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Table of Contents
152 MAINTENANCE-CHASSIS
Fork oil change
To
drain
out
the
old oil,
remove the drain bolt
from the lower end of
the outer tube. With
the
front
wheel on
the
ground
and
the
front brake
fully_ applied,
push down
on
the
handlebar
a
few times
to
pump out
the" oil. Install the drain bolt.
Remove
the
top
plug
and pull
out the
spring
from
the inner
tube.
Pour
in the
type and
amount
of
oil
specified in Table
J
16, and check the
oil level. If the
oil
is below
the specified
level,
add oil
and re-check
the
oil
level.
NOTE: After
the front fork
oil
is
changed and
before
checking the oil
level, pump the
forks
several
times to
expel
air
from the
upper
and
lower
chambers.
Table J17
Fork Oil
Type
Capacity
Oil Level
SAE
150
cc
440
±
2 mm from
top
of
5W20
inner tube
Spring tension
Since
the spring
becomes
shorter
as it
weakens,
check
its
free
length
to
determine its
condition
.
If
the
spring
of
either
fork leg
is shorter
than the service
limit, it
must be replaced.
If the
difference
of both old and
new
spring length
is
great,
the
old
sp ring sh
ou
ld
also
be
replaced in order to keep the fork leg
balanced
for
motorcycle stability.
A. Free Length
Table J18
Fork
Spring Free Length
Standard
Service
Limit
452
mm
442mm
Inner
tube
damage
Visually inspect
th
e
inner tube,
and
repair any
damage.
If
the damage is
not repairable,
replace the
inner
tube.
Since
damage to
the inner
tube damages
the
oil
seal
,
replace
the
oil
seal whenever the inner
tube
is repaired
or
replaced.
Temporarily assemble
the inner
and
outer
tubes, and
pump them
back
and
forth
manual-
ly to check for
smooth
operation.
rn~T~[]
~:p~:~n~~r
~::e~s~:n!;~d~~:'.yf~~~:::d
by subsequent straightening, can weaken the inner tube.
SWING ARM
Swing
arm
bearing wear
Measure
the
outside
diameter
of
the
swing
arm
sleeve
at both
ends with
a
micrometer.
Replace
the
swing arm sleeve if
the
diameter
is
less
than the service
limit or if it shows visible damage.
Table J19
Swing Arm Sleeve Diameter
Standard
Service
Limit
21.987-22.000
mm
21
.96
mm
The
rollers
in
the needle
bearings wear so little
that
the wear
is
difficult
to
measure. Instead, inspect
the
needle bearings
for
abrasions, color
change,
or
other
damage.
If there is any doubt as to the
condition
of
any
needle bearing,
replace all
the needle
bearings.
Whenever
the
swing arm
sleeve
is replaced,
also
replace
the
needle
bearings.
Pivot sha~
To
measure
the
pivot
shaft
runout,
set
the pivot
shaft
on
V blocks
at
the ends
of
the
shaft,
and
set
a
dial
gauge

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Table of Contents

   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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