressure inside the brake line can cause fluid to leak [a] or the hose to burst if the line is not properl...

  • Page 63

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

  • Page 64

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

  • Page 65

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

  • Page 66

    2-48 periodic maintenance periodic maintenance procedures • remove the push rod [a]. • with the outer tube compressed by hands, remove the top plug wrench [a]. Caution removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut fr...

  • Page 67

    Periodic maintenance 2-49 periodic maintenance procedures • remove the base valve assembly [a] from the subtank [b]. Note ○ slowly compress the piston rod until it stops so that the base valve assembly can be removed easily. Caution disassembling the base valve assembly can lead to trouble. Do not d...

  • Page 68

    2-50 periodic maintenance periodic maintenance procedures • pump [a] the piston rod [b] slowly several times to expel air. • replace the o-rings [a] on the base valve assembly with new ones. • apply specified fork oil to the o-rings [a] [b] and bushings [c] on the base valve assembly. • with the pis...

  • Page 69

    Periodic maintenance 2-51 periodic maintenance procedures • protect the piston rod end [a] with a rag [b] to prevent fork damage. • discharge the extra oil off the cylinder unit by pumping [c] the piston rod to full stroke. Caution be careful not to bend or damage the piston rod when the piston rod ...

  • Page 70

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

  • Page 71

    Periodic maintenance 2-53 periodic maintenance procedures • replace the o-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the o-ring. • slowly turn the adjuster assembly [a] clockwise until re- sistance is felt and check the clearance between the lock- nut [b] ...

  • Page 72

    2-54 periodic maintenance periodic maintenance procedures • raise the outer tube and temporarily tighten the fork top plug (subtank). Special tool - top plug wrench, 49 mm: 57001-1653 [b] • after installing the front fork, torque the top plug [a]. Special tool - top plug wrench, 49 mm: 57001-1653 th...

  • Page 73

    Periodic maintenance 2-55 periodic maintenance procedures • loosen the front fork lower clamp bolts [a]. • remove the front fork. ○ with a twisting motion, work the fork leg [b] down and out. Note ○ set rebound and compression damping setting to the softest settings before disassembling to prevent t...

  • Page 74

    2-56 periodic maintenance periodic maintenance procedures • raise the outer tube and temporarily install the fork top plug [a] (subtank) to the outer tube [b] with the top plug wrench [c]. Special tool - top plug wrench, 49 mm: 57001-1653 • hold the axle holder [a] with a vise. ○ protect the axle ho...

  • Page 75

    Periodic maintenance 2-57 periodic maintenance procedures • with the outer tube compressed by hands, remove the top plug wrench [a]. Caution 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 76

    2-58 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 inverted position for more than 20 min- utes to allow the fork oil to fully drain. • clean the threads [a] of subtank and base ...

  • Page 77

    Periodic maintenance 2-59 periodic maintenance procedures • replace the o-rings [a] on the base valve assembly with new ones. • apply specified fork oil to the o-rings [a] [b] and bushings [c] on the base valve assembly. • with the piston rod held immovable in fully compressed position [a], gently i...

  • Page 78

    2-60 periodic maintenance periodic maintenance procedures • drain the extra oil from the subtank oil hole [a]. • with the cylinder unit in horizontal position, move [a] the piston rod [b] by hand to inspect it if operating smoothly. ○ if the piston rod is not extend, remove the base valve assembly a...

  • Page 79

    Periodic maintenance 2-61 periodic maintenance procedures • clamp the axle holder with a vise. ○ protect the axle holder with a rag 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 tight. • compress the o...

  • Page 80

    2-62 periodic maintenance periodic maintenance procedures • apply a non-permanent locking agent to the threads of a adjuster assembly. • torque the adjuster assembly [a]. Torque - adjuster assembly: 58 n·m (5.9 kgf·m, 43 ft·lb) • loosen and remove the fork top plug (subtank) from the outer tube and ...

  • Page 81

    Periodic maintenance 2-63 periodic maintenance procedures rear shock absorber inspection • bounce [a] the rear of the motorcycle up and down and check for smooth suspension stroke. • remove the rear frame (see rear frame removal in the frame chapter). • check for a broken or collapsed spring. • chec...

  • Page 82

    2-64 periodic maintenance periodic maintenance procedures • using the suitable tool [a] and press, push the reservoir cap [b] in 10 mm (0.39 in.). • remove the circlip [c] from the gas reservoir. • pull the gas reservoir cap [b] out of the gas reservoir using the pliers [a]. • pry or tap [a] at the ...

  • Page 83

    Periodic maintenance 2-65 periodic maintenance procedures • using the grinder, shave off the stop portion [a] of the rod. • remove: nut [b] washer [c] piston [d] • install the new piston and tighten the locknut. ○ discard a washer or two. • pour kyb k2-c (sae 5w or bel-ray se2 #40) oil into the gas ...

  • Page 84

    2-66 periodic maintenance periodic maintenance procedures • mount the circlip [a] in the groove in the gas reservoir. • pull up the gas reservoir cap [a] against the circlip. The end of the gas reservoir cap must align [b] with the end of the gas reservoir [c]. Warning if the end of the gas reservoi...

  • Page 85

    Periodic maintenance 2-67 periodic maintenance procedures • push the seal assembly into the rear shock body until it just clears the circlip groove. • check the circlip. If it is deformed or damaged, replace it with a new one. • fit the circlip [a] into the groove in the rear shock body [b]. Caution...

  • Page 86

    2-68 periodic maintenance periodic maintenance procedures swingarm and uni-trak linkage inspection • check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-12...

  • Page 87

    Periodic maintenance 2-69 periodic maintenance procedures • slide the holder belt [a] out off. • remove number plate bolt [b] and number plate [c]. • remove the handlebar pad [d]. • remove: handlebar holder bolts [a] handlebar holders (upper) [b] handlebar [c] • loosen the front fork upper clamp bol...

  • Page 88

    2-70 periodic maintenance periodic maintenance procedures • install the handlebar [b] on the handlebar holder (lower) so that the protruded scales of the both side adjust to the same width [a]. • apply 2-stroke oil to the threads of the handlebar holder bolts. • install the handlebar holder (upper) ...

  • Page 89

    Periodic maintenance 2-71 periodic maintenance procedures electrical system spark plug cleaning and inspection • remove: seat (see seat removal in the frame chapter) fuel tank (see fuel tank removal in the fuel system chapter) spark plug cap • clean the plug hole [a], using the compressed air [b]. •...

  • Page 90

    2-72 periodic maintenance periodic maintenance procedures general lubrication and cable inspection general lubrication • before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • lubricate the points listed below with indicated lubrican...

  • Page 91

    Periodic maintenance 2-73 periodic maintenance procedures cable inspection • with the cable disconnected at the both ends, the cable should move freely [a] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [b], or if the cable housing is kinked [c], re...

  • Page 92

    2-74 periodic maintenance periodic maintenance procedures brakes: front master cylinder clamp bolts brake lever pivot nut front caliper mounting bolts brake pedal mounting bolt rear master cylinder push rod cotter pin rear master cylinder mounting bolts rear caliper holder shaft suspension: front fo...

  • Page 93: Fuel System

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

  • Page 94

    3-2 fuel system exploded view.

  • Page 95

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

  • Page 96

    3-4 fuel system exploded view.

  • Page 97

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolts 34 3.5 25 2 air cleaner duct clamp screw 2.0 0.20 17 in·lb 3 air cleaner duct mounting nuts 3.0 0.31 27 in·lb 4 air cleaner duct mounting bolt 3.0 0.31 27 in·lb 5 air cleaner housing bolts 9.8 1.0 8...

  • Page 98

    3-6 fuel system specifications item standard throttle grip and cable throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) hot starter lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) carburetor make/type keihin fcr40 starter jet #72 leak jet #70 main jet #175 throttle valve cutaway ca1.5 jet needle ncvr...

  • Page 99

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

  • Page 100

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

  • Page 101

    Fuel system 3-9 throttle grip and cable • remove the rear frame assy (see rear frame removal in the frame chapter). • remove the carburetor. • unscrew the bolt [a]. • remove the throttle pulley cover [b]. • loosen the mounting bolts [a]. • remove the cables [b] from the carburetor. • free the tips [...

  • Page 102

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

  • Page 103

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

  • Page 104

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

  • Page 105

    Fuel system 3-13 carburetor • read the fuel level [d] in the gauge and compare it to the specification. Service fuel level (below the bottom edge of the carb. Body) standard: 6.5 ±1 mm (0.256 ±0.039 in.) if the fuel level is incorrect, adjust it. • turn the fuel tap to the off position and remove th...

  • Page 106

    3-14 fuel system carburetor • bend the tang [a] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float height standard: 8 ±1 mm (0.315 ±0.039 in.) note ○ float height [a] is the distanc...

  • Page 107

    Fuel system 3-15 carburetor • remove the fuel tank (see fuel tank removal). • disconnect the throttle sensor connector [a]. • loosen the clamp screws [a] of both carburetor holder and air cleaner duct fully. • remove: engine mounting bracket bolts [b] engine mounting bracket [c] • remove: seat (see ...

  • Page 108

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

  • Page 109

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

  • Page 110

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

  • Page 111

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

  • Page 112

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

  • Page 113

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

  • Page 114

    3-22 fuel system carburetor • remove the carburetor (see carburetor removal). • before disassembling the carburetor, check the fuel level (see service fuel level inspection). If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. • turn the throttle pulley to chec...

  • Page 115

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

  • Page 116

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

  • Page 117

    Fuel system 3-25 carburetor • assembly: throttle valve [a] jet needle [b] circlip [c] retainer [d] spring [e] jet needle holder [f] o-ring [g] throttle valve plate [h] ○ assemble the valve plate so that the hole side downward [i]. • apply a non-permanent locking agent to the link screw. • insert the...

  • Page 118

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

  • Page 119

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

  • Page 120

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

  • Page 121

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

  • Page 122

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

  • Page 123

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

  • Page 125: Cooling System

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

  • Page 126

    4-2 cooling system exploded view.

  • Page 127

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 water pump cover bolts 9.8 1.0 87 in·lb 2 coolant drain bolt 6.9 0.70 61 in·lb 3 water pump impeller bolt 9.8 1.0 87 in·lb 4 right engine cover bolts 9.8 1.0 87 in·lb 5 water hose clamp screws 1.5 0.15 13 in·lb 6 radiator...

  • Page 128

    4-4 cooling system specifications item service limit coolant type permanent type antifreeze for aluminum engines and radiators color green mixed ratio soft water 50%, antifreeze 50% freezing point -35°c (-31°f) total amount 1.05 l (1.11 us qt.) radiator cap relief pressure 112 ∼ 142 kpa (1.14 ∼ 1.45...

  • Page 129

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

  • Page 130

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

  • Page 131

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

  • Page 132

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

  • Page 133

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

  • Page 134

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

  • Page 135

    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 136

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

  • Page 137

    Cooling system 4-13 radiator radiator installation • fit the projections [a] of the screen in the holes [b] of the radiator. Torque - water hose clamp screws: 1.5 n·m (0.15 kgf·m, 13 in·lb) radiator mounting bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) radiator screen bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) ra...

  • Page 138

    4-14 cooling system radiator • wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • install the cap [a] on a cooling system pressure tester [b]. • watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The gauge hand must remain within...

  • Page 139: 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 140

    5-2 engine top end exploded view.

  • Page 141

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head cover bolts 9.8 1.0 87 in·lb 2 cylinder head bolts (m10) 59 6.0 44 s, mo 3 cylinder head bolts (m6) 12 1.2 104 in·lb s 4 cylinder bolt 12 1.2 104 in·lb 5 camshaft cap bolts 9.8 1.0 87 in·lb s, mo 6 camshaft ...

  • Page 142

    5-4 engine top end exploded view.

  • Page 143

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 12 1.2 104 in·lb 2 exhaust pipe holder nuts 21 2.1 15 3 muffler mounting bolts 21 2.1 15 4 cylinder bolt 12 1.2 104 in·lb s 5 muffler pipe mounting bolts – – – l 6. Top ring 7. Oil ring 8. Circle ...

  • Page 144

    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.) inlet 37.743 ∼ 37.857 mm (1.4859 ∼ 1.4904 in.) 37.64 mm (1.482 in.) camshaft journal clearance 0.020 ∼ 0.062 mm (0.00079 ∼ 0.0024 in.) 0.15 mm (0....

  • Page 145

    Engine top end 5-7 specifications item standard service limit cylinder and pistons cylinder inside diameter 96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) 96.10 mm (3.783 in.) piston diameter 95.970 ∼ 95.980 mm (3.7783 ∼ 3.7787 in.) 95.82 mm (3.772 in.) piston/cylinder clearance 0.020 ∼ 0.042 mm (0.00079 ...

  • Page 146

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

  • Page 147

    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 148

    5-10 engine top end special tools and sealant valve seat cutter, 55° - 35: 57001-1247 spark plug wrench, hex 16: 57001-1262 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 s...

  • Page 149

    Engine top end 5-11 special tools and sealant valve guide driver attachment d: 57001-1659 kawasaki bond (silicone sealant): 92104-0004.

  • Page 150

    5-12 engine top end cylinder head cover cylinder head cover removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) spark plug cap • remove the cylinder head cover bolts [a] and remove the cylinder head cover [b]. Cylinder head cover installation • apply silicon sealant [a] to...

  • Page 151

    Engine top end 5-13 camshaft chain tensioner camshaft chain tensioner removal caution this is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: when removing the ten...

  • Page 152

    5-14 engine top end camshaft chain tensioner • replace the chain tensioner gasket with a new one. • tighten: torque - chain tensioner mounting bolts [a]: 9.8 n·m (1.0 kgf·m, 87 in·lb) • take out the holder plate [b]. • install the o-ring and tighten the cap bolt. Torque - chain tensioner cap bolt: 5...

  • Page 153

    Engine top end 5-15 camshaft camshaft removal • remove: cylinder head cover (see cylinder head cover re- moval) timing inspection plug [a] balancer shaft plug [b] special tool - filler cap driver: 57001-1454 • first, bring the piston to the tdc (of either the compres- sion or exhaust stroke). ○ plac...

  • Page 154

    5-16 engine top end camshaft • remove: bolt [a] auto-decompressor [b] (with the sprocket) • remove: circlips [a] camshaft installation • assemble the auto-decompressor weights [a] and spring [b] to install it to the sprocket [c]. • replace the circlips [d] with new ones, and install them. • apply a ...

  • Page 155

    Engine top end 5-17 camshaft • engage the camshaft chain with the camshaft sprockets. ○ pull the tension side (exhaust side) of the chain taut to install the chain. ○ the timing marks on the sprocket must be aligned with the cylinder head upper surface. • pull the chain taut and fit it onto the cams...

  • Page 156

    5-18 engine top end camshaft • apply grease to the rubber portions of the oil pipes. • assemble: camshaft caps [a] oil pipes [b] • while keeping the camshaft caps parallel, install them. • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ following ...

  • Page 157

    Engine top end 5-19 camshaft camshaft and camshaft cap wear inspection • measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [a]. • install the camshaft caps (see camshaft installation) note ○ do not turn the camshaft when the plastigauge is be- tween...

  • Page 158

    5-20 engine top end cylinder head cylinder compression measurement • start the engine. • thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • stop the engine. • remove: fuel tank (see fuel tank re...

  • Page 159

    Engine top end 5-21 cylinder head problem diagnosis remedy (action) carbon accumulation on piston and in cylinder head (combustion chamber) is suspected due to damaged valve stem or piston oil rings. Remove the carbon deposits and replace damaged parts if necessary. The cylinder compression is highe...

  • Page 160

    5-22 engine top end cylinder head • remove the 10 mm cylinder head bolts following the tight- ening sequence as shown. • tap lightly up with a plastic mallet [a] to separate the cylin- der head [b] from the cylinder. • remove the cylinder head gasket. Cylinder head installation • fit the projection ...

  • Page 161

    Engine top end 5-23 cylinder head • tighten the 10 mm cylinder head bolts in the numbered sequence [1 ∼ 4]. Torque - cylinder head bolts (m10): 59 n·m (6.0 kgf·m, 44 ft·lb) • tighten: torque - cylinder bolt [a]: 12 n·m (1.2 kgf·m, 104 in·lb) cylinder head bolts (m6) [b]: 12 n·m (1.2 kgf·m, 104 in·lb...

  • Page 162

    5-24 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve removal • remove the cylinder head (see cylinder head removal). • remove the valve lifter and the shim from the valve. Note ○ use the valve spring compressor ass...

  • Page 163

    Engine top end 5-25 valves valve guide removal • remove: valve (see valve removal) oil seal spring seat • heat the area around the valve guide up to 120 ∼ 150°c (248 ∼ 302°f). Caution do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oi...

  • Page 164

    5-26 engine top end valves • ream the valve guide with valve guide reamer [a], even if the old guide is reused. Special tool - valve guide reamer, 5.5: 57001-1079 valve/valve guide clearance measurement (wobble method) ○ if a small bore gauge is not available, inspect the valve guide wear by measuri...

  • Page 165

    Engine top end 5-27 valves valve seat inspection • remove the valve (see valve removal). • check the valve seating surface [a] between the valve [b] and valve seat [c]. • measure the outside diameter [d] of the seating pattern on the valve seat. If the outside diameter is too large or too small, rep...

  • Page 166

    5-28 engine top end valves seat cutter operation care 1. This valve seat cutter is developed to grind the vale for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. 3. Do not fail...

  • Page 167

    Engine top end 5-29 valves • measure the outside diameter [o.D.] of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Original seating surface [b] ○ remove all pittings o...

  • Page 168

    5-30 engine top end valves • the seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. • when the engine is assembled, be s...

  • Page 169

    Engine top end 5-31 valves valve seat repair.

  • Page 170

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

  • Page 171

    Engine top end 5-33 cylinder and piston • install the top ring [a] so that the "r" mark [b] faces up. Note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston rings. • apply engine oil to the inside wall of the small end of ...

  • Page 172

    5-34 engine top end cylinder and piston • apply engine oil to the cylinder bore. • determine the position of the piston ring ends. • install the cylinder while compressing the piston rings with your fingers or the special tool [a]. Special tools - piston ring compressor grip: 57001-1095 piston ring ...

  • Page 173

    Engine top end 5-35 cylinder and piston piston ring groove width inspection • measure the groove width at several points around the piston with a vernier caliper. Piston ring groove width standard: top 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) service limit: top 1.1 mm (0.043 in.) if any of the groove wi...

  • Page 174

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

  • Page 175

    Engine top end 5-37 carburetor holder carburetor holder installation • fit the recess [a] of the holder on the projection [b] of the cylinder head. ○ the marked side [a] of the carburetor holder [b] face to the carburetor. • when installing the clamp screws refer to the cable, wire, and hose routing...

  • Page 176

    5-38 engine top end muffler warning to avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler removal • loosen the muffler clamp bolt [a]. • remove the exhaust pipe holder nut [b]. • remove the exhaust pipe [c]. • remove seat (see sea...

  • Page 177: Engine Right Side

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

  • Page 178

    6-2 engine right side exploded view.

  • Page 179

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

  • Page 180

    6-4 engine right side exploded view.

  • Page 181

    Engine right side 6-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 ratchet guide bolt 8.8 0.90 78 in·lb l 2 kick pedal bolt 25 2.5 18 l 3 shift pedal bolt 9.8 1.0 87 in·lb 4 ratchet plate mounting bolt 9.8 1.0 87 in·lb s 5 ratchet plate mounting screw (kx450d6f) 6.4 0.65 56 in·lb l, s...

  • Page 182

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

  • Page 183

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

  • Page 184

    6-8 engine right side clutch lever and cable due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the periodic maintenance chart. Warning to avoid a serious burn, never touch the hot engine or exhaust chamber during clutch ad...

  • Page 185

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

  • Page 186

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

  • Page 187

    Engine right side 6-11 clutch cover and right engine cover • when installing the cover doesn’t go well, the cover is installed according to the following procedures. ○ fit the water pump shaft [a] and groove [b] of the balancer shaft while turning the water pump shaft. • tighten: torque - right engi...

  • Page 188

    6-12 engine right side clutch clutch removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the clutch cover (see clutch cover removal). • remove: clutch spring bolts [a] clutch spring clutch pressure plate [b] • remove: washer [a] needle bearing [b] p...

  • Page 189

    Engine right side 6-13 clutch • install the washer so that stamp mark [a] facing the out- side. • tighten the clutch hub nut [a] using the clutch holder [b]. Special tool - clutch holder: 57001-1243 torque - clutch hub nut: 98 n·m (10 kgf·m, 72 ft·lb) • install the friction plates and steel plates, ...

  • Page 190

    6-14 engine right side clutch • tighten: torque - clutch spring bolts [a]: 8.8 n·m (0.90 kgf·m, 78 in·lb) • install the clutch cover (see clutch cover installation). • check the release shaft lever positions. ○ pushing [b] the release shaft lever [c] lightly frontward measure the distance [a] betwee...

  • Page 191

    Engine right side 6-15 clutch clutch plate assembly free play inspection/adjust- ment • assemble the following parts. Clutch hub [a] friction plates [b] steel plates [c] friction plates [d] spring plates [e] spring [f] bolts [g] ○ the friction plates [b] have many lining blocks than other plates [d]...

  • Page 192

    6-16 engine right side clutch clutch housing finger damage inspection • visually inspect the clutch housing fingers [a] that come in contact with the friction plate tangs. If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace t...

  • Page 193

    Engine right side 6-17 primary gear primary gear removal • remove: right engine cover clutch (see clutch removal) • temporarily install the clutch housing [a]. • using the gear holder [b], secure the primary gear. Special tool - gear holder, m2.0: 57001-1557 • remove the clutch housing. • remove the...

  • Page 194

    6-18 engine right side external shift mechanism external shift mechanism removal • remove: shift pedal bolt [a] shift pedal [b] • remove: right engine cover (see right engine cover removal) clutch housing (see clutch removal) circlip [a] oil pump driven gear [b] • pull out the shift shaft [c]. • rem...

  • Page 195

    Engine right side 6-19 external shift mechanism • set up the shift ratchet assembly as shown in the figure. Ratchet [a] pawls [b] pins [c] springs [d] ○ assembly the shift ratchet so that groove [e] of the pawl faces the crankcase side [f]. • then install the ratchet assembly [a] to the ratchet plat...

  • Page 196

    6-20 engine right side external shift mechanism external shift mechanism inspection • check the shift shaft [a] for bending or damage to the splines. If the shaft is bent, straighten or replace it. If the splines are damaged, replace the shift mechanism. • check the return spring [b] for cracks or d...

  • Page 197

    Engine right side 6-21 kickstarter kick pedal assy removal • remove: mounting bolt [a] kick pedal assy [b] kick pedal assy installation • install the kick pedal assy [a] at the angle shown. 17 ∼ 27 mm (0.67 ∼ 1.1 in.) [b] • apply a non-permanent locking agent to the kick pedal bolt. • tighten: torqu...

  • Page 198

    6-22 engine right side kickstarter idle gear installation • apply engine oil to the inside of the idle gear. • replace the circlip [a] with a new one. • install the idle gear [c] facing embossed letter [b] to the outside. • install the circlip. Kickshaft removal • remove: right engine cover (see rig...

  • Page 199

    Engine right side 6-23 kickstarter kick shaft assembly disassembly/assembly • the kick shaft assembly consists of the following parts. [a] kick gear [e] ratchet gear [b] circlip [f] kick shaft [c] washer [g] kick spring [d] spring [h] spring guide • check the kick shaft assembly parts for damage. An...

  • Page 201: Engine Lubrication System

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

  • Page 202

    7-2 engine lubrication system exploded view.

  • Page 203

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt m10 (for transmission room oil sump) 20 2.0 15 2 engine oil drain bolt m6 (for crank room oil sump) 7.0 0.71 62 in·lb 3 oil pump (scavenge) cover bolts 9.8 1.0 87 in·lb s 4 oil pump (feed)...

  • Page 204

    7-4 engine lubrication system lubrication system chart.

  • Page 205

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

  • Page 206

    7-6 engine lubrication system specifications item standard engine oil grade castrol “r4 superbike” 5w-40 (kx450d6f ∼ d7f), castrol “power1 r4 racing” 5w-40 (kx450d8f) or api sg, sh, sj or sl with jaso ma viscosity sae 10w-30, 10w-40, or 10w-50 capacity oil change - when filter is not removed 0.96 l ...

  • Page 207

    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 208

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

  • Page 209

    Engine lubrication system 7-9 engine oil and oil filter oil filter change • refer to the oil filter change in the periodic maintenance chapter. Oil screen (scavenge) removal • remove the oil pump (scavenge) cover (see oil pump (scavenge) cover removal). • pull out the oil screen [a] from the crankca...

  • Page 210

    7-10 engine lubrication system engine oil and oil filter oil screen (feed) removal • split the crankcase (see crankcase disassembly in the crankshaft/transmission chapter). • remove: bolts [a] oil screen [b] oil screen (feed) installation • replace the o-ring [a] with a new one. • apply grease to th...

  • Page 211

    Engine lubrication system 7-11 engine oil and oil filter • check the screen [a] carefully for any damage, holes, broken wires gasket pulling off. If the screen is damaged, replace it. • install the oil screen (see oil screen (scavenge) installa- tion). Oil screen (feed) cleaning • remove the oil scr...

  • Page 212

    7-12 engine lubrication system oil pressure relief valve oil pressure relief valve removal • remove: clutch (see clutch removal in the engine right side chapter) right engine cover (see right engine cover removal in the engine right side chapter) • remove the oil pressure relief valve [a]. Oil press...

  • Page 213

    Engine lubrication system 7-13 oil pump oil pump (scavenge) removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) coolant (see coolant draining in the coolant system chapter) • remove: shift pedal (see external shift mechanism in the engine right side chapter) fly...

  • Page 214

    7-14 engine lubrication system oil pump oil pump (feed) removal • remove: clutch (clutch removal in the engine right side chap- ter) circlip [a] oil pump driven gear [b] shaft [c] oil pump idle gear [d] special tool - outside circlip pliers: 57001-144 • remove: oil pump cover bolts [a] oil pump cove...

  • Page 215

    Engine lubrication system 7-15 oil pump • install the oil pump cover [a]. • while pushing the oil pump cover, tighten the oil pump cover bolts following the sequence number as shown. ○ thread length of the bolt is 16 mm (0.63 in.) only in the bolt installed thirdly. (kx450d6f ∼ d7f) ○ thread length ...

  • Page 216

    7-16 engine lubrication system oil pressure oil pressure measurement • remove the oil filter cover [a]. • install the o-rings to the oil pressure cap. Special tool - oil pressure cap: 57001–1656 • install the oil pressure cap. • attach the oil pressure gauge adapter [a] and oil pressure gauge [b]. S...

  • Page 217: Engine Removal/installation

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

  • Page 218

    8-2 engine removal/installation exploded view.

  • Page 219

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

  • Page 220

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

  • Page 221

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

  • Page 222

    8-6 engine removal/installation engine removal/installation • remove: radiator mounting bolts [a] radiator [b] • remove: muffler (see muffler removal in the engine top end chapter) water hoses [b] bolt [c] radiator screen [d] • remove: radiator mounting bolts [a] radiator [b] • loosen: carburetor cl...

  • Page 223

    Engine removal/installation 8-7 engine removal/installation • pry open the clamps [a]. • disconnect: magnet lead connector [b] gear position switch connector [c] ignition coil lead connector [d] spark plug cap • remove: ignition coil [a] upper engine bracket bolts (left and right) [b] upper engine m...

  • Page 224

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

  • Page 225: Crankshaft/transmission

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

  • Page 226

    9-2 crankshaft/transmission exploded view.

  • Page 227

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 crankcase bolts (m6) 12 1.2 104 in·lb s 2 crankcase bolts (m7) 15 1.5 11 s 3 gear set lever nut 8.8 0.90 78 in·lb 4 engine oil drain bolt (m10)(for transmission room oil sump) 20 2.0 15 5 engine oil drain bolt ...

  • Page 228

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

  • Page 229

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

  • Page 230

    9-6 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine removal in the engine removal/installation chapter). • set the engine on clean surface while parts are being re- moved. • remove: magneto cover (see magneto cover removal in the electrical syst...

  • Page 231

    Crankshaft/transmission 9-7 crankcase • remove: gear position switch finger spring [a] • remove: circlip [a] special tool - outside circlip pliers: 57001-144 • remove the crankcase bolts [a]. • install the jig [a] between the crankshaft flywheels. Special tool - crankshaft jig: 57001-1174 • attach t...

  • Page 232

    9-8 crankshaft/transmission crankcase • remove: oil screen (feed) [a] (see oil screen (feed) removal in the engine lubrication system chapter) shift rods [b] (see transmission shaft removal) 2 shift forks [c] (see transmission shaft removal) shift drum [d] (see transmission shaft removal) transmissi...

  • Page 233

    Crankshaft/transmission 9-9 crankcase • press the new transmission shaft bearing [a] in the left crankcase half, so that the sealed side [b] faces outside of the engine. Special tool - bearing driver set: 57001-1129 • press the new drive shaft bearing [a] in the right crankcase [b] half, so that the...

  • Page 234

    9-10 crankshaft/transmission crankcase • next, press the outside release shaft needle bearing [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 output shaft and release shaft oil...

  • Page 235

    Crankshaft/transmission 9-11 crankcase • install: shift drum [a] (see transmission installation) shift rods [b] (see transmission installation) shift forks [c] (see transmission installation) • install: crankshaft [a] dowel pins [b] • replace the o-ring [a] with a new one. • install the oil screen (...

  • Page 236

    9-12 crankshaft/transmission crankcase • using a plastic hammer [a], press [b] the rear portion of the crankcase, and tap the area around the crankshaft of the left crankcase half. While maintaining the mating surfaces of the right and left crankcase halves constantly parallel, mate the crankcase ha...

  • Page 237

    Crankshaft/transmission 9-13 crankcase • to install the shift drum cam [a], use the driver [b] to bring the gear set lever [c] to the bottom of the crankcase. • mate the shift drum pin [d] into the shift drum hole. ○ fit the groove [e] of the shift drum cam on the shift drum pin. • apply non-permane...

  • Page 238

    9-14 crankshaft/transmission crankshaft crankshaft removal • disassemble the crankcase (see crankcase disassem- bly). • using the hand pull out the crankshaft [a] from the right crankcase half [b]. Crankshaft installation • apply high-temperature grease to the outer side of the crankshaft bearings a...

  • Page 239

    Crankshaft/transmission 9-15 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 240

    9-16 crankshaft/transmission crankshaft • next, correct the vertical misalignment by either driving a wedge [a] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. Caution do not hammer the crank half at the point [b]. If flywheel misalignment c...

  • Page 241

    Crankshaft/transmission 9-17 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 length of the arbor to determi...

  • Page 242

    9-18 crankshaft/transmission transmission transmission shaft removal • disassemble the crankcase (see crankcase disassem- bly). • pull out the shift rods [a] allowing the shift fork guide pins to free from the shift drum [b]. • remove the shift fork [c]. • remove the shift drum. • pull out the drive...

  • Page 243

    Crankshaft/transmission 9-19 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 244

    9-20 crankshaft/transmission transmission kx450d6f 1. Circlip (small) 2. Circlip (middle) 3. Circlip (large) 4. Ball bearing (one side sealed) 5. 2nd gear (17t) 6. 3rd gear (16t) 7. 4th gear (19t) 8. 1st gear (15t) 9. Ball bearing 10. Drive shaft 11. Collar 12. O-rings (2) 13. Oil seal 14. Ball bear...

  • Page 245

    Crankshaft/transmission 9-21 transmission kx450d7f ∼ 1. Circlip 2. Toothed washer 3. Ball bearing (one side sealed) 4. 2nd gear (17t) 5. 4th gear (19t) 6. 3rd gear (16t) 7. 5th gear (24t) 8. 1st gear (16t) 9. Bushing 10. Ball bearing 11. Drive shaft 12. Collar 13. Oil seal 14. O-rings 15. Ball beari...

  • Page 246

    9-22 crankshaft/transmission transmission shift fork bending inspection • visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [a] shift fork/gear groove wear inspection ...

  • Page 247

    Crankshaft/transmission 9-23 balancer balancer removal • remove: right engine cover (see right engine cover removal in the engine right side chapter) magneto cover (see magneto cover removal in the electrical system chapter) flywheel (see flywheel removal in the electrical sys- tem chapter) balancer...

  • Page 248

    9-24 crankshaft/transmission bearings/oil seals bearing replacement caution do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • remove the ball bearing and/or needle bearing outer race using a press or puller. Note ○ in the absence of the above mentioned tools, sati...

  • Page 249

    Crankshaft/transmission 9-25 bearings/oil seals • check the needle bearing. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition ...

  • Page 251: Wheels/tires

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

  • Page 252

    10-2 wheels/tires exploded view.

  • Page 253

    Wheels/tires 10-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 spoke nipples not less than 2.2 not less than 0.22 not less than 19 in·lb 2 front axle nut 78 8.0 58 3 front axle clamp bolts 20 2.0 15 al 4 rear axle nut 108 11 80 5. Spokes 6. Front tire 7. Rims 8. Front axle 9. Swingarm...

  • Page 254

    10-4 wheels/tires specifications item standard service limit wheels (rims) rim runout (with tire installted): axial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) radial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) axle runout/100 mm (3.94 in.) tir 0.1 mm (0.004 in.) or less tir 0.2 mm (0....

  • Page 255

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

  • Page 256

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

  • Page 257

    Wheels/tires 10-7 wheels (rims) • insert the axle [a] from right side. • tighten the right [b] axle clamp bolts temporally. • tighten the axle nuts [c]. • tighten the left axle clamp bolts [d]. Torque - front axle: 78 n·m (8.0 kgf·m, 58 ft·lb) left axle clamp bolts: 20 n·m (2.0 kgf·m, 15 ft·lb) note...

  • Page 258

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

  • Page 259

    Wheels/tires 10-9 wheels (rims) • check the drive chain slack (see drive chain slack in- spection in the periodic maintenance chapter). • tighten the axle nut. Torque - rear axle nut: 108 n·m (11 kg·m, 80 ft·lb) • install the new cotter pin [a] and spread its end. Note ○ when inserting the cotter pi...

  • Page 260

    10-10 wheels/tires wheels (rims) axle inspection • visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • place the axle in v blocks that are 100 mm (3.937 in.) [a] apart, and set a dial gauge on the axle at a point halfway between the blocks. Turn the ax...

  • Page 261

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

  • Page 262

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

  • Page 263

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

  • Page 264

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

  • Page 265: Final Drive

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

  • Page 266

    11-2 final drive exploded view.

  • Page 267

    Final drive 11-3 exploded view torque no fastener n·m kgf·m ft·lb remarks 1 rear sprocket nuts 34 3.5 25 2 engine sprocket nut 127 13 94 3 engine sprocket cover bolts 9.8 1.0 87 in·lb 4. Engine sprocket 5. Output shaft 6. Chain slipper 7. Swingarm 8. Chain guide 9. Locknut 10. Adjusting bolt 11. Cha...

  • Page 268

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make daido – – – type d.I.D 520dma2 – – – length 114 links – – – sprocket rear sprocket war...

  • Page 269

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

  • Page 270

    11-6 final drive drive chain • install the clip [a] so that the closed end [b] of the "u" pointed in the direction of chain rotation [c]. • adjust the drive chain slack (see drive chain slack ad- justment). • check the rear brake..

  • Page 271

    Final drive 11-7 sprockets engine sprocket removal • remove: engine sprocket cover bolts [a] engine sprocket cover [b] drive chain guide [c] • remove: drive chain [b] (free of engine sprocket) • flatten the bended sprocket washer [a]. • remove the engine sprocket nut [c] and sprocket washer, and pul...

  • Page 272

    11-8 final drive sprockets rear sprocket installation • install the rear sprocket [a] so that the marked side [b] faces out. • install the rear sprocket bolts and tighten the nuts. Torque - rear sprocket nuts: 34 n·m (3.5 kgf·m, 25 ft·lb) sprocket wear inspection • refer to the sprocket wear inspect...

  • Page 273: Brakes

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

  • Page 274

    12-2 brakes exploded view.

  • Page 275

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

  • Page 276

    12-4 brakes exploded view.

  • Page 277

    Brakes 12-5 exploded view torque no. Fastener n·m kgf·m ft·lb re- marks 1 brake hose banjo bolts 25 2.5 18 2 rear master cylinder mounting bolts 9.8 1.0 87 in·lb 3 rear master cylinder push rod locknut 17 1.7 13 4 caliper bleed valve 7.8 0.80 69 in·lb 5 brake pad bolt 17 1.7 13 6 rear brake pad bolt...

  • Page 278

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

  • Page 279

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

  • Page 280

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

  • Page 281

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

  • Page 282

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

  • Page 283

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

  • Page 284

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

  • Page 285

    Brakes 12-13 caliper caliper installation • tighten the brake pad bolts if it was removed. Torque - brake pad bolts: 17 n·m (1.7 kgf·m, 13 ft·lb) front brake: • install the caliper and tighten the bolts. Torque - caliper mounting bolts (front): 25 n·m (2.5 kgf·m, 18 ft·lb) rear brake: • before insta...

  • Page 286

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

  • Page 287

    Brakes 12-15 brake pad brake pad removal for front brake pad • unscrew the pad bolt [a]. • take the piston side pad [b]. • push the caliper holder toward the piston, and then re- move another pad [c] from the caliper holder. For rear brake pad • remove: plug [a] • unscrew the pad bolt [a]. • take th...

  • Page 288

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

  • Page 289

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

  • Page 290

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

  • Page 291

    Brakes 12-19 brake disk brake disc inspection • visually inspect the disc [a]. If it is scratched or damaged, replace the disc. • measure the thickness of each disc at the point [b] where it has worn the most. Replace the disc if it has worn past the service limit. Thickness standard: front 2.85 ∼ 3...

  • Page 292

    12-20 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 293: Suspension

    Suspension 13-1 13 suspension table of contents exploded view................................... 13-2 specifications .................................... 13-8 special tools ..................................... 13-10 front fork (kx450d6f ∼ d7f) .......... 13-11 air pressure ............................

  • Page 294

    13-2 suspension exploded view kx450d6f.

  • Page 295

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

  • Page 296

    13-4 suspension exploded view kx450d7f ∼ d8f.

  • Page 297

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

  • Page 298

    13-6 suspension exploded view.

  • Page 299

    Suspension 13-7 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 swingarm pivot shaft nut 98 10 72 2 rocker arm pivot nut (kx450d6f) 83 8.5 61 rocker arm pivot nut (kx450d7f ∼ ) 59 6.0 43 3 tie-rod mounting nut (front, rear) (kx450d6f) 83 8.5 61 tie-rod mounting nut (front, rear) (kx450d7...

  • Page 300

    13-8 suspension specifications item standard service limit front fork air pressure atmospheric pressure – – – (adjustable range) rebound damping adjustment (from the seated position adjuster turned fully clockwise) 13 clicks counterclockwise (kx450d6f) 9 clicks counterclockwise, (eur) 10 clicks cont...

  • Page 301

    Suspension 13-9 specifications item standard service limit (adjustable range) spring preload adjustment (adjusting nut position from the center of the mounting hole upper) 127.5 mm (5.020 in.) (kx450d6f ∼ d7f) 128.5 mm (5.059 in.) (kx450d8f) 121.5 ∼ 138.5 mm (4.783 ∼ 5.453 in.) (kx450d6f, d8f) 122.1...

  • Page 302

    13-10 suspension special tools oil seal & bearing remover: 57001-1058 steering stem nut wrench: 57001-1100 hook wrench r37.5, r42: 57001-1101 bearing driver set: 57001-1129 jack: 57001-1238 bearing remover shaft, 9: 57001-1265 bearing remover head, 15 × 17: 57001-1267 fork oil seal driver, 48: 57001...

  • Page 303

    Suspension 13-11 front fork (kx450d6f ∼ d7f) air pressure the standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race thr...

  • Page 304

    13-12 suspension front fork (kx450d6f ∼ d7f) compression damping adjustment • place the jack under the frame so that the front wheel off the ground. Special tool - jack: 57001-1238 • to adjust compression damping, turn the adjuster [a] on the front fork top plugs with the blade of a screwdriver unti...

  • Page 305

    Suspension 13-13 front fork (kx450d6f ∼ d7f) • loosen the upper [a], and lower [b] fork clamp bolts. • remove the front fork. ○ with a twisting motion [a], work the fork leg [b] down and out. Front fork installation • install the fork so that the distance between the top end of the outer tube and th...

  • Page 306

    13-14 suspension front fork (kx450d6f ∼ d7f) front fork disassembly (each fork leg) • loosen the front fork upper clamp bolts [a]. • loosen the fork top plug (subtank) [a] with the top plug wrench [b]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] • remove the front fork (see front fork remo...

  • Page 307

    Suspension 13-15 front fork (kx450d6f ∼ d7f) • place a drain pan under the front fork and drain fork oil [a]. Note ○ pump the fork tube several times to discharge the fork oil. • raise the outer tube and temporarily install the fork top plug [a] (subtank) to the outer tube [b] with the top plug wren...

  • Page 308

    13-16 suspension front fork (kx450d6f ∼ d7f) • remove the push rod [a]. • with the outer tube compressed by hands, remove the top plug wrench [a]. Caution 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...

  • Page 309

    Suspension 13-17 front fork (kx450d6f ∼ d7f) • grasp the outer tube and stroke [a] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • remove the following parts from the inner tube. [a] guide bushes [b] washer [c] oil seal [d] retaining ring [e] dust...

  • Page 310

    13-18 suspension front fork (kx450d6f ∼ d7f) front fork assembly • when the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain. • replace the following with new ones: dust seal [a] retaining ring [b] oil seal [c] guide bushe...

  • Page 311

    Suspension 13-19 front fork (kx450d6f ∼ d7f) • with the piston rod in fully compressed position, pour the specified amount of fork oil [a]. Recommended oil: khl15-10 (kayaba01) or equivalent recommended quantity: 170 ml (5.75 us oz) (kx450d6f) 191 ml (6.46 us oz) (kx450d7f) note ○ plug the two oil h...

  • Page 312

    13-20 suspension front fork (kx450d6f ∼ d7f) • holding the top plug wrench [a] with a vise. • holding the subtank [b] with the top plug wrench, torque the base valve assembly [c]. Special tool - top plug wrench, 49 mm: 57001-1653 torque - base valve assembly: 28 n·m (2.9 kgf·m, 21 ft·lb) • protect t...

  • Page 313

    Suspension 13-21 front fork (kx450d6f ∼ d7f) • make sure about 16 mm (0.63 in.) [a] of push rod thread is exposed from the locknut [b]. • completely wipe off the fork oil from the spring [a], collar [b] and cylinder unit [c]. • insert above-mentioned parts into the fork. • temporarily tighten the fo...

  • Page 314

    13-22 suspension front fork (kx450d6f ∼ d7f) • insert the push rod [a] into the piston rod. • replace the o-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the o-ring. • slowly turn the adjuster assembly [a] clockwise until re- sistance is felt and check the cl...

  • Page 315

    Suspension 13-23 front fork (kx450d6f ∼ d7f) • raise the outer tube and temporarily tighten the fork top plug (subtank). Special tool - top plug wrench, 49 mm: 57001-1653 • after installing the front fork, torque the top plug [a]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] the torque of f...

  • Page 316

    13-24 suspension front fork (kx450d6f ∼ d7f) cylinder unit inspection • inspect the piston rod [b] of cylinder unit [a] for scratches or bending. If it has scratches or is bent, replace cylinder unit with a new one. Inner tube inspection • visually inspect the inner tube [a], repair any damage. • ni...

  • Page 317

    Suspension 13-25 front fork (kx450d6f ∼ d7f) spring tension inspection • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring ...

  • Page 318

    13-26 suspension front fork (kx450d8f) air pressure the standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race through t...

  • Page 319

    Suspension 13-27 front fork (kx450d8f) compression damping adjustment • place the jack under the frame so that the front wheel off the ground. Special tool - jack: 57001-1238 • to adjust compression damping, turn the adjuster [a] on the front fork top plugs with the blade of a screwdriver until you ...

  • Page 320

    13-28 suspension front fork (kx450d8f) • loosen the upper [a], and lower [b] fork clamp bolts. • remove the front fork. ○ with a twisting motion [a], work the fork leg [b] down and out. Front fork installation • install the fork so that the distance between the top end of the outer tube and the uppe...

  • Page 321

    Suspension 13-29 front fork (kx450d8f) front fork disassembly (each fork leg) • loosen the front fork upper clamp bolts [a]. • loosen the fork top plug (subtank) [a] with the top plug wrench [b]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] • remove the front fork (see front fork removal). ...

  • Page 322

    13-30 suspension front fork (kx450d8f) • place a drain pan under the front fork and drain fork oil [a]. Note ○ pump the fork tube several times to discharge the fork oil. • raise the outer tube and temporarily install the fork top plug [a] (subtank) to the outer tube [b] with the top plug wrench [c]...

  • Page 323

    Suspension 13-31 front fork (kx450d8f) • remove the push rod [a]. • with the outer tube compressed by hands, remove the top plug wrench [a]. Caution 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. ...

  • Page 324

    13-32 suspension front fork (kx450d8f) • grasp the outer tube and stroke [a] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • remove the following parts from the inner tube. [a] guide bushes [b] washer [c] oil seal [d] retaining ring [e] dust seal ...

  • Page 325

    Suspension 13-33 front fork (kx450d8f) front fork assembly • when the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain. • replace the following with new ones: dust seal [a] retaining ring [b] oil seal [c] guide bushes [d] ...

  • Page 326

    13-34 suspension front fork (kx450d8f) • with the piston rod in fully compressed position, pour the specified amount of fork oil [a]. Recommended oil: khl15-10 (kayaba01) or equivalent recommended quantity: 191 ml (6.46 us oz) note ○ plug the two oil holes on the subtank [b] with fingers. • pump [a]...

  • Page 327

    Suspension 13-35 front fork (kx450d8f) • holding the top plug wrench (57001-1653) [a] with a vise. • holding the subtank [b] with the top plug wrench, torque the base valve assembly [c] using the top plug wrench (57001-1705) [d]. Special tool - top plug wrench, 49 mm: 57001-1653 top plug wrench, 36 ...

  • Page 328

    13-36 suspension front fork (kx450d8f) • make sure about 16 mm (0.63 in.) [a] of push rod thread is exposed from the locknut [b]. • completely wipe off the fork oil from the spring [a], collar [b] and cylinder unit [c]. • insert above-mentioned parts into the fork. • temporarily tighten the fork top...

  • Page 329

    Suspension 13-37 front fork (kx450d8f) • insert the push rod [a] into the piston rod. • replace the o-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the o-ring. • slowly turn the adjuster assembly [a] clockwise until re- sistance is felt and check the clearanc...

  • Page 330

    13-38 suspension front fork (kx450d8f) • raise the outer tube and temporarily tighten the fork top plug (subtank). Special tool - top plug wrench, 49 mm: 57001-1653 • after installing the front fork, torque the top plug [a]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] the torque of fork to...

  • Page 331

    Suspension 13-39 front fork (kx450d8f) cylinder unit inspection • inspect the piston rod [b] of cylinder unit [a] for scratches or bending. If it has scratches or is bent, replace cylinder unit with a new one. Inner tube inspection • visually inspect the inner tube [a], repair any damage. • nick or ...

  • Page 332

    13-40 suspension front fork (kx450d8f) spring tension inspection • since a spring becomes shorter as it weakens, check its free length [a] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and th...

  • Page 333

    Suspension 13-41 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 334

    13-42 suspension rear shock absorber • adjust the high speed compression damping, turn the high speed compression damping adjuster with a 17 mm wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. High speed compression damping standard: 1 1/6 turns...

  • Page 335

    Suspension 13-43 rear shock absorber • using the hook wrenches [a], loosen the locknut [b] on the rear shock absorber. Special tool - hook wrench r37.5, r42: 57001-1101 • using the stem nut wrench [a], turn the adjusting nut [b] as required. Turning the adjusting nut downward marks the spring action...

  • Page 336

    13-44 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 (see muffler removal in the engine top end chapter) rear frame with air cleaner housing • using the jack under the...

  • Page 337

    Suspension 13-45 rear shock absorber • using the hook wrenches [c], loosen the locknut [b] and turn the adjusting nut [a] all way up. Special tool - hook wrench r37.5, r42: 57001-1101 • remove the rear shock absorber from the vise. • slide down the rubber bumper [a]. • remove the spring guides [b] f...

  • Page 338

    13-46 suspension swingarm swingarm removal • place the jack [a] under the frame so that the rear wheel is off the ground. Special tool - jack: 57001-1238 • remove rear wheel (see rear wheel removal in the wheels/tires chapter) clamps [b] brake pedal [c] (see brake pedal removal in the brakes chapter...

  • Page 339

    Suspension 13-47 swingarm • unscrew the screws [a] • separate the chain slipper [b] from the swingarm. Swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • tighten the following: torque - swingarm pivot shaft nut: 98 n·m (10 kgf·m, 72 ft·lb...

  • Page 340

    13-48 suspension swingarm swingarm bearing, sleeve inspection caution do not remove the bearings for inspection. Re- moval may damage them. • inspect the needle bearings installed in the swingarm. ○ the rollers in a bearing normally wear very little, and wear is difficult to measure. Instead of meas...

  • Page 341

    Suspension 13-49 tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • unscrew the nut [a] and remove the guide roller [b]. Caution when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tap...

  • Page 342

    13-50 suspension tie-rod, rocker arm rocker arm installation • apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve. • tighten: torque - rear shock absorber mounting nut (lower): 34 n·m (3.5 kgf·m, 25 ft·lb) rocker arm pivot nut: 8...

  • Page 343

    Suspension 13-51 tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearing, grease seals and oil seals with new ones. • apply plenty of grease to the oil seal and needle bearings [a]. Note ○ install the grease seals so that the deep groove side of the rip out-ward....

  • Page 344

    13-52 suspension uni-trak maintenance uni-trak linkage inspection • refer to the 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 sleeve. If t...

  • Page 345: Steering

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

  • Page 346

    14-2 steering exploded view.

  • Page 347

    Steering 14-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 handlebar holder bolts 25 2.5 18 2t 2 steering stem head nut 98 10 72 3 steering stem nut 4.9 0.50 43 in·lb t 4 front fork clamp bolts (upper) 20 2.0 15 al 5 front fork clamp bolts (lower) 20 2.0 15 al 6. Handlebar holder (upp...

  • Page 348

    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 349

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

  • Page 350

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

  • Page 351

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

  • Page 352

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

  • Page 353

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

  • Page 354

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

  • Page 355: Frame

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

  • Page 356

    15-2 frame exploded view.

  • Page 357

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolt 34 3.5 25 2 upper footpeg bracket bolts 54 5.5 40 l 3. Front fender bolts 4. Kx450d6f ∼ d7f 4. Kx450d8f g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 358

    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) right & left side cover (see side cover removal) muffler (see muffler removal in the engine top end chapter) rear fender (see rear fender remo...

  • Page 359

    Frame 15-5 frame engine guard installation • install the engine guard as shown. Right engine guard [a] collar [b] bolt [c] engine guard [d] bolts [e].

  • Page 360

    15-6 frame seat seat removal • remove the bolts [a]. • pull the seat [b] out from the back. Seat installation • insert the hooks [a] of the seat under the flange collar [b] and brackets [c]. • tighten the seat mounting bolts..

  • Page 361

    Frame 15-7 side cover side cover removal • remove: bolts [a] side cover [b] • remove the other side according to similar procedure. Side cover installation • stick the pads [a] on the inside of the right side cover [b]. • install the dampers [c]. • insert the tabs [a] of the cover into the air clean...

  • Page 362

    15-8 frame fender front fender removal • unscrew the bolts [a] and remove the front fender [b]. Rear fender removal • remove: seat (see seat removal) • unscrew the bolts [a] and remove the rear fender [b]. Rear flap removal • unscrew the screws [a] and remove the rear flap [b]..

  • Page 363: Electrical System

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

  • Page 364

    16-2 electrical system exploded view.

  • Page 365

    Electrical system 16-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 gear position switch screws 2.9 0.30 26 in·lb l 2 flywheel nut 78 8.0 58 3 stator bolts 4.0 0.41 35 in·lb l 4 spark plug 13 1.3 113 in·lb 5 magneto cover bolts 9.8 1.0 87 in·lb 6 crankshaft sensor bolts 7.0 0.71 62 in...

  • Page 366

    16-4 electrical system specifications item standard magneto crankshaft sensor resistance 180 ∼ 280 Ω (at 20°c (68°f)) magneto output voltage in the text stator coil resistance in the text ignition system ignition timing 10° btdc @1 800 r/min (rpm) ignition coil: 3 needle arcing distance 7 mm (0.26 i...

  • Page 367

    Electrical system 16-5 special tools and sealant timing light: 57001-1241 spark plug wrench, hex 16: 57001-1262 hand tester: 57001-1394 throttle sensor setting adapter #1: 57001-1400 peak voltage adapter: 57001-1415 filler cap driver: 57001-1454 needle adapter set: 57001-1457 rotor puller: 57001-156...

  • Page 368

    16-6 electrical system wiring diagram.

  • Page 369

    Electrical system 16-7 precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the ...

  • Page 370

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

  • Page 371

    Electrical system 16-9 flywheel magneto magneto cover removal • remove the left radiator shroud. • drain the engine oil from the crank room oil sump (see engine oil change in the periodic maintenance chapter). • pull the stopper [a] to this side to remove the magneto lead connector [b]. • disconnect...

  • Page 372

    16-10 electrical system flywheel magneto • hold the flywheel steady with the rotor holder [a], and remove the flywheel nut [b]. Special tool - rotor holder: 57001-1654 • remove the rotor holder. • screw the rotor puller [a] into the flywheel. • remove the flywheel from the crankshaft by turning in t...

  • Page 373

    Electrical system 16-11 flywheel magneto stator removal • remove: magneto cover (see magneto cover removal) stator bolts [a] crankshaft sensor bolts [b] wiring holder [c] wiring grommet [d] • remove the stator [e] and crankshaft sensor [f] as a set. Stator installation • route the leads according to...

  • Page 374

    16-12 electrical system flywheel magneto ○ connect the hand tester [a] to the connector [b] as shown in the table 1, using the needle adapter set [c]. ○ start the engine. ○ run it at the rpm given in the table 1. ○ note the voltage readings (total 2 measurements). Special tools - hand tester: 57001-...

  • Page 375

    Electrical system 16-13 ignition timing ignition timing inspection • remove the timing inspection plug [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 • sta...

  • Page 376

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

  • Page 377

    Electrical system 16-15 ignition system ignition coil inspection measuring arcing distance the most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3-needle method. • remove the ignition coil. • connect the ignition ...

  • Page 378

    16-16 electrical system ignition system spark plug gap inspection • refer to the spark plug cleaning and inspection in the periodic maintenance chapter. C.D.I. Unit removal • remove: belt (open) [a] bolt [b] number plate [c] • disconnect the main harness connector [a]. • unscrew the mounting bolts [...

  • Page 379

    Electrical system 16-17 ignition system ignition coil primary peak voltage check • disconnect the spark plug cap from the spark plug, but do not remove the spark plug. • connect the good spark plug [a] to the spark plug cap, then touch the engine with it. Note ○ measure the voltage with each lead co...

  • Page 380

    16-18 electrical system ignition system.

  • Page 381

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

  • Page 382

    16-20 electrical system ignition system charge coil peak voltage check • disconnect the connector of the magneto lead connector from the main harness. • to check the peak voltage, do the following procedures. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not ...

  • Page 383

    Electrical system 16-21 ignition system • to check the output voltage, do the following procedures. ○ connect the digital voltmeter [a] as follows. Tester (+) → blue lead tester (–) → black/blue lead ○ start the engine. ○ measure the throttle sensor output voltage with the engine idling speed and wi...

  • Page 384

    16-22 electrical system throttle sensor throttle sensor inspection note ○ if the variable rheostat is not available, refer to throttle sensor output/input voltage check in the c.D.I. Unit in- spection. ○ when inspecting the throttle sensor the throttle valve of the carburetor shall be completely clo...

  • Page 385

    Electrical system 16-23 throttle sensor throttle sensor position adjustment • remove the carburetor (see carburetor removal in the fuel system chapter). • measure the resistance between the blue and black lead terminals of the sensor side connector. Blue lead terminal [a] black lead terminal [b] yel...

  • Page 386

    16-24 electrical system switches engine stop switch inspection • using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). Special tool - hand tester: 57001-1394 if the switch has an open or short, repair it or replace it with a new one. En...

  • Page 387

    Electrical system 16-25 switches • remove: o-ring [a] gear position switch finger [b] spring [c] gear position switch installation • insert the spring into the hole in the shift drum. • insert the switch finger [a] so that the small diameter [b] is toward hole side. • apply grease to the o-ring. • c...

  • Page 389: Appendix

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

  • Page 390

    17-2 appendix cable, wire, and hose routing 1. Throttle cables 2. Marked (aaa) cable is accelerator side. 3. Band (hold the engine stop switch lead.) 4. Engine stop switch lead 5. Hot starter cable 6. Clutch cable 7. Clamp (clamp the clutch and hot starter cable.) 8. Clamp (clamp the throttle cables...

  • Page 391

    Appendix 17-3 cable, wire, and hose routing 1. Clutch cable 2. Engine stop switch lead 3. Hot starter cable 4. C.D.I. Unit 5. Clamps (clamp the clutch cable.) 6. Main harness 7. Gear position sensor lead 8. Flywheel lead 9. Clamp (clamp the gear position sensor lead and magneto lead.) 10. Clamp (cla...

  • Page 392

    17-4 appendix cable, wire, and hose routing 1. Spark plug cap 2. Clamp (clamp the carburetor drain and air vent hoses.) 3. Clamp (clamp the gear position sensor lead.) 4. Gear position sensor lead 5. Clamp (clamp the gear position sensor lead, radiator overflow hose and breather hose.) 6. Breather h...

  • Page 393

    Appendix 17-5 cable, wire, and hose routing 1. Install the clamps as shown in the figure. 2. Clamps (install the clamp screws as shown in the figure.) 3. Carburetor.

  • Page 394

    17-6 appendix cable, wire, and hose routing 1. Left radiator 2. Right radiator 3. Water hose (to cylinder head) 4. Water hose (to water pump) 5. Radiator overflow hose 6. Joint pipe 7. Clamp (position the clamp claw to left side.) 8. Clamp (position the clamp claw down- ward.).

  • Page 395

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

  • Page 396

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

  • Page 397

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

  • Page 398

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

  • Page 399

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

  • Page 400

    Model application year model beginning frame no. 2006 kx450d6f jkakxgdc □ 6a000001 or jkakx450dda000001 2007 kx450d7f jkakxgdc □ 7a012001 or jkakx450dda012001 2008 kx450d8f jkakxgdc □ 8a021001 or jkakx450dda021001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1...