Kawasaki VN800 Motorcycle Service ManualThis quick reference guide will assist you in locating a desired topic or p cedure. ‘@ Zend 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 con- tents for the exact pages to locate the specific topic required. Quick Reference Guide (General Information 1 [Fuel System [CoolingSystem [Engine TopEnd [clutch [Engine Removal/installation _7 [CrankshafuTransmission ____8 | [Wheels/Tires [FinalDrive 10 [Brakes 0} |a} o>} jon] |B] joo] fro Suspension 12 Steering 13 Frame 14 [Electrical System 15) [Appendix SCS Supplement-2000 ~ 2001 Models _17 Supplement-2002 ~ 2003 Models _18 Supplement-2004 Model 19.2 sbiu® sansisisA xaivO er A0gS-tagm: amelqqua | } Ce deny ern Bt é “gidbowt E00 - a abceoanese 1 | sep nataee pod denilan teal | TFA beta Porras et 8 ep tg.“ | ta apie eal teva Taw te| i 4 VULCAN 800 VN800 Kawasaki Motorcycle Service ManualLIST OF ABBREVIATIONS a ‘ampere(s) ib pound(s) BOC | after bottom dead center m mever(s) ac alternating current min rminuce(s) ToC | after top dead center N newton (s) BBDC before bottom dead center Pa pascal(s) B0C | bottom dead center Ps horsepower BTOC | before top dead center psi pound(s) per square inch c Gegree(s) Celsius r revolution oc direct current ‘pm revolution(s) per minute F farad(s) roc top dead center * degree(s) Fahvenhet TA total indicator reading f foot. feet v volt(s) 9 cgrem(s) w watt(s) h hour(s) Qa ohm(s) L liter(s) Read OWNER’S MANUAL before operating.Pett tatatet tt tote tr ted NM ce n sag GROAN: RE hyena a EMISSION CONTROL INFORMATION “To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) contol systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission contral system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 4, Crankease Emission Control Systam This system eliminates the releaso of crankcase vapors Into the atmosphere. Instead, the ‘vapors are routed through an oll soparator to the intake side of the engine, While the engine is operating, the vapore are drawn into combustion chamber, where they are burned along ‘with the fuel end air supplied by the carburetion system. 2. Exhaust Emission Contiol System ‘This system reduces the emount of pollutants discharged into the atmosphere by the exhaust of this motoceycle. The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. 3. Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmoscher. Instead, fue! vapors ae routed into the running engine to be burned, or stored in @ canister ‘when the engine is stopped, Liquid fuel is caught by a vapor separator and cetuined to the fue! tank, ‘The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's “tampering provisions.” *Sec, 203(e) The following acts and the causing thereof are prohibited... (3)(A) for any person to remove or render inoperative any device or element of design insialled fon or in a motor vehicle or motor vehicle engine in compliance with regulations under this ttle prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or alement ot design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fieet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on of in'@ motor vehicle oF motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser.” (Continued on next page.) TOR weraws Pad SeeNOTE © The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: 2. Maledjustment of vehicle components such that the emission standards are exceaded. 1b Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. @. Addition of components or accessories that result in the vehicle exceeding the standards, d. Permanently removing, disconnecting. or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING 510,000 PER VIOLATION. SR ee ed ; Zz TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenence, reper, or replacement, of any 225 davice or element of design incorporated into any new vehicle for the purpose of noise contro prior S35 tots sele or delivery to the ultimate purchaser or while itis in use, or (2) the use of the vehicle after SS such device or element of design has been removed or rendered inoperative by any person. a $5 Among those acts presumed to constitute tampering are the acts listed below: £2 efeplecement ofthe original exhaust system or mutter witn 2 component not in compliance with £2 Federal regulations. FE eRemoval of the muffier(s) or eny internal portion of the mutfer(s). 35% _ @Removal of the sir box or air box cover. ‘® Modifications to the muffier(s) or air intake system by cutting, drilling, or other means if such ©“ rmodicetons ecu in increased noise levels. eg 5 umcigaunnciepen pais cipiaenuipine i PSS erate ree te TEER PTS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 proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: ‘© Follow the Periodic Maintenance Chart in the Service Manual @Be alert for problems and non-scheduled maintenance. @ Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog, Follow the procedures in this manual care- fully. Don't take shortcuts @ Remember to keep complete records of main- tenance and repair with dates and any new parts installed, How to Use This Manual In this manual, the product is divited into ite major systems and these systems make up ‘the manual’s chapters. The Quick Reference Guide shows you all of the product's system and. assists in locating their chapters. Each chapter in tum has its own comprehensive Table of Contents. For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow sate operating and maintenance practices. OG This warning symbol identifies special Instructions or procedures which, if not correctly followed, could result in per= sonal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa- tion, NOTE This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. indicates a procedural step or work to be done. Olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also procedes the text of a NOTE. x Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oll, grease or a locking agent during assembly.j biowsi1e4 nto KeuiboN) SA AS voy awore ain vied, cwiqach et rated i iuees bas qeenatimgnon mm 28 eh ated oF Twraert, eines be okieT warren ene iii oe otae 4 dog 6 obi gnaw Aid ae Go _raD WEL teu ASST tate mas alta ll edger 0 4 dean at erp ve Binet a mY inom Tig inti at Eco 9 Yat fen SHONBAS 3208 soe Ure vere Sengitatad Mad bent ameense MGITUAD exreriniam bre grimy Bar weit oycwth. eran fabasge eeiitsiel iodanye gilantar AAT.» oe Mitta eBrabe-o 10 aenaltaussers [te ph tase 100. ocratfod vila aq91do megane | tomas — ymin komen cides aia 5 dete H sheen Aetp-haenh Se printlonersnr PND a Rake Shun Samet phar i sbencry ite lo 1) acm un sok eran amc et Whi stone WEEE ene CVA, eerie enon arti) singe sr ch oat aT0%, ants ee eres lutions Cave weit 60 Sn TS eae ool eT a Hi ot aoe 1S ER 8, eK ent Oe plane 2 ies herr ba tds A, evetil Ik ota senalvonalty Bes eT OH ar SY Cia test at eects tate 42h 1a he hr ey ge FBI A BN ew a “PORE Wars Te ES a Qaeanie We eae wes ION HT © Frater beeline sie te evagete Palin Hh te Soba we" arch dtnarnegiac matteee. a Ye tal eo lie ony texatywe axectte Mitnocd (ianere gaieh pene ean FoF Phare Penge o leone aT [patie ag Wea 5 citer Pci -ariilsadd Core hota chy ebreiahrst ji seve ert SB ont rie = PSE teReree noReDMat {en conrpiaaers Soon poe atA testing chee pituictines Bo captyhesr.s hes A atc sina AROS, hitter vnee yin, sue) Ie oR IG a8 ee NET BS iptetied conannebae pd inary ESV voaiamr Yeam tat ernmastnicee ie Ree Fa ae eye: ae Ee age i rate 9 83 ob cals air ao Ate ita Sire Unt SSGeN GRA atewrA Eileen eeatlauip (i ys Bea ert is. tee sree ooh hen eA SOS sr taal att tne pec Reno Wink ‘ot SemiLerONy Rett the Few uisy onremsoret Yirgua BIL Om Ort ch Dal la Hew yallenie ove 3) Plot aeesavune ti ome meek e a8 gu Preteate:n ni Jon ob pakDsne ee sate ringyaeseesernmiancst tnengune 30 Bt ira alnvegpens vosyig 28 [Pit yom M8 Hi pier ot esis pe abvibrt bn bet esate aes Zoe hay Being pewraw sch ls nets oct Ie pekeisanoe bees suet 29 well gern eY fee su sonamrocag a hasncheg ect oprmuminit 2 Wi Sate Aiantibare tre HA press Sones sire ‘STEN mM Dareneetig bon araterraome “teat [Pewote tare net gmc lauren 28 tar Aokiffos Sicie'e Sed a Daag RAMP TG AT 69.8 res eure eB ote ®, * Seah PORE ee ee ee ed sorurnaindai. She tases ni iit pene aE Lar Segieg aust Rpoot yaw] eaerot Pitas pew ees et ahaa a8 x3 canboer! & Steen Nee wes AGAR pousis:) Ont amie Suit Peale ate ok PC ak OE LE, genet ats ip isha yT eAoG orth wate sgibrracis mid FEA? tht —rikribe sinercecalcnyrne, geal SrimcinanD ee ee ee er priniral ates, “isunetl ant? vel) ot wott ek Gant baie Sy ev dirson al BI Oy abt eT AOF) Dae emaRIYE Mat Suen) a SAT somata eoGENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ... Model Identification. General Specifications. za Periodic Maintenance Chart. Technical information - Sealed Battery... Torque and Locking Agent. Special Tools and Sealant.. Cable, Wire, and Hose Routing... f=)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 aiven below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: a (2) 3) (4) (5) (6) (8) (9) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. Battery Ground Disconnect the ground (-) wire from the battery before performing any disassembly operations ‘on the motorcycle. This prevents the engine trom accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive \wire to the positive (+) terminal of the battery Installation, Assembly Generally, installation or assembiy is the reverse of removal or disassembly. However, if instal lation or assembly sequence is given in this Service Manual, follow It. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assem- bled in the same way. It is preferable to mark and record the locations and routing whenever possible, Tightening Sequence ‘When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or ‘screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening ‘sequence and method indicated. If tightening sequence instructions are not given, tighten them ‘evenly ina cross pattem. Conversely, to remove a part, fist loosen all the bolts, nuts, or screws that are retaining the part a 1/4-tum before removing them. Torque ‘When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench, Force ‘Common sense should dictate how much force is necessary in assembly and disassembly, If ‘a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden of plastic-faced mallet. Uso ‘an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. Edges Waich for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine ‘or tuming it over. High-Fiash Point Solvent A high-fiash point solvent is recommended to reduce fire danger. A commercial solvent com- ‘monly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. Gasket, O-Ring Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks, (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam- age.GENERAL INFORMATION 1-3 Before Servicing (11)Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil o the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless itis absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer ‘and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the ‘end of the race that contacts the press fit portion, and press it evenly over the base component. (13)0il Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally dam- ages seals. Cil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer's marks, press it in with the marks facing out. (14)Circlip, Retaining Ring, and Cotter Pin ‘When installing circiips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as r2- moval weakens and deforms them. if old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem. (15)Lubrication Engine wears generally at its maximum while the engine is warming up and betore all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it of and apply fresh grease or oll. Some oils and greases in particular should be used only in certain applications and may be harmful f used in an application for which they are not intended. (16)Direction of Engine Rotation To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos- itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, itis furthermore necessary to rotate the engine in the direction of positive rotation as well. (17)Replacoment Pans When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function onee they are removed. There- fore, always replace these parts with new ones every time they aro removed. Although the pre- viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oll seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts. (18)Electrical Wires All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe color. For example, a yellow wire with thin red stipes is referred to as a “yellowed” wire; it would be a “red/yellow’ wire if the colors were reversed. Unless in- structed otherwise, electrical wires must be connected to wires of the same color Two-Color Electrical ——fed | — Wire strands (@...... Yel |ow/Red —n se1-4 GENERAL INFORMATION Before Servicing (19)Inspection When parts have been disassembled, visually inspect these parts for the following concitions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20)Specitications Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have "Service Limits indicate the usable limits. If the measurement shows excessive wear or dete- riorated performance, replace the damaged parts,GENERAL INFORMATION 1-5 Model Identification r ‘vvs0o. and Canada Models) Left Side View: \YN800-A1 (US and Canada Models) Right Side View:1-6 GENERAL INFORMATIONGENERAL INFORMATION 1-7 General Specifications tems VN800-A1, A2, A3, A, AS Dimensions: Gvorall length 2.370 mm, (CN) (US) 2 360 mm Overall wicth 825 mm vorall height 1170 mm Wheelbase 1625 mm Road clearance 160 mam Seat height 710 mm Dry mass 225 kg, (CA) 228.5 kg Curb mass: Front 107 kg, Rear 137 kg, (CA) 137.5 kg Fuel rank capacity 1501 Performance: Minimum turning radius 29m Engine: Typ Coating system Bore and swoke Displacement Compression ratio Maximum horsepower Maximum torque CCarburetion system Stanting system Ignition syste Timing advance Ignition timing Spatk plug Cylinder numbering method Firing order Valve timing: Inlet Open Close Duration Exhaust Open Close Duration 4-sitoke, SOHC, V 2-cylinder Lquid-cooled 88.0 x 66.2 mm 805 mL. 95 40.5 KW (55 PS) @7 000 r/min (rpm), (CN) 44.1 KW (60 PS) @7 500 r/min (rpm), (ST) 24.2 KW (33 PS) @3 000 r/min(rpm), (FA) 39.3 KW (63 PS) @7 000 r/min (spm) (UTAC's norm), (us) 64. N-m (6.5 kg-m, 47.0 ft-1b) @3 300 r/min rpm) (CN) 64.7 N-my (8.8 kg-m, 87.7 f-lb) @3 500 r/min (opm), (ST) 55 N-m (56 kg-m, 40 5 ft-lb} @3 000 t/min (com), (FR)(UK)(US) ~~~ Carburetor, Keihin CVK 36 Blectic starter Bettery and coil (transstorized) Electronically advanced (digital igniter) From 5,0" BTDC @1 000 r/min (rom) to 37.5! BTDC @6 760 r/min (rpm) NGK CR7E or ND U22ESR-N Front to roar, 1-2 42 2BTDC, AD ~ 19° BTC 78" ABDC, 71" ABDC 280", 270° 72, BBDC, AZ ~ 69° BEDC 28" ATDG. 31" ATOC. 280", 280"1-8 GENERAL INFORMATION General Specifications hems VN300-A1, Az YN800-A3,A4,A5 Lubrication system Forced lubiieation (wel sump) 7 Engine oi: Grade SE, SF or 8G class + Viecosity SAETOW-40, 101-50, 20W-40, or 20W-50, ie Capacity 32 a Brive Train: Primary reduction system: Tyre Gear : Reduction ratio 2.184 (69/88) = Chath ype Wet mult disc “Transmission: Tyre S-speed, constant mesh, return shift & Gear ratios: ist 2.280 (36/18) 2.593 (88/15) 2n¢ 1.800 (22/20) 1.880 (8320) 8rd 1.230 (22/26) 1.230 (32128) ath 1.000 (29/29) 1,000 (2029) sth 0.857 (24/28) 0.857 (24/28) Final dive system: Tyee Chain drive ~ Reduction rato 2.875 (46/10) 2.470 (42/17) Overall dive ratio. 5,362 @Top gear 4.625 @ Top gear Frame: Type Tubulzr, double cradle - Caster (rako angio) ae - Tra 149mm - Front tire: Tyee Tube - Size 00-21 48H Rear tre: Type Tube - Size 140/90-16 71H - Front suspension: Type Telescopic fork - ‘Wheel travel_| 150 mm: ~ Rearsuspersion: Type ‘Swingarm (uni-trak) a Wheel travel | 100 mm - Brake Type: Front Single dice - Rear Drum = Electrical Equipment: Battery 12 12 An = Headlight Tye Semi-sealed beam = ub 12.V 60155 W (quartz-halogen) - “Talorake light 42.V 5/21 W x 2, (CN) (US) 12V 827 Wx 2 | — ‘Akornator: Type ‘Three-phase AC - Rated ouput | 23.5 8/14 V @8 000 rimin (rpm) = Spectications aubjact to change without notice, and may not apply to every country. (CA): California Model ICN): Canada Modat (FR): France Modal (ST): Switzerland Model (UK): U.K Model (US): US. ModelGENERAL INFORMATION 1 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running Cconditon. The initial maintenance i vitally important and must not be neglected FREQUENCY Whichever 7 ODGNETER READING: 5000 10 OO ‘OPERATION 15-000, 0. 000K 25-000 30 000 km, ‘Spark plug - clean ‘Spark plug - check lo lo jeje ‘Valve clearance check ‘Air suction valve = check ‘Air clearer element - clean Throte ari slay - check beh lle ele ole Idle speed ~ agus” Fuel hoses, connections — crack jole ble Fuel system = check” Jele ‘Gooiant = change [Exeporative emission conirel system (Cal) - check” Engre ail - change Oil fier - replace ‘Ol soreen = clean adaior hoses. connectons - chaok" |e le le lol Fuel hose - replace (Chitch - adjust Drive chain waar - check © lole| ole lololo| |e lele bel bk epebPb beh Drive chain - lubricate Diva chain slack - check” Brake thing or pad wear check Brake fuid level - check” 5 bP ‘Brake fivid - change { ‘Brake hoses. connections - check lee ‘Brake hose - repiace ‘Brake master cylinder cup and dusi seal - reslane ‘Caliper piston seal and dust seal -reciace: Behe play - check” [Brake light sorte - chacie Brake camehat - lubricate Brake cable - replace” ‘Seeing - checs Steering stem beating - lubricate Front fork oll -change: Tire wear = check” ‘Spoke tightness and rim runout - check ‘Swingarm pivet_unisirak Inkage -lubrcale ‘General lubrication = perform le |e |ele ‘Nuts, bolis, and fastener tightness -checi™ le le ole le lee ple For higher odometer sacings, repent atthe Frequency interval established here, Feploce, add, adjust, clean, or torque if necessary. (Cal): Calforais Model any4-10 GENERAL INFORMATION n - Sealed Battery Technical Informat ‘A sealed battory is instal in this model, The battery Is a sealed type, and so cannot be performed the electrolyte level heck and topping-uo. ()) Construction Sealing plug Filter Safery valve Lid (P.?.) Terminal (lead-calcium alloy) Filler plug Pole (lead-caicium alloy) [Negative plate (lead and leaé-calcium alloy) * Special separator Positive plate (ead and lead-calcium alloy) (i) Main Features 1) Maintenance free, . It is not necessary to check the electrolyte level end top-up the akecvolyte 2) No electrolyte leakage [AS the electrolyte is retained firmly in the special seperstors, there is no {tee electrolve in the bottory. 3) Instant activation system. 1 can be used instantly after fling only the elactiolyte without initial charge, 4) One-push motion electrolyte filing...» Its possibi to fil the electrolyte by easy one-push mation, 8) Safety SOMstrUCtON yvumeem Saf the battery intemal pressure rises abnormally high, the safety valve ‘opens to release the ges inside the bettery to restora the normal pressure and prevent the battery from rupturng. After restoring the nornal pressure, the safety valve closes and the battery is sealed again, Moreover, a ceremic iter is disposed on top of the safety vave under tne lid to remove rik of ignition or explosion caused by fre from outside. 6) Compact and high performance: No presence of free electiolyte allows the battery mede lower in height, thus reaulting in enhanced volume eificiency. Moraover, gas being absorbed inside the battry oiminates the naed for a ges exhaust tube. 7) Strong chargo/clischerge charactaristies ...It ean amply withstand deep charge/discharge cycles. (il) Principle of Sealing Structure ‘A leed-acid battery operates under the following chemical reaction: e) (2) Discharge (+) oO Poo: + 2HsSOn + Po z PSO. + 2H2O + —PBSOs (Lead peroxide) (Sulfuric acid) (Sponay load) Charge (Load sulfate) (water) (Lead sulfate) Positive active Electrolyte ‘Negative active Positve active Electrolyte Negative active material ‘mateiel material material Normally in an ordinary leact-aeic banery when it comes to an end of a charge, where the lead sulfeto being a discharge product returns to lead perexide end spongy lead, the charge currant flewing thereafter is used exclusively © decompose lectralyticaly wator from the electrolyte, thus resulting in generation of hycrogen gas from the negative olate end oxygen {gas from the positive plate. The gases so generated are released out of the battery, causing the amount af slectrolyio decreased to require occasional water replenishment. 'A maintenance free battery, however, isso designed that, when It's overcharged, even ifthe positive plate is fully charged, the nagatve plate remains not fully turned to spongy lead. Therefore, even winen the positive plate is overcharged generating ‘oxygen gas, the negative plate is no fully cherged, hence generating no hydrogen gas. ‘Moreover, te oxygan gas generated from the rasitve plate immediately reacts with the charged active material on the negative plate, and retuins to water, wth the ultimate result of no water loss.GENERAL INFORMATION 1-11 Technical Information - Sealed Battery Pb + 120: =» (PbO) Negative activé Oxygen gonerated © Nogative sctive atrial, ‘rom positiva plate material (charged state) (PbO) + HSOs PSO! tO Electrolyte Nogative active Water material (charged state) “Thus, the negative plate is made as not to get fully charged. Even ifthe overcharge continues, the oxygen gas generated inside the battery is absorbed by the negative plate, a process called oxygen cycle, which keeps water loss theoretically at nil, and allows the battery to be sealed. (IV) Filling the Battery with Electrolyte ‘caUTION ‘Do nol remove the aluminum seal sheet sealing the filler ports unt just betoro use. Be sure to use the dedicated electrolyte container for correct electrolyte volume, (Check to see that there is no pesiing, teas or hole inthe sealing sheet (© Pico the battery on a vol surtoco. ‘@ Remove the sealing sheet [A] ©When removing, check to hear an air-sucking sound “Shoosh!" from filer ports [8 NOTE (OA battery whose sealing sheet has any peeling, tars, holes, or fram ‘which the eitsucking sound was not heerd requires @ reireshing ‘charge (intial charee) (© Take the eloctioyta containor out ofthe vinyl bag. (© Detach the strip of eaps [A] from the container NOTE 200 net discard the stip of cops because itis used as the battery lugs later, ©De not peel back or pierce the sealed areas [8] ‘@Place the electrolyte container upside down with the six sealed aress in line withthe six bartary filler cons (© Push the container down strongly enough to brezk the seals. Now the loctrolyte should start to flow into the battery. NOTE (©De not tt the container as the slectclyte ow may be interrupted.1-12 GENERAL INFORMATION Technical Information - Sealed Battery (@Mcke sure air bubbles [A] ara coming up from all ei filer ports. Leave the container this way for 8 minutes or longer NOTE | ff na air bubbles are coming up trom a filer port ta0 the bottom of the bottle two or three times. Novar remove the container from the battery, CAUTION Fill until the container is completely emptied. Be certain that all the electoiyte has flowed out. ‘@Top the bottom the same way a¢ above i thora ig any olectrolyte loft in the container. ‘@Nowr pull the container gently out of the batter: Let tho battory st for 20 minutes. During this time, the electrolyte permeates the spacial separators and the gas generated by chemical reaction is released. ‘@Fit te stip of caps (AA) Eighty into the filer ports until the strip is at the same level as the top of the battery NOTE (000 nat hammer. Press down evenly with both hands. ‘CAUTION ‘Once you installed the stip of caps after tiling the battery, never remove i, nor add any water or electrolyte (W) Initial Change ‘While a sealed battery can be used after only filing with electrobte, a battery may not be able to suticently move a starter ‘motor to start an engine in the cases shown in the table below, vihere an initial change is required before use. Honever, it battery shows a terminal voliage of higher than 12.6 V alter 10 minutes of fling (Note 1), no initial change is necessary. Condition requiring initial charge ‘Charging method ‘At low temperatures (lower than O°C) 14A x2 ~ Shou Battery has been stored in high temperature and humidity. ‘Seal has been removed, or broken ~ peeling, tear or hole. (you did not hear the air-sucking sound “Shoosh!” as you removed the seal.) 1AA x18 ~ 20 hours ‘Battery as old as 2 yoars oF move after manufecturs Battery manufacturing date is printed on battery top. Empl) 120 100 BT Day Month Year _ Mtg. location Note 1: Terminal voltage ~ To maacure battery terminal voltage, use @ digital veltmeterGENERAL INFORMATION 1-13 Technical Information - Sealed Battery (V) Precautions 1}, No need of topping-up No topping-up is necessary inthis battery until it ends its life under normal use. Eorebly pring off the saaing plua to add waters very dangerous. Never do that, 2) Refreshing chargo ifan engine will not star, a hom sounds week. or lamps are dim. it indicates the bettzy has been discherged. Give refresh cherge for & to 10 hours with charge eurrent shown inthe specifcaton (sae the Electrical System chepte). When 3 fast charge i inewtably required, co i folowing precisly the maximum charge current and time conditions indicated on the battery if retresh-charged according fo the method specified above. '¢ performance m ons other Never r iby chance an excessive amount of gas ata, jenerated due to overcharging the safely valve operates to keep the battery 3). When you do not use the motoreyela for months Give a refresh charge before you store the motorcycle and store it witht ‘once a month during storage, 4) Battery tite 1 the battery will not start the engine even after several refresh charges, the battery has exceeded its usoful lif, Replace it. (Provided, however, the vehicle's starting eystom has no problem.) egative lead removed, Give a refresh charge ‘Keep the battery away from sparks and open lames during charging, since the battery gives off an explosive gas mixture ‘ofhydragen and oxygen. When using a battery charger, connect the battery tothe charger before tuming onthe charger. ‘This procedure provents sparks atthe battery terminals which could Ignite any battery gases. [No fire shouid be drawn near he battery, orno terminals should have the tightening loosened. ‘The electrolyte contains sulfuric acld, Be careful not tohave Ittouch your skin or eyes. If touched, wash It of wit barat ‘emeunt of water, Got medleal atontion If savere. (Vil) Interchangeabitity with Ordinary Battery ‘A sealed battery can fully display its performance only when combined with a proper vahicie electric system. Therelore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Bo careful fa saalod battery is inctalled on a motorcycle which had an ordinary battery as original equipment, the sealed battery’ Iie will be shortened.1-14 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: LL: Apply a non-permanent locking agent to the threads. : Apply an oil to the threads, seated surface, or washer. Tighten the fasteners following the specified sequence. SS: Apply silicone sealant. Fastener Torque Remarks, Nem | kgm | ftlb Fuel System: Carburetor damper plate mounting bolts, at | 41 | 95inb Air cleaner element cover mounting nut 1 | ta | 98 int Air cleaner housing mounting bolts 11 | tt | 95inwb Cooling System Water pump impeller nut a | 1 | 98 in Water hose fiting bolts 11 | 14 | 95intb Radiator fan switch 18 | 18 | 130 ss Water temperature sensor 78 | 0.80 | 69inib ss Coolant drain plug a | 44 | 95inb Engine Top End: Cylinder head cover bolts 12 | 1.2. | 104 ind Cylinder head nuts: 10mm so | 40 | 29 s 8mm 25 | 25 | 180 8 Cylinder head bolts 12 | 1.2 | 104 intb s Cylinder nuts 25 | 28 | 180 Camshaft cap bolts 25 | 25 | 180 Camshatt sprocket bolts 49 | 50 | 36 L Camshaft chain tensioner cap bolts, 20 | 20 | 145 Camshaft chain guide bolts 11 | tt | 98inb L Intake manifold bolts 2 | 1.2 |104inb Cylinder head cover damper plate bolts 12 | 12 |104inw) 1,8 Clutch: CClutch hub nut 132 | 135 | 98 ° Clutch spring bolts as | oso | 78in-b Right engine cover bolts 12 | 1.2 |104inwb) Lb (1) | Engine Lubrication System: Engine drain plug 20 | 20 | 145 Oil pump mounting bolts 1 | 1 | 9sinw L Oil pump drive chain guide bolt 12 | 1.2. | 104 int & | outer ts | 18 | 130 | Oil fiter plate mounting bolts 78 | 0.80 | 69inb | Oil screen plug 20 | 20 | 145 Oil pressure relief valve 1s | 15 | 11.0 L Oil pressure switch is | 15 | 110 83 Oil pressure switch adapter 20 | 20 | 145 Oil pipe mounting bolts (crankcase inside) 1 | 1.1 | 95 intb L Gil pipe mounting bolts (crankease outside) 54 | 0.55 | 48inb iL Oil passage cover screw (crankcase inside) 5.4 | 0.55 | 48 inb I;GENERAL INFORMATION 1-15 Torque and Locking Agent Engine Removal/installation: Engine mounting nuts Engine mounting bracket bolts Down tube mounting bolts Crankshatt/Transmission: Crankease bolts: Connecting rod big end cap nuts Primary gear bolt Balancer gear bolt Starter clutch gear bolt Starter clutch bolts Output shatt bearing stopper bolts Balancer shaft bearing stopper bolts Shift drum bearing stopper bolts Transmission cover bolts External shift mechanism cover bolts Shift shaft return spring pin Shift drum position lever bolt Neutral switch Shift pedal pivot bott Shift pedal pivot nut Shift drum cam mounting screw Shitt lever camp bolt Wheels/Tires: Front axle clamp bolt Front axle nut Rear axle nut Spoke nipples Final Drive: Engine sprocket nut Rear sprocket nuts Rear sprocket stud bolts Brakes: Torque link nuts Caliper mounting bolts Disk mounting botts Brake hose banjo bolts Bleed valve Brake pedal bolt Master cylinder clamp botts Brake lever pivot bolt Brake lever pivot nut Reservoir cap screw Front brake light switch screws ‘Suspension: Front fork clamp bolts: Front fork bottom Allen bolts Rear shock absorber nuts ‘Swingarm pivot shaft nut 10 mm 6mm upper lower 4 | 45 | 33 23 | 23 | 165 44 | 45 | 33 30 | 40 | 29 8 1 | 1.1 | 95 ina ae | 47 | 34 157 | 160 | 115 ° 69 | 70 | 51 3 eal Ol Bt L a4 | 35 | 25 L 12 | 12 | 104 ini at | 4.4) | 95 int ri | tt | 95 int 1 | 4.4) | 95 int a1 | 1.4 | 95 int 29. pine woe: L at | 1.4) | 95 intb is | 15 | 10 20 | 30 | 22 29 | 30 | 22 - | - - L 12 | 1.2 | 104 jntb 34 | 35 | 25 as | 90 | 65 os | 100 | 72 4.0 | 0.41 | 36 into | 1o7 | 13.0 | 94 ° 7m | 75 | 54 - - - ih 34 | a5 | 26 34 | 35, 25 23 | 23 | 165 25. |. 328 18.0 78 | 0.80 | 69inb 2a | 23:| 165 1 | 44 | 95 int 10 | 0.10 | 9inb 5.9 | 0.60 | 52inib 18 | 0.15 | 13 int 12 | 0.12 | 10inb 20 | 20 | 145 aa | 35 | 25 20 | 20 | 145 L so | 60 | 43 ga_| 100 | 72 |1-16 GENERAL INFORMATION Torque and Locking Agent Rocker arm pivot shaft nut es | 100] 72 Tie-rod nuts so | 60 | 43 Steering: Handlebar clamp bolts M4.) 25, 25 Handlebar holder mounting nuts Hw | 35 25 Handlebar weight mounting screws - = - L Steering stem head bolt 4 | 45 33 Steering stem nut 49 | 0.50 | 49 inib Frame: Rear frame mounting bolts 4 | 45 33 Side stand pivot bolt a | 45 33 Helmet hook mounting screw - - - L Electrical System: Alternator cover bolts 12 | 12 |104inw] L() Timing inspection cover screw 49 | 0.50 | 43inb Alternator rotor bolt 157 | 160 | 115 ° Stator coil bolts 13 | 13° | 113 into Pickup coil bolts 29 | 0.30 | 26 inib Altemator lead clamp bolts 7.8 | 0.80 | 69 inib Spark plugs 1 | 18 | 130 Starter motor mounting bolts 11 | 44 | 98 intb Starter motor through bolts 4.9 | 0.50 | 43 inib Starter motor terminal nut 1 | 44 | 98 int Starter motor cable nuts 4.9 | 0.50 | 43 in-b Side stand switch mounting bolts 3.9 | 0.40 | 35 inib he The table, reading tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads, Basic Torque for General Fasteners of Frame Parts Threads dia. Torque mm em kgm 5 34-49 085 ~ 0.50 30 ~ 43 intb 6 59-78 (0.60 — 0.80 52 — 69 ind 8 44-19 14-19 10.0 - 13.5, 10 25 — 34 26-35 19-25 12 44 - 61 45 ~ 62 33 ~ 45 [ 14 73 = 98 7.4 = 10.0 54-72 16 115 ~ 155 11.5 ~ 16.0 3-115 18 165 = 225 17 = 23 125 ~ 165 20 225 ~ 325 23 ~ 83 165 ~ 240GENERAL INFORMATION 1-17 Special Tools and Sealant ‘Steering Stam Bearing Driver: 57001-7137 Comprossion Gauge: 57001-221 Inside Cirlip Piers: 57001 -143 Valve Spring Compressor Assembly: §7001-241 'S Piston Pin Puller Assembly: 5701-910 Fuel Level Gauge: §7001-1017 a Fork Cylinder Holder Handle: 5701-183 Oil Pressure Gauge Adapter, PT ¥& 57001-1033 ®1-18 GENERAL INFORMATION Special Tools and Sealant Fork Cylinder Holder Adaptor: 67001-7057 Head Pipe Outer Race Press Shaft: §7001-1075 Oil Seal & Bearing Remover, 57001-1058 Head Pipe Outer Race Driver: 67001-1076 sts S Rim Protector: 87001-1063 Steering Stem Nut Wrench: 67001-1100 Bead Breaker Assembly: 87001-1072 Head Pie Outer Race Driver: §7001-1106 Steering Stem Bearing Driver Adapter: 57001-1074 Outer Race Remover: 57001-1107GENERAL INFORMATION 1-19 Special Tools and Sealant Valve Seat Cutter, 45° - 32: 57001-1115 ae Seat Cutter, 45° ~ 30: 67001-1187 2 © Valve Seat Curter, 2° ~ 028: 87001-1119 Valve Seat Cutter, 32° ~ 088: 57001-1199 © 2 Valve Soat Cutter, 60° ~ @30: 87001-1123, vVavve Spring Compressor Adep' © & \Velva Soat Cutter Holder Bar. 57001-1128 ‘Valve Seat Curter Holder, 08: 87001-1208 Sy Beating Driver Set: 67001-1129 Rotor Puller, M16/M18/M20/i22 x 1.5: 67001-12161-20 GENERAL INFORMATION Special Tools and Sealant Fore Qutor Tube Weight 57001-1218 il Fiker Wrench: 67001-1248 ) S Front Fork Oil Seal Driver: 67001-1219 Boaring Remover Shatt: 7001-1265 ~ Jack: 57001-1238 Bearing Remover Head, 16 x 917; 87001-1267 pone & Plot Screw Adjuster, A: 67001-1239 Carburetor Drain Plug Wrench, Hex 2: 67001-1269 =, SS Clutch Holder 57001-1243 Foxk Oil Level Gauge: 57001-1280 ome “seGENERAL INFORMATION 1-21 Special Tools and Sealant Flywheel Holder: 87001-1313 Hand Tester: 57001-1394 ‘Compression Gauge Adapter, M10 X 1.0: 67001-1317 Spark Plug Wrench, 16min (Gwne’s Too!): 82110-1132 “ty Valve Seat Cutter, 60" - 933: 57001-1334 Kawasaki Bond (Silicone Sealant): 66019-120 “Be Vacuum Gauge: 7001-1369 Kewasaks Bond (Liquid Gasket-Bieck): 92104-1008 “Be1-22 GENERAL INFORMATION Cable, Wire, and Hose Routing Clamp (LH Switch Leads) Clamp (Brake Hose) Damper Clamos Band Grommet eareyeGENERAL INFORMATION 1-23 Cable, Wire, and Hose Routing ‘y wioyy pamel,, (9p007 yous 1UBh o¥e1g JOY |1-24 GENERAL INFORMATION Cable, Wire, and Hose RoutingGENERAL INFORMATION 1-25 Cable, Wire, and Hose Routing Direct the oil proceure ewitch lead to the downware. (apaly grease to the terminal.) Clamps Clamp Alternator Leads, Pickuo Coil Leads Run the leads inside the rive chain cover. 5. Starter Motor Lead Air Cleone: Drain Hosa Clamp1-26 GENERAL INFORMATION Cable, Wire, and Hose Routing Except for California Model - | 1, Fuel Hose 2. Ditect the choke cable to the upward. (Do not run the choke cable below the manifold. ) 3. Hose (Green) 4. Do not overtighten the band. 5. Incart the hase and to the bracket.GENERAL INFORMATION 1-27, Cable, Wire, and Hose Routing California Model1-28 GENERAL INFORMATION Cable, Wire, and Hose Routing Fepowy e1us0}1e9 rouuosg “91GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing 1. Install the hose with the mark up. 2. Hose [between the thermostat and the reserve tank)1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing Position the clamp bolt at this point Radiator Align the marks ight Engine CoverFUEL SYSTEM 2-1 Fuel System Table of Contents Exploded Viow ‘Specifications - Throttle Grip and Cables Free Play Inspection Free Play Adjustment Cable Lubrication Idle Speed Adjustment Service Fuel Level inspection.. Service Fuel Level Adjustment... Fuel System Cleanliness Inspection Carburetor Removal. Carburetor installation .. Carburetor Disassembly/Assembly. Carburetor Clesning.. Carburetor inspection Air Cleaner... Al Cleaner Housing Removal Element Removal Element Cleaning and Inspection Fuel Tank. Fuel Tank Removal... Fuel Tank Installation Fuel Tank and Cap Inspection .. Fuel Tank Cleaning... Fuel Tap Inspection i Evaporative Emission Contre! System (eat Model on Parts Removal/Installation . Hose Inspection. ‘Soparator inspection... Soparator Operation Test. Canister Inspection ...2-2 FUEL SYSTEM Exploded View G Apply greose. TH 11 Nem (1.1 kgem, 96 ith) CA: Caltomia Modal GN: Canada Model ST: Switzerland Modet US: US Moda!2-4 FUEL SYSTEM Specifications Trem I Standara Throttle Grip and Cables Throttle grip free play 2~3mm Carburetor: Make, Type Keihin, CVK36. Idle speed 41000 + 50 ¢/min (rpm) | (ST) (CA) 1900 =50 cin (rpm) Mein jet #95 Main air jot #100 | Noodle jat #5 - Jet noodle N2PE : Pilot jot #8 me Pilot air jot #70 a Pilot screw 1 xtuins out e Stanor jet #70 | = Service fuel level 20 21mm - above upper edge of float chamber Float height 16.5 42mm = Optional pars: Main jet #190. 132, 138, 120 - (ST): Switzerland Mode! (CA): California Model ‘Special Too! ~ Fuel Level Gauge: §7001-1017 Pilot Screw Adjuster, A: 57001-1238 ‘Carburetor Drain Plug Wrench, Hex 8: 57001-1269Throttle Grip and Cables Free Play inspection (© Check that ihe throtle grip moves smooth from full open to clase, ‘and the throttle closes quickly and completely i al stacring positions by the return spring ‘kif the throtle grip does not return properiy, check the throttle cable touting, gre tree play, and catie damage. Thon lubricate the throtia ceanle (© Fun the engine et the idle speed, and turn the handlebar al the way to the rght and let o ensure thal the idle speed does not change. ‘if the ile speed increase, check the throtte cable free play and the ‘cable routing. © Check the trotte grip free play (Al. Ifthe trae play is incorrect, adjust the throtle cable, Trratie Grip Free Play ‘Stendard: 2 ~S.mm Free Play Adjustment ‘@Looson tha lockruts (A) ‘eScrew te adjusters [B) in completely so as to give the thotile grip plenty of play. ‘@Tuin out tho docslerator cable [C] adjustar unti there is no play when the thromle grip is completely closed ‘@Tichten the locknut (@Tum the accslerator cable [0] adjuster until the proper amount of throttle grip free play fs obtained. @Tichten the jocknut. rIF the propor amount of free play connot be obtainad by using tho ‘adjusters, use the adjusters middle of the throtle cables (0Frst give the throttle grip plenty of play by turning the adjusts ‘rip in fully ‘@Romove the fuol tank (see Fuel Tank Removal). @Loosan the locknuts [A]. (@Turn the adjuster [8] fully atthe midéla of tho throttle cablos so a 10 give the throtte grip pienty of play. With the throttle grio completely closed, tum the decelerator cable [C] edjustor unt the innor cable just bocomes tight. ‘eTighten tha locknut, (eum the accelerator cable (D] adjuster until the correct throttle grip free play is obtain (eTighter the locknut atthe Por jon with incorrectly routed could reeuitin an uneate riding condition. Cable Lubrication \Wherever the cable is remioved, lubricate the throtte cable as follows: ‘Apply 2 thin coating of grease to the cable lower ends. (@Lupricsta the cablo with a ponatting rust inhibitor. FUEL SYSTEM 2-52:6 FUEL SYSTEM Carburetor Idle Speed Inspection 'Stert the engine and warm it up thoroughly. ‘© With the engine idling. turn the handlebar to both sides. 2 1f handlebar maveant changes the idle speed, the throttle cables mey bbe improperly adjusted or incorectly routed, or damaged. Ee sure to correct any of these conditions before nding (S22 Cable Routing section in General Information chapter) ccablet could resutt in an unsafe rising condition. ‘© Chock idle spood. J the ile epeed is cut of the specitod range, adjust Idle Speed Standareé: 1,000 + 50 rimin (rpm) (Switzerland, U.S. Modets) 1,200 50 r/min (rpm) Idle Speed Adjustment ‘eStart the engine and warm it up thoroughly (@ Tur the adjusting screw [A] until the idle speed ie correct. Open znd close the throttle 2 few times to make sure that the idle speed is within the specified range. Readjust if necessary. Service Fus! Level Inspection IS ‘Gasoline is extremely tammable and can be explosive under certain, conditions. Turn the Ignition switch OFF. De not smoke. Make sure tho area le wollvontilated and free ftom any source of flame or sparks; this includes any appliance with a pill f@Siuate the matoreyele so that It's perpendicular to tha ground, ‘@Flemove the fuel tenk and air cleaner (see Fuel Tank Removal, Air CCleaner Housing Removal). fePrepare an auxiliary fuel tank and connect the fuel hose to the carburetor. (@Propare a suitable fuel hose, Connect the fuel level gauge [A] to the carburetor float chamber with the fuel hose. ‘Special Tool ~ Fuel Level Gauge: 57001-1017 f@Hoid the gauge vertically against the sie of the carburetor body so that the “zoro" line [3] is several milimotors higher than the upper ‘2090 [C] of the float chamber. (© Feed fuel tothe carburetor, then tum the carburetor drain plug [D] out 2 few turns. ‘© Wait unt tha fuel level in the gauge sortiesFUEL SYSTEM 2-7 ‘@keoping the gauge vartca, slowly lower the gauge until the "zero" line is even with the upper edge of the floet chamber. NOTE Do not lower the "zero" fine below the upper edge of the Host ‘chamber. If the gauge is lowered and then raised again, the uel level ‘measured shows somewhat higher than the actual fuel level. Ifthe ‘gauge is lowered too far, ump the fuel into 2 suitable container and Start the procedure over agein. Read the fuel level [E] in the gauge and compare tothe specification. ‘@Screw in the corouretor drain plug. ‘@Stop feading and remove the fus level gauge Seif the fuel level is incomact, adjust it (see Service Fuel Level Adjust- ment), Service Fuel Level (above upper edge of float chamber) Standard: == 2.0 41mm Service Fuel Level Adjustment Gasoline Is extremely lammable and can be explosive under certain conditions, Turn the Ignition switch OFF. Do not amcke. Make sure the area l@ well-ventilated and tree trom any source of flame oF ‘sparks; this Includes any appliance with a pilot ight. le Romove the carburetor, and drain the fuel into sultable container Remove the float chamber. ‘@Romove the pin [A] and take out the tost (8). (eWhen removing and installing the pin, note the following. © Be careful not to snap the pin holder leg (Cl. (©Whon removing it tap [D] tho let ond of the pin. (©When installing it. press (E] the right end of the pin. ‘@end the tang [A] on the float arm very slighty to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard: = 16.5.4. 2mm2-8 FUEL SYSTEM NOTE (2Do not push the needle od [in during the Hloat height measure. ment (8). ‘@Acsombie tho earburator, and recheck the uel lvel IF tre fuo! level cannot be adjusted by this method, the float or the lost valve (C] is damaged, Fuel System Cleanliness Inspection Ao Gasoline fe extremely flammable and can be explosive under certain Conditions. ‘Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or ‘parks; this includes any appliance witha pifot ight ‘@Romove the fucl tank (ace Fuel Tank Removal) ‘@Connect a suitable hose [A] to the fiting at the bottom of the carburetor float bow. (@ Run tho lower end of the heee into @ suitable container. (eTurn our the drain plug [8] 2 few tums and drain the float bow ‘Special Tool ~ Carburetor Drain Plug Wrench, Hex 3: 57001-1269 (eCheck to s00 it water or dirt comes out. eTiohten the drain plug, >If any water or dit appears during the above inspection, clean the fuel systom (see Carburstor Cleaning and Fuel Tark Cleaning). Carburstor Removal oN Gasoline Is exiromely flammable and can be explosive under certain Conditions. Tur the Ignition switch OFF. Do net smoke. Make sure ‘he area's woll-ventittod and troe from any source of flame or Sparks; this Includes any appllance with a pilot light eRemove Seat (see Frame chapter) Fuel Tank (see Fusl Tank Removal) Ait Claaner Housing (see Air Cleaner Housing Removal) Vacuum Hose (A) : ‘@Loaton the carburetor clamp screw (8). ‘@Rtemove the bolts (C] and carburetor holder plate [0]. ‘@Remove the cerburetor and throtte cable ends, ‘@Stutf pises of lint-free, clean cloth Into the earbu If the pilot screw is worn or damaged on the tasored portion, it will prevent the engine from idling smoothly. Replace i (eCheck that the vacuum piston [A] moves smoothly in the carburetor body, The surface of the piston must not be excessively worn. ‘if the vacuum piston does not move emccthly ori ts very Ioose in carburetor body, replace the carburetor.2.12 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal ‘@Remove: Seet (o09 Frame chaptor) Fuel Tank (see Fuel Tank Removal) Mounting Bolts [A] and Surge Terk [B] Air Cleaner Element (s2e Air Cleaner Element Removal) Mounting Bolts [A] 'emove the air cleaner housing [A] from the carburetor (8). Disconnect the engine breether hese [C] and vacuum switch valve hose (D] Element Removal ‘@Romovs: Nut [A] and Washer Air Cleaner Cover [8] Element [A] (@Push a clean lint-free towel into the carburetor intake to keep dirt or ctherforcign material from entoring 1 dirt oF dust Is allowed to pass through into the carburetor, the throttle may become stuck, possibly causing accident,FUEL SYSTEM 2-13 ‘CAUTION W dirt gels through into the engine, excessive engine wear and possibly engine damage wil occu Element Cleaning and Inspection ‘@ Remove the air cleaner element (see Element Removal), ‘@C'can the element by topping it hehtly te looson dust ‘@8iow away the remaining dust by applying compressed air [A] from the inside to the outsce (from the cean side io the diy sie), ‘@Visually check the element for tears or breaks and check the sponge ‘gasket [8] also. SIF me slement or gasket has any wars or breaks, replace the element2.14 FUEL SYSTEM Fuel Tank Fuel Tank Removal Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. De not smoke. Make sure the area is well-ventilated and free from any source of flame or Sparks; this includes any appitance with a plit light. CALTION, _ For California model, t gasoline, solvent, water or any other liquid ‘enters the canister, the canister’s vapor absorbing capacity ls greatly reduced. Ifthe canister does become contaminated, replace it with ara one. ‘© Turn the fue! tap (A t0 tha ON oF RES position. Remove Fuol Hose (8) Fuel Tap Vacuum Hose [C] eFemeve: Seat (see Frame chapter) ‘Mounting Beit [A] and Meter instruments [B] (soe Electical System chapter) Fuel Tank Mounting Bolts [A] Fuel Tank Evaporative Emission Hoses (California model) Fuel Tank Installation Read the above WARNING. Route the hoses correctly (590 General Information chapter). (@8e sure io install the rubber damoers [A] in place @Be sure the hoses are clamped securely to prevent laaks,FUEL SYSTEM 2-15 Fuel Tank and Cap Inspection ‘© Visuelly inspect the gesket [A] on the tank for any damage + Feplace the gasket if itis damaged. (@Femove the fusl tank and drain it Check to see if the breather pipe (also the fuel return pipe for the California model) in the tank is not clogged. Chack the tank cap breather also. 2 the breather pipe is cleggod, blow the bresther free with compressed ot the tank cap breather is clogged, replace the tank cap, 2 ‘CAUTION ‘Do not apply compressed air fo the ar vent holes [B] inthe tank cap. ‘This could cause damage and clogging ofthe labyrinth in the ay Fuel Tank Cleaning PEs Clean the tank in a wellentisted area, and take care that there are ‘no sparks of flame anywhere near the working area. Because ofthe danger of highly flammable liquids, de not use gasoline or low fash- point solvents to clea th tank ‘@Romove the fuel tank end drain fePour soma high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. ‘@Pour high flash-point solvent through the tap in al aver positions. ‘@Pour the solvent out of the tank. ‘@ Remove the fuel tap [A] from the tank by taking out the bolts [2] with washers. ‘@Clean the fuel tap filter screens in a high flash-point solvent. ‘@Dry the tank and screens with compressed ai Install the fuel tap on tha tank. ‘@lrnstall the fuel tark (see Fuel Tank Installation) Fuel Tap Inspection ‘@Fomave the fuel te. {Cock tho ‘uel ap fitar areane (A for ary breaks or detrortin. “IF the sreone nave any Breaks oF ae ceteroatd, they may allow cit to reach the carburetor. causing poor running. Replace the fuel tp Fe the fu! tep lake, oF allows fue! to flow when it is ON or RES position without engine running, replace the damagod gasket [8] or Onrngs (Ch2.16 FUEL SYSTEM Evaporative Emission Control System (California Model Only) ‘The Evaporative Emission Canto} System routes fuel vapors from the {uel system into the running engine or stores the vepors in a canister ‘when the engine is stopped. Altnough no adjustments are raquired, a ‘thorough visual inspection must be mace atthe intervals specified by the Periodic Maintenance Char. Parts Removall installation es sce s capac ten reer S25 See eros eee Peles poten en CAUTION itgasoline, solvent, water or any other liquid enters the canister, th canister’s vapor absorbing capactly 's greally reduced. the canister does become contzminated, replace it with a new one, (@7o prevent the gasoline from flowing into or out of the canister, hold the saparetor perpendicular to the ground, {@Connect the hoses according fo the diagram of the system, Make sure they do not get ainched or kinked, Hose Inspsction ‘@Chack that the hoses ara securely connected. ‘@Replace any kinked, deterorated or damaged hoses. ‘Separator Inspection ‘@Dieconnect the hosas from the liquid vapor soparator, and remova tho separator from the motorcycle (Visually inspect the separator for cracks and other demege. DF the soparetor has any cracks oie badly damegad, roplace it with 9 new one, ‘Separator Operation Test Pw ‘Gasoline is exiremely flammable and can be explosive under certain Conditions. Tum the ignition sch OFF. Do not smoke. Make sure the area Is well-ventilated end free from any source of flame or rks this inekides any appliance with a pilot ight. ‘@Connect the hoses to the separator, and install the seperator on the motorcycleFUEL SYSTEM 2-17 ‘@ Disconnect the breether hose from the seperstor, and inject about 20, mL of goeoline into the separator through the hose fitting, ‘e Disconnect the fual return hose from the fuel tank. ‘@ un the open end of the return hose into the container and hold it evel with the tank top. ‘eStar the engine, and let it idle “if the gesoline in the separatar comes out of the hose, the separator works well. IFit dees nt, replaco tho soparator with a naw one. Canister Inspection ‘@Flemove the conistar, and disconnect the hoses from the canister. ‘@Visuelly inspect the canister for cracks and other damage, >If the canister has any cracks or bad damage. replace itwith anew one, NOTE (OThe canister is designed to work weil through the motoreyele's fife Without any maintenance if tis used under normal conditions.eases eer eee woes Seas: anew mentee rama oe ve ; a : Tce fra aeetat poten esl 1 *COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View Coolant Flow Chart. Specifications... Coolant set Coolant Level Inspection... Coolant Draining... Coolant Filing Pressure Testing Resorve Tank Removal Water Pump, Mechanical Sea. Water Pump Impeller Removal Water Pump Impeller Installation Mechanical Seal Removal Mechanical Seal installation... Water Pump Shaft Removal Water Pump Shaft installation. Water Pump Inspection. Radiator, Radiator Fan. Radiator, Redistor Fan Removal Radiator Fan Installation. Radiator Inspection. Radiator Cap inspection Thermostat nm Thermostat Removal Thermostat InspeCtION veces Radiator Fan Swivch, Water Temperature Sensor Radiator Fan Switch, Watet Temperature Sensor Removal Radiator Fan Switch, Water Tempereture Sensor installation. Radiator Fan Switch, Water Temperature Sensor Inspection.3-2 COOLING SYSTEM Exploded View G = Apply oraase. ‘88: Apply silcone seslant.Coolant Flow Chart COOLING SYSTEM 3-3 Pe m@eeRo Radiator Fan Switch Water Temperature Sensor Right Engine Cover Water Pump impeller 5. To Crankoasa From Rear Cylinder Head . From Front Cylinder Head oc) e- tebe Sa Thermostat When the engine is cold, the thermostat is closed so that the coolant flow is restricted through tre air bieeder hola, causing the engine to warm up more quickly, Redistor Cop Feserve Tanke When the engine is very hot, the pressure valve in the radiator cap allows air and vapor to escape into the resorve tank. When the engine cools down, the pressure drop draws the vacuum valve (another small valve) open, admitting coolant from the reserva tank into the radiator.3-4 COOLING SYSTEM ‘Specifications Standard ‘Service Limit Freezing point Total amount rem) ‘Coolant provided when shipping: Type Color Mixed ratio Permanent type of antiteaze (soft water and ethylene glycol plus corrosion and rust inhibitor chernicals for aluminum engines and radiators) Green Soft water 50%, coolant 50% =36°C (31°F) 2.AL (reserve tank full level including radiator and engine) Radiator cap: Relief pressure 93 ~ 123 kPa (0.95 ~ 1.25 kg/em*, 14 ~ 18 psi) ‘Thermostat: \Vaive opening temperature Vaive full opening Hit 58 ~ 62°C (136 ~ 144 °F) Brom or more @95°C (203 °F) ‘Speciat Tao! ~ Outside Cireip Pers: 7001-144 Kawasaki Bond (Silcone Sealant $6019-120 SeCOOLING SYSTEM 3-5 Coolant Coolant Level Inspection NOTE (Check the level when the engine is cold (roam or ambient temper ture). ‘@Situate te motoreycle so that itis perpendicular to the ground (on its side stand) ‘@Chock the coolant lovel through the coolant level gauge [A] on the coolant reserva tank [8] Seif the coolant lave! is lower than the “L* (Low) lovel line [C], add coolent to the *F” (Full) level ine [0]. ‘mixture of coolant and soft water. ‘Adding water alono diluios the coolant and degrades lis anticorro: ‘son properties. The luted coolant can attack the aluminum engine parts. In en emergency, soft water alone can be added. But the diluted coolant must be returned tothe corract mixture ratio within 3 ‘CAUTION For reflling, add the speci .dded often, or the roservolr tank has run ‘completely dry; there ls probably leakage In the cooling system. Check the system for leaks. Coolent Draining Pe ‘To avolé burns, do not remove the radstor cap or try to change the coolent when the engine Is sill hot. Wall unt it cools down, ‘Coolant on tres will make them slippery and can cause an accident ‘and injury. Immediately wipe up or wash away any coctant that pil ‘nthe frame, engine, or other painted parts | Since cootantis harmful tothe humen body, do not use for drinkin [Shon cee nt erm ts fre armen Data eck ose for ees | ‘eFomove: Meter Instruments (see Elactical System chapter) Radiator Cop [A] ‘© Placa a container undsr the drain plug [A] at the bottom of the right cranes ‘©DDizin the eoolent from the radiator and engine by removing the drain plug ‘@Femove the cap and pump out the coolant using a syringe or some cther suitable device.3.6 COOLING SYSTEM Coolant Filling (Tighten the crain plug. ‘Torque ~ Drain Plug: 11 Nom (1:1 kg-m, 95 In-tb) ‘9Fl the raciator up to the radiator file: neck [A] with coolant. and install the radiator cap. NOTE © Pour in the eoatant stowly so that it can expel the alto the engine and rediator, (9Fl the reserve tank up to the “F” level ine with coolant, and instal te cap CAUTION Soft or distilled water must be used withthe aniireeze (see below for antifreeze) in the cooling system. hard water is used inthe systam, it causes scales accumulation in the water passages, and considerably reduces the efficiency ofthe ‘cooling systam. Water and Coolant Misture Ratio (Recommended) ‘Soft Water + 50% Coolant 2 50% Freezing Point =3s'6 (30°F) Total Amount ak NOTE Choose # suitable mixture ratio by refering to the coolant manufacturers directions. ‘eStart ihe engine, warm it up thoroughly until the radiator fan turns on and then stop the angina. ‘@ Check the coolant level in the reserve tank after the engine cools dawn. ‘ifthe coolant level & lower than the *L” leval line, add coolant to the "Flava line. CAUTION ‘De not add more coolant above the °F level ine. Pressure Testing ‘@Rornove the motor inetrumienta (200 Electrical System chapter). le Remove the radiator cap, and install a cooling systom pressure testor [A] om the filer mack. NOTE oWer the cap sealing surfaces with watar or coolant to prevent ‘pressure leaks. ‘© Bulls up prassure in the system carafull until the preseure reaches 123, KPa (4.25 kg/m, 18 psi)COOLING SYSTEM _3-7 CAUTION During pressure tasting, do not exceed the pressure for which the system Io designed, The maximum pressure le 123 kPa (1.25 kgfem?,18 ps). (@Wetch the gauge for atleast 6 seconds. elf the pressure holds steady, the eystor i alright. elf the pressure drops soon, chock for leaks. Reserve Tank Removal @Remove: ‘Seat (s09 Frame chepter) Fuel Tank (soa Ful System chapter) Coolant Hose (A) Rear Wheel (see Wheole/Tirse chapter) Rear Shock Absorber (s99 Suspension chapter) Bolts [A] and Rear Whoel Mud Guard (8) Bolts (Al and Reserve Tank [6]3-8 COOLING SYSTEM Water Pump, Mechanical Seal Water Pump Impeller Removal ‘e0eain: Engine Oil (see Engine Lubrication System chapter) oolant (see Coolant Draining) eRemove Right Engine Cover (see Clutch chapter) Nut [A] Impeller (8) Water Pump Impeller Installation ‘©80 sure to inetall tho rubber saal [A] and sealing sest [3] into the impeller {C] by hand unti the seat bottoms out ‘@Appiy @ little coolant to the siding surface [D] of the mechanical sel ‘and sealing seat to give the seal initial lubrication ‘@1B» sure wo instal anew O-ring [E] on the shat. hten the impeller nut ‘Torque ~ Water Pump Impellor Nut 11 N-m (1.1 kg-m, 95 mb) Mechanical Seal Removal @Remove: ‘Clutch (see Clutch chapter) Water Pump Impeller (see Weter Pump Impeller Removal) O-ring ‘ery tha mechanical soal flange [A] off with a small chisel [8] ‘@Pull the mechanical geal [A] out of the erankcaso with por. CAUTION ‘Be carelul not to damage the water pump shaft and the Inner sealing surface ofthe crankcase. Discard the mechanical seal Mechanical Seat Installation NOTE (Since the replacement mechanical seal hes an adhesive coated body, 40 not apply liquid gasket to the exterior surtaca of tha body. ‘ePress [A] the new mechanical seal (B] ito the: hole by using 2 suitable socket (C] until it bottoms out. CAUTION Be careful not to damage the water pump shalt and mechanical seal,COOLING SYSTEM 3-9 Water Purp Shaft Removal Salt the crankcese (299 Crankshaft/Tranemission chapter), ‘@ Remove the orci [A] from the water pump shait (B]. ‘Special Too! ~ Outside Cirelip Plers: S7001-144 ‘remove the shat from tho outside ofthe crankcase to the inside, Water Pump Shaft Installation insect the wetor oump shaft from outside of the erankease tothe inside. ‘instal the ciclip tothe shaft. ‘Special Tool ~ Outskie Circlip Pliers: S7O01-148 Water Pump Inspection (eCheck the diainage outlet passage (A] at the bottom of the right crankcase for coolant leaks. rif the mechanical cal is damaged, the coolant leaks through the seal ‘and drains through the passage. Replace the mechanical seel and impeller with new ones.3.10 COOLING SYSTEM Radiator, Radiator Fan Radiator, Radiator Fan Removal ‘@Romove: Coolent (see Coclant Draining) Scat (see Frame chacter) Fuel Tank (see Fuel System chapter) Hom Lead Connectors [A] Boks [8] and Hom (C] Radiator Hose [A] Radiator Fan Connector [A] Fan Switch Lead Connectors [8] Water Tomporature Sensor Lead Connector [C] Radiator Hose [D] Radiator Mounting Bolts [E) Rodistor Redistor Fan Mounting Botts (4) Radiator Fan [8] Radiator Fan Installation (© Be sure to attach the ground lead [A] to the fan mounting bol (8),COOLING SYSTEM 3-11 Radiator Inspection ‘© Check the radiator core If there ere obstructions to air Flow, remove them. eIi the comugated fins are deformed, carefully etrsighten them. “tlt the air passages of the radiator core ere blocked moze than 20% by lnremavablo obstructions or ireparably deformed fins, replace the radiator with a new one. ‘CAUTION ‘When cleaning the radlator with steam cleaner, be careful of the following to prevent radiator damage. 1) Koop the steam gun away more than 0.5 m rom the radiator core, 2) Hols the steam gun perpendicular tothe core suriace. 3) Run the stoam gun horizontally following the core fin direction. Flunning i vertically may damace the tn. Radiator Cap Inspection (© Check the conaiton ofthe top [A and bottom [8] valve seals. elt any one of them shons visible damage, replace the cap with a new Valve Spring [C] ‘instal the cap [A] on # cooling oyster pressure tester (8). NOTE (OWet the cap sealing surfaces with water or coolant 10 prevent ‘bvessure leaks. o 5 © ‘@ Watching the pressure geuge, slowly pump the pressure tester to build Up the pressure, Tho gaugo pointer must remain within the roliaf pressure range in the table below at least 6 seconds. Continue to pump the tester until the telief valve opens, indicsted by the gauge pointer flicks downward. The rallet valve must open within the specified range. Radiator Cap Rellet Pressure Standarct 93 ~ 123 kPa (095 ~ 1.28 Kplom?14 ~ 78 ps) “It the cap cannot hold the specitied pressure, or it It holds too much pressure. replace it with 2 new one.3-12 COOLING SYSTEM ‘Thermostat Thermostat Removal eRemove: Coolant (see Coolant Draining) Soat (ee Frame enacter) Fual Tank (see Fusl System chapter) ‘Thermostat Housing Cover Botts [A] Thermostat Housing Cover [8] Themostat Thermostat Inspection ‘@Romove the thermostat, and inspect the thermostat valve [A] at room temperature. “lf the valve is open. replace the thermostat with a new one. (@To check valve opening temperature, suspend the thermostat [A] in @ container of water ang raisa the temperature of tna water. [8] Thermometer +l the measurement is out ofthe specified range, replece the thermostat ‘with a new one. ‘Thermostat Valve Opening Temperature Standard: 58 ~ 62°C (190 ~ 144°F)COOLING SYSTEM 3-13 Radiator Fan Switch, Water Temperature Sensor Radiator Fan Switch, Water Temperature Sensor Removal CALTION ‘The fan awitch or the water temperature sensor should never be allowed to fall en 2 hard surface. Such a sheek to thelr parts can damage them. Drain the coolant (see Coolant Draining) Remove: Fuel Tank (soe Fuel System chepter) Radiator Fan Switch Lead Connectors [A] Cover [B] and Radiator Fen Switch ‘Water Temperotura Soncor Load Connector [C] Water Temperature Sensor [0] Radiator Fan Switch, Water Temperature Sensor Installation ‘@Apply slicone seaiznt to the threads of the fan switch and water Temperature sensor ‘Sealant ~ Kawasaki Bond (Silicone Sealant): 56019-1209 ‘eTighten the fan switch and water temperature sensor Torque ~ Radiator Fan Switch: 18 Nem (1.8 ka-m, 13.0 #5) Nem (0.80 kg.m, 69 In-) Radiator Fan Switch, Water Temperature Sensor Inspection ‘© Refor to Electrical Syetam chantor for thoes inspections.fet deveresucoas mS cide oa OF SC wee 8 nO De Da Ne hia oie Ee isi tas to ar i nan sa ep WEL e epee oem na et Popa ata wl jacln Sree seer ansnent uBE 10) ed aaesatii epee ard antares oa | Sind, Eig ance ae ee : vere tea Orme pranks scala See tar - - oes mare” wn Sara tree ; sont aa Skene rel ella epee renga wale, € +ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded Viow - 42 Valves Specifications Valve Cieerencs Adjusiment Clean Ait Syston Valve Removel ‘Air Suction Vawve inspection. \Vacuurn Switch Valve Test. Cylinder Head Cover sewn Cylinder Heaa Cover Removal Cylinder Head Cover Installation. : Cylinder Head Covor Assomby.. ae Camshaft, Camshaft Chain Camshaft Rema... Camshaft Installation... Camshaft Assembly... Camshaft, Camshaft Cap Wear. ‘Camshatt Chain Removal... Camshaft Chain Wer... ‘Camshaft Chain Tensioner. ‘Camshat Chain Tensioner Removal... 6-12 Camshaft Chain Tensioner Installation Rocker Shaft, Rockor Aa em Rocker Shaft, Rocker Arm Removal locker Shaft. Rocker Arm Installation... Gylinder Head.. ‘Cylincer Compression Measurement Cylinder Head Removal Cylinder Head Inctalation Cylinder Head Cover Assembly. Valve Installation Valve-to-Guide Clearance Measuremant (Wobble Method) Valve Seat Inspection \Valvo Soat Rosi. Cylinder, Pistons Cylinder Removal. Cylinder inctalaton.. Piston Removal Piston Installation. (Cylindor Wear Piston Wear . Piston Rina, Piston Ring Groove Wer. Piston Ring End Gap. Carburetor Hokie. Carburetor Holder inetalation. Mutter. Muffler Removel... Muffler Inetaletion ‘Muttler Cover Removel Muffler Cover installzton.4-2 ENGINE TOP END Exploded View et me eral Side ply non-permanent looking agont. pemiee 2 14: 25m (25 kgm, 18.0 0) -, @® ‘T5: 39 Nem (8.0 kgm, 29 fedb) ay ; Te: 49 en (20 kgm, 26 fb)ENGINE TOP END 4-3 Pains Mark4-4 ENGINE TOP END Specifications Item Standard ‘Clean Air System: ‘Vacuum switch vaive closing pressure: Open — Close 57 ~ 65 kPa (430 ~ 490 mmHg) ‘Camshafts Cam height Inlet Exhaust Camshaft journal, Camshaft cap clearance Camshaft joumal diameter Camshaft bearing inside diameter Camshaft runout Camshaft chain 20-link length Rocker arm inside diameter |__ Rocker shaft diameter [Cylinder Head : Cylinder compression Cylinder head warp 35.305 ~ 35.413 mm. 95.033 ~ 25.141 mm 0.028 ~ 0.071 mm 26.950 ~ 26.972 mm 27.000 ~ 27.021 mm. TIR 0.02 mm or less 127.00 ~ 127.36 mm 16.000 - 16.018 mm 15.985 ~ 15.984 mm (usable range) 855 ~ 1315 kPa (8.7 ~ 18.4 kgticm?, 124 ~ 191 psi) © 470 min (rpm) 35.21 mm. 34.93 mm 0.16 mm. 26.92 mm. 27.08 mm. TIR 0.1 mm 128.9 mm 16.05 mm. | 45.94 mm. Valves: Valve clearance: Inlet Exhaust | Valve head thickness: Inlet Exhaust Valve stem bend Valve stem diameter: Inlet Exhaust Valve guide inside diameter Valvelvalve guide clearance (wobble method): Inlet Exhaust Valve seat cutting angle Valve seat surface: Width Outside diameter, Inlet Exhaust Valve spring tree length Cylinder, Piston: Cylinder inside diameter Piston diameter Piston/cylinder clearance Oversize pistons and rings Piston ring/groove clearance: | Too Second Piston ring groove width: Top Second Piston ring thickness: Top & Second Piston ring end gap: Top ‘Second 0.10 — 0.15 mm, 0.20 ~ 0.25 mm. 0.5 mm 0.8mm TIR 0.01 mm or loss 4.975 ~ 4.990 mm 4,955 ~ 4.970 mm 5.000 ~ 5.012 mm 0.03 - 0.12 mm. 0.10 ~ 0.18 mm. 45°, 92°, 60° 0.5 ~ 1.0 mm 30.9~31.1 mm. 26.9 ~ 27.1 mm 40.5 mm '88.000 ~ 88.012 mm 187.975 ~ 87.990 mm }0.010 ~ 0.037 mm 40.5 mm 10.03 ~ 0.07 mm, 0.02 ~ 0.06 mm 1.02 ~ 1.04 mm 1.01 ~ 1.03 mm 0.97 ~ 0.99 mm, 0.25 ~ 0.40 mm. 0.40 ~ 0.55 mm. 0.3 mm 0.5 mm TIR 0.05 mm 4.96 mm 4.94 mm 5.07 mm 0.26 mm 0.32 mm 0.17 mm 0.16 mm. 4.42 mm 1.11 mm 0.90 mm. 0.7 mm 0.9 mmENGINE TOP END 4-5 ‘Special Tool ~ Compression Gauge: 5701-221 Valve Spring Compressor Assembly: 57001-241 Piston Pin Puller Assembly: $7001-910 Valve Seat Cutter, 45° ~ 992: $7001-1115 Valve Seat Cuner, 32° ~ 028: 57001-1119 Valve Seat Cutter, 60” ~ 290: 57001-1123 Valve Seat Cutter Holdor Bar: 57001-1128 Valve Seat Cutter, 48° ~ 030: 57001-1187 Valve Seat Cutter, 92° ~ 088: 57001-1199 Valve Spring Compressor Adoptor, 22: 57001-1202 Valve Seat Cutter Holder, 0S: 57001-1208 Fork Oil Level Geuae: 57001-1290 Compression Gaugo Adapter, MIO X 1.0: 87001-1917 Valve Seat Cuter, 0° ~ 033: s7001-1334 Vacuum Gauge: 57001-1968 Spark Plug Wreneh, 18mm (Owner's Tool: 92110-1132 NOTE ©The following valve seat cutters can be used instead of the above tools. Inlet Valves: Exhaust Valves: Valve Sea Cutie, 55 ”-035: 57001-1247 ((nsioad of Valve Seat Cutter: 69-083: 57001-1934) ‘Valve Seat Cutter, 45°-032: 57001-1115 (Ganstead of Valve Seat Cutter: 5°-090: 57001-1187) Valve Seat Cutter, 32-930: $7001-1120 ((nstead of Valve Seat Cutter: 32°0728: 57001-1118)4-6 ENGINE TOP END Clean Air System Air Suction Valve Inspection ‘@ Visually inspect the raad [A] for eracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assemby. ‘eChock the reed contact areas [8] of the valve holder for grooves, scratches, any signs of seperetion from the holder, or heat demage, If there is any doubt as to the condition of the teed contact areas, roplaco the air suction valve as an ascombiy. “IF any carbon oF other foreign pansies have accumulated between the reed and the reed contact area, wash the valve assembly with a high flash-point solvent ‘CAUTION ‘Do not serape of the deposits witha scraper as this could damage the rubber, requiring replacement ofthe suction valve assembly. Vacuurn Switch Valve Test Using the vacuum gauge and a syringe, inspect the vacuum switch ‘operation a¢ follows: ‘@Remove the vacuum switch valve ‘@Connect the vecuum gauge [A] and syringe [B] or fork oil evel geuge to the vacuum hosos as shown. ‘Speclal Tool ~ Vacuum Gauge: 57001-1369 Fork Oil Level Gauge: §7001-1280 ‘©Gredually reise the vacuum (lower the pressure) applied to the vacuum ‘switch valve, and heck the valve operation. When tho vacuum is low, the vacuum switch vaive should permit airto flow. When the vacuum raises to 57 ~ 85 kPa (430 ~ 480 mm Ha), it should stop air flow. If the vacuum switch valve does not operate as described, replace it with a naw one, NOTE O70 check ak flow through the vacuum switch valve, just blow through the air cleener hose. ‘Vacuum Switch Valve Closing Pressure (Open + Close) Standart, 57 ~ 65 kPa (230 ~ 490 mmHg) 1. During Casing loner hott Song Diaphragm Valve Secondsrr si Hows: 2, During Engine arating igh Vacuum Secandery sr carat HoveENGINE TOP END 4-7 Cylinder Head Cover Cylinder Head Cover Removal eRemove. ‘Soat (coo Frame chapter) Fuel Tank, Alt Cleaner Housing and Carburetor (see Fuel Systern ccheptet) ‘Mutfler (for Roar Hoad Cover) (s2° Muffler Removal) ‘Vacuum Switch Valve [A] and Hose (8) Coolant Hose Clamp Bolt [C] ‘Tharmostat Housing (D] Radiator Hose [E] Coolent Hose Clomp Bolts [A] and Hoses (8) ‘Spark Plug Cap Front lgrition Coll [C] (for Front Heed Cover) (see Electrical System chapter) Cover Botts [A] ylindar Hoad Cover (8) A Suction Valve Head Cover Gasket Cylinder Head Cover Installation ‘slr the plug pine (A) was removed, insal it with the chamfered side TB] foces urward, end apoty grease tothe O-rings (C). install Pin (01 Head Cover Gasket [€] ‘A Suction Valve [F] (as shown) install the washers with the metal side [A] faces upward. Tighten the cover bolts. “Torque ~ Cylinder Head Cover Bolts: 12 Nem (1.2 kg-m, 104 n-ib)4-8 ENGINE TOP END Cylinder Head Cover Assembly ‘@Apply a.non-parmanent locking agent to the threads of the damper plate bolts [1 ~ 7], and tighten them to the tightening sequence. [A] Cylinder Heaa Cover {[B] Damper {C] Damper Plate Torque ~ Cylinder Head Cover Damper Plate Bolts: 12 Nn (1.2 gem, 108 ina)ENGINE TOP END 4-9 Camshaft, Camshaft Chain Camshaft Removal @Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) ‘Tensioner Cap Bolt (A), Washer (B] and Spring ‘CAUTION ‘Do not turn over the crenkehalt while the tenaionor cap bolt is removed. The tensioner body is loose trom the cylinder while thecap bolt Is removed. Turning the crankshaft could damage the tensioner body and/or cylinder, and also the valves because upsetting the camhatt chain ting, ‘@Ratoase the etopper [A] and push the push rod [8] into the tonsioner body [C) ([D} Cylinder [E] Camehatt Chain Guide NOTE ‘oTemporariy, install the tensioner cop bolt {A} only to prevent the tensionot bod) irom falling into the crankcase. eRamove: Comshaft Cap Botts (A) Camshaft Cap [8] @Disengage the camshaft chain [C] from the camshaft sprocket [D], ‘and remove the camehatt. ‘CAUTION ‘The crankshaft may be turned while the camshalt Is removed. ‘Always pull the chain taut while turning the crenkshalt. This avoids kinking he chain on the lower (erankehat) sprocket. & kinked chain | could damage both the chain and the sprocket Camshaft Installation # (@Apply engine cil to all am perts and journals. Ss NOTE (The front and rear camshafts are diferent. The rear camshaft (4 ‘has a groove {814-10 ENGINE TOP END (@5etthe front piston at TDC. (Align the front piston TDC mark {A} and timing mark (8) by tuming ‘the crankshaft counterclockwise (C] (lft sie view). ‘© Engage the camshaft chain [A] with the camshaft sorocket [8]. Align the timing mark line [C] on the comshatt sprocket with the ‘yinder head upper surface (0) (install the camshatt cap and tighten the cap bolts (E]. ‘Torque ~ Camehatt Cap Bolts: 25 N-m (2.8 kg-m, 18.0 fb) ‘lnstall the front camshaft chain tensioner as follows (Remove the cap bolt installed tempcraril. ‘OHold the tensioner body and push the push roc (A] until the rod touches to the chain guide [8) lightly. ‘Olnstall the spring, washer [C] and cap bolt (D] Torque ~ Camshait Chain Tensioner Cap Bolt: 20 Nem (2.0 kg-m, 18.5 fb) NOTE (installing the rear camshaft is the same as for the front camshat Buc noting the following. (@Ser the rear piston at TDC. (Align the rear piston TDC mare [A] and timing mark [8] by turning the crankshaft counterclockwise [C] 305" (left side view). Camshaft Assembly @Cicen the sorocket bolt [A] and threads of the camshaft. 0 sure to install the pin (B] ‘@Apply a non-permanent locking agent to the threads of the bolt, and tighten it. The sprockets are dental, ‘Torque ~ Camshaft Sprockot Bolt 49 N-m (5.0 kg-m, 36 ib)ENGINE TOP END 4-11 Camshaft, Camshaft Cap Wear ‘@Mescure each clestence between the camshaft joumal end the camshaft cap using plastigago (Press gauge) [A]. ‘Tighten tho camshaft cap bots. ‘Torque ~ Camshatt Cap Bolts: 25 Nem(2.5 km, 10.0 fb) NOTE (0.0 not tun the camshaft when the plastigage is between tne journal and comshoft cop. ‘If any clearance excseds the servic limit, measure the diameter of each ‘camshaft journal with a micrometer Camshelt Journal, Camshaft Cap Clearance Standard: 0.028 ~ 0.071 mm ‘Service Limit 0.18 mm “kif the camshaft journal diameter is less than the service jimi, replace the cemshaft with ¢ new one and measure the clearance agai, ‘Camshaft Journal Diameter ‘Standard: 26.950 ~ 26.972 mm ‘Service Lim: 26.92 mm ‘if the clearance stil remains out of the limit replace the cylinder head unt Camshaft Chain Removal Front Camshaft Chain: eRemove ‘Aiternator Rotor (see Eleotical Systom chapter) Bolte [A] and Bleck Chain Guide [8] Bolt (C], Washer [D] and White Chain Guide TE) ‘@Disengage the camshaft chain [F] from the crankshaft sprocket and thon remove the chain. Roar Camshaft Chal eRemove Primary Gear (¢00 Crankshafy/Transmission chapter) Cluteh (see Clutch chapter) Boks [A] end Black Chain Guide (8 White Chain Guido (C] ‘edisengage the camshaft chain [D] from the crankshaft sprockst and then remove the chain Camshatt Chain Wear ‘@Hold the chain teut with a force of about 5 kg is some manne, and megéure 2 20-link length, Since the chain may wear unevenly, tke measurement at several places. ‘kif any measurement exceeds the service imit, replace the chain. Camshaft Chain 20-ink Loneth Standard: 127.00 ~ 127.38 mm Service Limit: 128.3:mm4-12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal ‘@Romove: Engine (sae Engine Removal/instalation chapter) ‘Camshaft (see Camshait Removal) Cylindor Hoad (902 Cylindar Head Removel) ‘Remove the camshatt chain tensioner body from the cylinder. Camshaft Chain Tensioner installation ofefer: Cylinder Had installation Camshat InstallationENGINE TOP END 4-13 Rocker Shaft, Rocker Arm Rocker Shalt, Rocker Aim Removal @Remove: ylinder Head Cover (cylinder Head Cover Removal) Camshaft Cap Rocker Shatts [A] Rocker Arms [B] and Springs (C) Rocker Shaft, Rocker Arm Installation ply molybxienum disulfide greese tothe rocker shaft. ‘@lncert the rocker shaft ito the camsshatt cap and rocker arm so that the ‘notch side [A] faces tothe spring side ‘@Align the bolt holes [B] of the camshaft cao and rocker shaft.4-14 ENGINE TOP END Cylinder Head Cylinder Compression Measurement ‘@Warm up the engine thoroughly ‘@Stop the engine, and remove the spark plugs. ‘Special Tool — Spark Plug Wranch, 16mm (Owner's Tool): 92110-1132 (@ Measure the cylinder compression ‘OUsing the starter motor, tum the engine over with the throtle fully ‘open untl the compression gauge stops rising: the compression is the highest reading obtainable. ‘Special Tool ~ Compression Gauge: 57001-221 [A] Compression Gauge Adapter, MIO X 1.0: 57001-1317 6) NOTE (OBe sure the battery is uly charged. Be sure na air leaks out of the cylinder head gasket. cylinder Compression Usable Range: 855 ~ 1315 kPa (87 ~ 13.4 kglem’, 128 ~ 191 ps!) @470 min (rpm) (© Repest the macsuremant forthe other cylinder IF cylinder compression Is higher than the usable range, check the following: (1) Carbon build-up on the evinder the piston crown (2) Cylinder heed gasket is not the original pet. (3) Valve stern oil seals and/or piston rings are damaged. IF cylinder compression is lower then the usable range, check the following (1) Condition of the valve soat is wrong, (2) Valve elaarance is too small. (3) Piston /cviinder clearance is excessive (8) Cylinder head is warped and/or head gasket is damaged (8) Piston ring/pision ring groove clearence is excessive. eed combustion chamber anc Cylinder Head Removal @Remove: Engine (see Engine Removal/Instalation) Camshaft (see Camshaft Removal) Bolts [A] and Intake Manifold [8] ‘Gmm Cylinder Head Nuts [A]ENGINE TOP END 4-15 Cylinder Heed Bolt (A] Cylinder Head Nuts [3] 10 mm Cylinder Head Nuts (C] Cylinder Heed Cylinder Head Instaliation NOTE ©The camshaft coo it machined with the cylinder hes, so f 2 new oplinder need 1s insialled, use the cap that Is supplied with the new head. © The rear eylinder haad has a breather pipe fitting. Be careful not to -mbx up the front and rear heads. @ Release the stopper end push the push rod into the tensioner body [A], and tighten the cap bolt (B] only temporary e insiat: Oil Pipe (CI White Chain Guide [0] Knock Pins (] New Cylinder Hood Gasket @Tighten the nead nuts and bolt following the tightening sequence [1 ~T Torque ~ Cylinder Head Nuts: 0mm (1 ~ 4]: 39 Nem (40 kg-m, 29 Mb) 8 ram (5 ~ 6]: 25 Nem (25 kom, 18.0 fb) Cylinder Hoad Bolt [7]: 12 N-m (1.2 kg-m, 104 into) ‘eTightan the 8 mm cylinder head nuts. ‘Torque ~ Cylinder Head Nuts (8 mm): 25 N-m (2.5 kg-m, 16.0) Apply grease to the O-rings [A]. ‘@ nstall the intake manifold, and tighten the bolts. Torque ~ intake Manifold Bolte: 12 N-m (1.2 kg-m, 104 in-ib) Cylinder Head Assembly instal the cube: dampers [A] between the fins [B] as shown. (OThe end of the damper should be recessed 3 ~ 5 mm (C] inside the top of the lower fn.4.16 ENGINE TOP END Front Cylinder Head: TA] Rubber Dampers (18) [6] 170 mm [C] 165 mm [0] 168 mm [E] 154mm (F1133.mm [G] 140mm [H] 148 mm {70mm [79 mm esr Cylinder Head: [A] Rubber Dampers (17) [8] 40mm [C] 38 mm [0] 36 mm (@\hea installing the breather pioe fing (A) in the reer cylinder heed, align the fitting with the mark (8). [C] Fitting Hose (ol 37 ~ 43"Valves Valve Clearance Adjustment NOTE Valve clearance must be cheeked and adjusted when the engine fe 0d (at roam temperature), eFemove: Cylinder Had Cover (s00 Cylinder Head Cover Removal) ‘Timing Inspaction Covge (Engine Left Side) (© Set the front piston at TOC (see Camshaft instalation) (© Using thickness ceuge [A], measure the valve cleacance between the rocker arm [8] and the shim (C] (© Sot the roar piston at TDC by turing the erenkshatt counterclockwiso 305" (sa2 Camshaft Installation) (@Using a thickness qauge, measure the valve clearance between the rocker arm and the shim. Valve Clearance Standard: IN: 0.10~0.15 mm EX; 0.20 ~ 0.25 mm Jit tha vane claaranca ie not within the specified range, frst record the learence, and then adjust it. (@To change the valve clearance, side the rocker arm [A] sideways and cchengo tho shim [8]. Replace the shim with ono of a different thickness. NOTE © Mark and record the shim locations so thet the shims con be reinstalled in ther eriginal positions. (@To select @ new shim which brings the valve clearance within the spoatiod tango, rfor to the Valvo Cloarance Adjustment Charts, ORemeasure any vahe clearence that was adjusted. Readjust if necessery. CAUTION ‘Do not put chim eicck under the shim. This may cause the shim to op out at high rpm, causing extensive engine damage. Bo not grind the shim. This may cause It to fracture, causing extensive engine dam: ENGINE TOP END 4-174-18 ENGINE TOP END VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE PRESENT SHIN rar PART No_(o2036 7) nara a aa] a [ee [vs aa [ava MAR O[€ [1] 0 [a] a [a] woo] se] cole | 7] 7 |e |e | 80 | Oe B32, THICKNESS (a) 2.00 [z05|2.10|216)226|2.25)230 235 ]2.00/2. 12.50] 2:5] 2.60 2.08 2702 75|2.0/205/2-90]2.95)3. -g[oce = wen} [rao]sae]an[aoe]xso] as] 20] ae] ae[ 2 [sao] aae| ao] 200 [ane [ao] 2 78] a0] sas] 00 Z[ace ~ oon | [1.95/20 /20s]200/205|220|226 230)2.95|2a0|2.05|250|255|200|265| 2701275 |2—0|235|2.90|295 3 010 ~ 018 SPECIFIED CLEARANCE/NO CHANGE REQUIRED F [one ~ ozo} —(2ns[avo[exe[zzo|2as]2.0] 2.35] 2.00[2.es|2.0[255] 200]2.05]2.7|275 zm [20s] 2m0[295] 300] Utaarsoas] [avolers sz0|22s 250[2.35|200|20s[2.50[2s5|200] zs] 70]275[200|2.05|220| 25/300 oze= 020] [avs[as0 s25|2s0 255/2.09]245/z=0[2.5[2the seat wich is within the specified range, lap the valve to the seat 1s described below. (©.Grind the coat at 2 60" angle unti the seat wicth is within the specified range (0To make the 60" grind, ft 60° cutter into the holder, and slide it into the valve guide. e | | engagement oy machining Ground volume saith 45" cutte by 32 cure Grains vous by 60 cutterENGINE TOP END 4-23 (Turn the holder, while pressing down lightly (After making the 60" grind, return to the seat width measurement step above. {@1La0 the valve to the aoat, ence the seat width and 0.0. are within the anges specced sbove. (Put a litle coarse grinding compound on the face of the valve in a ‘number of placas around the vaive head, (© Spin the valve against the saat until the grinding compound produces a sirooth, matched surfece on both the seat and the vaive. (© Repeat the process with » fine grinding compound. (Al Lapper [B] Valve Seat [c] Vatve (@TThe seating area should be marked about in the midale of the valve face. 1 the seat area is not in the right place on the valve. check to be sure the valve is the correct part. IFitis, it may have boen refaced too much; roplaco it @ Sure 10 remove all grirding compound before essembly. ‘@\When the engine is assembled, be cure to adjust tho vawe cloarance (609 Valve Clearance Adjustment),4.24 ENGINE TOP END valve Seat Repair [SeEe ey (Cstant_) Machinists ye on eat 1 ‘Grind Took 48° cutter Porposs: make seating ar smooth and round 1 Meanure Seating Area 0.0. pao enteral Took ier Caliper Purpose: chace wat OD, fg aguinet spc. fe ne ee ee | Results saree Too small OK Too bie a5 Grine Machinis’s Took a5" Cutter Bi otnet Purpose: increase O.D. of seat meroree t ‘BP Grind Too: 37° Cutter Purpose: reduce 0.0, of sat aroa tospac. y T ‘Measure Seat With Tool: Vernier Cainer. Purpose: check seat width =| a Too narrow (Tor "oo wide WS Gane ais Took 45" Core Gre onsest Porposa: inreae width of tat feabevond spec. to reco 0.0. aa Took a0" cutter Purpose: reduce sot width . Tov. Toole! valve lapper, grinding compound Purpose: perfectly match valve Bnd seat area; cheek talve head for damane FINISHEDENGINE TOP END 4-25 Cylinder, Pistons Cylinder Removal @ Remove: Cylinder Had (s00 Cylinder Head Removal) Gylinder Nut (A) Cylindor Cylinder Installation Install the new cylinder gasket Sat the piston at top position. @ Apply engine oll to the cylinder bore and piston skin. @install the cylinder [A] s0 that the tensioner mounting ole faces rearward Tighten the oylinder nut. ‘Torque ~ Cylindar Nut: 25 N-m (2.5 kgm, 18.0 Rb) Piston Removal (@ Remove the cylinder (see Cylinder Removal). (© Prace 2 claan cloth under the piston and remove the piston pin snap ting, (@ Remove the piston pin. ‘Special Too! ~ Piston Pin Puller Assembly: 5700T-910 [A] (© Carefully spread the ring opening with your thumbs end then push up ‘on tho opposite side of tha ring [A] to remove it (© Remove the 3-piece oil ring with your thumbs in the same manner. Piston Installation {© Do not mix up the top and eecond rings. (© Install the top ing (A] so that the “R mark (8) faces up. (CInstall the second ring [C] so that the “RIN” mer (D] faces up.4-26 ENGINE TOP END ‘©The piston ring openings must be positioned as shown in the figure. “The openings ofthe ol ring steel rails must be about 30 ~ 45" of angla {from the opening ofthe top ring. [A] Top Ring [0] OW Ring Expander {[B] Second Ring TE} Arrow [C] OW Ring Stee! Rais ‘@7The errow on the piston head must point towerd the exhaust side of the eying CALTION Do not reuse snap rings, as removal weakens and deforms them. ‘They could tall out and ecore the cylinder wall, Cylinder Wear Since there ie a difference in eylinder wear in different directions, take 4 Side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the Fure. “If any of the eviinder inside diameter measurements exceeds the service lit, th cylinder will have to be bored 10 oversize and then honed. [A] 10mm [8] 60 mm [c] 20mm Cylinder Inside Diameter Standard: 88.000 ~ 88.012mm Service Limit, 88.11 mm Piston Wear ‘® Measure the outside diamater [A] of each piston § mm [8] up from the bottom of the piston at a right angle to the direction ofthe piston pin. + ifthe maasurement is under service limit, replace the piston. Piston Diameter ‘Standard 87.978 ~ 87.900 mm Service Limi: 87.83 mmENGINE TOP END 4-27 Piston Ring, Piston Ring Groove Wear ‘@Cheok tor uneven groove wear by inspecting the ring seating. “eThe rings should ft perfactly parallel to groove surfaces. If not, the piston must be replaced. ‘@\With the piston nnge in their grooves, maka several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Platon Ring/Groove Clearance Standard Service Limit Top 009~ 007mm OAT mm ‘Second 9.02~ 008mm 0.18 mm Piston Ring End Gap ‘@Plece the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the eviinder, where cvlincer wea is low. @iescure the gap [8] between the ands of the ring with a thickness ‘Service Limit 07 mm 0.9mm4-28 ENGINE TOP END Carburetor Holder Carburetor Holder installation (install me carburetor nolder [so thatthe up mark (8) faces upward.Muffler ENGINE TOP END 4.29 Muttler Removal Front Muffler: @ Remove: ‘Clamp Bolts [A] and Front Exhaust Pipe Cover [8) Exhaust Pipe Bolts (A) Muffler Bolts (A) Clamp Bott (8) Front Muffler (C] Rear Muttler: @Romove: Front Muitier Reer Exheust Pipe Cover [A] Exhaust Pipo Bolts [8] eer Muffler [C] Muttier installation ‘@inszal the grommets [4] on the hook [8] of the exhaust pips @Slip the hook into the brace [C] of the exhaust cover (D].4-30 ENGINE TOP END Mufiler Cover Removal ‘@Remove the muffler cover [4] from the muffler as follows: ‘Hold the both ends on the cover. (OPush (8] the upper end of the cover and then slide up (C] the cover as shown Mutter Cover Installation ‘@insen the pins [A] of the muttler cover into the holes (8) on the mutter, NOTE Do not move the mutler cover to the font and re0rCLUTCH 5-1 Clutch Table of Contents Exploded View ... ‘Specifications... Clutch Lever and Cable. Lover Free Play Inspection Lover Free Play Adjustment Cable Removal es Cable Installation Cable Lubrication. Clutch Lever Installation Right Engine Cover... Right Engine Cover Removal... Right Engine Cover Installation Release Shaft Removal Release Shaft Installation ... Clutch . oe Clutch Removal, Clutch Installation... ise Clutch Plate, Wear, Damage Inspection Clutch Plate Werp Inspection... Clutch Spring Froa Length Measurement. Oo VIN aoa oaaaraEEEDS5-2_ CLUTCH Exploded View G: Apply grease. L: Apply non-permanent locking agent. ae apa on TH: 8.6 Nem (0.90 kgm, 78 ita) ! A Testa Non (2 hg fin) a Betenaiasigmsne ox AR! an PCLUTCH 5-3 ‘Specifications item’ Standard Service Limit (Clutch Lever: Clutch lever free play 2-3mm = Cluteh: Friction plate thickness 2.9 ~ 31 mm 28mm Friction and steel plate warp 0.2 mm or ess 0.3 mm Cluteh spring free length 34.2. mm 33.1 mm Special Tool ~ Clutch Holder: 57001-12635-4 CLUTCH Clutch Lever and Cable Lever Free Play Inspection ‘@Pull the clutch lever just enough to take up the free play [A] ‘@ Measure the gap betweon the lover and tha lover hotdor. “IF the aan is too wide, the dlutch may not reloaso fully. Ifthe gap is too narrow, the clutch may not engage fully. In either case, adjust it Clutch Lever Free: Standard: Lever Free Play Adjustment ‘@Loceon the locknut [A] atthe clutch lever. (eTurn the acjuster [8] until the proper amount of clutch lever free play is obvained. ‘Tighten the locknut securely. ‘kit it connot be done, use tha adjuster at the middle of the cable, ‘@Locean tha locknut [A] at the middle of the eutch cable. (eTurn the adjusting nut (B] until the proper amount of clutch lever free play is obtained. Tighten the jocknut securely “eit it eannet be done, use the mounting nuts at the lower end of the cable, ‘@Ramove the front mutter (gee Engine Top End chapter) ‘@ Loosen the locknut (A at the clutch lever Turn the adjuster [B] so that § ~ 6 mm [C] of throads are visible. ‘Slide the dust cover [A] at the clutch cable lower and out of place. ‘@Loosen both mounting nuts [3] atthe clutch cover as far as they will 90. ‘@Puil the clutch outer cable [C] tight and tighten the mounting nuts against the bracket (0) Slip the rubber dust cover back onto place. ‘@TTurn the adjuster at the clutch lover until the foe play i coroct (eTighten the knurled locknut a the clutch lever. (@A‘ter the adjustment, stat the engine and check that the clutch doss not aio and that it releases proporyCLUTCH 5-5 Cable Removal Slide the cust cover at the clutch cable lower end out of place. ‘@Lcosen the nuts, and slide the lower end of the clutch ceble to give the cable plenty of pay. ‘@ Loosen the focknut atthe clutch lever, and screw in the adjuster. ‘@Line up the sicts (A) in the clutch lever, locknut (B], end adjuster IC], and then free the cable from the lever. ‘@F roa the elutch inner cable tip from the cutch release lever (@Push the release lavar toward the front ofthe motorcycle and tape the release lever tothe clutch cover to pravert the releese shaft from falling out. ‘@Puil the clutch cable out ofthe frame Cable Installation ‘@fun the clutch cable correctly (see Ganera Information chapter) ‘@ Adjust the clutch cable (sae Lever Free Play Adjustment). Cable Lubrication ‘Whenever the cluich cable is removed, lubricate the cluteh cable a¢ follows. ‘@ Apply a thin costing of grease 0 the ceble upper and lower ends. (© Lubricate the cable with ¢ penetrating rust inhibitor Clutch Lever Installation ‘@ install the clutch lever so that the mating surface [A] ofthe lever holder is aligned with the punch mark [B] on the handlebar5-6 CLUTCH Right Engine Cover Right Engine Cover Removal ‘@Fiemove: Engine Oil (disin, see Engine Lubrication System chapter) Cooiant (drain, s89 Cooling Systom chapter) Front Mufiler (see Fuel System chapter) Clutch Cable Down Tube (see Frame chaprer) Coolant Hose [A] Clutch Cover Bolts (8] Coolant Pipe [C} rom the engine) (¢Turn the release aver [D] tovaid the reer as shown, end remove the Fight engine cover. Right Engine Cover Installation @ install the knock pins [A], and replace the cover gasket with & new Check to see that the washer [8] is in place @Aoply 2 non-permanent locking agent to the threeds of the right ‘engine cover bolt [C] ‘@Apply a soap ond wator solutin to the seal [A]. Do not apply a grease (Fol 0 the £23. ighten the cover bolts, ‘Torque — Right Engine Cover Bolt 2 N-m (1.2 gum, 104 inst) Release Shaft Removal CAUTION ‘Do not remove the chitch release laver and shaft assembly unloss It is absolutely necessary. if removed, the oll seal replacement may be requires. ‘@ Remove the right engine cover (soo Right Engine Cover Romova)). @Remove the crclip [A] from the lease shart ‘@Pull the lever and sheft assembly [8] out of the right engine cover, Release Shaft Installation ‘@ Apply high-temperature grease to the oil seal lips cn the lower ridge of the clutch cover ‘@ Appiy cil to the boaringe in tho holo of the right ongine cover. felnsert the release shat straight into the lower hole of the right engine CAUTION ] When ingerting the reloace shat, be eareful not to remove the spring of the ol sea,Clutch Clutch Removal @Romove: Right Engine Cover (soe Right Engine Cover Removal) Clutch Spring Bolts (Al Guten Springs | CGlutch Spring Plate (B] (with thrust bearing and pusher [C]}) Fretion Plates, Stee Platas ‘Clutch Hub Nut [4] (Holding the clutch hub [8], remove the nut. ‘Special Too! ~ Clutch Holder: 57001-1249 {C] Remove: ‘Clutch Hua ‘Spacer [A] Clutch Housing Thrust Spacer Needle Bearing and Bushing Clutch Installation ‘instal the following parts on the drive shaft (A] Thrust Spacer {8} Bushira [C] Nevdle Bearing [0] Clutch Housing [E] Spacer (F] Ciuten Hub [6] Washer TH] Nut CLUTCH 5-75-8 CLUTCH ‘CInstall she thrust spacar (A so that the steppad side (B] faces inward (© Replace the clutch hub nut with a new one. ‘© Appiy oll the threads and seating surface of the hub nut. (C Holding the clutch hub, tighten the clutch hub nut Special Tool ~ Clutch Holder: 57001-1243 Torque — Clutch Hub Nut: 132 Nom (13.5 kgm, 98 ftlb) ‘@ Install the fiction plates and steel plats, starting with 2 friction plate ‘and aiternating them. ‘CAUTION It new dry Wietion plates and sta plates are installed, apply engine oll fo the surfaces of each plate io avold clutch plate seizure ‘Olnstall the last fiction plate [A] fitting the tangs in the grooves in the housing as shown, ‘@inetall the cluten spring plato and epring, and tighten tho clutch spring bits Torque - Clutch Spring Bolts: 8.8 N-m (0.90 kg-n, 78 in-b) ‘@ nstait the right engine cover (829 Right Engine Cover Installation), Clutch Plate, Wear, Damage Inspection @Visuely inspect the friction end steel pletes for signs of seizure, ‘overheating (discoloration), or uneven wer. (@tMeesure the thickness ofthe fiction plete [A] at several points. If any plates show signs of damage, or if they have won past the service limit, replace them with new ones. Friction Pate Thickness Standard: 28 ~ 3.1mm Service Limit’ 2.8 mm Clutch Plate Warp Inspection (© iace each tition plat or staal plate on a sutace plate and measure the gap between the surface plate [A] and each fiction plate or ste! plate (B] with a thicknoss gauge [C]. The gap is the amount ot fiction or steel plate warp. “kif any plate is warpad over the service limit, replace it with 3 new one. Friction and Stee! Plate Warp Standard: 0.2mm or lacs Service Limit 0.3mm Clutch Spring Free Length Measurement ‘@ Measure the free length of the clutch springs (A) >It any spring is shorter than the saves limit it must be replaced. ‘Clutch Spring Free Lengtn Standard: 34.2mm Service Limit: 33.1 mmENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View .. Engine Oil Flow Chart. ‘Specifications. e Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Ol Filter Change Oil Screen Cleaning il Pump, Gil Pump Drive Chain. Oil Pump Removal Oil Pump installation Oil Pump Drive Chain Wear Oil Pump Drive Chain Guide Installation Oil Pressure Measurement ll Pressure Measurement il Pressure Switch Oil Pressure Switch Removal. Oil Pressure Switch Installation il Pipe, Relief Valve Oil Pipe (Crankcase Outside) Removal . Oil Pipe (Crankcase Outside) Installation, Oil Passage Cover Removal/Installation Oil Pipe (Crankcase Inside) Removel..... Oil Pipe (Crankcase Inside) Installaton ... Relief Vaive Inspection.6-2 ENGINE LUBRICATION SYSTEM Exploded View / | = Apply arease. LL: Apply non-permanent locking agent | Ss: Apply siicona sealant. 1: 6.4 Nem (0.85 hg-m, 48 rb) 12: 718 Nem (0.80 kg-m. 69 insb) 33: 11 Nem (1-1 hom, 95 ib) Tas 12 Nem (1.2 kgm, 104 ind) z 4) “78: 15 Nem (1.5 kgm. 11.0 feb) 6: 18 Nem (1.8 kom, 13.0 feb) \ No Tiown aceasta e \ osENGINE LUBRICATION SYSTEM 6-3 Engine Oil Flow Chart 41, Loft Crankcasa 2. Right Crenkease 3, Oil Scrson Plug 4 Oil Screen 5. Oil Pump 6, Oil Fiter 7. Oil Prossure Switch 8 Oil Pips 9. Crankshaft 10. Rolief Vawe 11. Output Shaft 12. Drive Short 13. Front Cylinder Heed 14, Rear Cylinder Heed 18. Cemshett Cap 18, Rocker Am 17. Camshaft6-4 ENGINE LUBRICATION SYSTEM Specifications Oil pump drive chain 20-link length 127.0 ~ 127.4mm Item ‘Standard Service Limit Engine Oil Grade | SE, SF, or SG class Viscosity | SAE 10W-40, 10W-50, 20W-40, | or 20w-50 Capacity: 2.7L (whan filter is not removed) 2.9L (whon filtor is removed) 3.2L (whan engine is completaly dry) Oil Pump: Oil Pressure Measurement: Oil pressure @4.000 r/min(rpm).. oil temp. 100°C (212°F) 365 ~ 410 kPa(3.6 ~ 4.2 kg/em*, 51 ~ 60 psi) ‘Special Tool ~ Oil Pressure Gaugo, 10kglem* $700T-164 (Oil Pressure Gauge Adapter, PT : S7001-1033 ilFiter Wench: 57001-1249, Sealant ~ Kawasak! Bond (Slicone Sealant): 56019-120ENGINE LUBRICATION SYSTEM _6-5 Engine Oil and Oil Filter Eo ‘Motoreyele operation wih Ineuflcont, deterlorated, or contaminated engine oll will cause accelerated wear and may result In transmission selzure, aceldent, and injury. gine or Oil Level Inspection ‘© Check that the engine oil level is betwoon the uppar {A] and lower [B} level ines next tothe gauge [Cl] NOTE © Situate the motoreyale so that itis perpendicular to the ground. Mf tne motorcyele has just been used. wait several minutes for al the ola drain down. (Off tha oil has just boon changed, start the engine and run it for several ‘minutes at ale speed. This fils tha oilfiter with oil. Stop the engine. then wait several minutes unui the oil settes. CAUTION Racing the engine before the oll reaches every partcancause engine setzure. UU the engine oil gets extremely low or ithe oll pump or oll passages ‘clog up or ctherwize do not function properly, the oll pressure ‘warning light will ight. I this light stays on when the engine running ebove the icle speed, stop the engine immedtately and tind te oat Engine Oil Change ‘eSupport the motorcycle perpendicular to the ground after waning up the engine. ‘@Remove the engino drain plug (Al to drain the oil. OThe oll in the oll titer can be rained by removing the filter (see il Fiter Change), +4Replace the drain plug gaskat (B] with 2 new one it itis damaged. Tighten the drain plug ‘Torque ~ Engine Drain Plug: 20 Nem @2.0ka-m, 14.5 fb) ‘@Pour in tho spocifiod typo and amount of cil Engine ol Grade: SE, SF, or SGclass Visoosily: SAE 10Ws0, 10WS0, 2040, or 20050 Amount: 27 L (when flier is not removed) 2.9L (when filter Io removed) 2.2 L (whan engine Is completely dry)6-6 ENGINE LUBRICATION SYSTEM Oil Fitter Change ‘@Drain tho ongino oil (see Engine Oil Chango). ‘@Remove the cl iter [A] withthe ol fiter wrench (8). Special Tool ~ Oil Fitter Wrench: 57001-1249 ‘@Ropizce the fiter with a new o ‘@Appiy engine cil to the gasket before install ighten the filter withthe ol iter wrench or with hands about X turns after the gasket contacts the mounting surface ofthe oil itor plato. Torque ~ Oi Filter: 18 Nem (1.8 kg-m, 12.0 feb) ‘@Pour in the specified tyne and amount af oil (eee Engine Oil Change). ii Screen Cleaning {@Diain the engine oil (see Enaine Oil Chenge). ‘@Femove the ol screen plug [A], soring, and washe ull out the ol ecraen (A). ‘© Caan the sereen with high flash-point solvent. (© Check the screen carefully for eny damage, +f the sorgen is demeged, replace it with a new one. (@CCheck the O-ring [8] on the oll sereen plug for damage. “if the O-ring is damaged, replace it with a new one. @install, Oil Seroon and Rubber Gasket (C] Washer (0) Spring (E] (Apply grease to the O-ring, and tighten the plug. Torque ~ Oll Screen Plug: 20 Nem (2.0 kg-m, 14.5 Ro)ENGINE LUBRICATION SYSTEM _ 6-7 Oil Pump, Oil Pump Drive Chain Oil Pump Removal ‘Split the crankcase (see crankshafi/Trensmission chats). @Remove: Crankshott Cirelip (A) ‘eRemove the sprocket [8] end balancer shaft [C) along with the oit ‘pump chain [D]. eRemove: il Pump Mounting Botts [E) il Pump Shatt (F], Pump Body, and Rotors Oil Pump Installation Check that the knock pin (A] isin piace ‘@ Apply grease to the O-ring [8] on the pump body. ‘@ Apply 2 non-permanent lacking agent to the threads of the mounting bolts (Al, and tighten ther Torque ~ Oll Pump Mounting Bolts: 11 Nem (1-1 kgem, $5 inst) ‘@ install 2 new clctip (B] on the shaft so thet the sherp edge faces awey from the sprocket and opening is on tha shaft fat surace (C} Oil Pump Drive Chain Wear ‘@Hold the chain taut with a force of about § kg in some manner, and | measure a 20-link length, Since the chain may wear unevenly, take measurement at several places | if any measurement exceeds the servic limit, replace the chain. link Length te ane oteeT | (Ol! Pump Drive Chain 2o41nk Length Standard: 127.0 ~ 1274 mm Service Limit 128.9 mm i! Pump Drive Chain Guide Installation ‘install the chain guide [A] so thet the upper surfece [8] of the chain ‘uide touches the flat surface [C] of ihe lat crankcase ‘@ Apply a non-permanent locking agent tothe threads ofthe chain guide bolt (D], and tighten it ‘Torque ~ Oll Pump Drive Chaln Guide Bolt: 12 Nem (12 kgem, 108 Inib)6-8 ENGINE LUBRICATION SYSTEM. Oil Pressure Measurement Oil Pressure Measurement ‘@Fomeve the oil pressure ewitch (see Oil Pressure Switch Removel) without draining the engine oil install the gauge and adepter. ‘Spectal Too! ~ Ol Pressure Gauge, 10 kglem*: S7001-184 [A] Olt Pressure Gauge Acapter, PT : 57001-1033 [J ‘@Run the engina et the specified speed, and read the oil pressure geuge If the cil pressure is significantly below the specification, inspect the cil pump and relief valve °F the oil pump and reliet valve are not at fault. inspect the rest of the lubrication system. OmPressure ‘Stand 355 ~ 410 kPa (8 ~ 42 kg/cm", 51 ~ 60 psi) @4,000 r/min (rpm), oll temp. 100°C (212 °F) ‘eSt0p the engine. ‘@ Remove the oil pressure gauge and adapter ‘Install tha oil pressure ewitsh (s00 Oil Prescure Switch Installation)ENGINE LUBRICATION SYSTEM 6-9 Oil Pressure Switch Oil Pressure Switch Removal (@Romove: Engine Oil (drain, soe Engine Oil Chengo) Switch Cover (Al ‘Switch Leed Terminal [8] (Oil Pressure Switch [C] if Pressure Switch Installation ‘@ Apply silicone seelant to the threads of the oll pressure switch, and tighten it Sealant ~ Kawasak! Bond (Slicone Sealant: $6019-120 ‘Torque ~ ll Pressure Saitoh: 18 N-m (15kg-m, 17.0 fb)6-10 ENGINE LUBRICATION SYSTEM. Oil Pipe, Relief Valve Oil Pipe (Crankesse Outside) Removal @Romove ‘Altertor Cover (s22 Electrical System chapter) Oil Pipe Mounting Bolts (A) Oil Pipe (3) Oil Pipe (Crankcase Outside) installation ‘@ Apply gresse to the O-rings (A). ‘© Apply a non-permanent locking agent tothe thraads of the mounting bolts, and tighten them, ‘Torque ~ Oi Pipe Mounting Bolts (Crankcase Outside) : 64 Nem (0.55 kg-m, 48 indo) Oil Passage Cover Removalllastalation @Femove: Oil Pipo (Crankease Outsida) ‘Atwornator(se@ Elactcal Systam chapter) Left Balancer (see Grankshaf/Trensrission chapter) Oi Passage Cove Screws [A] 0 Passage Cover [8] @lnstall a new gasket Ply & non-permanent locking agent to the threads of the cover screws, and tighten tham Torque ~ Oil Passage Cover Screws : 5-4 Nem (0.55 kg-m, 48 ink) Oi Pipe (Crankcase Inside) Removal (© Split the crankcase (see Crarkshaft/Transmission chapter) @ Remove: Oil Pipe Mounting Bolts (A) Oil Pines (8)ENGINE LUBRICATION SYSTEM 6-11 Oi Pipe (Crankcase Inside) Installation ‘© Apply grease to the O-rings [A]. ‘@ Apply 8 non-pomanont locking agent tthe threads of the mounting bolts, and tighten them. Torque ~ Oil Pipe Mounting Bolts (Crankcase inside): 11 N-m (1.1 kg-m, 98 in.) Relief Valve Inspection ‘@Spiit the crankcase (522 Crankshait/Trensmission chepter). ‘@Remove the relief vaNe [A] from tho right crankcase. {@Chock to 220 if the steel ball inside the valve slides smoothly when pushing i in with a wooden or other soft rad, and see iit omnes back 10 its seat by valve spring pressure. NOTE inspect the valve i ite assembled state. Disassembly end assembly ‘may change the valve performance. 4k1f any rough spots are found during above inspection, wash the vawve cleen with @ high flash-point sokent and blow out any foreign particles that may be in the valve with compressed ait. RG Clean the parts in a well-ventilated aes, and take care that there are ro sparks or flame anywhere near the working area. Because of the anger of highly flammable liqulds, do not use gascline or low ttash-point solvents. Jif cleaning does not solve the problem, replace the relief valve as en assembly, The relief valve is precision mede with no allowance for replacement of indvidval parts. ‘@ Apply @ non-permanent locking agent to the threads of the relief vale, and tighten it Torque ~ Oil Proseure Rel 4 Valve 15 Nem (15 kgem, 11.0 fb)che Bearers ngleotiey sahiowa at a re omen - ‘Sonia (earl Mies] OW Da fart Seremban dake Sat ei Hy ee Sh A Per ak Ta Sede tes 10, Se OR Ce a ee a < ainesarr eye a RR ED Swi ippbinas Vaasa ES end WY Kn cari : | Sane: 02 itty Sl in Greece sie 1 tear j Se ies G uated « a 8 . Ne in teenie a LNG SL a aeeetimde 2 Faas Wi ORNS ES * aa Wr Rt tl le eh ln ET FAWN Ye HO See en, Sls Hey At pe me Ma 7 - sre re hin et ' - A at. : “ef To mt torae eee 5 - - ® -ENGINE REMOVAL / INSTALLATION 7-1 Engine Removal / Installation Table of Contents Exploded View Specifications te Engine Removal/Installation... Engine Removal. Zi Engine Installation... GREGOR [A]7-2_ENGINE REMOVAL / INSTALLATION Exploded View TH: 23 Nem (2.3 ko-m, 18.5 feb) 12: 44 Nem (4.5 kg-m, 33 tub)ENGINE REMOVAL / INSTALLATION 7-3 Specifications ‘Special Too! ~ Jack: 57001-12387-4 ENGINE REMOVAL / INSTALLATION Engine Removal/Installation Engine Removal @Remove: Engine Oil (drain, s2¢ Engine Lubrcotion System chepter) Coolant (drain, ee Cooling System chapter) Fuel Tank (see Fuel System chapter) Mutter (see Engine Top End chapter) Ai Cleaner Housing (see Fuel System chapter) Carburetor (see Fuel System chapter) Vacuum Switch Valve Radiator (se2 Cooling System chapter) ‘Thermostat Housing [A] Woter Hose Fitting Bolts [8] and Fittings Engine Sprocket [A] (s20 Final Drive chante) Ignition Swen (8) Alternator Lead Connector (C] Pickup Coil Lead Connector (D] Oil Pressure Switch Lead (A) Stansr Motor Laed [8} Nauta! Switch Lead Connector (A) (© Suppor the frame withthe jack ‘Special Too! ~ Jack: $7001-1238 'Squeeza the brake lever and hold it with a band, Support the engine with a stand [A] @ Remove: Clutch Cable Down Tube (8) (see Frame chapter) Engine Mounting Bolts [C] and Nuts Engino Mounting Brackst [D] (@.Using the stand, ake out the engi tothe rightENGINE REMOVAL / INSTALLATION 7-5 Engine Installation ‘install the engine mounting bracket and down tube. ‘Torque ~ Engine Mounting Bracket Bolt: 29 N-m (2.3 kg-m, 165 tb) ‘Down Tube Mauniing Bolts: 44 Nem (4.5 gem, 33 Rb) @Tichten the engine mounting bolts and nuts. ‘Torque ~ Engine Mounting Bolts and Nuts: 44 Nem (8.5 kgm, 33 Hb) ‘@ install the rerioved parts (see appropria chapters) Adjust ‘Throttie Cables (s02 Fuel System chapter) Drive Chain (see Final Drive chapter)CRANKSHAFT / TRANSMISSION 8-1 Crankshaft / Transmission Table of Contents Right Balancer, Starter Clutch Instlltion.. Starter Clutch Inspection. Balancor Damper inspaction Torque Limiter. . Torque Limiter Removal. ‘Torque Limiter Inspection Priany Beat me Primary Geat Removal. Primary Gear Installation on Exploded View Specifeations.. Crankcase Spiiting Crankcase Splitting. Grankcase Assembly. Bearing. Ol Seal Installation a. Crankshaft / Connecting Rods. (Crankshaft Removal Crankshaft Installation... Connecting Rod Removal Transmission... Connecting Rod Installation Shift Pedal Fomoval Connecting Rod Big End Bearing Shift Pedal installation Tngor/Crankpin Wear Extemal Shift Mechanism Removal Crankshaft RUROUE nom Extamal Shift Mechanism instalation Crankshaft Main Bearing / Extemal Shift Mechanism Inspection em. Main Journal Wear... i ou Transmission Shaft, Shift Fork Removal... Crankshaft Side Cearence. Transmission Shaft, Shift Fork Installation Balancer, Startor Clute eft Balancor Removal ~ Left Balancer Installation Right Balancer, Starter Clutch Removal ‘Transmission Assembly. Shift Drum Removal Shift Drum Disessembly/AssembWy8-2_ CRANKSHAFT / TRANSMISSION Exploded View G: Apply grease. LL: Apply non-permanent locking agent. LG: Apply Liquid gasket. & ply Liquid ga © & ©: apy it : Follow epecfied lightening eaquence, Ti: Nem (1.1 ka, 88 ind) Ta: 12.Nem (12 kgm, 104 int) 4A_G@® ‘T3: 15 Nam (1.5 kgm, 11.0 fbb) ‘Ta: 29 Nem (3.0 kgim, 22 fb) TS: 39 N-m (4.0 kgm, 29 ftlb) Te: 45 Nom (4.7 kgim, 24 ftlb) T7: 69 Nom (7.0 kgm, 51 ftlb) Ta: 157 Nom (18.0 kgm, 115 feb) T9: 34 Nom (8.5 kgm, 25 fb) g°CRANKSHAFT / TRANSMISSION 8-38-4 CRANKSHAFT / TRANSMISSION Specifications Connecting rod big end bearing insert/crankpin tem Standard Crankshaft, Connecting Rods: Connecting rod big end side clesrance 0.16 ~ 0.46 mm 0.026 ~ 0.054 mm. clearance Crankpin diameter: 42.984 ~ 43.000 mm Marking None 42.984 ~ 42.992 mm 1 42.993 ~ 43.000 mm Corning igenstow donor, | 800 4800 en Marking None 148,000 ~ 46.020 mm ° 46.011 ~ 46.020 mm - Connecting rod big end bearing insert thickness: Brown 1.483 ~ 1.487 mm Bleck 4.487 ~ 1.491 mm Blue 1.491 ~ 1.498 mm | Connecting rod big end bearing insert selection Con-red Big End | Crankpin Dismetor | Beering Insert Bore Diamatar | Marking | | Size Cotor Part Number None | 1 Brown | __ 19084-1059 Hee, Sone Black 13034-1088 o 1 ° Nene Blue 773084. 1087 Connecting rod bend 01/100 mm 0.2/100 mm Connecting rod twist 0.18/100 mm 02/100 mm Crankshatt side clearance 0.05 ~ 0.55 mm 0.75 mm Crankshaft wob longth 96.86 ~ 96.95 mm 96.6 mm Crankshaft runout TIR 0.02 mm or loss TIR 0.08 mm Crankshaft main journal diameter 42.984 ~ 43.000 mm 42.96 mm Crankcase main bearing bore diameter 43.025 mm ~ 43.014 mm 43.09 mm Transmission: Shift fork gar thickness 49~ 6.0mm 4mm Gear shift fork groove width 5.05 ~ 5.15 mm 5.2 mm Shift fork guide pin diamotor 59~60mm 5.8 mm Shift drum groove width 605 ~ 6.20 mm 63mm Special Tool ~ Outside Circlip Piers: S7001-144 Bearing Driver Set: 57001-1129, Flywheel Holder: 57001-1313 ‘Sealant ~ Kawasail Bond (Liguid Gaskel-Black): 92108-1008,CRANKSHAFT / TRANSMISSION 8-5 Crankcase Splitting Crankcase Splitting ‘@ lemove the engine (see Engine Removal/installation chapter) ‘@Sot the engine on @ clean surface and hold the engine stody wrile parts are being removed. @Femove: Starter Motor (see Electrical System chepter) Oil Filter (see Engine Lubrication System chapter) Pleto Bolts [A] (Ol Fiter Plate [B] and O-rings (2) ‘Clutch (coe Clutch chapter) Primary Gaar (see Primary Gear Removal) Right Balancer (coe Right Balancer, Starter Clutch Removal) Torque Limiter Water Pump Impaler (see Cooling System chepter) Lah Beloncer (see Loft Balancer Removal) Altemator Rotor (see Electrical System chapter) External Shift Mechanism (see Extemal Shift Mechanism Removal) Damper (A end Tronemission Cover (8] Cylinder Heads, Cylinders, and Pistons (sae Engine Top End chapter) Left Crankcase Bolts: ‘6 mm Bolts [A] 10mm Bolts [8] Right Cranksase Bolts: ‘8 mm Bolte (A) (@Put the engine so that the left crankease is down. ‘@Pry the points [A] 10 split the crankcase halves apart, and remove the right crankcase half8-6 CRANKSHAFT / TRANSMISSION Crankcase Assembly ‘CAUTION The right and let crankcase halves are machined athe facory in the assembled state, so the crankcase halves must be replaced as a set. @With @ high-flash point solvent. clean off the mating surfaces of the ‘erankezses halves and wipe dry. ‘@Using compressad air, blow out tho oil passages in the crankoase halves. ‘cece 1 see that the folowing pars arin pace. Let Crankease: Oil Pipo (Crankease Inside) Oil Pump (AD Jalencer Shaft (B) Shit Orum “Trensmission Shafts and Gears Shift Forks and Shift Rods Crankshaft and Connecting Roce Oiler Adapter Bott (C) Knock Pins [D] Right Crankcase: Water Pump Shaft [A] Role! Velve [8] il Pipe (Crankease Insise) [C] ‘@Apply liquid gasket to the mating surface [A] of the right crankcase half ‘CAUTION Do not epply liquid gasket to the oll passage (B] and hole [C) install the right crenkcase, iting the oil pump shaft projeetion [} imo the weter pump shaft slot (8).CRANKSHAFT / TRANSMISSION 8-7 @ Tighten the crankcase bolts 2 follows: (OTighten the right crankcase half 6 mm bolts [A]. ‘Torque ~ Crankcase Bolts (6 mm: 14 Nem (1.1 kg-m, 95 in-b) (©Tighten the let crenkease half 10 mm bolts [11 ~ 3] to the tightaning ‘sequence, and then tightan the 6 mm belts [A], ‘Torque ~ Crantease Bolts (10 rip: 39 Nem (4.0 ka-m, 29th) Grankcase Bolts (6 rams 1 Nem (1.1 kg-m, 95 int) (@Aftortightoning ail erankcaso bolts, check the following items. (© Drive shaft and output shaft wan freely. ‘OWhile spinning the output she", goars chitt smoothly from the 1st to ‘th gear, and Sth to st When the output shaft stays stl the gear can not be shifted to 2nd ‘gear or other higher gear positions. Bearing, Oil Seal Installation ‘ean installing a bearing other than the following perts, press it in with the marked side facing out. ‘Special Teo! ~ Bearing Oriver Set: 57001-1129, Right Crankcose: (install th rignt balancer bearing [A] as folows: (OTemporaily press the bearing into the right crankcase unt itis leveled with the outboard end of the besring housing [3]. (Attar installing the left balancer (see Lett Balancer Installation). press the bearing until it stops at the shoulder ofthe balancer shaft [C). (@ Install the water pump shaft besring and seal as shown. [A] 04 Seal [5] Marked sie [C] Ball Bearing (without seal) [D] Bat Bearing (beth sides soal) [E] Mechanical Seal (see Cooling System chapter) @ inetall the output shaft bearig [A) Into the right crankease [8] with the sealed side [C] facing the crankcase,8-8 CRANKSHAFT / TRANSMISSION Loft Crankease: ‘@instal the needle beering [A] into the leit crankcase [B] with the ‘marked side [C] facing inside, and level the besring with the outboard ‘ond of the beating nousing,CRANKSHAFT / TRANSMISSION 8-9 Crankshaft / Connecting Rods Crankshaft Rernoval split the crankcase (see Crankcase Splitting) ‘@Remove the crankshait Crankshaft Installation ‘@lnser the eranksnaft tapered enc in tothe loft crankcase [A] ‘@lrstall the let connecting rod (B] into the reer cylinder opening (C1, ‘and right connecting rod [D] into the iront evincier opening [E]. Connecting Rod Removal (@ Romove ths crankshatt (see Crankshaft Removal). NOTE (© Mark and recard the lacations of the connecting ads and thet big end caps so thet they can be reassembled in ther original positions. ‘@ Remove the connecting rod big end cap nuts, and take off the rod and ‘cap with the bearing inserts from the crankshaft Connecting Rod Installation CAUTION ‘To minimize vibration, the connecting rods should have the came weight mark Big Ene Cap (A] Connecting Rod (8) Woight Mark, Alphabet (C} Diameter Mark (D] (1 the connscting rods, boaring inserts, or crankshatt ae replaced with ‘naw one, solect tha Dearing insert and check clearance with a plasti- ‘gage (oress gauce) beiore assembling engine to be sure the corect bboaring insons aro installed.