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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 kx450e9f left side view kx450e9f right side view frame number engine number.

  • Page 16

    1-8 general information general specifications items kx450e9f, eaf 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 1 480 mm (58.27 in.) road clearance 340 mm (13.4 in.) seat height 965 mm (38.0 in.) curb mass: 112.1 kg (247...

  • Page 17

    General information 1-9 general specifications items kx450e9f, eaf drive train primary reduction system: type gear reduction ratio 2.727 (60/22) clutch type wet, multi disc transmission: type 5-speed, constant mesh, return shift gear ratios: 1st 1.750 (28/16) 2nd 1.412 (24/17) 3rd 1.188 (19/16) 4th ...

  • Page 18

    1-10 general information general specifications items kx450e9f, eaf effective disc diameter: front (effect. Dia.) 225 mm (8.86 in.) rear (effect. Dia.) 215 mm (8.46 in.) specifications subject to change without notice, and may not apply to every country..

  • Page 19

    General information 1-11 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 21: Periodic Maintenance

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

  • Page 22

    2-2 periodic maintenance rear sprocket warp (runout) inspection ......................................................................... 2-36 brakes.................................................................................................................................. 2-36 brake lever and...

  • Page 23

    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 24

    2-4 periodic maintenance periodic maintenance chart frequency operation each race or 2.5 hr every 3 races or 7.5 hr every 6 races or 15 hr every 12 races or 30 hr see page wheels/tires-inspect • 2-31 rear sprocket-inspect † • 2-36 front fork-inspect and clean • 2-48 front fork oil-change • 2-48 rear...

  • Page 25

    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 26

    2-6 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks camshaft chain tensioner cap bolt 5.0 0.51 44 in·lb cylinder bolt 12 1.2 106 in·lb s exhaust pipe cover bolts 12 1.2 106 in·lb exhaust pipe holder nuts 20 2.0 15 s muffler mounting bolts 20 2.0 15 s muffler cla...

  • Page 27

    Periodic maintenance 2-7 torque and locking agent torque fastener n·m kgf·m ft·lb remarks gear positioning lever nut 8.8 0.90 78 in·lb shift drum cam bolt 24 2.4 18 l balancer weight mounting nut 52 5.3 38 primary gear nut 98 10 72 lh wheels/tires front axle 79 8.0 58 front axle clamp bolts 20 2.0 1...

  • Page 28

    2-8 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks steering steering stem head nut 98 10 72 steering stem nut 4.9 0.50 43 in·lb handlebar clamp bolts 25 2.5 18 2t, al frame rear frame mounting bolts 34 3.5 25 upper footpeg bracket bolts 54 5.5 40 l radiator shr...

  • Page 29

    Periodic maintenance 2-9 specifications item standard service limit fuel system throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – idle speed 2 000± 50 r/min (rpm) – – – air cleaner element oil high quality foam air filter oil – – – cooling system coolant: type (recommended) permanent type ant...

  • Page 30

    2-10 periodic maintenance specifications item standard service limit wheels/tires rim runout (with tire installed): axial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) radial tir 1.0 mm (0.039 in.) or less tir 2 mm (0.08 in.) front and rear tires air pressure 100 kpa (1.0 kgf/cm², 14 psi) – – –...

  • Page 31

    Periodic maintenance 2-11 specifications item standard service limit rear shock absorber oil: oil viscosily k2-c (kayaba) or equivalent – – – electrical system spark plug gap 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) – – – br: brazil model eur: europe model tir: total indicator readings.

  • Page 32

    2-12 periodic maintenance special tools inside circlip pliers: 57001-143 steering stem nut wrench: 57001-1100 jack: 57001-1238 spark plug wrench, hex 16: 57001-1262 filler cap driver: 57001-1454 top plug wrench, 49 mm: 57001-1653 top plug wrench, 36 mm: 57001-1705.

  • Page 33

    Periodic maintenance 2-13 periodic maintenance procedures fuel system fuel hose and connections inspection ○ if the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [a] or the hose burst. Replace the fuel hose if any fraying, cracks [b] or bulges [c...

  • Page 34

    2-14 periodic maintenance periodic maintenance procedures throttle body cleaning • check the throttle bore for cleanliness as follows. ○ remove the throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter). ○ check the throttle bore [a] at the throttle valve for carbon dep...

  • Page 35

    Periodic maintenance 2-15 periodic maintenance procedures idle speed inspection notice this motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can cau...

  • Page 36

    2-16 periodic maintenance periodic maintenance procedures idle speed adjustment • start the engine and warm it up thoroughly. • turn the idle adjusting screw [a] until the idle speed is correct. To increase idle speed [b] to decrease idle speed [c] • open and close the throttle a few times to make s...

  • Page 37

    Periodic maintenance 2-17 periodic maintenance procedures • separate the element [a] from the frame [b]. • clean the element [a] in a bath of a high-flash point sol- vent using a soft bristle brush. • squeeze it dry in a clean towel [a]. Do not wring the ele- ment or blow it dry; the element can be ...

  • Page 38

    2-18 periodic maintenance periodic maintenance procedures fuel tank cleaning warning gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working a...

  • Page 39

    Periodic maintenance 2-19 periodic maintenance procedures • check the coolant level. The coolant level [a] should be at the bottom of the filler neck [b]. If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap. Recommended coolant: perma...

  • Page 40

    2-20 periodic maintenance periodic maintenance procedures water hoses and connections inspection ○ the high pressure inside the water hoses [a] can cause coolant to leak [b] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze th...

  • Page 41

    Periodic maintenance 2-21 periodic maintenance procedures • using a thickness gauge [a], measure the clearance be- tween each cam lob and valve lifter for all four valves. ○ for the purpose of adjusting the valve clearances, record the measured values. Valve clearance: between cam and valve lifter s...

  • Page 42

    2-22 periodic maintenance periodic maintenance procedures adjustment shims thick- ness p/no. Mark thick- ness p/no. Mark 2.00 92025-1870 0 2.55 92025-1881 55 2.05 92025-1871 5 2.575 92025-1985 58 2.10 92025-1872 10 2.60 92025-1882 60 2.15 92025-1873 15 2.625 92180-1059 63 2.20 92025-1874 20 2.625 92...

  • Page 43

    Periodic maintenance 2-23 periodic maintenance procedures cylinder head warp inspection • remove the cylinder head (see cylinder head removal in the engine top end chapter). • lay a straightedge [a] across the lower surface of the head at several different points, and measure warp by inserting a thi...

  • Page 44

    2-24 periodic maintenance periodic maintenance procedures cylinder wear inspection note ○ measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • visually inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly w...

  • Page 45

    Periodic maintenance 2-25 periodic maintenance procedures piston, piston ring and piston pin replacement • refer to the cylinder and piston section in engine top end chapter. Exhaust system inspection • the exhaust system, in particular the muffler body, is de- signed to reduce exhaust noise and con...

  • Page 46

    2-26 periodic maintenance periodic maintenance procedures • clean the adhered silicone sealant. • install the new muffler baffle assembly [a] into the inner pipe [b]. • while suppressing the muffler baffle for shrink, install the muffler body [c]. Note ○ when replacing the muffler baffle assembly, i...

  • Page 47

    Periodic maintenance 2-27 periodic maintenance procedures clutch clutch lever (clutch cable) free play inspection • slide the clutch lever dust cover [a] out of place. • check that the clutch cable upper end is fully seated in the adjusting bolt [b]. • check that the clutch lever [c] has 8 ∼ 13 mm (...

  • Page 48

    2-28 periodic maintenance periodic maintenance procedures clutch plates inspection • remove the clutch plates (see clutch removal in the clutch chapter). • visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear. If any plates show signs of damage, rep...

  • Page 49

    Periodic maintenance 2-29 periodic maintenance procedures recommended engine type castrol “power1 r4 racing” 5w-40 or api sg api sh, sj or sl with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, 10w-50 capacity 0.96 l (1.01 us qt.) (when filter is not removed) 0.98 l (1.03 us qt.) (when filter is ...

  • Page 50

    2-30 periodic maintenance periodic maintenance procedures • apply grease to the grommet [a]. • install the filter to the filter cover [b] so that the grommet faces outside. Notice inside out installation stop oil flow, causing engine seizure. • replace the oil filter cover o-rings [a] with new ones....

  • Page 51

    Periodic maintenance 2-31 periodic maintenance procedures wheel/tires air pressure inspection/adjustment • using tire air pressure gauge [a], measure the tire pres- sure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from...

  • Page 52

    2-32 periodic maintenance periodic maintenance procedures spoke tightness inspection • check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - spoke nipples: 2.2 n·m (0.22 kgf·m, 19 in·lb) warning a missing spoke places an add...

  • Page 53

    Periodic maintenance 2-33 periodic maintenance procedures wheel bearing inspection • raise the front/rear wheel off the ground. Special tool - jack: 57001-1238 • spin the wheel lightly, and check for roughness, binding or noise. If roughness, binding, abnormal noise is found, replace the hub bearing...

  • Page 54

    2-34 periodic maintenance periodic maintenance procedures drive chain slack adjustment • loosen the left and right chain adjuster locknuts [a]. • remove the cotter pin [b] and loosen the axle nut [c]. If the chain is too tight, back out the left and right chain adjusting bolts [d] evenly, and push t...

  • Page 55

    Periodic maintenance 2-35 periodic maintenance procedures drive chain wear inspection • rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. [a] bushing [b...

  • Page 56

    2-36 periodic maintenance periodic maintenance procedures • if a special lubricant is not available, a heavy oil such as sae90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • apply oil to the sides of the rollers so that oil will penetrate int...

  • Page 57

    Periodic maintenance 2-37 periodic maintenance procedures note ○ usually it is not necessary to adjust the pedal position, but always adjust it when the master cylinder is disas- sembled or pedal position is incorrect. ○ usually it is not necessary to adjust the pedal position, but alway adjust it w...

  • Page 58

    2-38 periodic maintenance periodic maintenance procedures brake fluid level inspection • check the brake fluid level in the front or rear brake reser- voir [a] and the front or rear reservoir must be kept above the lower level line [b]. If the fluid level in front or rear reservoir is lower than the...

  • Page 59

    Periodic maintenance 2-39 periodic maintenance procedures brake fluid change warning when working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do...

  • Page 60

    2-40 periodic maintenance periodic maintenance procedures • remove the rubber cap [a] on the bleed valve [b]. • attach a clear plastic hose [a] to the bleed valve on the caliper, and run the other end of the hose into a container. • change the brake fluid as follows: ○ repeat this operation until fr...

  • Page 61

    Periodic maintenance 2-41 periodic maintenance procedures brake pad wear inspection • remove the front brake caliper (see caliper removal in the brakes chapter). • check the lining thickness and condition of the pads in each caliper. If either pad is damaged, replace both pads in the caliper as a se...

  • Page 62

    2-42 periodic maintenance periodic maintenance procedures • remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • slide the dust cover [a] on the push rod [b] out of place, and remove the circlip [c]. Special tool - inside circlip pliers: 57001-143 • pull out the push ...

  • Page 63

    Periodic maintenance 2-43 periodic maintenance procedures • remove the caliper holder [a] from the caliper [b] and remove the anti-rattle spring [c]. • using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ ...

  • Page 64

    2-44 periodic maintenance periodic maintenance procedures • using compressed air, remove the piston. ○ cover the caliper opening with a clean, heavy cloth [a]. ○ remove the piston by lightly applying compressed air [b] to where the brake line fits into the caliper. Warning the piston in the brake ca...

  • Page 65

    Periodic maintenance 2-45 periodic maintenance procedures • install the anti-rattle springs [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 hole...

  • Page 66

    2-46 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 67

    Periodic maintenance 2-47 periodic maintenance procedures rear brake • remove: brake hose clamps [a] • remove: rear master cylinder mounting bolts [a] • slide the rear master cylinder [a] backward. • remove: banjo bolt [b] washers [c] • remove: bolts [a] rear caliper guard [b].

  • Page 68

    2-48 periodic maintenance periodic maintenance procedures • remove: banjo bolt [a] washers [b] brake hose [c] • there are washers on each side of the brake hose fitting. Replace them with new ones when installing. • when installing the hoses, avoid sharp bending, kink- ing, flatting or twisting, and...

  • Page 69

    Periodic maintenance 2-49 periodic maintenance procedures • turn the handlebar to one side, and loosen the fork top plug [a]. Special tool - top plug wrench, 49 mm: 57001-1653 [b] • remove: front fork (see front fork removal in the suspension chapter) note ○ set rebound and compression damping setti...

  • Page 70

    2-50 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 71

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

  • Page 72

    2-52 periodic maintenance 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. Notice disassembling the base valve assembly can lead to trouble. Do not di...

  • Page 73

    Periodic maintenance 2-53 periodic maintenance procedures • with the piston rod in fully compressed position, pour the specified amount of fork oil [a]. Recommended oil: khl15-10 (kayaba 01) or equivalent recommended quantity: 191 ml (6.46 us oz.) (kx450e9f) 198 ml (6.69 us oz.) note ○ plug the two ...

  • Page 74

    2-54 periodic maintenance 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. Notice be careful not to bend or damage the piston rod when the piston rod i...

  • Page 75

    Periodic maintenance 2-55 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. • clamp the axle holder with a vise. ○ protect the axle holder with a rag when using a vise. Warning clampi...

  • Page 76

    2-56 periodic maintenance periodic maintenance procedures • slowly turn the adjuster assembly [a] clockwise until re- sistance is felt and check the clearance between the lock- nut [b] and adjuster assembly to provide more than 1 mm (0.04 in.) [c]. • turn the locknut [a] counterclockwise until it co...

  • Page 77

    Periodic maintenance 2-57 periodic maintenance procedures • raise the outer tube [a] and temporarily tighten the fork top plug (subtank) [b]. Special tool - top plug wrench, 49 mm: 57001-1653 [c] • install the front fork to the frame (see front fork installa- tion in the suspension chapter). ○ loose...

  • Page 78

    2-58 periodic maintenance periodic maintenance procedures rear shock absorber oil change the oil should be changed in the rear shock absorber at least once per racing season. The frequency for best per- formance must be based upon riding conditions and rider ability. • remove the rear shock absorber...

  • Page 79

    Periodic maintenance 2-59 periodic maintenance procedures • slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm (0.39 in.) down. • remove the circlip [a]. • lightly move the piston rod back and forth, and pull ...

  • Page 80

    2-60 periodic maintenance periodic maintenance procedures • pour kyb k2-c (sae 5w or bel-ray se2 #40) oil into the gas reservoir to 50 ∼ 60 mm (2.0 ∼ 2.4 in.) [a] from the gas reservoir upper end. Recommended oil: k2-c (kayaba) or equivalent • replace the bladder [a] with a new one. Notice the bladd...

  • Page 81

    Periodic maintenance 2-61 periodic maintenance procedures • mount the circlip [a] in the groove in the gas reservoir. • pour kyb k2-c oil into the rear shock body to 50 mm (2.0 in.) [a] from the lower end of the rear shock body [b]. Recommended oil: k2-c (kayaba) or equivalent • insert the piston en...

  • Page 82

    2-62 periodic maintenance 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]. Notice ...

  • Page 83

    Periodic maintenance 2-63 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: 57001-1238...

  • Page 84

    2-64 periodic maintenance periodic maintenance procedures steering adjustment • using the jack, raise the front wheel off the ground. Special tool - jack: 57001-1238 • remove number plate (see number plate removal in the frame chapter). • remove the handlebar pad [a]. • remove: handlebar clamp bolts...

  • Page 85

    Periodic maintenance 2-65 periodic maintenance procedures • install the steering stem head to the front fork. • tighten the steering stem head nut. Torque - steering stem head nut: 98 n·m (10 kgf·m, 72 ft·lb) • tighten the loosened front fork clamp bolts. Torque - upper front fork clamp bolts: 20 n·...

  • Page 86

    2-66 periodic maintenance periodic maintenance procedures frame frame inspection • clean the frame with steam cleaner. • visually inspect the frame and rear frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. Warning a repaired frame may fail in use, possibly ...

  • Page 87

    Periodic maintenance 2-67 periodic maintenance procedures • fit the spark plug cap [a] so that align it to the rised line [b] on the head cover. ○ pull the plug cap to make sure the installation of the spark plug cap. Spark plug replacement • refer to the spark plug cleaning and inspection. General ...

  • Page 88

    2-68 periodic maintenance 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 89

    Periodic maintenance 2-69 periodic maintenance procedures brakes: front master cylinder clamp bolts front caliper mounting bolts brake lever pivot nut brake pedal mounting bolt rear master cylinder push rod cotter pin rear caliper holder shaft rear master cylinder mounting bolts suspension: front fo...

  • Page 91: Fuel System (Dfi)

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

  • Page 92

    3-2 fuel system (dfi) fuel injector removal ....................................................................................................... 3-60 fuel injector installation .................................................................................................... 3-61 fuel injector ...

  • Page 93

    Fuel system (dfi) 3-3 dummy page.

  • Page 94

    3-4 fuel system (dfi) exploded view.

  • Page 95

    Fuel system (dfi) 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle pulley cover bolts 7.0 0.71 62 in·lb 2 throttle cable mounting bolts 7.0 0.71 62 in·lb 3 air cleaner duct mounting bolt 2.0 0.20 18 in·lb 4 air cleaner duct mounting nuts 3.0 0.30 26 in·lb 5 air cleaner housin...

  • Page 96

    3-6 fuel system (dfi) exploded view.

  • Page 97

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

  • Page 98

    3-8 fuel system (dfi) dfi system dfi system.

  • Page 99

    Fuel system (dfi) 3-9 dfi system 1. Capacitor 2. Ecu 3. Gear position switch 4. Water temperature sensor 5. Crankshaft sensor 6. Vehicle-down sensor 7. Ignition coil 8. Fuel tank 9. Fuel pump 10. Pressure regulator 11. Inlet air pressure sensor 12. Fuel injector 13. Throttle sensor 14. Inlet air tem...

  • Page 100

    3-10 fuel system (dfi) dfi system dfi system wiring diagram.

  • Page 101

    Fuel system (dfi) 3-11 dfi system part names 1. Ecu 2. Fi indicator light harness connector 3. Fuel injector 4. Inlet air pressure sensor 5. Inlet air temperature sensor 6. Throttle sensor 7. Water temperature sensor 8. Spark plug 9. Ignition coil 10. Frame ground 11. Fuel pump 12. Vehicle-down sens...

  • Page 102

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

  • Page 103

    Fuel system (dfi) 3-13 dfi system 35. Ground for ecu 36. Ground for ecu *: kds (kawasaki diagnostic system).

  • Page 104

    3-14 fuel system (dfi) dfi parts location ecu [a] kawasaki diagnostic system connector [b] fuel pump [a] throttle body assy [b] inlet air temperature sensor [a] throttle sensor [a] water temperature sensor [b] crankshaft sensor [c] vehicle-down sensor [a] ignition coil [b] capacitor [c].

  • Page 105

    Fuel system (dfi) 3-15 dfi parts location fuel injector [a] inlet air pressure sensor [b] fi indicator light harness connector [a].

  • Page 106

    3-16 fuel system (dfi) specifications item standard digital fuel injection system idle speed 2 000 ±50 r/min (rpm) throttle body assy: type single barrel bore 43 (1.69 in.) ecu: make keihin type digital memory type, with built in ic igniter, sealed with resin fuel pressure (high pressure line) 294 k...

  • Page 107

    Fuel system (dfi) 3-17 special tools and sealant oil pressure gauge, 5 kgf/cm²: 57001-125 fork oil level gauge: 57001-1290 vacuum gauge: 57001-1369 hand tester: 57001-1394 needle adapter set: 57001-1457 sensor harness adapter: 57001-1561 fuel pressure gauge adapter: 57001-1593 fuel hose: 57001-1607 ...

  • Page 108

    3-18 fuel system (dfi) dfi servicing precautions dfi servicing precautions there are a number of important precautions that should be followed servicing the dfi system. ○ connect these connectors until they click [a]. ○ never any of the dfi electrical connectors are discon- nected. The ecu memorizes...

  • Page 109

    Fuel system (dfi) 3-19 troubleshooting the dfi system outline when an abnormality in the system occurs, the condition of the problem is stored in the memory of the ecu (elec- tronic control unit). With the engine stopped and conduct a self-diagnosis inspection, the service code [a] is indicated by t...

  • Page 110

    3-20 fuel system (dfi) troubleshooting the dfi system ○ after measurement, remove the needle adapters and ap- ply silicone sealant to the seals [a] of the connector [b] for waterproofing. Sealant - liquid gasket, tb1211: 56019-120 • always check the connected battery condition before re- placing the...

  • Page 111

    Fuel system (dfi) 3-21 troubleshooting the dfi system ○ when checking a harness [a] for short circuit, open one end [b] and check the continuity between the other end [c] and ground [d]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed. • narro...

  • Page 112

    3-22 fuel system (dfi) troubleshooting the dfi system dfi diagnosis flow chart inquiries to rider ○ each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ try to find out exactly what problem occurred under exactly what condi...

  • Page 113

    Fuel system (dfi) 3-23 troubleshooting the dfi system sample diagnosis sheet rider name model engine no. Frame no. Date problem occurred environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: temperature □ hot, □ warm, □ cold, □ very cold, □ always problem fr...

  • Page 114

    3-24 fuel system (dfi) troubleshooting the dfi system □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect). □ brake dragging. □ clutch slipping. □ engine overheating. □ engine oil...

  • Page 115

    Fuel system (dfi) 3-25 dfi system troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in dfi system. ○ the ecu may be involved in t...

  • Page 116

    3-26 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Unstable (rough) idling: fuel...

  • Page 117

    Fuel system (dfi) 3-27 dfi system troubleshooting guide symptoms or possible causes actions (chapter) surge: unstable fuel pressure fuel pressure regulator trouble (inspect and replace fuel pump) or kinked fuel line (inspect and replace fuel pump) (see chapter 3). Fuel injector trouble inspect (see ...

  • Page 118

    3-28 fuel system (dfi) dfi system troubleshooting guide symptoms or possible causes actions (chapter) water temperature sensor trouble inspect (see chapter 3). Inlet air temperature sensor trouble inspect (see chapter 3). Throttle sensor trouble inspect (see chapter 3). Knocking: fuel poor quality o...

  • Page 119

    Fuel system (dfi) 3-29 self-diagnosis self-diagnosis outline the self-diagnosis system has two modes and can be switched to another mode by grounding the self-diagnosis terminal. User mode the ecu connected fi indicator light goes on when dfi system and ignition system parts are faulty. In case of s...

  • Page 120

    3-30 fuel system (dfi) self-diagnosis • keep the fi indicator light assy (option p/no. 23016 -0034) gy/r or y lead [a] ground. ○ count the blinks of the light to read the service code. Keep the lead ground until you finish reading the service code. • to enter the self-diagnosis dealer mode, ground t...

  • Page 121

    Fuel system (dfi) 3-31 self-diagnosis self-diagnosis flow chart.

  • Page 122

    3-32 fuel system (dfi) self-diagnosis how to read service codes ○ service codes are shown by a series of long and short blinks of the fi indicator light as shown below. ○ read 10th digit and unit digit as the fi indicator light blinks. ○ when there are a number of problems, all the service codes can...

  • Page 123

    Fuel system (dfi) 3-33 self-diagnosis service code table ser- vice code fi indicator light problems 11 throttle sensor malfunction, wiring open or short 12 inlet air pressure sensor malfunction, wiring open or short 13 inlet air temperature sensor malfunction, wiring open or short 14 water temperatu...

  • Page 124

    3-34 fuel system (dfi) self-diagnosis backups ○ the ecu takes the following measures to prevent engine damage when the dfi or the ignition system parts have troubles. Service codes parts output signal usable range or criteria backups by ecu 11 throttle sensor throttle sensor output voltage 0.391 ∼ 4...

  • Page 125

    Fuel system (dfi) 3-35 throttle sensor (service code 11) the throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ecu senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttl...

  • Page 126

    3-36 fuel system (dfi) throttle sensor (service code 11) • remove: left radiator shroud (see radiator shroud removal in the frame chapter) capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect...

  • Page 127

    Fuel system (dfi) 3-37 throttle sensor (service code 11) throttle sensor output voltage inspection • measure the output voltage at the throttle sensor in the same way as input voltage inspection, note the following. ○ disconnect the throttle sensor connector and connect the measuring adapter [a] bet...

  • Page 128

    3-38 fuel system (dfi) throttle sensor (service code 11) if the reading is within the standard, remove the ecu and check the wiring for continuity between main harness and sub harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ throttle sensor conne...

  • Page 129

    Fuel system (dfi) 3-39 throttle sensor (service code 11) throttle sensor circuit 1. Ecu 2. Throttle sensor *: y in case of kx450e9f.

  • Page 130

    3-40 fuel system (dfi) inlet air pressure sensor (service code 12) inlet air pressure sensor removal notice never drop the inlet air pressure sensor, especially on a hard surface. Such a shock to the sensor can damage it. • remove: fuel tank (see fuel tank removal) inlet air pressure sensor connecto...

  • Page 131

    Fuel system (dfi) 3-41 inlet air pressure sensor (service code 12) • tighten the screws [a] securely. • connect the inlet air pressure sensor connector [b]. Inlet air pressure sensor input voltage inspection note ○ be sure the battery is fully charged. • disconnect the inlet air pressure sensor conn...

  • Page 132

    3-42 fuel system (dfi) inlet air pressure sensor (service code 12) if the reading is out of the standard, remove the ecu and check the wiring for continuity between main harness and sub harness connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ inlet air p...

  • Page 133

    Fuel system (dfi) 3-43 inlet air pressure sensor (service code 12) if the wiring is good, check the sensor for various vacuum. • remove the inlet air pressure sensor [a] and disconnect the vacuum hose from the sensor. • connect an auxiliary hose [b] to the inlet air pressure sen- sor. • temporarily ...

  • Page 134

    3-44 fuel system (dfi) inlet air pressure sensor (service code 12) id: idling ps: standard atmospheric pressure (absolute) pv: throttle vacuum pressure (absolute) st: standard of sensor output voltage (v) to: throttle full open ur: usable range of sensor output voltage (v) vv: inlet air pressure sen...

  • Page 135

    Fuel system (dfi) 3-45 inlet air pressure sensor (service code 12) inlet air pressure sensor circuit 1. Ecu 2. Inlet air pressure sensor.

  • Page 136

    3-46 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor removal/installation notice never drop the inlet air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • remove the seat (see seat removal in the frame chap-...

  • Page 137

    Fuel system (dfi) 3-47 inlet air temperature sensor (service code 13) • remove: left radiator shroud (see radiator shroud removal in the frame chapter) capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harne...

  • Page 138

    3-48 fuel system (dfi) inlet air temperature sensor (service code 13) inlet air temperature sensor resistance inspection • remove the inlet air temperature sensor (see inlet air temperature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitiv...

  • Page 139

    Fuel system (dfi) 3-49 water temperature sensor (service code 14) water temperature sensor removal/installation notice never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • drain the coolant (see coolant draining in the cooling system ch...

  • Page 140

    3-50 fuel system (dfi) water temperature sensor (service code 14) • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown. • measure the o...

  • Page 141

    Fuel system (dfi) 3-51 water temperature sensor (service code 14) water temperature sensor inspection • remove the water temperature sensor (see water tem- perature sensor removal/installation). • suspend the sensor [a] in a container of machine oil so that the heat-sensitive portion and threaded po...

  • Page 142

    3-52 fuel system (dfi) crankshaft sensor (service code 21) the crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft sensor removal/installation • refer to the starter coil removal/installation in the elec- trical system chapter. C...

  • Page 143

    Fuel system (dfi) 3-53 gear position switch (service code 25) gear position switch removal • remove: shift pedal (external shift mechanism removal in the crankshaft/transmission chapter) • remove the gear position switch connector [a]. • open the clamps [a]. • remove: screws [a] gear position switch...

  • Page 144

    3-54 fuel system (dfi) gear position switch (service code 25) gear position switch inspection note ○ be sure the transmission mechanism is good condition. • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the gear position switch lead connector [a]....

  • Page 145

    Fuel system (dfi) 3-55 gear position switch (service code 25) gear position switch circuit 1. Ecu 2. Frame ground 3. Gear position switch.

  • Page 146

    3-56 fuel system (dfi) vehicle-down sensor (service code 31) when motorcycle is down, if opening of the throttle valve is 3/8 or more, stop the engine after 3 seconds. If throt- tle valve opening is 3/8 or less, hold the engine speed at 3000rpm for 3 seconds after the motorcycle fell over the 3 seco...

  • Page 147

    Fuel system (dfi) 3-57 vehicle-down sensor (service code 31) • remove: capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v bat...

  • Page 148

    3-58 fuel system (dfi) vehicle-down sensor (service code 31) vehicle-down sensor output voltage inspection • remove the vehicle-down sensor. ○ remove the vehicle-down sensor, and connect the mea- suring adapter [a]. Special tool - measuring adapter: 57001-1700 main harness [b] vehicle-down sensor [c...

  • Page 149

    Fuel system (dfi) 3-59 vehicle-down sensor (service code 31) if the reading is within the standard, remove the ecu and check the wiring for continuity between main harness side connectors. ○ disconnect the ecu and sensor connectors. Wiring inspection ecu connector [a] ←→ vehicle-down sensor connecto...

  • Page 150

    3-60 fuel system (dfi) fuel injector (service code 41) notice never drop the fuel injector, especially on a hard surface. Such a shock to the injector can damage it. Fuel injector removal • remove: rear frame (see rear frame removal in the frame chapter) fuel tank (see fuel tank removal) • be sure t...

  • Page 151

    Fuel system (dfi) 3-61 fuel injector (service code 41) fuel injector installation • replace the o-ring [a] and dust seal [b] with a new one. • assemble the delivery pipe [a] and the fuel injector [b]. • fit the projections [a] on the delivery pipe to the hollows [b] of the throttle body assy. • tigh...

  • Page 152

    3-62 fuel system (dfi) fuel injector (service code 41) • insert the fuel hose joint [a] straight into the delivery pipe. • push the joint lock [b]. • push and pull [c] the fuel hose joint back and forth more than two times and make sure it is locked and does not come off. Warning leaking fuel can ca...

  • Page 153

    Fuel system (dfi) 3-63 fuel injector (service code 41) • connect a digital meter [a] to the injector terminal. • measure the fuel injector resistance. Fuel injector resistance connections: r/w terminal ←→ bl/r terminal standard: 11.7 ∼ 12.3 Ω @20°c (68 °f) if the reading is out of the standard, repl...

  • Page 154

    3-64 fuel system (dfi) fuel injector (service code 41) • measure the power supply voltage with the engine stopped. Power supply voltage standard: battery voltage if the voltage is out of the standard, check the power sup- ply wiring (see fuel injector circuit). If the reading is within the standard,...

  • Page 155

    Fuel system (dfi) 3-65 fuel injector (service code 41) injector fuel line inspection • remove: fuel tank (see fuel tank removal) fuel hose (see fuel injector removal) ○ be sure to place a piece of cloth around the fuel outlet pipe of fuel pump and delivery pipe of throttle body assy. • check the inj...

  • Page 156

    3-66 fuel system (dfi) fuel injector (service code 41) fuel injector circuit 1. Ecu 2. Fuel injector 3. Frame ground 4. Capacitor 5. Engine stop switch.

  • Page 157

    Fuel system (dfi) 3-67 fuel pump (service code 46) fuel pump removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any ...

  • Page 158

    3-68 fuel system (dfi) fuel pump (service code 46) • install the fuel pump [a] to the fuel tank. • gradually tighten the fuel pump bolts evenly following the specified tightening sequence [1 ∼ 6]. Torque - fuel pump bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the removed parts (see appropriate ch...

  • Page 159

    Fuel system (dfi) 3-69 fuel pump (service code 46) fuel pump operating voltage inspection note ○ be sure the battery is fully charged. • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the fuel pump lead connector and connect the harness adapter [a]...

  • Page 160

    3-70 fuel system (dfi) fuel pump (service code 46) pressure regulator removal ○ the pressure regulator [a] is built into the fuel pump and can not be removed. Fuel filter cleaning ○ the fuel filter [a] is built into the pump and can not be cleaned or checked. If the fuel filter is suspected of clogg...

  • Page 161

    Fuel system (dfi) 3-71 ignition coil (service code 51) ignition coil removal/installation • refer to the ignition coil removal/installation in the elec- trical system chapter. Ignition coil input voltage inspection • refer to the ignition coil peak voltage inspection in the electrical system chapter...

  • Page 162

    3-72 fuel system (dfi) ecu notice never drop the ecu, especially on a hard surface. Such a shock to the ecu can damage it. Ecu removal • remove: number plate (see number plate removal in the frame chapter) bolt [a] connector bracket [b] ecu connector [c] • pull the ecu [a] together with rubber prote...

  • Page 163

    Fuel system (dfi) 3-73 ecu ecu power supply inspection • remove the number plate (see number plate removal in the frame chapter). • visually inspect the ecu connectors. If the connector is clogged with mud or dust, blow it off with compressed air. • remove the ecu (see ecu removal). • visually inspe...

  • Page 164

    3-74 fuel system (dfi) ecu • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown. • connect a digital meter [a] to the connector [b] wit...

  • Page 165

    Fuel system (dfi) 3-75 fuel line fuel pressure inspection note ○ be sure the battery is fully charged. • remove: left radiator shroud (see radiator shroud removal in the frame chapter) fuel tank (see fuel tank removal) fuel hose (see fuel injector removal) ○ be sure to place a piece of cloth around ...

  • Page 166

    3-76 fuel system (dfi) fuel line • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown. Note ○ inspect the fuel leakage from the connect...

  • Page 167

    Fuel system (dfi) 3-77 fuel line fuel flow rate inspection warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance ...

  • Page 168

    3-78 fuel system (dfi) fuel line • disconnect: capacitor lead connector [a] • connect the power supply harness (option p/no. 26011 -0246) [a] to the capacitor lead connector [b] of the main harness. • connect the power supply harness (option p/no. 26011 -0246) to the 12 v battery [c] as shown then, ...

  • Page 169

    Fuel system (dfi) 3-79 throttle grip and cable if the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the thro...

  • Page 170

    3-80 fuel system (dfi) throttle grip and cable • loosen the mounting bolts [a]. • remove the cables [b] from the throttle body assy. • free the tips [c] from the pulley. • pull out the cables from the frame. • lubricate the cable. • apply grease to the tips of the cables. • install the throttle cabl...

  • Page 171

    Fuel system (dfi) 3-81 throttle body assy idle speed inspection • refer to the idle speed inspection in the periodic main- tenance chapter. Throttle bore cleaning • refer to the throttle body cleaning in the periodic main- tenance chapter. Throttle body assy removal warning gasoline is extremely fla...

  • Page 172

    3-82 fuel system (dfi) throttle body assy throttle body assy installation • install the throttle body assy so that fit the projection [b] on throttle body assy and groove [a] of the throttle body holder. • install the removed parts (see appropriate chapters). • remove: left radiator shroud (see radi...

  • Page 173

    Fuel system (dfi) 3-83 throttle body assy • remove the screw [a] to pull out the injector from the throttle body assy together with the delivery pipe assy [b]. Note ○ do not damage the insertion portions of the injector when they are pulled out from the throttle body. • pull out the injector [a] fro...

  • Page 174

    3-84 fuel system (dfi) throttle body assy • tighten the delivery pipe mounting screw [a] securely. • install the inlet air pressure sensor [a] to the vacuum hose. • install the plate so that fit the hollow [a] on the plate and projection [b] on the throttle body assy. • tighten the plate mounting sc...

  • Page 175

    Fuel system (dfi) 3-85 air cleaner air cleaner housing removal • remove the rear frame (see rear frame removal in the frame chapter). • unscrew the bolts [a]. • remove the air cleaner housing [b] from the rear frame. Air cleaner housing installation • install the air cleaner housing to the rear fram...

  • Page 176

    3-86 fuel system (dfi) fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a p...

  • Page 177

    Fuel system (dfi) 3-87 fuel tank • pull [b] the fuel hose joint [a] out of the fuel outlet pipe. Warning fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose ...

  • Page 178

    3-88 fuel system (dfi) fuel tank • push and pull [b] the hose joint [a] back and forth more than two times, and make sure it is locked and does not come off. Warning leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose joint is in- stalled correctly on the delive...

  • Page 179: Cooling System

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

  • Page 180

    4-2 cooling system exploded view.

  • Page 181

    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 water hose clamp screws 3.0 0.31 27 in·lb 5 radiator mounting bolts 9.8 1.0 87 in·lb 6 radiator ...

  • Page 182

    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 1.1 l (1.2 us qt.) radiator cap relief pressure 112 ∼ 142 kpa (1.14 ∼ 1.45 k...

  • Page 183

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

  • Page 184

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

  • Page 185

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

  • Page 186

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

  • Page 187

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

  • Page 188

    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 189

    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 190

    4-12 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: radiator shrouds (see radiator shroud removal in the frame chapter) regulator/rectifier (see regulator/rectifier removal in the electrical system chapter) • loosen: clamp screws [a] • remove: clamp [b...

  • Page 191

    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: 3.0 n·m (0.31 kgf·m, 27 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) • ...

  • Page 192

    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 193: 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 ................. 5-8 cylinder head cover ......................... 5-11 cylinder head cover removal .... 5-11 ...

  • Page 194

    5-2 engine top end exploded view.

  • Page 195

    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 1.2 106 in·lb s 4 camshaft cap bolts 9.8 1.0 87 in·lb s, mo 5 camshaft sprocket bolts 12 1.2 106 in·lb l...

  • Page 196

    5-4 engine top end exploded view.

  • Page 197

    Engine top end 5-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 exhaust pipe cover bolts 12 1.2 106 in·lb 2 exhaust pipe holder nuts 20 2.0 15 s 3 muffler mounting bolts 20 2.0 15 s 4 cylinder bolt 12 1.2 106 in·lb s 5 muffler clamp bolt 16 1.6 12 6 camshaft chain tensioner mounting b...

  • Page 198

    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/camshaft cap clearance 0.020 ∼ 0.062 mm (0.00079 ∼ 0.0024 in....

  • Page 199

    Engine top end 5-7 specifications item standard service limit inlet outer 39.28 mm (1.546 in.) 37.8 mm (1.49 in.) inner 36.05 mm (1.419 in.) 34.5 mm (1.36 in.) cylinder and pistons cylinder inside diameter: kx450e9f 96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) 96.10 mm (3.783 in.) kx450eaf 96.025 ∼ 96.0...

  • Page 200

    5-8 engine top end 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 201

    Engine top end 5-9 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 se...

  • Page 202

    5-10 engine top end special tools and sealant valve guide driver attachment d: 57001-1659 valve guide driver attachment g: 57001-1728 liquid gasket, tb1211f: 92104-0004.

  • Page 203

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

  • Page 204

    5-12 engine top end cylinder head cover • install the spark plug cap [a] so that align it to the rised line [b] on the head cover. ○ pull up the spark plug cap lightly to make sure of the in- stallation of the spark plug cap..

  • Page 205

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

  • Page 206

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

  • Page 207

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

  • Page 208

    5-16 engine top end camshaft • remove: bolts [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. • fit the...

  • Page 209

    Engine top end 5-17 camshaft 1st pin [a] 2nd pin [b] 29th pin [c] mark (exhaust) [d] punch mark (inlet) [e] cylinder head upper surface [f] • plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase. • be sure to install the positioni...

  • Page 210

    5-18 engine top end camshaft • uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ following the sequence numbers on the camshaft caps. Tighten the cap bolts [1 ∼ 8] after applying molybdenum disulfide oil to the thread of them. Torque - camshaft cap ...

  • Page 211

    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 212

    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 213

    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 214

    5-22 engine top end cylinder head • remove the cylinder head bolts (m6) [a] and loosen the cylinder bolt [b] for prevent damage. • remove the cylinder head bolts (m10) following the loos- ening sequence as shown. • remove the cylinder head [a]. Note ○ when do not remove the cylinder head easily, tap...

  • Page 215

    Engine top end 5-23 cylinder head • install: dowel pins [a] new cylinder head gasket [b] • install the cylinder head. ○ the camshaft caps are machined with the cylinder head; therefore, if a new cylinder head is installed, use the caps that are supplied with the new head. • replace all the cylinder ...

  • Page 216

    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 217

    Engine top end 5-25 valves • hammer lightly on the valve guide arbor [a] to remove the guide. Special tool - valve guide arbor, 5.5: 57001-1021 valve guide installation • apply a thin coat of oil to the outer surface of the valve guide. • heat the area around the valve guide up to 120 ∼ 150°c (248 ∼...

  • Page 218

    5-26 engine top end valves valve/valve guide clearance measurement (wobble method) ○ if a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below. • insert a new valve [a] into the guide [b] and set a dial...

  • Page 219

    Engine top end 5-27 valves valve seat repair • for the instructions on how to use the valve seat cutter [a], follow the operation manual provided by the manu- facturer. Special tools - valve seat cutter holder, 5.5: 57001-1125 [b] valve seat cutter holder bar: 57001-1128 exhaust: valve seat cutter, ...

  • Page 220

    5-28 engine top end valves marks stamped on the cutter the marks stamped on the back of the cutter [a] represent the following. 60° ........................... Cutter angle [b] 37.5 ....................... Cutter outer diameter [c] repair operating procedures • clean the seat area carefully. • coat ...

  • Page 221

    Engine top end 5-29 valves if the outside diameter [a] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low. • grind the seat at a 32° angle [b] until the sea...

  • Page 222

    5-30 engine top end valves valve seat repair.

  • Page 223

    Engine top end 5-31 cylinder and piston cylinder removal • remove: cylinder head (see cylinder head removal) front camshaft chain guide [a] cylinder bolt [b] water temperature sensor connector [c] • tap lightly up with a plastic mallet to separate the cylinder from the crankcase. • remove the cylind...

  • Page 224

    5-32 engine top end cylinder and piston • install the top ring [a] so that the "r" mark [b] faces up. Note ○ if a new piston or cylinder is used, check piston to cylin- der clearance (see piston/cylinder clearance), and use new piston rings. • apply engine oil to the inside wall of the small end of ...

  • Page 225

    Engine top end 5-33 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 226

    5-34 engine top end 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 1.13 mm (0.0445 in.) if any of the groove ...

  • Page 227

    Engine top end 5-35 cylinder and piston piston, piston pin, connecting rod wear inspection • visually inspect the snap rings [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the dia...

  • Page 228

    5-36 engine top end throttle body assy holder throttle body assy holder removal • remove: throttle body assy (see throttle body assy removal in the fuel system (dfi) chapter) throttle body assy holder bolts [a] throttle body assy holder [b] throttle body assy holder installation • replace the o-ring...

  • Page 229

    Engine top end 5-37 muffler warning the muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler removal • loosen the muffler clamp bolt [a]. • remove the exhaust pipe holder nuts [b]. • remove the exhaust pipe [c]. • rem...

  • Page 230

    5-38 engine top end muffler muffler baffle replacement • refer to the muffler baffle change in the periodic main- tenance chapter..

  • Page 231: Clutch

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

  • Page 232

    6-2 clutch exploded view.

  • Page 233

    Clutch 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 clutch cover bolts 9.8 1.0 87 in·lb 2 right engine cover bolts 9.8 1.0 87 in·lb 3 clutch spring bolts 8.8 0.90 78 in·lb 4 clutch hub nut 98 10 72 5. Friction plates (the lining blocks are many (kx450e9f).) 6. Friction plates (the...

  • Page 234

    6-4 clutch specifications item standard service limit clutch lever clutch lever free play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) – – – clutch friction plate thickness 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.) friction plate warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.) steel plate warp 0.2 mm (0...

  • Page 235

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

  • Page 236

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

  • Page 237

    Clutch 6-7 clutch lever and clutch cable • loosen the adjusting nuts [a] fully. • free the clutch inner cable tip [b] from the clutch release lever [c]. Notice do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with a new one...

  • Page 238

    6-8 clutch 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: clutch cover bolts [a] clutch cover [b] clutch cover installat...

  • Page 239

    Clutch 6-9 clutch cover and right engine cover right engine cover installation • three dowel pins [a] are installed at the mating surface between the crankcase and the right engine cover. • apply grease to the o-rings [b], and install them to the crankcase. ○ install the lower o-ring so that the tap...

  • Page 240

    6-10 clutch clutch cover and right engine cover • press the kick shaft oil seal [b] so that the bearing surface flush with the right engine cover surface [a]. Special tool - bearing driver set: 57001-1129 • apply grease to the oil seal lip..

  • Page 241

    Clutch 6-11 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 spring plate [b] • remove: washer [a] needle bearing [b] push rod holde...

  • Page 242

    6-12 clutch clutch • remove: toothed washer [a] clutch housing [b] clutch installation • check the clutch plate assembly free play (see clutch plate assembly free play inspection/adjustment). • apply molybdenum disulfide oil to the inside of the clutch housing. • install: clutch housing [a] toothed ...

  • Page 243

    Clutch 6-13 clutch • install the friction plates and steel plates, starting with a friction plate [a] and alternating them. Finishing with a friction plate. ○ when install the new plate, apply engine oil to the plate surface. Kx450e9f: ○ install the friction plates which the lining blocks [b] on the...

  • Page 244

    6-14 clutch clutch • check the release shaft lever positions. ○ pushing [b] the release shaft lever [c] lightly forward, measure the distance [a] between the lever and cable bracket [d]. Release shaft lever position standard: 68.6 ∼ 76.4 mm (2.70 ∼ 3.01 in.) if the lever position is not within the s...

  • Page 245

    Clutch 6-15 clutch clutch plate assembly free play inspection/ad- justment • assemble the following parts. Clutch hub [a] friction plates [b] steel plates [c] friction plates [d] spring plates [e] spring [f] bolts [g] kx450e9f: ○ install the friction plates [b] to the both ends of the plate assembly...

  • Page 246

    6-16 clutch 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 the friction...

  • Page 247

    Clutch 6-17 clutch release shaft installation • replace the oil seal with a new one. • apply grease to the oil seal lip. • apply engine oil to the bearing in the hole of the crankcase. • apply grease to the part where the push rod comes in contact. • insert the release shaft straight into the hole o...

  • Page 249: Engine Lubrication System

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

  • Page 250

    7-2 engine lubrication system exploded view.

  • Page 251

    Engine lubrication system 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt (m10) 20 2.0 15 2 engine oil drain bolt (m6) 7.0 0.71 62 in·lb 3 oil pump (scavenge) cover bolts 9.8 1.0 87 in·lb 4 oil pump (feed) cover bolts 9.8 1.0 87 in·lb 5 oil filter cover (right e...

  • Page 252

    7-4 engine lubrication system lubrication system chart.

  • Page 253

    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 254

    7-6 engine lubrication system specifications item standard engine oil grade castrol “power1 r4 racing” 5w-40 or api sg api sh, sj or sl with jaso ma, ma1 or ma2 viscosity sae 10w-30, 10w-40, or 10w-50 capacity oil change - when filter is not removed 0.96 l (1.01 us qt) oil change - when filter is re...

  • Page 255

    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 256

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

  • Page 257

    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 258

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

  • Page 259

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

  • Page 260

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

  • Page 261

    Engine lubrication system 7-13 oil pump oil pump (scavenge) removal • drain: engine oil (see engine oil change in the periodic main- tenance chapter) • remove: flywheel (see flywheel removal in the electrical sys- tem chapter) • remove: oil pump cover bolts [a] lower camshaft chain guide [b] oil pum...

  • Page 262

    7-14 engine lubrication system oil pump • install: oil pump cover [a] lower camshaft chain guide [b] • while pushing the oil pump cover, tighten the oil pump cover bolts [c]. Torque - oil pump (scavenge) cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) oil pump (feed) removal • remove: clutch (clutch remo...

  • Page 263

    Engine lubrication system 7-15 oil pump • while pushing the oil pump cover [a], tighten the oil pump cover bolts. [b] l = 20mm [c] l = 16mm torque - oil pump (feed) cover bolts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • install the oil pump idle gear [a] facing the stepped side [b] to the outside. • replace t...

  • Page 264

    7-16 engine lubrication system oil pressure oil pressure measurement • remove: oil filter cover bolts [a] oil filter cover [b] • 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 oi...

  • Page 265: Engine Removal/installation

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

  • Page 266

    8-2 engine removal/installation exploded view.

  • Page 267

    Engine removal/installation 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 middle engine mounting nut 49 5.0 36 s 2 middle engine bracket nuts 29 3.0 21 s 3 upper engine mounting bolts 49 5.0 36 s 4 upper engine bracket bolts 29 3.0 21 s 5 lower engine mounting nut 49 5.0 36 s 6 swi...

  • Page 268

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

  • Page 269

    Engine removal/installation 8-5 engine removal/installation engine removal • raise the rear wheel off the ground with the jack [a]. Special tool - jack: 57001-1238 warning when the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall t...

  • Page 270

    8-6 engine removal/installation engine removal/installation • remove: water hoses [a] right engine guard [b] • remove the bolts [c], and remove the brake pedal [d] and rear master cylinder [e] as a set. • remove: upper engine bracket bolts (left and right) [a] upper engine mounting bolts and nuts (l...

  • Page 271

    Engine removal/installation 8-7 engine removal/installation engine installation • install the engine. ○ first, insert the front portion of the engine, and then install the rear portion. • install the swingarm pivot shaft, all engine bracket and mounting bolts temporarily. ○ insert the swingarm pivot...

  • Page 273: Crankshaft/transmission

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

  • Page 274

    9-2 crankshaft/transmission exploded view.

  • Page 275

    Crankshaft/transmission 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase bolts (m6) 12 1.2 106 in·lb s 2 crankcase bolts (m7) 15 1.5 11 s 3 engine oil drain bolt (m10) 20 2.0 15 4 engine oil drain bolt (m6) 7.0 0.71 62 in·lb 5 piston oil nozzle 3.0 0.30 26 in·lb 6 piston oil...

  • Page 276

    9-4 crankshaft/transmission exploded view.

  • Page 277

    Crankshaft/transmission 9-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 ratchet guide bolt 8.8 0.90 78 in·lb 2 kick pedal bolt 25 2.5 18 l 3 shift pedal bolt 9.8 1.0 87 in·lb 4 upper ratchet plate mounting bolt 9.8 1.0 87 in·lb s 5 lower ratchet plate mounting bolt 15 1.5 11 l, s 6 g...

  • Page 278

    9-6 crankshaft/transmission specifications item standard service limit crankshaft connecting rod big end radial clearance 0.002 ∼ 0.014 mm (0.00008 ∼ 0.00055 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 0.0...

  • Page 279

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

  • Page 280

    9-8 crankshaft/transmission crankcase crankcase disassembly • remove the engine from the frame (see engine removal in the engine removal/installation chapter). • set the engine on clean surface while parts are being re- moved. • remove: piston (see piston removal in the engine top end chap- ter) rig...

  • Page 281

    Crankshaft/transmission 9-9 crankcase • remove: circlip [a] balancer drive gear [b] • remove the crankcase bolts [a]. • pry a pry point [a] at the crankcase mating surface, and split the crankcase. If crankcase splitting can not easily, split the crankcase according to the following procedures. ○ in...

  • Page 282

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

  • Page 283

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

  • Page 284

    9-12 crankshaft/transmission crankcase • replace the oil seals, if removed. • press the output shaft, shift shaft and release shaft oil seals [c] so that oil seal lip [a] face to the engine outside and oil seal surface flush with the left crankcase surface [b]. Special tool - bearing driver set: 570...

  • Page 285

    Crankshaft/transmission 9-13 crankcase • apply a non-parmanent locking agent to the piston oil noz- zle bolt [a]. • tighten: torque - piston oil nozzle bolt: 7.0 n·m (0.71 kgf·m, 62 in·lb) • install: crankshaft (see crankshaft installation) oil screen (feed) (see oil screen (feed) installation in th...

  • Page 286

    9-14 crankshaft/transmission crankcase • tighten the crankcase bolts, starting with the periphery of the crankshaft, then outward. • replace the washers [a] with a new one. • tighten: torque - crankcase bolts (m6): 12 n·m (1.2 kgf·m, 106 in·lb) crankcase bolts (m7): 15 n·m (1.5 kgf·m, 11 ft·lb) note...

  • Page 287

    Crankshaft/transmission 9-15 crankcase • replace the circlip [a] with a new one, and install it to the output shaft..

  • Page 288

    9-16 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 grease to the outer side of the crankshaft bearings and use the bearin...

  • Page 289

    Crankshaft/transmission 9-17 crankshaft • carefully align the oil passage hole in the right flywheel [a] with the one in the crankpin [b] at rebuilding of the crankshaft as shown. Crankshaft inspection connecting rod big end radial clearance inspection • set the crankshaft on v blocks, and place a d...

  • Page 290

    9-18 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. Notice do not hammer the crank half at the point [b]. If flywheel misalignment ca...

  • Page 291

    Crankshaft/transmission 9-19 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 292

    9-20 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 forks [c]. • remove the shift drum. • pull out the driv...

  • Page 293

    Crankshaft/transmission 9-21 transmission transmission shaft disassembly • remove the transmission shafts. • remove the circlips, washers, then gears. Special tool - outside circlip pliers: 57001-144 • do not reuse the removed circlips. Transmission shaft assembly • apply engine oil liberally to the...

  • Page 294

    9-22 crankshaft/transmission transmission 1. 2nd gear (17t) 2. Circlip 3. Toothed washer 4. Bushing 5. 4th gear (19t) 6. 3rd gear (16t) 7. 5th gear (24t) 8. 1st gear (16t) 9. Drive shaft 10. Output shaft 11. 1st gear (28t) 12. 5th gear (21t) 13. 3rd gear (19t) 14. 4th gear (19t) 15. 2nd gear (24t) 1...

  • Page 295

    Crankshaft/transmission 9-23 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 296

    9-24 crankshaft/transmission balancer balancer removal • hold the flywheel [a] with the rotor holder [b] to loosen the balancer weight mounting nut [c] special tools - grip [d]: 57001-1591 rotor holder: 57001-1730 • remove: right engine cover (see right engine cover removal in the clutch chapter) ma...

  • Page 297

    Crankshaft/transmission 9-25 primary gear primary gear removal • remove: right engine cover (see right engine cover removal in the clutch chapter) clutch (see clutch removal in the clutch chapter) • temporarily install the clutch housing [a]. • remove: oil pump drive shaft [b] oil pump gear [c] • us...

  • Page 298

    9-26 crankshaft/transmission external shift mechanism shift pedal removal • remove: shift pedal bolt [a] shift pedal [b] shift pedal installation • install the shift pedal so that the split portion [a] on the pedal align with the punch mark [b] on the shift shaft. • tighten: torque - shift pedal bol...

  • Page 299

    Crankshaft/transmission 9-27 external shift mechanism external shift mechanism installation • install the gear positioning lever [a]. ○ fit each end of the spring [b] or original positions. ○ install the color and washer [c]. • tighten: torque - gear positioning lever nut [d]: 8.8 n·m (0.90 kgf·m, 7...

  • Page 300

    9-28 crankshaft/transmission external shift mechanism • before installing the shift shaft, apply grease to the oil seal lips and shift shaft splines. • insert the shift shaft [a]. • replace the circlip [b] with a new one. • install the oil pump driver gear [c]. • install the removed parts (see appro...

  • Page 301

    Crankshaft/transmission 9-29 kickstarter kick pedal assy removal • remove: mounting bolt [a] kick pedal assy [b] kick pedal assy installation • install the kick pedal assy [a] as shown. 15.6 ∼ 25.6mm (0.614 ∼ 1.00 in.) [b] • apply a non-permanent locking agent to the kick pedal bolt. • tighten: torq...

  • Page 302

    9-30 crankshaft/transmission kickstarter idle gear installation • make sure to position the circlip [a] in original position. Replace it, if removed. • apply molybdenum disulfide oil to the inside [b] of the idle gear. • replace the circlip [a] with a new one. • install the idle gear [c] facing embo...

  • Page 303

    Crankshaft/transmission 9-31 kickstarter • install the ratchet guide [a]. • tighten: torque - ratchet guide bolt: 8.8 n·m (0.90 kgf·m, 78 in·lb) • insert the kick shaft assembly [b] into the crankcase. ○ securely engage the stopper portion [c] of the ratchet gear with the guide. • insert the spring ...

  • Page 304

    9-32 crankshaft/transmission kickstarter • fit the spring end [a] and hollow [b] on the spring guide..

  • Page 305

    Crankshaft/transmission 9-33 bearings/oil seals bearing replacement notice 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, satis...

  • Page 306

    9-34 crankshaft/transmission bearings/oil seals • check the needle bearing. ○ the rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition ...

  • Page 307: Wheels/tires

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

  • Page 308

    10-2 wheels/tires exploded view.

  • Page 309

    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 79 8.0 58 3 front axle clamp bolts 20 2.0 15 al, s 4 rear axle nut 110 11.2 81.1 al: tighten the two clamp bolts alternately two ti...

  • Page 310

    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 311

    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 bearing remover head, 20 × 22: 57001-1293 bearing remover head, 25 × 28: 57001-1346 bearing remover shaft, 13: 57001-1377.

  • Page 312

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

  • Page 313

    Wheels/tires 10-7 wheels (rims) • tighten the axle nut [a]. • tighten the left axle clamp bolts [b]. Torque - front axle nut: 79 n·m (8.0 kgf·m, 58 ft·lb) left front axle clamp bolts: 20 n·m (2.0 kgf·m, 15 ft·lb) note ○ tighten the two clamp bolts alternately two times to en- sure even tightening to...

  • Page 314

    10-8 wheels/tires wheels (rims) • squeeze the front brake lever, and hold it with a band [a] to prevent the motorcycle from running forward. Warning motorcycle may fall over unexpectedly resulting in an accident or injury . Be sure to hold the front brake when removing the rear wheel. • remove: rear...

  • Page 315

    Wheels/tires 10-9 wheels (rims) • fit the projection [a] on the cap to the groove [b] on the collar. ○ the collars are identical. • apply grease to the grease seal lips of the rear hub. • fit the collars [a] and caps [b] on the both sides of the rear hub. • engage the joint of the drive chain, and i...

  • Page 316

    10-10 wheels/tires wheels (rims) note ○ when inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [a] up to next alignment. ○ it should be within 30 degree. ○ loosen one and tighten again when the slot goes past the near...

  • Page 317

    Wheels/tires 10-11 tires air pressure inspection/adjustment • refer to the air pressure inspection/adjustment in the pe- riodic maintenance chapter. Tire removal • remove the wheel from the motorcycle. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the d...

  • Page 318

    10-12 wheels/tires tires • step on the side of the tire opposite valve stem, pry the tire off the rim with the tire irons [a] of the bead breaker protecting the rim with rim protectors [b]. • begin to remove the tire beads from the rim, and com- pletely remove the tire beads that are valve stem of t...

  • Page 319

    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..

  • Page 320

    10-14 wheels/tires hub bearing front hub bearing removal • remove front wheel (see front wheel removal) grease seals [a] • use the bearing remover to remove the hub bearings [a]. Notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place wooden block...

  • Page 321

    Wheels/tires 10-15 hub bearing • using a suitable bar [a], tap the around of the bearing inner race evenly to remove the bearings [b]. Hub bearing installation • before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the ...

  • Page 322

    10-16 wheels/tires hub bearing hub bearing inspection since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. Note ○ do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones. • turn each...

  • Page 323: Final Drive

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

  • Page 324

    11-2 final drive exploded view.

  • Page 325

    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 70 7.1 52 3 engine sprocket cover bolts 9.8 1.0 87 in·lb g: apply grease. Ho: apply heavy oil. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 326

    11-4 final drive specifications item standard service limit drive chain chain slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) – – – chain 20-link length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) standard chain: make daido – – – type did 520dma2 (kx450e9f) – – – did 520dma4 length 114 links – – – sproc...

  • Page 327

    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 328

    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 effectiveness..

  • Page 329

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

  • Page 330

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

  • Page 331: Brakes

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

  • Page 332

    12-2 brakes exploded view.

  • Page 333

    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 pin 17 1.7 12 4 caliper bleed valve 7.8 0.80 69 in·lb 5 front caliper mounting bolts 25 2.5 18 6 front brake disc mounting bolt...

  • Page 334

    12-4 brakes exploded view.

  • Page 335

    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 10 1.0 88 in·lb 3 rear master cylinder push rod locknut 17 1.7 12 4 caliper bleed valve 7.8 0.80 69 in·lb 5 brake pad pin 17 1.7 12 6 rear brake pad pin pl...

  • Page 336

    12-6 brakes specifications item standard service limit brake adjustment lever play adjustable (to suit rider) – – – brake fluid recommended disc brake fluid: – – – type front dot4 – – – rear dot4 brake pads lining thickness: front 4.0 mm (0.16 in.) 1 mm (0.04 in.) rear 6.4 mm (0.25 in.) 1 mm (0.04 i...

  • Page 337

    Brakes 12-7 special tool jack: 57001-1238.

  • Page 338

    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 339

    Brakes 12-9 brake lever, brake pedal • install the joint pin [a], washer [b] and a new cotter pin [c]. ○ bend the ends [d] of the cotter pin. • adjust the brake pedal position (see brake lever and pedal position adjustment in the periodic maintenance chapter)..

  • Page 340

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

  • Page 341

    Brakes 12-11 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 342

    12-12 brakes brake fluid • repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [a]. 2. Quickly open and close the bleed valve while holding the brake applied [b]. 3. Release the brake [...

  • Page 343

    Brakes 12-13 calipers caliper removal front brake • loosen the banjo bolt [a] on the caliper side once, and tighten again lightly. • loosen the brake pad pin [b] before the caliper removal if the caliper is to be disassembled. • remove the caliper mounting bolts [c] and remove the caliper [d] from t...

  • Page 344

    12-14 brakes calipers • bleed the brake line (see bleeding the brake line). • check the brake for good braking power, no brake drag, and no fluid leakage. Warning after servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in ...

  • Page 345

    Brakes 12-15 calipers caliper dust boot and friction boot damage • check that the dust boot [a] and friction boot [b] are not cracked, worn, swollen, or other wise damaged. If they show any damage, replace it. [c] front caliper [d] rear caliper caliper piston and cylinder damage • visually inspect t...

  • Page 346

    12-16 brakes calipers caliper holder shaft wear the caliper body must slide smoothly on the caliper holder shafts [a]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature. •...

  • Page 347

    Brakes 12-17 brake pad brake pad removal front brake • unscrew the pad pin [a]. • take the piston side pad [b]. • remove another pad [c] from the caliper holder. Rear brake • remove: pad pin plug [a] • unscrew the pad pin[a]. • take the piston side pad [b]. • remove another pad [c] from the caliper ...

  • Page 348

    12-18 brakes brake pad brake pad inspection • refer to the brake pad wear inspection in the periodic maintenance chapter..

  • Page 349

    Brakes 12-19 master cylinder notice 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 the...

  • Page 350

    12-20 brakes master cylinder rear master cylinder removal • remove the brake pedal joint pin (see brake pedal re- moval). • unscrew the master cylinder mounting bolts [a], and re- move the master cylinder [b] backward. • unscrew the brake hose banjo bolt [c]. • when removing the brake hose, temporar...

  • Page 351

    Brakes 12-21 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 352

    12-22 brakes brake disc brake disc removal • remove the wheel (see front/rear wheel removal in the wheels/tires chapter). • unscrew the mounting bolts [a], and take off the disc [b]. Brake disc installation • install the brake disc on the wheel so that the marked side [a] faces out. • apply a non-pe...

  • Page 353

    Brakes 12-23 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 355: Suspension

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

  • Page 356

    13-2 suspension exploded view.

  • Page 357

    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 plugs 30 3.1 22 3 upper front fork clamp bolts 20 2.0 15 al 4 lower front fork clamp bolts 20 2.0 15 al 5 adjuster assembly locknut 28 2.9 22 6 adjuster assembly 55 5.6 40 l 7. ...

  • Page 358

    13-4 suspension exploded view.

  • Page 359

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

  • Page 360

    13-6 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 (kx450e9f) 10 clicks counterclockwise (eur, br) 12 clicks ...

  • Page 361

    Suspension 13-7 specifications item standard service limit rocker arm large 19.987 ∼ 20.000 mm (0.78688 ∼ 0.78740 in.) 19.85 mm (0.781 in.) small 15.950 ∼ 16.000 mm (0.62795 ∼ 0.62992 in.) 15.92 mm (0.627 in.) rocker arm mounting bolt runout tir 0.1 mm (0.004 in.) or less tir 0.2 mm (0.008 in.) br: ...

  • Page 362

    13-8 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 head, 20 × 22: 57001-1293 bearing remover shaft, 13: 57001-1377 fork oil seal driver, 48: 57001...

  • Page 363

    Suspension 13-9 front fork air pressure if you felt that a front fork is strong during a driving, place the jack under the frame so that the front wheel off the ground, and remove the screw [a] at the top of the front fork top plugs to let the air pressure equalize. Special tool - jack: 57001-1238 n...

  • Page 364

    13-10 suspension front fork seated positions adjuster turned fully clockwise [a]. Rebound damping adjuster setting standard: 13 clicks [b] (kx450e9f) 10 clicks (eur, br) 12 clicks softer (counterclockwise) [c] harder (clockwise) [d] *: although you can turn the adjuster beyond the ad- justable range...

  • Page 365

    Suspension 13-11 front fork • 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 upper surface of the steering stem head is specified dimension. [a] 10 ...

  • Page 366

    13-12 suspension front fork • 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 collar (kx450eaf) [c] oil seal [d] retaining ring [e] dus...

  • Page 367

    Suspension 13-13 front fork • install the oil seal by using the fork oil seal driver [a]. Special tool - fork oil seal driver, 48: 57001-1509 • install the retaining ring to the outer tube. • push the dust seal into the outer tube, and put the spring band on the dust seal. • pour the fork oil (see f...

  • Page 368

    13-14 suspension front fork • temporarily assemble the inner [a] and outer tubes [b], and pump them back and forth manually to check for smooth operation. Notice if the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube...

  • Page 369

    Suspension 13-15 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 370

    13-16 suspension rear shock absorber seated position: adjuster turned fully clockwise [a]. High speed compression damping standard: 1 1/2 turns out [b] (kx450e9f) softer (counterclockwise) [c] (kx450e9f) 10 clicks harder (clockwise) [d] * : although you can turn the adjuster beyond the ad- justable ...

  • Page 371

    Suspension 13-17 rear shock absorber • using the hook wrenches, loosen the locknut [a] on the rear shock absorber. Special tools - hook wrench r37.5, r42 [b]: 57001-1101 hook wrench [c]: 57001-1641 • using the stem nut wrench [a], turn the adjusting nut [b] as required. Turning the adjusting nut dow...

  • Page 372

    13-18 suspension rear shock absorber notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing • remove the tie-rod mounting bolt and nut [a] (rear), and turn the tie-rod [b] downward. • remove the rear shock abs...

  • Page 373

    Suspension 13-19 rear shock absorber • using the hook wrenches [c], loosen the locknut [b] and turn the adjusting nut [a] all way up. Special tools - hook wrench r37.5, r42: 57001-1101 hook wrench: 57001-1641 • remove the rear shock absorber from the vise. • slide up the rubber bumper [a]. • remove ...

  • Page 374

    13-20 suspension rear shock absorber rear shock absorber scrapping warning the shock contains high-pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity, causing serious injury. To avoid injury, do not point a suitable jig toward your face or body ...

  • Page 375

    Suspension 13-21 swingarm swingarm removal • remove: rear wheel (see rear wheel removal in the wheels/tires chapter) rear flap (see rear fender flap removal in the frame chapter) brake hose clamps [a] • remove: bolts [a] and nuts [b] chain guide plate [c] chain guide [d] • unscrew the rocker arm piv...

  • Page 376

    13-22 suspension swingarm • remove the screws [a] • remove the chain slipper [b] from the swingarm. Swingarm installation • apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • install the collars to the both sides of the swingarm. • tighten: torque - swingarm ...

  • Page 377

    Suspension 13-23 swingarm swingarm bearing, sleeve inspection notice 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 measu...

  • Page 378

    13-24 suspension 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 chain guide roller [b]. Notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing o...

  • Page 379

    Suspension 13-25 tie-rod, rocker arm rocker arm installation • apply plenty of grease to the inside of the rocker arm, needle bearings, grease seals and outside of the sleeve. • tighten: torque - rocker arm pivot nut: 59 n·m (6.0 kgf·m, 44 ft·lb) lower rear shock absorber mounting nut: 34 n·m (3.5 k...

  • Page 380

    13-26 suspension tie-rod, rocker arm tie-rod and rocker arm bearing installation • replace the needle bearing and grease seals with new ones. • apply plenty of grease to the grease seal and needle bearings [a]. Note ○ install the grease seals so that the deep groove side of the rip out-ward. • insta...

  • Page 381

    Suspension 13-27 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 and measure the outside diameter of the sleeve. If ...

  • Page 383: Steering

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

  • Page 384

    14-2 steering exploded view.

  • Page 385

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

  • Page 386

    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 387

    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..

  • Page 388

    14-6 steering steering stem steering stem, stem bearing removal • remove: front wheel (see front wheel removal in the wheels/tires chapter) front fender (see front fender removal in the frame chapter) number plate (see number plate removal in the frame chapter) handlebar pad [a] breather hose [b] (p...

  • Page 389

    Steering 14-7 steering stem • take off the upper stem bearing inner race (tapered roller bearing) [a]. • drive out the bearing outer races from the head pipe. ○ remove the outer races pressed into the head pipe, using the head pipe outer race remover [a], and hammer the head pipe outer race remover ...

  • Page 390

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

  • Page 391

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

  • Page 392

    14-10 steering handlebar handlebar removal • remove: number plate (see number plate removal in the frame chapter) clutch holder [a] engine stop switch [b] clamps [c] left handlebar grip [d] • remove: throttle grip assy [a] (see throttle cable replacement in the fuel system (dfi) chapter) master cyli...

  • Page 393

    Steering 14-11 handlebar • apply grease to the throttle cable upper end and clutch cable upper end. • apply a 2-stroke oil to the edge (slash area) of the han- dlebar. [a] 120mm (4.72in.) • install the throttle grip assy so that the grip [a] is in as far as it will go. • position the throttle grip a...

  • Page 395: Frame

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

  • Page 396

    15-2 frame exploded view.

  • Page 397

    Frame 15-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 rear frame mounting bolts 34 3.5 25 2 upper footpeg bracket bolts 54 5.5 40 l 3 radiator shroud bolts 9.8 1.0 87 in·lb g: apply grease. L: apply a non-permanent locking agent. R: replacement parts.

  • Page 398

    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 and left side cover (see side cover removal) muffler (see muffler removal in the engine top end chapter) rear fender (see rear fender re...

  • Page 399

    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 400

    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 401

    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 pad [a] on the inside of the right side cover [b]. • install the damper [c]. • insert the tabs [a] of the side cover into slits [b] ...

  • Page 402

    15-8 frame radiator shroud radiator shroud removal • remove: bolts [a] radiator shroud [b] radiator shroud installation • install: radiator shroud [a] bolts (l = 12) [b] bolt (l = 16) [c].

  • Page 403

    Frame 15-9 number plate number plate removal • remove the bolt [a]. • remove the band [b] from the handlebar. • remove the number plate [c] upward. Number plate installation • insert the projections [a] of the number plate into the holes [b] of the steering stem. ○ run the cluth cable through front ...

  • Page 404

    15-10 frame fender front fender removal • unscrew the bolts [a] and remove the front fender [b]. Rear fender removal • remove: seat (see seat removal) sidecover (see side cover removal) • unscrew the bolts [a] and remove the rear fender [b]. Rear flap removal • unscrew the screws [a] and remove the ...

  • Page 405: Electrical System

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

  • Page 406

    16-2 electrical system exploded view.

  • Page 407

    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 coil bolts 9.8 1.0 87 in·lb l 4 spark plug 13 1.3 115 in·lb 5 magneto cover bolts 9.8 1.0 87 in·lb 6 crankshaft sensor bolts 7.0 0.71 6...

  • Page 408

    16-4 electrical system specifications item standard magneto magneto output voltage 29.6 v or more at 4 000 r/min (rpm) stator coil resistance 0.4 ∼ 1.1 Ω (at 20°c (68°f)) ignition system ignition timing 10° btdc @2 000 r/min (rpm) ignition coil: 3 needle arcing distance 7 mm (0.26 in.) or more prima...

  • Page 409

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

  • Page 410

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

  • Page 411

    Electrical system 16-7 special tools and sealant dummy page.

  • Page 412

    16-8 electrical system wiring diagram (kx450e9f).

  • Page 413

    Electrical system 16-9 wiring diagram (kx450e9f).

  • Page 414

    16-10 electrical system wiring diagram (kx450eaf).

  • Page 415

    Electrical system 16-11 wiring diagram (kx450eaf).

  • Page 416

    16-12 electrical system precautions there are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the...

  • Page 417

    Electrical system 16-13 electrical wiring wiring inspection • visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • pull each connector [a] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clea...

  • Page 418

    16-14 electrical system flywheel magneto magneto cover removal • drain the engine oil (see engine oil change in the peri- odic maintenance chapter). • remove the left radiator shroud (see radiator shroud re- moval in the frame chapter). • disconnect the magneto lead connector [a] from the main harne...

  • Page 419

    Electrical system 16-15 flywheel magneto magneto cover assembly • if removed, the oil seal replacement may be required. • press the balancer shaft oil seal [b] so that the magneto cover end [a] is flushed as shown. Special tool - bearing driver set: 57001-1129 • apply grease to the oil seal lips. • ...

  • Page 420

    16-16 electrical system flywheel magneto flywheel installation • using a high-flash point solvent, clean off any oil or dirt that may be on the crankshaft taper [a] or in the hole [b] of the flywheel. Dry them with a clean cloth. • fit the woodruff key [c] securely in the slot of the crank- shaft. •...

  • Page 421

    Electrical system 16-17 flywheel magneto stator coil installation • route the leads according to the cable, wire, and hose routing section in the appendix chapter. • apply a non-permanent locking agent to the stator coil bolts. • install the stator and tighten the stator coil bolts. Torque - stator ...

  • Page 422

    16-18 electrical system flywheel magneto table 2 stator coil resistance connections tester range tester (+) to tester (–) to reading × 1 Ω one yellow lead another yellow lead 0.4 ∼ 1.1Ω if there is more resistance than shown in the table, or no hand tester reading (infinity), the stator has an open ...

  • Page 423

    Electrical system 16-19 charging system regulator/rectifier removal • remove: right radiator shroud (see radiator shroud removal in the frame chapter) nuts [a] bolts [b] bracket [c] • remove the regulator/rectifier connector [d]. Regulator/rectifier installation • install the regulator/rectifier con...

  • Page 424

    16-20 electrical system charging system capacitor removal • remove: left radiator shroud (see radiator shroud removal in the frame chapter) • remove the connector [a], and pull the capacitor [b] up- ward. Capacitor installation kx450e9f • face the lead of the capacitor upward, and insert the ca- pac...

  • Page 425

    Electrical system 16-21 ignition timing ignition timing inspection • remove the timing inspection cap[a]. Special tool - filler cap driver: 57001-1454 • attach the timing light [a] to the ignition coil lead in the manner prescribed by the manufacturer. Special tool - timing light: 57001-1241 • start...

  • Page 426

    16-22 electrical system ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Ignition coil removal • remove: f...

  • Page 427

    Electrical system 16-23 ignition system • install the spark plug cap [a] aligned with the line [b] of the cylinder head cover. 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 c...

  • Page 428

    16-24 electrical system ignition system measuring coil resistance if the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. ...

  • Page 429

    Electrical system 16-25 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 430

    16-26 electrical system ignition system.

  • Page 431

    Electrical system 16-27 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 432

    16-28 electrical system ignition system crankshaft sensor inspection • remove: magneto lead connector (see magneto cover re- moval). • set the hand tester [a] to the × 100 Ω range and connect it to the green/white [b] and white/yellow [c] leads in the connector. Special tool - hand tester: 57001-139...

  • Page 433

    Electrical system 16-29 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 435: Appendix

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

  • Page 436

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

  • Page 437

    Appendix 17-3 cable, wire, and hose routing kx450e9f 1. Clutch cable 2. Kawasaki diagnostic system connector 3. Ecu 4. Main harness 5. Clamp the clutch cable. 6. Gear position switch lead 7. Magneto lead 8. Water temperature sensor connector 9. Clamp the main harness and engine stop switch lead. 10....

  • Page 438

    17-4 appendix cable, wire, and hose routing kx450eaf 1. Clutch cable 2. Kawasaki diagnostic system connector 3. Ecu 4. Main harness 5. Clamp the clutch cable. 6. Gear position switch lead 7. Magneto lead 8. Water temperature sensor connector 9. Clamp the main harness and engine stop switch lead. 10....

  • Page 439

    Appendix 17-5 cable, wire, and hose routing 1. Sub-harness connector (black) 2. Sub-harness connector (gray) 3. Bracket 4. Insert the sub-harness connectors into the bracket. 5. Regulator/rectifier connector 6. Sub-harness 7. Water temperature sensor connector.

  • Page 440

    17-6 appendix cable, wire, and hose routing kx450e9f 1. Engine stop switch lead 2. Radiator hose 3. Capacitor 4. Engine stop switch lead connector 5. Clamp the engine stop switch lead and regulator/rectifier lead with the frame pipe at the blue tape portion. 6. Ignition coil connector 7. Ignition co...

  • Page 441

    Appendix 17-7 cable, wire, and hose routing kx450eaf 1. Engine stop switch lead 2. Radiator hose 3. Capacitor 4. Engine stop switch lead connector 5. Ignition coil connector 6. Ignition coil 7. Sub-harness.

  • Page 442

    17-8 appendix cable, wire, and hose routing 1. Spark plug cap 2. 45° 3. Gear position switch lead 4. Clamp the gear position switch lead. 5. Radiator overflow hose 6. Clamp (clamp the breather hose and ra- diator overflow hose.) 7. Breather hose 8. Install the clamp as shown. 9. Align the white mark...

  • Page 443

    Appendix 17-9 cable, wire, and hose routing 1. Left radiator 2. Right radiator 3. Radiator hose (to cylinder head) 4. Radiator hose (to water pump) 5. Radiator overflow hose 6. Joint pipe 7. Clamp (position the clamp claw left side.) 8. Clamp (position the clamp claw down- ward.) 9. Run the radiator...

  • Page 444

    17-10 appendix cable, wire, and hose routing 1. To main harness 2. Clamp the sub-harness at the blue tape portion. 3. To intake air temperature sensor 4. Clamp the water temperature sensor lead and throttle sensor lead at the blue tape portion. 5. To water temperature sensor 6. Throttle sensor conne...

  • Page 445

    Appendix 17-11 cable, wire, and hose routing 1. Intake air temperature sensor lead 2. Run the intake air temperature sensor lead through the hole of the guide as shown. 3. Do not touch the intake air temperature sensor lead and rear shock absorber. 4. Do not show up the intake air temperature sensor...

  • Page 446

    17-12 appendix cable, wire, and hose routing kx450e9f 1. To spark plug cap 2. To main harness (black) 3. Vehicle-down sensor 4. Ignition coil 5. Capacitor (position the lead wire upward.) 6. Do not touch the high tension lead and engine ground lead. 7. To main harness (green) 8. To main harness.

  • Page 447

    Appendix 17-13 cable, wire, and hose routing kx450eaf 1. To spark plug cap 2. To main harness (black) 3. Vehicle-down sensor 4. Ignition coil 5. Capacitor (position the lead wire downward.) 6. Do not touch the high tension lead and engine ground lead. 7. To main harness (green) 8. To main harness.

  • Page 448

    17-14 appendix 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 ca...

  • Page 449

    Appendix 17-15 troubleshooting guide note ○ refer to the fuel system (dfi) chapter for most of dfi trouble shooting guide. ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more com...

  • Page 450

    17-16 appendix troubleshooting guide poor running or no power at high speed: firing incorrect: spark plug dirty, broken, or gap malad- justed spark plug cap or high tension wiring trou- ble spark plug cap shorted or not in good con- tact spark plug incorrect heat value ecu trouble crankshaft sensor ...

  • Page 451

    Appendix 17-17 troubleshooting guide shift return spring weak or broken shift shaft lever broken pawl guide plate broken shift pawl broken shift pawl spring tension lose gear seized gear positioning lever operation trouble shift drum broken jumps out of gear: shift fork ear worn, bent gear groove wo...

  • Page 452

    17-18 appendix troubleshooting guide handling and/or stability unsatisfactory: handlebar hard to turn: cable, hose, wire routing incorrect steering stem nut too tight steering stem bearing damaged steering stem bearing lubrication inade- quate steering stem bent tire air pressure too low handlebar s...

  • Page 453

    Model application year model beginning frame no. 2009 kx450e9f jkakxgec □ 9a000001 or jkakx450eea000001 2010 kx450eaf jkakxgec □ aa011001 or jkakx450eea011001 □ :this digit in the frame number changes from one machine to another. Part no.99924-1410-02 printed in japan.