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Table of Contents

   Also See for Kawasaki KLX110

   Summary of Contents for Kawasaki KLX110

  • Page 3 Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
  • Page 4 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch degree(s) Celsius revolution direct current revolution(s) per minute...
  • Page 5: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board. 1. Crankcase Emission Control System This system eliminates the release of cranckcase vapors into the atmosphere.
  • Page 6 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 maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 7: How To Use This Manual

    Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Motorcycle This note symbol indicates points of particular in- parts. Special tools, gauges, and testers that are terest for more efficient and convenient operation.
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing................................1-2 Model Identification ................................1-4 General Specifications ..............................1-5 Torque and Locking Agent..............................1-7 Special Tools..................................1-9 Cable, Wire and Hose Routing ............................1-14 Unit Conversion Table..............................1-18...
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.
  • Page 11 GENERAL INFORMATION 1-3 Before Servicing (14) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film.
  • Page 12: Model Identification

    1-4 GENERAL INFORMATION Model Identification KLX110–A1 Left Side View KLX110–A1 Right Side View...
  • Page 13: General Specifications

    GENERAL INFORMATION 1-5 General Specifications Items KLX110-A1 Dimensions: Overall length 1 555 mm Overall width 660 mm Overall height 955 mm Wheelbase 1 065 mm Road clearance 190 mm Seat height 650 mm Dry mass 64 kg Curb mass: Front...
  • Page 14 1-6 GENERAL INFORMATION General Specifications Items KLX110-A1 Drive Train: Primary reduction system: Type Gear, centrifugal Reduction ratio 3.048 (64/21) Clutch type Centrifugal & wet, multi disc Transmission: Type 3-speed, constant mesh, return shift Gear ratios: 3.273 (36/11) 1.938 (31/16) 1.350 (27/20)
  • Page 15: Torque And Locking Agent

    GENERAL INFORMATION 1-7 Torque and Locking Agent The following tables lists the tightening torque for the The table below, relating tightening torque to thread major fasteners requiring use of a non-permanent locking diameter, lists the basic torque for the bolts and nuts. Use agent or liquid gasket.
  • Page 16 1-8 GENERAL INFORMATION Torque and Locking Agent Fastener Remarks Torque Engine Removal/Installation: Engine mounting nuts Side stand mounting nut Crankshaft/Transmission: Crankcase screws 0.53 46 in Bearing retainer screw 5 mm 26 in Bearing retainer screw 6 mm 0.53 46 in Shift return spring pin Shift drum Allen bolt 0.53...
  • Page 17: Special Tools

    GENERAL INFORMATION 1-9 Special Tools Steering Stem Bearing Driver: 57001–137 Compression Gauge : 57001–221 Inside Circlip Pliers: 57001–143 Valve Spring Compressor Assembly : 57001–241 Outside Circlip Pliers: 57001-144 Bearing Puller Adapter: 57001–317 Bearing Puller : 57001–158 Piston Pin Puller Assembly: 57001–910 Fork Cylinder Holder Handle : 57001–183 Fork Cylinder Holder Adapter: 57001–1011...
  • Page 18 1-10 GENERAL INFORMATION Special Tools Fuel Level Gauge: 57001–1017 Bead breaker Assembly: 57001–1072 Valve Guide Reamer, 4.5: 57001–1020 Crankcase Splitting Tool Assembly: 57001–1098 Valve Guide Arbor, 4.5: 57001–1021 Steering Stem Nut Wrench: 57001–1100 Oil Seal & Bearing Remover: 57001–1058 Valve Seat Cutter, 45 –...
  • Page 19 GENERAL INFORMATION 1-11 Special Tools Valve Seat Cutter, 60 – 30 : 57001–1123 Crankshaft Jig: 57001–1174 Valve Seat Cutter Holder, 5.5 : 57001–1125 Bearing Puller Stud: 57001–1190 Valve Seat Cutter Holder Bar : 57001–1128 Valve Seat Cutter, 45 – 22: 57001–1205 Bearing Driver Set : 57001–1129 Valve Seat Cutter, 32 –...
  • Page 20: Special Tools

    1-12 GENERAL INFORMATION Special Tools Rotor Puller, M16/M18/M20/N22 x 1.5 : 57001–1216 Bearing Remover Shaft 9: 57001–1265 Valve Adjusting Screw Holder: 57001–1217 Bearing Removal Head 12: 57001–1266 Fork Oil Seal Driver: 57001–1219 Fork Oil Level Gauge: 57001–1290 Jack: 57001–1238 Flywheel Holder: 57001–1313 Spark Plug Wrench, Hex 16: 57001–1262 Compression Gauge Adapter, M10 x 1.0 : 57001–1317...
  • Page 21 GENERAL INFORMATION 1-13 Special Tools Hand Tester: 57001–1394 Clutch Holder: 57001–1508 Flywheel Puller, M28 1.0: 57001–1471 Kawasaki Bond (Liquid Gasket- Black): 92104–1003 Primary Clutch Holder: 57001–1507 Kawasaki Bond (Silicone sealant): 56019–120...
  • Page 22: Cable, Wire And Hose Routing

    1-14 GENERAL INFORMATION Cable, Wire and Hose Routing...
  • Page 23 GENERAL INFORMATION 1-15 Cable, Wire and Hose Routing 1. Throttle Cable 2. Engine Stop Switch Lead 3. Band 4. Handlebar 5. Frame 6. Carburetor 7. Clamp 8. Air Vent Hose 9. Regulator/Rectifier 10. Igniter 11. Crankcase Breather Hose 12. Magneto Leads 13.
  • Page 24 1-16 GENERAL INFORMATION Cable, Wire and Hose Routing...
  • Page 25 GENERAL INFORMATION 1-17 Cable, Wire and Hose Routing 1. Frame 2. Align the damper center with the frame hole. 3. Apply adhesive to diagonal line portion. 4. Clamp 5. Run the carburetor drain hose into a hole of the engine guard. 6.
  • Page 26: Unit Conversion Table

    1-18 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Torque: 0.1020 Prefix Symbol Power 0.7376 mega 1 000 000 8.851 kilo 1 000 9.807 centi 0.01 7.233 milli 0.001 86.80 micro 0.000001 Units of Pressure: Units of Mass: 0.01020 kg/cm 2.205...
  • Page 27 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart........2-2 Chain Lubrication..........2-13 Specifications ............. 2-3 Sprocket Wear Inspection ......... 2-13 Periodic Maintenance Procedures ......2-4 Chain Slipper Wear Inspection......2-13 Fuel System............2-4 Brakes..............2-13 Fuel Hose and Connection Inspection....2-4 Brake Lever, Brake Pedal Free Play Inspection 2-13 Fuel Tap Inspection..........2-4 Front Brake Free Play Adjustment ....
  • Page 28: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Initial Every 5 hours 50 hours 100 hours Page (1 month) (6 months) (12 months) OPERATION •...
  • Page 29: Specifications

    PERIODIC MAINTENANCE 2-3 Specifications Item Standard Service Limit Fuel System: Throttle grip free play 2 ~ 3 mm – – – Idle speed 1250 1350 r/min (rpm) – – – Air cleaner element oil High quality foam air filter oil –...
  • Page 30: Periodic Maintenance Procedures

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection • Check the fuel hose [A] for the following. Fuel leakage Loose or improperly positioned line clamp [B] Deteriorated or damaged line Replace the fuel hose if any fraying, cracks or bulges are noticed. •...
  • Page 31: Throttle Grip Free Play Adjustment

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Procedures Throttle Grip Free Play Adjustment • Loosen the locknut [A] at the upper end of the throttle cable. • Turn the adjuster [B] until the proper amount of throttle grip free play is obtained. •...
  • Page 32: Air Cleaner Element Cleaning And Inspection

    2-6 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE In dusty areas, the element should be cleaned more frequently than recommended interval. After riding through rain or on muddy roads, the element should be cleaned immediately. Since repeated cleaning opens the pores of the element, replace it with a new one.
  • Page 33: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-7 Periodic Maintenance Procedures • Turn the camshaft sprocket plate [A] counterclockwise and align the line [B] on the camshaft sprocket with the projection [C] on the mating surface of the cylinder head. • Measure the clearance of each valve by inserting a thickness gauge [A] between the adjusting screw and the valve stem.
  • Page 34: Clutch

    2-8 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the spark arrester and torque the spark arrester mounting bolts. Torque - Spark Arrester Mounting Bolts: 8.8 N m (0.9 kgf m, 78 in • Install the muffler cover. Clutch Clutch Adjustment •...
  • Page 35: Oil Filter Element Change

    PERIODIC MAINTENANCE 2-9 Periodic Maintenance Procedures • After the oil has completely drained, install the drain plug with its gasket. Replace the drain plug gasket with a new one if it is damaged. • Tighten the drain plug. Torque - Engine Oil Drain Plug: 29 N m (3.0 kgf m, 21 ft...
  • Page 36: Wheels/tires

    2-10 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Spoke Tightness Inspection • Check that all the spokes [A] are tightened evenly. Standard spoke tightening torque is shown below. Over- or under- tightening may cause breakage. Tightening Torque Spokes: 1.2 N (0.12 kgf m, 10 in •...
  • Page 37: Final Drive

    PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Final Drive Chain Slack Inspection • Support the mortorcycle perpendicular to the ground. NOTE Clean the drive chain if it is dirty, and lubricate it if it appears dry. • Rotate the rear wheel to find the position where the chain is tightest. •...
  • Page 38: Chain Wear Inspection

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten both chain adjuster locknuts. • Tighten the axle nut. Tightening Torque - Rear Axle Nut: 64 N m (6.5 kgf m, 47 ft • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary.
  • Page 39: Chain Lubrication

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Chain Lubrication The chain should be lubricated with a lubricant which will both prevent its exterior from rusting and also absorb shock and reduce friction in the interior of the chain. An effective, good quality lubricant specially formulated for chains is best for regular chain lubrication.
  • Page 40: Front Brake Free Play Adjustment

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the brake pedal free play [A] when the pedal is pushed down lightly by hand. Brake Pedal Free Play Standard: 30 mm If the pedal has improper play, adjust it. • Operate the pedal a few times to see that it returns to its rest position immediately upon release.
  • Page 41: Cam Lever Angle Adjustment

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Check that the brake cam lever [A] comes to an 80 angle [B] with the brake rod or cable [C] when the brake is fully applied. If it does not, adjust the brake cam lever angle. Cam Lever Angle Standard: Since a cam lever angle greater than 90...
  • Page 42: Brake Panel Lubrication

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Panel Lubrication • Disassemble the rear brake panel (see Brakes chapter). • Clean all old grease out of the brake parts with a cloth. • Apply high-temperature grease to the following. Brake Shoe Anchor Pin [A] Spring Ends [B] Cam Surfaces [C] Cam Shaft Groove [D]...
  • Page 43: Front Fork Inner Tube Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Measure the both diameters of the fork spring ends and insert the fork spring with the small diameter end [A] facing down. • Check both top plug O-ring [A] for damage and replace them if necessary.
  • Page 44: Swingarm Pivot Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the rubber bushings [A]. If they are worn, cracked, hardened, or otherwise damaged, replace them. Swingarm Pivot Inspection • Check for wear or damage to the shock absorber and the swing arm mount pivot point while compressing [A] the rear suspension a few times.
  • Page 45: Steering Adjustment

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Steering Adjustment • Remove the number plate. • Using the jack, raise the front wheel off the ground. Special Tool - jack: 57001–1238 • Remove the handlebar. • Loosen the front fork lower clamp bolts [A] and steering stem head nut [B].
  • Page 46: Steering Stem Bearing Lubrication

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Torque the handlebar clamp bolts. Torque - Handlebar Clamp Bolts: 25 N m (2.5 kgf m, 18 ft Tighten the clamp bolts, front first and then the rear. If the handlebar clamp is correctly installed, there will be no gap [A] at the front and a gap [B] at the rear after tightening.
  • Page 47: General Lubrication

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray,...
  • Page 48 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 49: Nut, Bolt And Fastener Tightness

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Nut, Bolt and Fastener Tightness Tightness Inspection • Check the tightness of bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 51 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View...................................3-2 Specifications ..................................3-6 Throttle Grip and Cable..............................3-7 Free Play Inspection..............................3-7 Free Play Adjustment..............................3-7 Throttle Cable and Choke Cable Installation ......................3-7 Cable Lubrication and Inspection..........................3-7 Carburetor ..................................3-8 Idle Speed Inspection..............................3-8 Idle Speed Adjustment...............................3-8 Fuel Level Inspection ..............................
  • Page 52: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 53 FUEL SYSTEM 3-3 Exploded View 1. Throttle Cable 2. Throttle Grip 3. Carburetor Cap 4. Spring 5. Retainer 6. Circlip 7. Jet Needle 8. Throttle Valve 9. Choke Cable 10. Idle Adjusting Screw 11. Spring 12. Air Screw 13. Pilot Jet 14.
  • Page 54 3-4 FUEL SYSTEM Exploded View...
  • Page 55 FUEL SYSTEM 3-5 Exploded View 1. Fuel Tank Cap 2. Fuel Tank 3. Fuel Tap 4. Air Cleaner Housing 5. Element G: Apply grease. O: High-quality foam-air filter oil AD: Apply adhesive.
  • Page 56: Specifications

    3-6 FUEL SYSTEM Specifications Item Standard Service Limit Throttle Grip and Cable: Throttle grip free play 3 mm - - - Carburetor: Make/Type KEIHIN PB18 - - - Main jet: - - - Jet needle NCFA - - - Throttle valve cutaway - - - Pilot jet #38/38...
  • Page 57: Throttle Grip And Cable

    FUEL SYSTEM 3-7 Throttle Grip and Cable Free Play Inspection Refer to Free Play Inspection in the Periodic Maintenance Chapter. Free Play Adjustment Refer to Free Play Adjustment in the Periodic Maintenance Chapter. Throttle Cable and Choke Cable Installation • Install the throttle cable and choke cable in accordance with the Cable, Harness, Hose Routing section in the General Information chapter.
  • Page 58: Carburetor

    3-8 FUEL SYSTEM Carburetor Idle Speed Inspection Refer to Idle Speed Inspection in the Periodic Maintenance Chapter. Idle Speed Adjustment Refer to Idle Speed Adjustment in the Periodic Maintenance Chapter. Fuel Level Inspection Gasoline is extremely flammable and can be explosive under certain conditions.
  • Page 59: Fuel Level Adjustment

    FUEL SYSTEM 3-9 Carburetor Fuel Level Adjustment Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and from any source of flame or sparks; this includes any appliance with a pilot light. •...
  • Page 60: Carburetor Removal

    3-10 FUEL SYSTEM Carburetor • Using a screwdriver, turn out the drain plug [A] a few turns and drain the carburetor to a suitable container and check to see if water or dirt come out. If any water or dirt appears during the above inspection, clean the fuel system.
  • Page 61: Carburetor Cleaning

    FUEL SYSTEM 3-11 Carburetor Carburetor Cleaning Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of high flammable liquids, do not use gasoline or low flash-point solvents to clean the carburetor.
  • Page 62: Carburetor Assembly

    3-12 FUEL SYSTEM Carburetor • Remove the following parts from the carburetor body. Idle Adjusting Screw [A] O-ring [B] Spring [C] Air Screw [D] Washer [E] Spring [F] O-ring [G] O-ring [H] Pilot Jet [A] Needle Jet [B] Needle Jet Holder [C] Main Jet [D] Float Valve Needle [E] Float [F]...
  • Page 63: Carburetor Inspection

    FUEL SYSTEM 3-13 Carburetor Carburetor Inspection Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 64 3-14 FUEL SYSTEM Carburetor • Remove the throttle valve [A] and jet needle. • Inspect the outside of the throttle valve for scratches and abnormal wear. If the valve is badly scratched or worn, replace it. • Inspect the inside of the carburetor body for these same faults. If it is badly scratched or worn, replace the entire carburetor.
  • Page 65: Air Cleaner

    FUEL SYSTEM 3-15 Air Cleaner Air Cleaner Housing Removal • Remove the left shroud. • Loosen the air cleaner duct clamp [A]. • Unscrew the air cleaner mounting bolts [A] and remove the air cleaner housing [B]. Air Cleaner Housing Installation •...
  • Page 66: Element Installation

    3-16 FUEL SYSTEM Air Cleaner • Stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor. • Wipe out the inside of the air cleaner housing [A] and the wire screen [B] with a clean damp towel. CAUTION Check inside of the inlet tract and carburetor for dirt.
  • Page 67: Fuel Tank

    FUEL SYSTEM 3-17 Fuel Tank Fuel Tank Removal Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 68: Fuel Tap Installation

    3-18 FUEL SYSTEM Fuel Tank Fuel Tap Installation • Be sure the O-ring is in good condition to prevent leaks. • Be sure to clamp the fuel hose to the tap to prevent leaks. Fuel Tap Inspection Refer to Fuel Tap Inspection in the Periodic Maintenance Chapter. Fuel Tank and Tap Cleaning Clean the tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area.
  • Page 69 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View............4-2 Valve Guide Removal........4-20 Specifications ............. 4-6 Valve Guide Installation........4-20 Camshaft Chain Tensioner.........4-8 Valve Clearance Inspection.......4-21 Camshaft Chain Tensioner Removal....4-8 Valve Clearance Adjustment ......4-21 Camshaft Chain Tensioner Installation....4-9 Valve Seat Inspection........4-21 Replacement Chain Tensioner Installation..4-10 Valve Seat Repair..........4-22...
  • Page 70: Exploded View

    4-2 ENGINE TOP END Exploded View...
  • Page 71 ENGINE TOP END 4-3 Exploded View 1. Intake Pipe 2. Valve Adjusting Cover 3. Valve Guide 4. Rocker Arm Shaft Stopper 5. Camshaft Sprocket Cover 6. Cylinder Head 7. Rocker Arm 8. Rocker Arm Shaft 9. Valve Adjusting Screw 10. Valve Adjusting Screw Locknut 11.
  • Page 72 4-4 ENGINE TOP END Exploded View...
  • Page 73 ENGINE TOP END 4-5 Exploded View 1. Camshaft Chain Tensioner 2. Piston 3. Piston Pin 4. Cylinder 5. Muffler L: Apply non-permanent locking agent. EO: Apply engine oil. R: Replacement parts T1: 5.2 N m (0.53 kgf m, 46 in...
  • Page 74: Specifications

    4-6 ENGINE TOP END Specifications Item Standard Service Limit Camshaft: Camshaft: Cam height Exhaust 29.021 mm 29.201 mm 28.92 mm Inlet 28.984 mm 29.164 mm 28.88 mm Camshaft chain 20-link length 127.00 127.48 mm 128.9 mm Rocker Arms, Shaft Rocker arm inside diameter 10.000 10.015 mm 10.05 mm...
  • Page 75: Compression Gauge :

    ENGINE TOP END 4-7 Specifications Item Standard Service Limit Cylinder, Piston: Cylinder inside diameter 52.997 53.009 mm 53.10 mm Piston outside diameter 52.981 52.993 mm 52.83 mm Piston/cylinder clearance 0.010 0.022 mm - - - Oversize piston and rings + 0.25 mm, +0.50 mm, 0.75 mm, - - - and +1.0 mm Piston ring/groove clearance:...
  • Page 76: Camshaft Chain Tensioner

    4-8 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 77: Camshaft Chain Tensioner Installation

    ENGINE TOP END 4-9 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation • Remove the tensioner cap bolt and O-ring. • While compressing the push rod [A], turn it clockwise [B] with a suitable screwdriver until the rod protrusion comes to about 10 mm from the tensioner body.
  • Page 78: Replacement Chain Tensioner Installation

    4-10 ENGINE TOP END Camshaft Chain Tensioner Replacement Chain Tensioner Installation A replacement chain tensioner (spare parts) has a push rod holder plate. • Install the tensioner on the cylinder block, and tighten the mounting bolts. Torque - Chain Tensioner Mounting Bolts: 5.2 N m (0.53 kgf m, 46 •...
  • Page 79: Camshaft Sprocket

    ENGINE TOP END 4-11 Camshaft Sprocket Camshaft Sprocket Removal • Remove: Left Shroud Engine Sprocket Cover (see Final Drive chapter) Magneto Cover (see Electrical System chapter) • Remove the camshaft sprocket cover bolts [A] and take off the cover [B]. •...
  • Page 80: Camshaft Sprocket Installation

    4-12 ENGINE TOP END Camshaft Sprocket Camshaft Sprocket Installation • Check crankshaft position to see that the "T" mark [A] on the magneto flywheel aligns with the index mark [B] on the crankcase. • Remember to pull the camshaft chain taut before rotating the crankshaft.
  • Page 81: Camshaft Chain Removal

    ENGINE TOP END 4-13 Camshaft Sprocket Camshaft Chain Removal • Drain the engine oil. • Remove: Left Shroud Camshaft Chain Tensioner Camshaft Sprocket Cylinder Head Magneto Cover (see Electrical System chapter) Magneto Flywheel (see Electrical System chapter) Woodruff Key (see Electrical System chapter) •...
  • Page 82: Rocker Arm, Rocker Arm Shaft

    4-14 ENGINE TOP END Rocker Arm, Rocker Arm Shaft Rocker Arm Removal • Remove Left Shroud Camshaft Sprocket Cover Camshaft Chain Tensioner Camshaft Sprocket Bolts [A] Camshaft Sprocket [B] Valve Adjusting Cover Bolts [A] Valve Adjusting Covers [B] Rocker Arm Shaft Stopper Screws [C] Rocker Arm Shaft Stopper [D] •...
  • Page 83: Rocker Arm & Arm Shaft Wear

    ENGINE TOP END 4-15 Rocker Arm, Rocker Arm Shaft Rocker Arm & Arm Shaft Wear • Visually inspect where the cam and valve stem wear on each arm. If there is any damage or uneven wear, replace the arm. Measure the inside diameter [A] of each rocker arm with a cylinder gauge.
  • Page 84: Camshaft

    4-16 ENGINE TOP END Camshaft Camshaft Removal • Remove: Left Shroud Camshaft Chain Tensioner Camshaft Sprocket Rocker Arms • Pull out the camshaft [A]. Camshaft Installation • Clean the camshaft with a high-flash-point solvent. • Apply clean engine oil to all cam parts. •...
  • Page 85: Cylinder Head

    ENGINE TOP END 4-17 Cylinder Head Compression Measurement • Warm up the engine thoroughly • Stop the engine. • Remove the spark plug and attach compression gauge and adapter firmly into the spark plug hole. Special Tools - Compression Gauge: 57001–221 [A] Compression Gauge Adapter, M10X1.0: 57001–1317 [B] •...
  • Page 86: Cylinder Head Removal

    4-18 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove the right and left shrouds. • Remove the exhaust pipe holder nuts [A], and muffler mounting bolt [B] and then the muffler with the exhaust pipe holder. • Remove the oil pipe banjo bolts [A], screws [B], and take of the oil pipe [C].
  • Page 87: Cylinder Head Installation

    ENGINE TOP END 4-19 Cylinder Head Cylinder Head Installation • Check to see that the two dowel pins [A] are in place on the cylinder. • Install a new cylinder head gasket [B]. • Fit the cylinder head onto the cylinder block using a screwdriver or wire to keep the chain from falling down into the cylinder block.
  • Page 88: Valve/valve Guide

    4-20 ENGINE TOP END Valve/Valve Guide Valve Removal • Remove: Cylinder Head Rocker Arm & Rocker Arm Shaft Camshaft • Using the valve spring compressor assembly to press down the valve spring retainer, remove the split keeper. Special Tools - Valve Spring Compressor Assembly: 57001–241 [A] Valve Spring Compressor Adapter, 20: 57001–1154 [B] •...
  • Page 89: Valve Clearance Inspection

    ENGINE TOP END 4-21 Valve/Valve Guide Valve Clearance Inspection Refer to Valve Clearance Inspection in the Periodic Maintanance Chapter. Valve Clearance Adjustment Refer to Valve Clearance Adjustment in the Periodic Maintanance Chapter. Valve Seat Inspection • Remove the valve. • Check the valve seat surface [A] between the valve [B] and valve seat [C].
  • Page 90: Valve Seat Repair

    4-22 ENGINE TOP END Valve/Valve Guide Valve Seat Repair • Repair the valve seat with the valve seat cutters. Special Tools - Valve Seat Cutter Holder, 5.5: 57001–1125 Valve Seat Cutter Holder Bar: 57001–1128 Inlet Special Tools - Valve Seat Cutter, 45 –...
  • Page 91 ENGINE TOP END 4-23 Valve/Valve Guide • Measure the outside diameter of the seating surface with a vernier calipers. If the outside diameter of the seating surface is too small, repeat the grind until the diameter is within the specified range. If the outside diameter of the seating surface is too large, make the grind described below.
  • Page 92: Valve Head Thickness Inspection

    4-24 ENGINE TOP END Valve/Valve Guide Valve Head Thickness Inspection • Measure the thickness of valve head. Valve Head Thickness [A] Inlet valve: Standard: 0.85 1.15 mm Service Limit: 0.5 mm Exhaust valve: Standard: 1.15 1.45 mm Service Limit: 0.5 mm If it is under the service limit, replace the valve.
  • Page 93: Valve To Guide Clearance Measurement

    ENGINE TOP END 4-25 Valve/Valve Guide Valve to Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the valve guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 94 4-26 ENGINE TOP END Valve/Valve Guide...
  • Page 95: Cylinder, Piston

    ENGINE TOP END 4-27 Cylinder, Piston Cylinder Removal • Removed the cylinder head. • Take out the cylinder block with lower camshaft chain guide, and remove the gasket. There are knock pins on the cylinder base. • Wrap a clean cloth [A] around the base of the piston so that no parts or dirt will fall into the crankcase.
  • Page 96: Piston Installation

    4-28 ENGINE TOP END Cylinder, Piston • Remove the piston by pushing its pin pull out the side that the snap ring was removed. Use the piston pin puller assembly [A] if the pin is tight. Special Tools - Piston Pin Puller Assembly: 57001–910 •...
  • Page 97: Cylinder Inside Diameter Measurement

    ENGINE TOP END 4-29 Cylinder, Piston • Fit a new piston snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. When installing a piston pin snap ring, compress it only enough to install it no more.
  • Page 98: Boring, Honing

    4-30 ENGINE TOP END Cylinder, Piston Boring, Honing When boring and honing a cylinder, note the following: There are two sizes of oversize pistons available. Oversize pistons require oversize rings. Oversize Pistons and Rings 0.25 mm Oversize 0.5 mm Oversize 0.75 mm Oversize 1.0 mm...
  • Page 99: Piston, Piston Pin, Connecting Rod Wear Inspection

    ENGINE TOP END 4-31 Cylinder, Piston If the clearance exceeds the service limit, remove the piston rings, and measure the thickness of the piston rings and the width of the ring grooves. If the ring has worn down to less than the service limit, replace the ring, if the groove width exceeds the service limit replace the piston.
  • Page 100: Muffler

    4-32 ENGINE TOP END Muffler Muffler Removal • Unscrew the muffler mounting bolt [A]. • Remove the exhaust pipe holder nuts [A]. Pull out the muffler mounting bolt and remove the muffler assembly. Muffler Installation • Check the gasket and replace it if damaged. •...
  • Page 101 CLUTCH 5-1 Clutch Table of Contents Exploded View...................................5-2 Specifications ..................................5-4 Clutch Cover..................................5-5 Clutch Cover and Oil Screen Removal ........................5-5 Clutch Cover and Oil Screen Installation........................5-6 Clutches .................................... 5-7 Clutch Removal ................................5-7 Clutch Installation...............................5-7 Secondary Clutch Disassembly ..........................5-9 Secondary Clutch Assembly ............................5-9 Primary Clutch Housing Wear..........................5-10 Primary Clutch Shoe Lining Wear..........................5-10 One-Way Clutch Inspection............................5-10...
  • Page 102: Exploded View

    5-2 CLUTCH Exploded View...
  • Page 103 CLUTCH 5-3 Exploded View G: Apply grease. L: Apply a non-permanent locking agent M: Apply molybdenum disulfide grease. EO: Apply engine oil. S: Follow the specific tightening sequence. T1: 2.9 N m (0.3 kgf m, 26 in T2: 5.2 N m (0.53 kgf m, 46 in T3: 3.4 N...
  • Page 104: Specifications

    5-4 CLUTCH Specifications Item Standard Service Limit Primary Clutch: Primary clutch housing inside diameter 104.0 104.2 mm 104.5 mm Primary clutch shoe groove depth 1.0 mm 0.5 mm Secondary Clutch: Friction plate thickness 3.3 mm 2.9 mm Friction plate warp 0.2 mm or less 0.3 mm Steel plate warp...
  • Page 105: Clutch Cover

    CLUTCH 5-5 Clutch Cover Clutch Cover and Oil Screen Removal • Drain the engine oil (see Engine Lubrication System). • Remove: Kick Pedal [A] Footpeg [B] Engine Guard [C] Brake Pedal (hanging) [D] Clutch Cover Screws [A] • Pull out the clutch cover [B]. •...
  • Page 106: Clutch Cover And Oil Screen Installation

    5-6 CLUTCH Clutch Cover Clutch Cover and Oil Screen Installation • Clean any metal particles and other dirt out of the oil screen. • Using compressed air, blow out any particles which may obstruct the oil passage [A] in the clutch cover. •...
  • Page 107: Clutches

    CLUTCH 5-7 Clutches Clutch Removal • Remove the clutch cover (see this chapter). • Remove: Release Ball Assembly [A] Release Cam [B] Ball Bearing [C] Ball Bearing Holder [D] • Remove the primary clutch hub nut [A], while holding the primary clutch steady with the primary clutch holder [B].
  • Page 108 5-8 CLUTCH Clutches • Install: Needle Bearing [A] Primary Clutch Housing [B] Needle Bearing [C] Primary Clutch Sleeve [D] If the one-way clutch and race dropped from the primary clutch housing, install it as follows. Put the one-way clutch [A] in the clutch housing halfway with the rotation mark [B] facing out.
  • Page 109: Secondary Clutch Disassembly

    CLUTCH 5-9 Clutches Secondary Clutch Disassembly • Remove the secondary clutch. • Unscrew the clutch spring bolts [A] and take off the spring plate [B] and springs [C]. • Remove the clutch hub [A] and clutch wheel [B]. • Remove the secondary clutch plate [C]. Secondary Clutch Assembly •...
  • Page 110: Primary Clutch Housing Wear

    5-10 CLUTCH Clutches Primary Clutch Housing Wear • Measure the inside diameter [A] of the clutch housing sliding surface. Use a vernier calipers and measure at several points as shown. If any measurement is greater than the service limit, replace the primary clutch housing.
  • Page 111: Clutch Plate Wear And Damage

    CLUTCH 5-11 Clutches Check that the rollers [A] in the one-way clutch is installed as shown when viewed from the right side of the engine. Clutch Plate Wear and Damage • Visually inspect the friction and steel plates for uneven wear, discol- oration, missing friction material, cracks, or other damage.
  • Page 112: Secondary Clutch Spring Free Length Measurement

    5-12 CLUTCH Clutches Secondary Clutch Spring Free Length Measurement • Measure the spring free length [A]. If measurement is less than the service limit, replace it. Clutch Spring Free Length Standard: 24.0 mm Service Limit: 23.0 mm Clutch Adjustment Refer to Clutch Adjustment in the Periodic Maintenance Chapter.
  • Page 113: Kickstarter

    CLUTCH 5-13 Kickstarter Kickstarter Removal • Remove the clutch cover. • Remove the return spring [A] with pliers. • Remove: Spring Guide [B] • Remove the kick shaft assembly [C], twisting it counterclockwise. • There is a thrust washer between the kick shaft end and the crankcase.
  • Page 114: Kickstarter Inspection

    5-14 CLUTCH Kickstarter Kickstarter Inspection • Visually inspect the parts and portion listed below. Kick shaft return spring [A] Ratchet gear spring [B] Ratchet portion [C] of the kick gear [D] and ratchet gear [E] If there is any kind of damage, replace the damaged part. •...
  • Page 115: External Shift Mechanism

    CLUTCH 5-15 External Shift Mechanism External Shift Mechanism Removal • Remove: Clutch Cover Primary Clutch Secondary Clutch Shift Pedal Clamp Bolt [A] Shift Pedal [B] • Move the shift mechanism arm out of its position on the end of the shift drum and pull out the shift shaft [A].
  • Page 117 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View...................................6-2 Specifications ..................................6-4 Engine Oil Flow Chart...............................6-5 Engine Oil..................................6-6 Oil Level Inspection..............................6-6 Oil Changing................................6-6 Oil Filter Element/Oil Screen.............................6-7 Oil Filter Element Change............................6-7 Oil Screen Cleaning..............................6-7 Engine Oil Pump................................6-8 Engine Oil Pump Removal............................6-8 Engine Oil Pump Installation............................6-8 Engine Oil Pump Inspection............................6-8...
  • Page 118: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 119 ENGINE LUBRICATION SYSTEM 6-3 Exploded View T1: 5.2 N m (0.53 kgf m, 46 in T2: 15 N m (1.5 kgf m, 11 ft T3: 29 N m (3.0 kgf m, 21 ft G: Apply grease. R: Replacement parts 1. Oil Pump 2.
  • Page 120: Specifications

    6-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Service Limit Engine Oil: Type: API SE, SF or SG - - - API SH or SJ with JASO MA Viscosity: SAE 10W-40 - - - Capacity: (When engine is completely dry) 1.1 L - - - (When filter is removed) 1.0 L...
  • Page 121: Engine Oil Flow Chart

    ENGINE LUBRICATION SYSTEM 6-5 Engine Oil Flow Chart 1. Camshaft 11. Oil Passage (Cylinder Head) 2. Oil Pipe 12. Oil Passage (Camshaft) 3. Cylinder Head 13. Oil Passage (Right Engine Cover) 4. Primary Clutch Housing 14. Oil Passage (Crankshaft) 5. Clutch Cover 15.
  • Page 122: Engine Oil

    6-6 ENGINE LUBRICATION SYSTEM Engine Oil Oil Level Inspection Refer to Oil Level Inspection in the Periodic Maintenance Chapter. Oil Changing Refer to Oil Changing in the Periodic Maintenance Chapter.
  • Page 123: Oil Filter Element/oil Screen

    ENGINE LUBRICATION SYSTEM 6-7 Oil Filter Element/Oil Screen Oil Filter Element Change Refer to Oil Filter Element Change in the Periodic Maintenance Chapter. Oil Screen Cleaning • Drain the engine oil. • Remove the clutch cover (see Clutch chapter). • Pull out the oil screen [A].
  • Page 124: Engine Oil Pump

    6-8 ENGINE LUBRICATION SYSTEM Engine Oil Pump Engine Oil Pump Removal • Remove the clutch cover (see Clutch chapter). • Remove the primary and secondary clutch assemblies (see Clutch chapter). • Turn the crankshaft so that the engine oil pump screws [A] can be removed through the pump gear holes, and remove the screws and oil pump [B].
  • Page 125: Oil Pipe

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pipe Oil Pipe Removal • Remove the banjo bolts [A] and oil pipe clamp screw [B]. Oil Pipe Installation • Before installation, flush out the pipe with a high-flash-point solvent. • Discard the used copper washers and install new washers on each side of the pipe fittings.
  • Page 127 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View...................................7-2 Engine Removal/Installation..............................7-4 Engine Removal ................................. 7-4 Engine Installation..............................7-6...
  • Page 128: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 129 ENGINE REMOVAL/INSTALLATION 7-3 Exploded View T1: 54 N m (5.5 kgf m, 40 ft T2: 23 N m (2.3 kgf m, 17 ft G. Apply grease.
  • Page 130: Engine Removal/installation

    7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Drain the engine oil (see Engine Lubrication chapter). • Squeeze the brake lever slowly and hold it with a band [A]. Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 131 ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Remove the bolts [A] and the engine guard [B]. • Remove the brake pedal return spring [A]. • Support the rear part of the frame on the jack [A]. • Support the engine with a suitable stand [A]. •...
  • Page 132: Engine Installation

    7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the three engine mounting bolts [A] and dismount the engine. Engine Installation • Support the engine with a suitable stand and set it at the correct position. • Install the lower [A], middle [B] and upper [C] engine mounting bolts from left side of the engine.
  • Page 133 CRANKSHAFT / TRANSMISSION 8-1 Crankshaft / Transmission Table of Contents Exploded View...................................8-2 Specifications ..................................8-4 Crankcase Splitting ................................8-5 Crankcase Splitting..............................8-5 Crankcase Assembly..............................8-5 Crankshaft, Connecting Rod.............................8-8 Crankshaft Disassembly and Assembly........................8-8 Disassembly ................................8-8 Assembly ..................................8-8 Connecting Rod Big End Seizure ..........................8-8 Connecting Rod Big End Radial Clearance.......................8-9 Connecting Rod Big End Side Clearance........................8-9 Crankshaft Runout..............................8-9...
  • Page 134: Exploded View

    8-2 CRANKSHAFT / TRANSMISSION Exploded View...
  • Page 135 CRANKSHAFT / TRANSMISSION 8-3 Exploded View 1. Left Crankcase Half 2. Right Crankcase Half 3. Shift Fork 4. Shift Rod 5. Shift Drum Cam 6. Shift Drum 7. Gear Position Switch 8. Drive Shaft 9. Output Shaft EO: Apply engine oil. G: Apply high-temperature grease.
  • Page 136: Specifications

    5.3 mm Special Tools - Outside Circlip Pullers : 57001–144 Bearing Puller : 57001–158 Crankcase Splitting Tool Assembly : 57001–1098 Bearing Driver Set : 57001–1129 Crankshaft Jig : 57001–1174 Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 Kawasaki Bond (Liquid Gasket-Black): 92104–1003...
  • Page 137: Crankcase Splitting

    CRANKSHAFT / TRANSMISSION 8-5 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder Head (see Engine Top End chapter) Cylinder (see Engine Top End chapter) Piston (see Engine Top End chapter) Clutch Cover (see Clutch chapter)
  • Page 138 8-6 CRANKSHAFT / TRANSMISSION Crankcase Splitting • Using a press and the bearing driver set, install new bearings until they bottoms out. Press the output shaft bearing [B] in the left crankcase half [A]. Special Tool - Bearing Driver Set: 57001–1129 •...
  • Page 139 CRANKSHAFT / TRANSMISSION 8-7 Crankcase Splitting • Make sure that the mating surfaces of the crankcase halves are completely free of oil or contamination. • Apply liquid gasket to the mating surface of the left crankcase half as shown. • Check that two dowel pins [A], O-rings [B] and drive shaft spacer [C] in place.
  • Page 140: Crankshaft, Connecting Rod

    8-8 CRANKSHAFT / TRANSMISSION Crankshaft, Connecting Rod Crankshaft Disassembly and Assembly CAUTION Since assembly of the crankshaft demands exacting tolerance, the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and equipment. The crankpin, connecting rod, and light crankshaft are available separately as spare parts, however it is recommended that the crankshaft assembly be replaced rather than attempting to replace the components.
  • Page 141: Connecting Rod Big End Radial Clearance

    CRANKSHAFT / TRANSMISSION 8-9 Crankshaft, Connecting Rod Connecting Rod Big End Radial Clearance • Set the crankshaft in flywheel alignment jig or on V blocks, and place a dial gauge [A] against the big end of the connecting rod. • Push [B] the connecting rod first towards the gauge and then in the opposite direction.
  • Page 142: Crankshaft Main Bearing Wear

    8-10 CRANKSHAFT / TRANSMISSION Crankshaft, Connecting Rod • In the case of both horizontal and vertical misalignment, correct the horizontal misalignment first. • Recheck big end side clearance after aligning crankshaft (see Con- necting Rod Big End Side Clearance). NOTE If crankshaft alignment cannot be corrected by the above method, replace the crankpin or crank halves as required.
  • Page 143: Transmission

    CRANKSHAFT / TRANSMISSION 8-11 Transmission Transmission and Shift Mechanism Removal • Split the crankcase. • Pull out the shift rods and take out the shift forks. • Remove the drive and output shaft assemblies as a set. • Holding the shift drum with suitable bar, unscrew the shift drum Allen bolt [A].
  • Page 144: Transmission And Shift Mechanism Installation

    8-12 CRANKSHAFT / TRANSMISSION Transmission Apply Engine Oil [G] Always install circlips so that the opening is aligned with a spline groove. To install a circlip without damage, first fit the circlip onto the shaft expanding it just enough to install it, and then use a suitable gear to push the circlip into place.
  • Page 145: Shift Fork Bending

    CRANKSHAFT / TRANSMISSION 8-13 Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. [A] 90 Shift Fork Ear/Gear Shift Fork Groove Wear •...
  • Page 146: Gear Dog/gear Dog Hole Damage

    8-14 CRANKSHAFT / TRANSMISSION Transmission Gear Dog/Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. Ball and Needle Bearing Wear CAUTION Do not remove the bearings for inspection.
  • Page 147 WHEELS / TIRES 9-1 Wheels / Tires Table of Contents Exploded View...................................9-2 Specifications ..................................9-4 Wheels (Rims)...................................9-5 Front Wheel Removal..............................9-5 Front Wheel Installation..............................9-5 Rear Wheel Removal ..............................9-5 Rear Wheel Installation..............................9-6 Wheels Inspection..............................9-7 Spoke Tightness Inspection............................9-7 Rim Runout Inspection...............................9-7 Axle Inspection................................9-7 Tires ....................................
  • Page 148: Exploded View

    9-2 WHEELS / TIRES Exploded View...
  • Page 149 WHEELS / TIRES 9-3 Exploded View 1. Nipple 2. Spoke 3. Front Tire 4. Rim 5. Front Axle 6. Rear Tire 7. Rear Axle G: Apply high-temperature grease. WL: Apply soap and water solution or rubber lubricant. T1: 44 N m (4.5 kgf m, 32 ft T2: 64 N...
  • Page 150: Specifications

    9-4 WHEELS / TIRES Specifications Item Standard Service Limit Wheels: Rim runout: Axial 0.5 mm or less 2 mm Radial 0.8 mm or less 2 mm Axle runout/100 mm (Rear: 110 mm) 0.1 mm 0.2 mm Tires: Standard tire: - - - Front: Size 2.50-14 4PR...
  • Page 151: Wheels (rims)

    WHEELS / TIRES 9-5 Wheels (Rims) Front Wheel Removal • Remove: Cotter Pin [A] Front Axle Nut [B] • Using a jack, raise the front wheel off the ground. • Remove: Front Brake Cable End [C] Front Axle [D] Front Wheel Front Brake Panel Collar Front Wheel Installation...
  • Page 152: Rear Wheel Installation

    9-6 WHEELS / TIRES Wheels (Rims) • Remove: Adjusting Nut [A] Cotter Pin [B] Rear Torque Link Nut [C] Rear Torque Link Bolt [D] Cotter Pin [E] Rear Axle Nut [F] CAUTION Do not depress the brake pedal deeply with the brake rod inserted into the brake cam lever joint, this may elongate the spring beyond its allowable spring extension.
  • Page 153: Wheels Inspection

    WHEELS / TIRES 9-7 Wheels (Rims) • Insert the cotter pins [A] through the torque link bolts [B] and spread its ends. • Insert the cotter pin through the axle nut to rear axle and spread its ends. • Adjust: Drive Chain Slack (see Final Drive chapter) Brake Pedal Free Play (see Brakes chapter) Wheels Inspection...
  • Page 154: Tires

    9-8 WHEELS / TIRES Tires Air Pressure Inspection/Adjustment • Remove the valve cap. • Using tire air pressure gauge [A], measure the tire pressure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider prefer- ence, but do not stray too far from the recommended pressure.
  • Page 155: Tire Removal

    WHEELS / TIRES 9-9 Tires Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. •...
  • Page 156: Tire Installation

    9-10 WHEELS / TIRES Tires Tire Installation • Inspect the rim and tire, and replace them if necessary. • Install the tube. • Apply a soap and water solution, or rubber lubricant to the rim flange and tire beads. • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire.
  • Page 157: Hub Bearing

    WHEELS / TIRES 9-11 Hub Bearing Hub Bearing Removal • Remove the wheel. • To remove the grease seals, pry out the grease seal using a screwdriver. • Using the bearing remover shaft and bearing remover head, remove the hub bearings [A]. Special Tools - Bearing Remover Shaft, 9: 57001–1265 [B] Bearing Remover Head,...
  • Page 158: Bearing Lubrication

    9-12 WHEELS / TIRES Hub Bearing Bearing Lubrication • Remove the hub bearings on the front and rear wheel hubs. • Wash the bearings with a high-flash-point solvent, dry them (do not spin them while they are dry), and oil them. •...
  • Page 159 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View.................................10-2 Specifications .................................. 10-4 Drive Chain..................................10-5 Chain Slack Inspection.............................10-5 Chain Slack Adjustment............................10-5 Drive Chain Removal ............................... 10-5 Drive Chain Installation ............................10-5 Chain Wear Inspection.............................10-5 Chain Lubrication ..............................10-5 Sprockets, Coupling................................ 10-6 Engine Sprocket Removal............................10-6 Engine Sprocket Installation.............................10-6 Rear Sprocket Removal ............................
  • Page 160: Exploded View

    10-2 FINAL DRIVE Exploded View...
  • Page 161 FINAL DRIVE 10-3 Exploded View 1. Engine Sprocket Cover 2. Engine Sprocket 3. Swingarm 4. Chain Slipper 5. Chain Guide 6. Locknut 7. Adjusting Nut 8. Chain Adjuster 9. Drive Chain 10. Coupling Damper 11. Rear Axle 12. Chain Tension Guide 13.
  • Page 162: Specifications

    10-4 FINAL DRIVE Specifications Item Standard Service Limit: Drive Chain: Make/type DID 420MBK1 - - - 88 links Drive chain slack 5 mm - - - 20 link length 254.0 254.6 mm 259 mm Sprocket: Engine sprocket diameter 49.1 49.3 mm 48.4 mm Rear sprocket diameter 141.76...
  • Page 163: Drive Chain

    FINAL DRIVE 10-5 Drive Chain Chain Slack Inspection Refer to Chain Slack Inspection in the Periodic Maintenance Chapter. Chain Slack Adjustment Refer to Chain Slack Adjustment in the Periodic Maintenance Chapter. Drive Chain Removal • Remove: Drive Chain Cover Engine Sprocket Cover •...
  • Page 164: Sprockets, Coupling

    10-6 FINAL DRIVE Sprockets, Coupling Engine Sprocket Removal • Remove: Bolts [A] Engine Sprocket Cover [B] • Remove the circlip [A] and take off the sprocket [B] with drive chain [C]. • Pull the collar and O-ring off the output shaft. Special Tool - Outside Circlip Pliers: 57001–144 Engine Sprocket Installation...
  • Page 165: Rear Sprocket Removal

    FINAL DRIVE 10-7 Sprockets, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). • Unscrew the rear sprocket bolts [A], and remove the rear sprocket [B]. Rear Sprocket Installation • Install the rear sprocket facing the tooth number making [A] outward. •...
  • Page 166: Coupling Bearing Removal

    10-8 FINAL DRIVE Sprockets, Coupling Coupling Bearing Removal • Pull out the coupling collar from the left. • Remove the oil seal. • Using the bearing driver set [A] or some other suitable tool, remove the bearing [B] by tapping from the drum side. Special Tools - Bearing Driver Set: 57001–1129 Coupling Bearing Installation •...
  • Page 167 BRAKES 11-1 Brakes Table of Contents Exploded View.................................11-2 Specifications .................................. 11-6 Brake Lever, Brake Pedal..............................11-7 Brake Lever, Brake Pedal Free Play Inspection.......................11-7 Front Brake Free Play Adjustment ........................... 11-7 Brake Pedal Free Play Adjustment .......................... 11-7 Brake Cable Removal...............................11-7 Brake Cable Installation ............................11-7 Brake Cable Lubrication............................11-7 Brake Pedal and Rod Removal..........................11-7 Brake Pedal and Rod Installation..........................11-8...
  • Page 168: Exploded View

    11-2 BRAKES Exploded View...
  • Page 169 BRAKES 11-3 Exploded View C: Apply cable lubricant. G: Apply grease. T1: 44 N m (4.5 kgf m, 32 ft 1. Brake Lever 2. Brake Cable 3. Cam Lever 4. Brake Panel 5. Brake Shoe 6. Camshaft...
  • Page 170 11-4 BRAKES Exploded View...
  • Page 171 BRAKES 11-5 Exploded View 1. Brake Pedal 2. Brake Lod 3. Adjusting Nut 4. Brake Shoe 5. Camshaft 6. Cam Lever G: Apply grease. T1: 8.8 N m (0.9 kgf m 79 in T2: 64 N m (6.5 kgf m, 47 ft T3: 7 N m (0.7 kgf m, 60 in...
  • Page 172: Specifications

    11-6 BRAKES Specifications Item Standard Service Limit Brake Lever and Pedal: Brake lever free play 5 mm - - - Brake pedal free play 30 mm - - - Brake Drum, Brake Shoes: Shoe lining thickness Front 2.10 3.00 mm 1.2 mm Rear 3.85...
  • Page 173: Brake Lever, Brake Pedal

    BRAKES 11-7 Brake Lever, Brake Pedal Brake Lever, Brake Pedal Free Play Inspection Refer to Brake Lever, Brake Pedal Free Play Inspection in the Periodic Maintenance Chapter. Front Brake Free Play Adjustment Refer to Front Brake Free Play Adjustment in the Periodic Mainte- nance Chapter.
  • Page 174: Brake Pedal And Rod Installation

    11-8 BRAKES Brake Lever, Brake Pedal Brake Pedal Return Spring [A] Brake Pedal Mounting Bolt [B] Brake Pedal [C] with Rod [D] Cotter Pin [A] Washer [B] O-rings [C] Brake Pedal and Rod Installation • Brake pedal and rod installation is the reverse of removal. •...
  • Page 175: Brake Panel And Drum

    BRAKES 11-9 Brake Panel and Drum Brake Lining Wear Inspection Refer to Brake Lining Wear Inspection in the Periodic Maintenance Chapter. Cam Lever Angle Adjustment Refer to Cam Lever Angle Adjustment in the Periodic Maintenance Chapter. Brake Panel Removal • Remove the front or rear wheel (see Wheels/Tires chapter).
  • Page 176: Brake Panel Assembly

    11-10 BRAKES Brake Panel and Drum Brake Panel Assembly • Lubricate the brake camshaft. • Fit the indicator [A] on the serration so that it points to the extreme right of the USABLE RANGE [B] (Rear panel only). Brake Drum Wear Inspection If the drum is worn unevenly or if it is scored, turn the drum down on a brake drum lathe or replace the hub with a new one.
  • Page 177: Camshaft Wear Inspection

    BRAKES 11-11 Brake Panel and Drum Camshaft Wear Inspection • Measure the shaft diameter [A]. If it is worn down to less than the service limit, replace the shaft. • Measure the inside diameter [B] of the camshaft hole. If it is worn past the service limit, replace the brake panel. Camshaft Diameter Front: Standard:...
  • Page 179 SUSPENSION 12-1 Suspension Table of Contents Exploded View.................................12-2 Specifications .................................. 12-6 Front Fork..................................12-7 Fork Oil Level Check (Simplify)..........................12-7 Oil Change/Oil Level Adjustment (each fork leg).....................12-7 Front Fork Removal..............................12-7 Front Fork Installation...............................12-8 Front Fork Disassembly (each fork )........................12-8 Front Fork Assembly (each fork)..........................12-9 Front Fork Inner Tube Inspection...........................12-10 Dust Seal/Oil Seal Inspection ..........................
  • Page 180: Exploded View

    12-2 SUSPENSION Exploded View...
  • Page 181 SUSPENSION 12-3 Exploded View 1. Circlip 2. Top plug 3. O-ring 4. Fork Spring 5. Cylinder Unit 6. Inner Tube 7. Dust Seal 8. Retaining Ring 9. Oil Seal 10. Outer Tube 11. Gasket 12. Allen Bolt 13. Steering Stem Head 14.
  • Page 182 12-4 SUSPENSION Exploded View...
  • Page 183 SUSPENSION 12-5 Exploded View 1. Pivot Shaft 2. Swingarm 3. Rear Shock Absober 4. Rubber Bushing 5. Flap: Note the installing direction. G: Apply grease. T1: 78 N m (8.0 kgf m, 58 ft T2: 25 N m (2.5 kgf m, 18 ft T3: 39 N m (4.0 kgf...
  • Page 184: Specifications

    12-6 SUSPENSION Specifications Item Standard Service Limit Front Fork: Oil viscosity SS-8 or SAE 10W20 – – – Oil capacity (completely dry) 163 ± 2.5 mL – – – Oil level (fully compressed, spring removed) – – – 89 ± 2 mm (from top of inner tube) –...
  • Page 185: Front Fork

    SUSPENSION 12-7 Front Fork Fork Oil Level Check (Simplify) Refer to Fork Oil Level Check (Simplify) in the Periodic Maintenance Chapter. Oil Change/Oil Level Adjustment (each fork leg) • Remove the front fork (see this chapter). • Remove the following. Top Plug Fork Spring The top plugs are under extreme spring force.
  • Page 186: Front Fork Installation

    12-8 SUSPENSION Front Fork • Remove the number plate. • Loosen the upper and lower fork clamp bolts [A]. • With a twisting motion, work the fork leg down and out. Front Fork Installation • If the fork leg was disassembled, check the fork oil level. •...
  • Page 187: Front Fork Assembly (each Fork)

    SUSPENSION 12-9 Front Fork • Take the cylinder base [A] out of the outer tube [B]. • Remove the retaining ring [A] from the outer tube. • Remove the oil seal [B]. Special Tool - Oil Seal & Bearing Remover: 57001–1058 Front Fork Assembly (each fork) •...
  • Page 188: Front Fork Inner Tube Inspection

    12-10 SUSPENSION Front Fork • Mesure the both diameters of the fork spring ends and insert the fork spring with the small diameter and [A] facing down. • Pour the fork oil (see Fork Oil change). • Install the front fork (see this chapter). Front Fork Inner Tube Inspection Refer to Inner Tube Inspection in the Periodic Maintenance Chapter.
  • Page 189: Rear Shock Absorber

    SUSPENSION 12-11 Rear Shock Absorber Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 • Remove the shock absorber mounting bolt [A], nut and pull off the shock absorber [B]. •...
  • Page 190: Swingarm

    12-12 SUSPENSION Swingarm Swingarm Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 • Remove: Rear Wheel (see Wheels/Tires chapter) Left Side Cover (see Frame chapter) Drive Chain Rear Shock Absorber Lower End •...
  • Page 191 STEERING 13-1 Steering Table of Contents Exploded View.................................13-2 Specifications .................................. 13-4 Steering...................................13-5 Steering Inspection..............................13-5 Steering Adjustment..............................13-5 Steering Stem Removal ............................13-5 Steering Stem Installation ............................13-5 Steering Stem Race Removal..........................13-6 Steering Stem Race Installation Notes........................13-7 Steering Stem Bearing Lubrication ..........................13-7 Steering Stem Bearing Inspection ........................... 13-7 Steering Stem Warp..............................13-7 Handlebar..................................13-8 Handlebar Removal..............................13-8...
  • Page 192: Exploded View

    13-2 STEERING Exploded View...
  • Page 193 STEERING 13-3 Exploded View 1. Handlebar Clamp 2. Handlebar 3. Steering Stem Head Nut 4. Steering Stem Head 5. Stem Locknut 6. Upper Steel Balls 7. Head Pipe 8. Lower Steel Balls 9. Steering Stem 10. Lower Inner Race 11. Lower Outer Race 12.
  • Page 194: Specifications

    13-4 STEERING Specifications Special Tools - Steering Stem Bearing Driver: 57001–137 Steering Stem Nut Wrench: 57001–1100 Jack: 57001–1238 Bearing Driver Set: 57001–1129 Bearing Puller: 57001–158 Bearing Puller Stud: 57001–1190 Bearing Puller Adapter: 57001–317...
  • Page 195: Steering Inspection

    STEERING 13-5 Steering Steering Inspection Refer to Steering Inspection in the Periodic Maintenance Chapter. Steering Adjustment Refer to Steering Adjustment in the Periodic Maintenance Chapter. Steering Stem Removal • Remove: Front Wheel (see Wheels/Tires chapter) Front Brake Cable Clamp Front Fender Handlebar (see Handlebar Removal) Front Fork (see Suspension chapter) •...
  • Page 196: Steering Stem Race Removal

    13-6 STEERING Steering • Install the stem head and washer, and tighten the stem head nut lightly. • Settle the bearing in place as follows; Tighten the stem locknut to 39 N m (4.0 kgf m, 29 ft lb) of torque. (To tighten the steering stem locknut to the specified torque, hook the wrench [A] on the stem locknut, and pull the wrench at the hole by 22.2 kg force [B] in the direction shown).
  • Page 197: Steering Stem Race Installation Notes

    STEERING 13-7 Steering Steering Stem Race Installation Notes • Apply engine oil to the outer races, and then drive them into the head pipe using the bearing driver set [A]. Special Tool - Bearing Driver Set: 57001–1129 • Drive the lower inner race [A] onto the steering stem using the stem bearing driver [B].
  • Page 198: Handlebar

    13-8 STEERING Handlebar Handlebar Removal • Remove: Engine Stop Switch [A] Throttle Grip Assembly [B] Brake Lever Holder [C] Handlebar Holders [D] Handlebar [E] Handlebar Installation • Apply adhesive cement to the inside of the left handlebar grip [A]. • Mount the handlebar clamps [B] so that the arrows [C] on the clamp point at the front [A].
  • Page 199 STEERING 13-9 Handlebar Position the throttle housing so that its vertical parting line [A] is aligned with punch mark [B] on the handlebar. Position the engine stop switch so that its edge [A] is aligned with the punch mark [B] on the handlebar. •...
  • Page 201 ELECTRICAL SYSTEM 14-1 Electrical System Table of Contents Exploded View.................................14-2 Specifications .................................. 14-4 Wiring Diagram................................14-5 Precautions ..................................14-6 Electrical Wiring ................................14-7 Wiring Inspection..............................14-7 Flywheel Magneto................................14-8 Magneto Cover Removal............................14-8 Magneto Cover Installation............................14-8 Magneto Cover Disassembly............................14-8 Magneto Cover Assembly ............................14-9 Magneto Flywheel Removal.............................14-9 Magneto Flywheel Installation..........................14-9 Flywheels Magneto Inspection..........................14-10...
  • Page 202: Exploded View

    14-2 ELECTRICAL SYSTEM Exploded View...
  • Page 203 ELECTRICAL SYSTEM 14-3 Exploded View G: Apply grease. SS: Apply silicone sealant. 1. Engine Stop Switch 2. Main Harness 3. Regulator/Rectifier 4. Igniter 5. Exciter Coil 6. Pickup Coil 7. Flywheel 8. Magneto Cover 9. Spark Plug 10. Gear Position Switch 11.
  • Page 204: Specifications

    14-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Magneto: Regulator/rectifier resistance in the text - - - Ignition System: - - - Pickup coil resistance (Blue/Yellow Ground) - - - Air gap 0.7 mm Ignition coil: Primary winding resistance 0.19 0.23 - - - Secondary winding resistance primary...
  • Page 205: Wiring Diagram

    ELECTRICAL SYSTEM 14-5 Wiring Diagram...
  • Page 206: Precautions

    14-6 ELECTRICAL SYSTEM Precautions There are a number of important precautions that need to follow during servicing electrical systems. Learn and observe all the rules below. The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 207: Electrical Wiring

    ELECTRICAL SYSTEM 14-7 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 208: Flywheel Magneto

    14-8 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Removal • Drain the engine oil. • Remove: Shift Pedal Engine Sprocket Cover (see Final Drive chapter) • Pull off the magneto connector [A]. • Unscrew the magneto cover screws [A] and remove the magneto cover [B].
  • Page 209: Magneto Cover Assembly

    ELECTRICAL SYSTEM 14-9 Flywheel Magneto Magneto Cover Assembly • Run the magneto lead [A] as shown. • Torque: Plate Screws [B]: 2.9 N m (0.3 kgf m, 26 in Exciter Coil Mounting Screws [C]: 5.2 N m (0.53 kgf m, 46 in Pickup Coil Mounting Screws [D]: 2.9 N m (0.3 kgf m, 26 in...
  • Page 210: Flywheels Magneto Inspection

    14-10 ELECTRICAL SYSTEM Flywheel Magneto Flywheels Magneto Inspection • There are three types of magneto problems: short, open (wire burned out), or loss in flywheel magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in flywheel magnetism, which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field, or just by aging, will result in low output.
  • Page 211: Ignition System

    ELECTRICAL SYSTEM 14-11 Ignition System The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the electrical connections while the engine is running.
  • Page 212: Ignition Coil Removal

    14-12 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal • Remove: Left Side Cover Spark Plug Cap • Disconnect the ignition coil leads [A]. • Unscrew the bolt [B] and remove the ignition coil [C]. Ignition Coil Installation • Installation is the reverse of removal. •...
  • Page 213: Spark Plug Removal/installation

    ELECTRICAL SYSTEM 14-13 Ignition System Spark Plug Removal/Installation • Remove the plug cap. • Remove or install the spark plug using the spark plug wrench [A]. Special Tool - Spark Plug Wrench, Hex 16: 57001–1262 Torque - Spark Plug: 13 N m (1.3 kgf m, 9.6 ft •...
  • Page 214 14-14 ELECTRICAL SYSTEM Ignition System • Connect the peak voltage adapter [A] between the terminal of primary lead (orange) and ground connection of the unit with the lead of the ignition coil [B] connected. Recommended Tool: Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI...
  • Page 215 ELECTRICAL SYSTEM 14-15 Ignition System...
  • Page 216 14-16 ELECTRICAL SYSTEM Ignition System Pickup Coil Peak Voltage Check: • To check the peak voltage, do the following procedures. Disconnect the magneto lead connector. NOTE Measure the voltage with each lead connected correctly. correct value may not be obtained if disconnected. Maintain the correct value of compression pressure for the cylinder (Be sure to measure the voltage with the spark plug installed to the cylinder head).
  • Page 217: Switches

    ELECTRICAL SYSTEM 14-17 Switches Switch Inspection • Using the hand tester, check to see that only the connections shown in the table have continuity (about zero ohms). Special Tool - Hand Tester: 57001–1394 If the switch has an open or short, repair it or replace it with a new one.
  • Page 218: Gear Position Switch Inspection

    14-18 ELECTRICAL SYSTEM Switches Gear Position Switch Inspection: • Remove the gear position switch head and examine the contact points for presence of oxidation, oil or dirt, etc. Clean the contact points, and ensure that the switch finger is working correctly. •...
  • Page 219 TROUBLESHOOTING 15-1 Troubleshooting Table of Contents Troubleshooting Guide ..............................15-2...
  • Page 220: Troubleshooting

    15-2 TROUBLESHOOTING Troubleshooting Guide NOTE Pickup coil trouble This is not an exhaustive list, giving every possi- Ignition coil damaged ble cause for each problem listed. It is meant sim- Igniter broken ply as a rough guide to assist the troubleshooting Flywheel magneto damaged for some of the more common difficulties.
  • Page 221 TROUBLESHOOTING 15-3 Troubleshooting Guide Compression low: Engine oil level too high Cylinder, piston worn Engine oil viscosity too high Piston rings bad (worn, weak, broken, or sticking) Clutch housing frozen on drive shaft Piston ring/land clearance excessive Clutch release mechanism trouble Cylinder head gasket damaged Gear Shifting Faulty: Cylinder head not sufficiently tightened down...
  • Page 222 15-4 TROUBLESHOOTING Troubleshooting Guide Transmission noise: Steering stem bearing damaged Crankcase bearing worn Race(s) dented or worn Metal chip jammed in gear theeth Steering stem lubrication inadequate Transmission gears worn or chipped Steering stem bent Engine oil insufficient or too thin Tire air pressure too low Kick ratchet gear not properly disengaging from kick Handlebar shakes or excessively vibrates:...

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