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Table of Contents

   Also See for Kawasaki KLE500

   Summary of Contents for Kawasaki KLE500

  • Page 2: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 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 °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLE500-B1 Left Side View KLE500-B1 Right Side View...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KLE500-B1 Dimensions Overall Length 2 215 mm (87.2 in.) Overall Width 880 mm (34.6 in.) Overall Height 1 270 mm (50.0 in.) Wheelbase 1 500 mm (59.0 in.) Road Clearance 180 mm (7.09 in.) Seat Height 850 mm (33.5 in.)
  • Page 17 GENERAL INFORMATION 1-9 General Specifications Items KLE500-B1 Engine Oil: Grade API SE, SF, SG or API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 3.4 L (3.6 US qt) Drive Train Primary Reduction System: Type Chain Reduction Ratio 2.652 (61/23)
  • Page 18 1-10 GENERAL INFORMATION General Specifications Items KLE500-B1 Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam Bulb 12 V 55/55 W (quartz-halogen) Tail/brake Light 12 V 5/21 W Alternator: Type Three-phase AC Rated output 17 A × 14 V @6 000 r/min (rpm)
  • Page 19: Unit Conversion Table

    GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 21: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Maintenance Procedure ......................2-14 Fuel System......................... 2-14 Throttle Cable Inspection ....................2-14 Idle Speed Inspection ....................... 2-15 Carburetor Synchronization Inspection................
  • Page 22 2-2 PERIODIC MAINTENANCE Steering Play Inspection ....................2-32 Steering Stem Bearing Lubrication ................... 2-33 Electrical System ......................... 2-34 Spark Plug Gap Inspection ....................2-34 Lights and Switches Operation Inspection................ 2-34 Headlight Aiming Inspection ..................... 2-36 Side Stand Switch Operation Inspection................2-37 Engine Stop Switch Operation Inspection.................
  • Page 23: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY * ODOMETER READING Whichever ×...
  • Page 24: Periodic Maintenance Chart

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY * ODOMETER READING Whichever × 1000 km comes first (× 1000 mile) Page OPERATION Every (0.6) (4) (7.5) (12) (15) (20) (24) Suspensions Front forks/rear shock absorber operation • • • 2-30 (damping and smooth stroke)-inspect Front forks/rear shock absorber oil •...
  • Page 25: Periodic Replacement Parts

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1000 km first (× 1000 mile) Page CHANGE/REPLACEMENT Every (0.6) (7.5) (12) (15) (24) (30) • Fuel hose 4 years 2-40 Air cleaner element 2 years 2-40 •...
  • Page 26: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 27 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Main Oil Pipe Upper Banjo Bolts M8 104 in·lb Main Oil Pipe Lower Banjo Bolt M10 14.5 Water Jacket Plug 87 in·lb Oil Pipe Bolts (in the cylinder head) 95 in·lb Main Oil Pipe Mounting Bolt 95 in·lb...
  • Page 28 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Upper Primary Chain Guide Mounting Bolt 95 in·lb Lower Primary Chain Guide Mounting Bolt 95 in·lb Connecting Rod Big End Nuts Return Spring Pin 14.5 Gear Positioning Lever Pivot Stud –...
  • Page 29 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Top Bolts Front Fork Bottom Allen Bolt Rear Shock Absorber Upper Mounting Nut Rear Shock Absorber Lower Mounting Nut Swingarm Pivot Nut Rocker Arm Pivot Nut Tie-Rod Mounting Nuts Steering Handlebar Clamp Bolts...
  • Page 30 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Neutral Switch Tail Light Mounting Nut 52 in·lb The table relating 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.
  • Page 31: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System – – – Throttle Grip Free Play 3 mm (0.08 0.12 in.) Idle Speed 1 200 ±50 r/min (rpm) – – – Engine Top End Valve Clearance Inlet 0.13 0.18 mm (0.0051 0.0071 in.) –...
  • Page 32 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Capacity when filter is not removed 2.8 L (3.0 US qt) – – – when filter is removed 3.0 L (3.2 US qt) – – – when engine is completely dry 3.4 L (3.6 US qt) –...
  • Page 33: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Steering Stem Nut Wrench: Oil Filter Wrench: 57001-1100 57001-1249 Jack: Vacuum Gauge: 57001-1238 57001-1369 Pilot Screw Adjuster, A: Filler Cap Driver: 57001-1239 57001-1454...
  • Page 34: Maintenance Procedure

    2-14 PERIODIC MAINTENANCE Maintenance Procedure Fuel System Throttle Cable Inspection Throttle Grip Free Play Inspection • Check throttle grip play [A] by lightly turning the throttle grip back and forth. If the free play is improper, adjust the throttle cable. Throttle Grip Free Play Standard: 3 mm (0.08...
  • Page 35: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Maintenance Procedure If the play can not be adjusted by using the adjuster at the throttle grip, use the adjuster [A] of the decelerator cable under the fuel tank. • Screw in the adjuster fully at the throttle grip and tighten the locknut.
  • Page 36: Carburetor Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Maintenance Procedure Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 37: Coolant Filter Cleaning

    PERIODIC MAINTENANCE 2-17 Maintenance Procedure Coolant Filter Cleaning ○ Before winter season starts, clean the coolant filter [A] in the carburetor system. • Drain the coolant (see Coolant Draining). • Remove the coolant filter from the cooling hoses in the carburetor system.
  • Page 38: Cooling System

    2-18 PERIODIC MAINTENANCE Maintenance Procedure • Remove the element assembly from the air cleaner hous- ing (see Air Cleaner Element Removal in the Fuel System chapter). • Separate the element [A] from the element holders [B]. • Clean the element in a bath of high-flash point solvent, and then dry it with compressed air or by shaking it.
  • Page 39: Radiator Hoses And Connections Inspection

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure Radiator Hoses and Connections Inspection ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 40 2-20 PERIODIC MAINTENANCE Maintenance Procedure • Unscrew the upper [A] and lower [B] caps on the alterna- tor cover. Special Tool - Filler Cap Driver: 57001-1454 • Check the valve clearance when the pistons are at TDC. ○ The pistons are numbered beginning with the engine left side.
  • Page 41: Clutch

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure • Measure the clearance of each valve by inserting a thick- ness gauge [A] between the adjusting screw [B] and the valve stem. Valve Clearance (when cold) Inlet 0.13 0.18 mm (0.0051 0.0071 in.) Exhaust 0.18 0.23 mm (0.0070 0.0090 in.)
  • Page 42: Wheels/tires

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Clutch Lever Free Play Adjustment • Slide back the dust cover [A]. • Loosen both adjuster nuts [B] at the right hand crankcase as far as they will go. • Loosen the knurled locknut [A] at the clutch lever. •...
  • Page 43: Wheel/tire Damage Inspection

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure Wear Indicator [A] Wear Indicator Position Mark [B] If any measurement is less than the service limit, replace the tire. Tread Depth Front DUNLOP BRIDGESTONE Standard 6.9 mm (0.27 in.) 6.0 mm (0.24 in.) Service Limit 1 mm (0.04 in.) Rear DUNLOP...
  • Page 44: Wheel Bearing Damage Inspection

    2-24 PERIODIC MAINTENANCE Maintenance Procedure Wheel Bearing Damage Inspection • Using a jack and attachment, raise the front wheel off the ground (see Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. • Inspect the roughness of the front wheel bearing by push- ing and pulling [A] the wheel.
  • Page 45: Final Drive

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure Final Drive Drive Chain Slack Inspection Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry.
  • Page 46: Drive Chain Wear Inspection

    2-26 PERIODIC MAINTENANCE Maintenance Procedure • Bend the cotter pin [A] over the nut. • Turn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary. • Check the rear brake. Wheel Alignment Inspection/Adjustment •...
  • Page 47: Drive Chain Lubrication

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure WARNING If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
  • Page 48: Brake Hose Damage And Installation Condition Inspection

    2-28 PERIODIC MAINTENANCE Maintenance Procedure Brake Hose Damage and Installation Condition Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 49: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B]. WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reser- voir are unidentified.
  • Page 50: Brake Light Switch Operation Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Brake Light Switch Operation Inspection Front Brake Light Timing Inspection • Turn on the ignition switch. • The brake light should go on when the brake lever is ap- plied or after the tip of brake lever moves about 10 mm (0.39 in.) [A].
  • Page 51: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection) or shock absorber clamps.
  • Page 52: Tie-rod Operation Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Tie-rod Operation Inspection • Remove the lower fairings (see Fairing Removal in the Frame chapter). • Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and rocker arm bearings (see Rocker Arm Bearing and Sleeve Inspection in the Suspension chapter).
  • Page 53: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure • Loosen: Both Fork Lower Clamp Bolts [A]. Steering Stem Head Nut [B]. • Adjust the steering. If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 54: Electrical System

    2-34 PERIODIC MAINTENANCE Maintenance Procedure • Pack the upper and lower tapered roller bearings [A] in the cages with grease, and apply a light coat of grease to the upper and lower outer races. • Install the steering stem, and adjust the steering (see Steering Play Inspection).
  • Page 55 PERIODIC MAINTENANCE 2-35 Maintenance Procedure Ignition Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) • Turn off the ignition switch. • The all lights should go off (see Switch Inspection in the Electrical System chapter).
  • Page 56: Headlight Aiming Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight and license plate light should go If the low beam headlight and license plate light do not go on, inspect or replace the following item.
  • Page 57: Side Stand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Headlight Beam Horizontal Adjustment • Insert the conventional screwdriver into the adjuster from underside of the headlight, turn the horizontal adjuster [A] on the headlight housing in or out until the beam points straight ahead. Turning the adjuster clockwise moves the headlight beam to the left.
  • Page 58: Engine Stop Switch Operation Inspection

    2-38 PERIODIC MAINTENANCE Maintenance Procedure Engine Stop Switch (see Switch Inspection in the Elec- trical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter) Junction Box (see Junction Box Inspection in the Elec- trical System chapter) Harness (see Wiring Inspection in Electrical System chapter)
  • Page 59: Bolts, Nuts And Fastener Tightness Inspection

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Throttle Inner Cable Upper and Lower Ends Fast Idle Inner Cable Upper and Lower end Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Side Stand Tie-Rod Pivot...
  • Page 60: Replacement Parts

    2-40 PERIODIC MAINTENANCE Maintenance Procedure Nut, Bolt and Fastener to be checked Wheels: Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Clip Brakes: Master Cylinder Clamp Bolts Brake Lever Pivot Nut Caliper Mounting Bolts Brake Pedal Lever Clamp Bolt Cam Lever Clamp Bolt Brake Rod Joint Cotter Pin Torque Link Nuts...
  • Page 61: Air Cleaner Element Replacement

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure Air Cleaner Element Replacement NOTE ○ Since repeated cleaning opens the pores of the foam element, replace it with a new one periodically. Also, if there is a brake in the element material or any other damage to the element, replace the element with a new one.
  • Page 62 2-42 PERIODIC MAINTENANCE Maintenance Procedure • Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap. ○...
  • Page 63 PERIODIC MAINTENANCE 2-43 Maintenance Procedure Water and Coolant Mixture Ratio (when shipping) Soft Water Coolant Freezing Point –35°C (–31°F) Total Amount 1.7 L (1.8 US qt) NOTE ○ Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. •...
  • Page 64: Radiator Hoses And O-ring Replacement

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Radiator Hoses and O-ring Replacement • Drain the coolant (see Coolant Draining). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Spark Plug Caps Thermostat Housing Cover [A] Pipe [B] Hoses [C] O-rings [D] To Cylinder Head [E] To Carburetor [F]...
  • Page 65: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure • Fill the engine with a good quality motor oil specified in the table. Torque - Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13 in·lb) • Check the oil level. Engine Oil Grade: API SE, SF, SG or API SH or SJ with JASO MA Viscosity: SAE 10W40...
  • Page 66: Brake Fluid Change

    2-46 PERIODIC MAINTENANCE Maintenance Procedure • When installing the hose, avoid sharp bending, kinking, flattening or twisting, and route the hose according to Ca- ble, Wire and Hose Routing in the Appendix chapter. • Tighten the banjo bolts to the specified torque. Torque - Brake Hose Banjo bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 67: Bleeding The Brake Line

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever is transmit- ted directly to the caliper for braking action. Air, however, is easily compressed.
  • Page 68: Caliper Rubber Parts Replacement

    2-48 PERIODIC MAINTENANCE Maintenance Procedure • Install the reservoir cap. • Remove the rubber cap from the bleed valve on the caliper. • Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a con- tainer.
  • Page 69: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-49 Maintenance Procedure Spark Plug Replacement • Remove: Lower Fairings (see Lower Fairings Removal in the Fuel chapter) • Carefully pull the spark plug caps from the spark plugs and unscrew the spark plug using an owner’s tool [A]. •...
  • Page 71 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Throttle Grip and Cables ......................Throttle Cable Inspection ....................Throttle Cable Lubrication....................Throttle Cable Removal ....................Throttle Cable Installation ....................Choke Cable........................... Choke Cable Free Play Inspection ................... Choke Cable Free Play Adjustment..................
  • Page 72: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 73 FUEL SYSTEM 3-3 Exploded View 1. Throttle Cable (Accelerator) 2. Throttle Cable (Decelerator) 3. Choke Cable 4. Pilot (Slow) Jet 5. Pilot (Slow) Air Screw 6. Float Valve 7. Jet Needle 8. Needle Jet 9. Needle Jet Holder 10. Main Jet 11.
  • Page 74 3-4 FUEL SYSTEM Exploded View...
  • Page 75 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Tap Mounting Bolts 0.51 44 in·lb Fuel Tap Cover Screws 0.08 7 in·lb Air Cut Valve Cover Screws 0.10 9 in·lb 4. Vacuum Switch Valve 5. Air Cleaner Housing 6.
  • Page 76: Specifications

    3-6 FUEL SYSTEM Specifications Item Standard Throttle Grip Free Play 3 mm (0.08 0.12 in.) Choke Cable Free Play 3 mm (0.08 0.12 in.) Carburetors Mark, Type KEIHIN CVK34 Idle Speed 1 200 ±50 r/min (rpm) Pilot Screw (Turns Out) 1 3/4 ±1/4 Synchronization Vacuum 2.7 kPa (2 cmHg) or less difference between two carburetors...
  • Page 77: Special Tools

    FUEL SYSTEM 3-7 Special Tools Fuel Level Gauge: Carburetor Drain Plug Wrench, Hex 3: 57001-1017 57001-1269...
  • Page 78: Throttle Grip And Cables

    3-8 FUEL SYSTEM Throttle Grip and Cables Throttle Cable Inspection Throttle Grip Free Play Inspection • Refer to the Throttle Cable Inspection in the Periodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Cable Inspection in the Periodic Maintenance chapter.
  • Page 79: Choke Cable

    FUEL SYSTEM 3-9 Choke Cable Choke Cable Free Play Inspection • Push the choke lever [A] all the way to the front. • Check the choke cable free play [B]. ○ Determine the amount of choke cable play at the choke lever.
  • Page 80: Carburetors

    3-10 FUEL SYSTEM Carburetors Carburetor Removal WARNING Gasoline is extremely flammable and can be ex- plosive 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 sparks;...
  • Page 81: Fuel Tank

    FUEL SYSTEM 3-21 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive 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 sparks;...
  • Page 82: Fuel Tank Installation

    3-22 FUEL SYSTEM Fuel Tank Fuel Tank Installation • Read the WARNING in the Fuel Tank Removal section. • Check the rubber dampers [A] on the frame and the one pasted under the fuel tank. If the dampers are damaged or deteriorated, replace them.
  • Page 83: Fuel Tap Inspection

    FUEL SYSTEM 3-23 Fuel Tank • Pour the solvent out of the tank. • Remove the fuel tap from the tank by taking out the bolts with nylon washers. • Clean the fuel tap filter screens in a high flash-point sol- vent.
  • Page 84: Fuel Hose

    3-24 FUEL SYSTEM Fuel Hose Fuel Hose and Connection Inspection • Refer to the Fuel Hoses and Connections Inspection in the Periodic Maintenance chapter.
  • Page 85 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Visual Leak Inspection ...................... Cooling System Pressure Testing ..................Flushing ..........................
  • Page 86: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 87 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Jacket Plug 87 in·lb Thermostat Housing Bolts 95 in·lb Radiator Cap Holder Mounting Bolts 95 in·lb Water Temperature Switch 69 in·lb Water Pipe Bolts 87 in·lb Radiator Fan Switch Radiator Hose Clamp Screws 0.25 22 in·lb...
  • Page 88: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...
  • Page 89: Special Tool And Sealant

    COOLING SYSTEM 4-5 Special Tool and Sealant Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001-1129 56019-120...
  • Page 90: Coolant Flow Chart

    4-6 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 91 COOLING SYSTEM 4-7 Coolant Flow Chart 1. Water Pump (driven by balancer shaft) 2. Cylinder Jacket 3. Cylinder Head Jacket 4. Water Temperature Switch 5. Air Bleeder Hole 6. Thermostat 7. Reserve Tank 8. Radiator Cap 9. Radiator 10. Radiator Fan 11.
  • Page 92: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reservoir tank. ○ If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case flush the cooling system.
  • Page 93: Flushing

    COOLING SYSTEM 4-9 Coolant Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the cooling system.
  • Page 94: Water Pump

    Apply silicone sealant to the area [A] where the mating surface of the crankcase contacts the water pump hous- ing gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply high temperature grease to the lips of the water pump housing oil seal.
  • Page 95: Mechanical Seal Inspection

    COOLING SYSTEM 4-11 Water Pump • Be sure to install the water pipe O-rings [A], and apply high temperature grease to them. • Install the water pump cover with the water pipe, being careful of the two knock pins [B]. Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Mechanical Seal Inspection...
  • Page 96: Impeller Assembly

    4-12 COOLING SYSTEM Water Pump Impeller Assembly • Clean the sliding surface of the mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole.
  • Page 97: Radiator, Radiator Fan

    COOLING SYSTEM 4-13 Radiator, Radiator Fan WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 98: Radiator Fan Removal

    4-14 COOLING SYSTEM Radiator, Radiator Fan Radiator Fan Removal • Remove the radiator (see Radiator Removal). • Remove the radiator fan mounting screws [A]. CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. 1) Keep the steam gun [A] away more than 0.5 m (20 in.) [B] from the radiator core.
  • Page 99: Radiator Hose And Connection Inspection

    COOLING SYSTEM 4-15 Radiator, Radiator Fan Radiator Hose and Connection Inspection • Refer to the Radiator Hoses and Connections Inspection in the Periodic Maintenance chapter. Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installation • Install the radiator hoses. Avoid sharp bending, kinking, flattening, or twisting.
  • Page 100: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant. • Remove the left lower fairing (see Lower Fairings Re- moval in the Frame chapter). • Turn the handlebar to right side fully. • Remove the radiator filler mounting bolts [A]. •...
  • Page 101 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. [B] Thermometer If the measurement is out of the specified range, replace the thermostat with a new one.
  • Page 102: Radiator Fan Switch, Water Temperature Switch

    Radiator Fan Switch, Water Temperature Switch Installation • Apply silicone sealant to the threads before mounting the water temperature switch. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant to the radiator fan switch on the radiator. •...
  • Page 103 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Main Oil Pipe Removal ....5-20 Specifications ........Main Oil Pipe Installation ..... 5-20 Special Tools and Sealant ....Cylinder Head........5-21 Clean Air System....... 5-11 Compression Measurement..5-21 Vacuum Switch Valve Removal ...
  • Page 104: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 105 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 95 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Chain Tensioner Mounting Bolts 95 in·lb Camshaft Chain Tensioner Cap Bolt 113 in·lb Camshaft Sprocket Bolts Rocker Shafts Valve Adjuster Locknuts Cylinder Head Bolts (10 mm)
  • Page 106 5-4 ENGINE TOP END Exploded View...
  • Page 107 ENGINE TOP END 5-5 Exploded View 1. “N” marked side faces up. 2. Install the piston so that the circle mark on the top of the piston come to front side of the engine. MO: Apply molybdenum disulfide oil. R: Replacement Parts...
  • Page 108: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Open → Close – – – Pressure 53 kPa (340 400 mmHg) Camshafts Cam Height: Exhaust 35.416 35.530 mm (1.3943 1.3988 in.) 35.32 mm (1.3905 in.) Inlet 35.476 35.590 mm (1.3967 1.4012 in.) 35.38 mm (1.3929 in.) Camshaft, Camshaft Cap...
  • Page 109 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Outside diameter: Exhaust 24.0 24.2 mm (0.945 0.953 in.) – – – Inlet 28.3 28.5 mm (1.114 1.122 in.) – – – Valve spring free length: Inner 36.3 mm (1.429 in.) 35 mm (1.3780 in.) Outer 40.4 mm (1.591 in.)
  • Page 110: Special Tools And Sealant

    5-8 ENGINE TOP END Special Tools and Sealant Piston Ring Pliers: Valve Guide Reamer, 5.5: 57001-115 57001-1079 Compression Gauge, 20 kgf/cm²: Piston Ring Compressor Grip: 57001-221 57001-1095 Valve Spring Compressor Assembly: Piston Ring Compressor Belt, 67 57001-241 57001-1097 Piston Pin Puller Assembly: Valve Seat Cutter, 45°...
  • Page 111 ENGINE TOP END 5-9 Special Tools and Sealant Valve Seat Cutter, 32° - 30: Valve Spring Compressor Adapter, 22: 57001-1120 57001-1202 Valve Seat Cutter, 60° - 30: Fork Oil Level Gauge: 57001-1123 57001-1290 Valve Seat Cutter Holder, 5.5: Valve Seat Cutter, 60° - 25: 57001-1125 57001-1328 Valve Seat Cutter Holder Bar:...
  • Page 112 5-10 ENGINE TOP END Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 113: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) • Remove the clamps [A] and take off the vacuum switch valve [B]. Vacuum Switch Valve Installation •...
  • Page 114: Vacuum Switch Valve Test

    5-12 ENGINE TOP END Clean Air System Vacuum Switch Valve Test Using the vacuum gauge and a syringe, inspect the vac- uum switch operation as follows. • Remove a vacuum switch valve. • Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown.
  • Page 115: Cylinder Head Cover

    ENGINE TOP END 5-13 Cylinder Head Cover Cylinder Head Cover Removal • Drain the coolant (see Coolant Draining in the Cooling System chapter). • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Lower Fairing (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System...
  • Page 116: Cylinder Head Cover Installation

    • Be sure to install the knock pins [C]. • Apply silicone sealant [D] as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the cover bolts [E]. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 117: Camshaft Chain Tensioner

    ENGINE TOP END 5-15 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. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 118: Camshaft, Camshaft Chain

    5-16 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Position the crankshaft at #2 piston TDC. ○ Using a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the "C" mark line [A] on the rotor is aligned with the notch [B] in the edge of the upper hole in the alternator cover.
  • Page 119: Camshaft And Sprocket Assembly

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain • Engage the camshaft chain with the camshaft sprockets. ○ Pull the tension side [A] (inlet side) of the chain taut to install the chain. ○ The timing marks [B] on the inlet sprocket [C] must be aligned with the cylinder head upper surface [D].
  • Page 120: Camshaft, Camshaft Cap Wear

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be mea- sured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.
  • Page 121: Rocker Shaft, Rocker Arm

    ENGINE TOP END 5-19 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove the camshafts (see Camshaft Removal). • Unscrew the rocker shafts [A] and remove the rocker arms [B] and springs [C]. ○ Mark and record the rocker arm locations so that the rocker arm can be reinstalled in their original positions.
  • Page 122: Oil Pipe

    5-20 ENGINE TOP END Oil Pipe Cylinder Head Oil Pipe Removal • Remove the oil pipe mounting bolts [A] and pull the oil pipes [B] and O-rings out of the cylinder head. Cylinder Head Oil Pipe Installation • Flush out the oil pipes with a high flash-point solvent. •...
  • Page 123: Cylinder Head

    ENGINE TOP END 5-21 Cylinder Head Compression Measurement • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running.
  • Page 124: Cylinder Head Removal

    5-22 ENGINE TOP END Cylinder Head If cylinder compression is lower than the usable range, check the following: 1. Gas leakage around the cylinder head - replace the damaged gasket and check the cylinder head for warping. 2. Condition of the valve seating. 3.
  • Page 125: Cylinder Head Installation

    ENGINE TOP END 5-23 Cylinder Head • Tap in the places shown with a mallet [A] to remove the cylinder head. Cylinder Head Installation • Install the rear chain guide, knock pins [A] and new gasket [B]. • Install a new cylinder head gasket with "UP" [A] marked side positioning to the right.
  • Page 126: Cylinder Head Warp

    5-24 ENGINE TOP END Cylinder Head Cylinder Head Warp • Clean the cylinder head (see Cylinder Head Cleaning). • Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and the head.
  • Page 127: Valves

    ENGINE TOP END 5-25 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Use a valve spring compressor assembly to press down the valve spring retainer, and remove the split keepers.
  • Page 128: Valve Guide Installation

    5-26 ENGINE TOP END Valves Valve Guide Installation • Apply molybdenum disulfide oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 150°C (248 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 129: Measuring Valve-to-guide Clearance (wobble Method)

    ENGINE TOP END 5-27 Valves Measuring Valve-to-guide Clearance (Wobble method) 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 guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 130 5-28 ENGINE TOP END Valves Seat Cutter Operating Cares 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 131 ENGINE TOP END 5-29 Valves • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 132 5-30 ENGINE TOP END Valves • Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 133 ENGINE TOP END 5-31 Valves...
  • Page 134: Cylinder, Piston

    5-32 ENGINE TOP END Cylinder, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the main oil pipe mounting bolt. • Remove the bolts [A] and pull out the water pipe with wa- ter pump cover [B] (see water pump removal in the Cool- ing System chapter).
  • Page 135: Piston Installation

    ENGINE TOP END 5-33 Cylinder, Piston • Remove the top and second rings with piston ring pliers. Special Tool - Piston Ring Pliers: 57001-115 • If the special tool is not available, carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.
  • Page 136: Piston Ring, Piston Ring Groove Wear

    5-34 ENGINE TOP END Cylinder, Piston Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. •...
  • Page 137: Piston Diameter

    ENGINE TOP END 5-35 Cylinder, Piston Piston Diameter • Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under the service limit, replace the piston.
  • Page 138: Carburetor Holder

    5-36 ENGINE TOP END Carburetor Holder Carburetor Holder Installation • Install the carburetor holders. The projection [A] faces upwards. • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. WARNING Install the clamp screws horizontally.
  • Page 139 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Spring Bolts 0.95 82 in·lb Clutch Hub Nut 13.5 EO: Apply engine oil. M: Apply molybdenum disulfide grease. R: Replacement Parts...
  • Page 140 6-4 CLUTCH Exploded View...
  • Page 141 CLUTCH 6-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Plug 0.15 13 in·lb Clutch Cable Holder Bolts 95 in·lb Clutch Cover Bolts 95 in·lb 4. Starter Lockout Switch CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. HG: Apply high temperature grease.
  • Page 142 6-6 CLUTCH Specifications Item Standard Service Limit Clutch Lever Position Non-adjustable – – – Clutch Lever Free Play 3 mm (0.08 0.12 in.) – – – Clutch Friction Plate Thickness 3.1 mm (0.114 0.122 in.) 2.75 mm (0.1082 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length...
  • Page 143 CLUTCH 6-7 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 56019-120...
  • Page 144: Clutch Lever And Cable

    6-8 CLUTCH Clutch Lever and Cable Clutch Lever Position Adjustment The adjuster has 5 position so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 145: Right Engine Cover

    • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the knock pins [B], and replace the cover gasket with a new one.
  • Page 146 6-10 CLUTCH Right Engine Cover • Free the clutch inner cable tip from the clutch release lever [A]. • Turn the release lever toward the rear [B] as shown in the figure. • Pull the lever and shaft assembly out of the clutch cover. Clutch Release Installation CAUTION Always install a new oil seal when the clutch release...
  • Page 147 CLUTCH 6-11 Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove the clutch spring bolts [A], washers [B] and springs. •...
  • Page 148 6-12 CLUTCH Clutch ○ The grooves [A] on the friction plate surfaces are cut tan- gentially and radially, install the friction plates so that the grooves run toward the center in the direction of the clutch housing rotation (counterclockwise viewed from the en- gine right side).
  • Page 149 CLUTCH 6-13 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch spring [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.1 mm (1.303 in.) Clutch Housing Finger Inspection...
  • Page 151 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan and Relief Valve......................
  • Page 152: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 153 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Plug 0.15 13 in·lb Main Oil Pipe Mounting Bolt 95 in·lb Main Oil Pipe Upper Banjo Bolt 104 in·lb Main Oil Pipe Lower Banjo Bolt 14.5 Rocker Shafts EO: Apply engine oil.
  • Page 154 7-4 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 155 ENGINE LUBRICATION SYSTEM 7-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe for Balancer Shaft Banjo Bolt 0.80 69 in·lb Oil Pipe for Drive Shaft Upper Banjo Bolt 0.80 69 in·lb Oil Pipe for Output Shaft Upper Banjo Bolt 0.80 69 in·lb Oil Pump Outer Oil Pipe Bolts...
  • Page 156: Engine Oil Flow Chart

    7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 157: Specifications

    ENGINE LUBRICATION SYSTEM 7-7 Specifications Item Standard Engine Oil Grade API SE, SF, SG or API SH or SJ JASO MA Viscosity SAE 10W-40 Capacity 2.8 L (when filter is not removed) 3.0 L (when filter is removed) 3.4 L (when engine is completely dry) Level Between upper and lower level lines Oil Pressure Measurement...
  • Page 158: Special Tools And Sealant

    7-8 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-125 56019-120 Oil Pressure Gauge Adapter, M14 × 1.5: 57001-1209...
  • Page 159: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Engine Oil Level Inspection •...
  • Page 160: Oil Pan And Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan and Relief Valve Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the engine guard (see Engine Guard Removal in the Frame chapter). •...
  • Page 161: Relief Valve Installation

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pan and Relief Valve Relief Valve Installation • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it. Torque - Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb) CAUTION Do not over apply a non-permanent locking agent to the threads.
  • Page 162: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain the coolant (see Coolant change in the Periodic Maintenance chapter). • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter).
  • Page 163: Oil Pump Installation

    Fill the engine oil (see Engine Oil Change in the Periodic Maintenance chapter). • Fill the coolant (see Coolant Filling in the Periodic Main- tenance chapter). Special Tool - Kawasaki Bond (Silicone Sealant): 56019 -120 Oil Pump Disassembly • Remove the oil pump from the lower case.
  • Page 164: Oil Pump Assembly

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Pull the pin [A] out of the pump shaft. • Pull the oil pump shaft [B] out of the body. • Remove the washer. Oil Pump Assembly • Assembly of the oil pump is the reverse of disassembly. •...
  • Page 165 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft/Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Clearance • Measure the bearing insert/crankpin clearance using a plastigage. ○ Remove the connecting rod big end caps and wipe each bearing insert and crankpin surface clean of oil. ○ Cut strips of plastigage to bearing insert width, and place a strip on the crankpin for each connecting rod parallel to the crankshaft so that the plastigage will be compressed...
  • Page 166 9-20 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods • Put the connecting rod big end caps on the rods and tighten the nuts to the specified torque. Torque - Connecting Rod Big End Cap Nuts: 36 N·m (3.7 kgf·m, 27 ft·lb) • Measure the bore diameter, and mark each connecting rod big end in accordance with the bore diameter.
  • Page 167 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft/Connecting Rods ○ Install the lower crankcase half, and tighten the case bolts to the specified torque. Torque - Crankcase 8 mm Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb) Crankcase 6 mm Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) NOTE ○...
  • Page 168 9-22 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankcase Main Bearing Bore Diameter Marks ○ 39.000 39.008 mm (1.5354 1.5357 in.) None: 39.009 39.016 mm (1.5358 1.5361 in.) □□ □□ Crankcase Main Bearing Bore Diameter ○ Marks, " " mark or no mark. • Select the proper bearing insert in accordance with the combination of the crankcase and the crankshaft coding.
  • Page 169 CRANKSHAFT/TRANSMISSION 9-23 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply oil to the inside of the balancer shaft bearing insert. • Align the timing mark [B] on the balancer gear [A] with the timing mark [B] on the balancer drive gear [C] of the crankshaft.
  • Page 170 9-24 CRANKSHAFT/TRANSMISSION Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
  • Page 171 Torque - Return Spring Pin: 20 N·m (2.0 kgf·m, 14.5 ft·lb) • Apply silicone sealant to the area [C]. Sealant - Kawasaki Bond (Silicone Sealant): 56129-120 • Replace the cover gasket with a new one.
  • Page 172 9-26 CRANKSHAFT/TRANSMISSION Transmission • Apply high temperature grease to the seal lips. • Insert the shift shaft into the crankcase half and fit the shift mechanism arm [A] to the shift drum [B]. • Install the external shift mechanism cover. •...
  • Page 173 CRANKSHAFT/TRANSMISSION 9-27 Transmission • Check to see that the set rings [A] and set pins [B] are in place in the transmission bearing housings. • Lift up the clutch housing and primary chain, insert the drive shaft assembly into the clutch housing, and install the drive shaft assembly in the upper crankcase half.
  • Page 174 9-28 CRANKSHAFT/TRANSMISSION Transmission • The ball bearings and collar are press-fit on the transmis- sion shafts. To remove the bearings [A], use a press or the bearing puller [B] and bearing puller adapter [C]. Special Tools - Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-317 ○...
  • Page 175 CRANKSHAFT/TRANSMISSION 9-29 Transmission • Install the spacer onto the drive shaft, facing the cham- fered side to the ball bearing. • Check that each gear spins or slides freely on the drive shaft without binding. Output Shaft Assembly • Assembly is the reverse of disassembly. Note the follow- ing.
  • Page 176 9-30 CRANKSHAFT/TRANSMISSION Transmission • Check the effect of ball-locking, after assembling the 5th gear and steel balls on the output shaft. ○ Check that the 5th gear [A] does not come out of the out- put shaft when moving it up and down by hand. •...
  • Page 177 CRANKSHAFT/TRANSMISSION 9-31 Transmission • Remove the cotter pin [A], and pull out the 3rd/4th shift fork guide pin [B]. • Remove the bolts [A] holding the shift drum ball bearing [B]. • Pull out the shift drum [C] slightly, and remove the 3rd/4th shift fork.
  • Page 178 9-32 CRANKSHAFT/TRANSMISSION Transmission • Install the washer, spring, gear positioning lever, collar and nut. • Set the shift drum in the neutral position, that is, fit the gear positioning lever [A] into the detent on the shift drum cam [B]. •...
  • Page 179 CRANKSHAFT/TRANSMISSION 9-33 Transmission • There are six points on the shift drum cam. The highest point [A] must be fitted into the back of the pin plate [B]. If these parts are assembled in the wrong position, the neutral indicator light will not light when the gears are in neutral.
  • Page 181 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-7 Wheel Inspection ......................10-8 Spoke Inspection ......................
  • Page 182: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 183 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spoke Nipple 35 in·lb Front Axle Nut Rear Axle Nut Rear Sprocket Nut 5. Sealed Side G: Apply grease. HG: Apply high temperature grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 184: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Radial 0.5 mm (0.02 in.) 1.5 mm (0.06 in.) Axial 0.8 mm (0.03 in.) 1.5 mm (0.06 in.) Axle Runout/100 mm (3.94 in.) Under 0.05 mm (0.002 in.) 0.2 mm (0.008 in.) Balance Weight 10 g (0.35), 20 g (0.71), –...
  • Page 185: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129 Oil Seal & Bearing Remover: Jack: 57001-1058 57001-1238 Rim Protector: Bearing Remover Head, 15 × 17: 57001-1063 57001-1267 Bead Breaker Assembly: Bearing Remover Shaft, 13: 57001-1072 57001-1377...
  • Page 186: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the cap. • Remove the cotter pin [A] and loosen the front axle nut [B]. • Raise the front wheel off the ground using the jack. Special Tool - Jack: 57001-1238 •...
  • Page 187: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) Rear Wheel Removal • Remove: Rubber Cap Cotter Pin [A] Rear Axle Nut [B] (loosen) • Raise the rear wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • Remove: Rear Axle Nut and Washer Indicators [C] •...
  • Page 188: Wheel Inspection

    10-8 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 189: Wheel Balance

    30 (1.06) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 g (0.35, 0.71 US oz), and 30 g (1.06 US oz) sizes. An imbalance of less than 10 grams (0.35 US oz) will not usually affect running stability.
  • Page 190: Tires

    10-10 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter. Tire Wear Inspection • Refer to the Tire Wear Inspection in the Periodic Mainte- nance chapter. Tire Removal CAUTION Do not lay the front wheel on the ground with the disc facing down.
  • Page 191: Tire Installation

    WHEELS/TIRES 10-11 Tires • Step on the side of the tire opposite valve stem, and pry the tire off the rim with the tire iron [B] of the bead breaker protecting the rim with rim protectors [A]. Special Tools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 CAUTION Take care not to insert the tire irons so deeply that...
  • Page 192: Hub Bearing

    10-12 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 193: Hub Bearing Inspection

    WHEELS/TIRES 10-13 Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 194: Speedometer Gear

    10-14 WHEELS/TIRES Speedometer Gear Disassembly and Assembly NOTE ○ It is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation).
  • Page 195 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools and Sealants ....................11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 196: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 197 FINAL DRIVE 11-3 Exploded View Torque Fastener marks N·m kgf·m ft·lb Drive Chain Guide Bolts 95 in·lb Engine Sprocket Nuts Rear Axle Nuts Rear Sprocket Nuts CO: Apply chain oil. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 198: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Chain Slack 45 mm (1.4 1.8 in.) – – – 20-link Length 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Standard Chain Make DAIDO KOGYO – – – Type DID520VL2 –...
  • Page 199: Special Tools And Sealants

    FINAL DRIVE 11-5 Special Tools and Sealants Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 200: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Wear Inspection •...
  • Page 201: Drive Chain Case And Chain Guide Removal

    FINAL DRIVE 11-7 Drive Chain Drive Chain Case and Chain Guide Removal • Remove the dvive chain case mounting bolts [A], [B], and then removed the chain case [C]. • The chain guide [D] is installed together with the chain case with chain case mounting bolts [B].
  • Page 202: Drive Chain Installation

    11-8 FINAL DRIVE Drive Chain Drive Chain Installation • Replace the link pin, link plate and grease seals. • Apply grease to the link pins [A] and grease seals. • Engage the drive chain on the engine and rear sprockets through the swingarm.
  • Page 203: Sprocket, Coupling

    FINAL DRIVE 11-9 Sprocket, Coupling Engine Sprocket Removal • Remove the bolts [A]. • Pull the engine sprocket cover [B]. • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 204: Rear Sprocket Removal

    11-10 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). • Remove the rear sprocket nuts [A]. • Remove the rear sprocket [B]. Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward.
  • Page 205: Coupling Bearing Removal

    FINAL DRIVE 11-11 Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling [A] Collar [B] Sleeve [C] Circlip [D] • Remove the bearing by tapping from the hub side. Special Tool - Bearing Driver Set: 57001-1129 [A] Coupling Bearing Installation • Replace the bearing with a new one.
  • Page 206 11-12 FINAL DRIVE Sprocket, Coupling • Spin [A] the bearing by hand to check its condition. If it is noisy, does not spin smoothly, or has any rough spots, it must be replaced. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
  • Page 207 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Master Cylinder ......... 12-17 Specifications ........12-6 Front Master Cylinder Removal ... 12-17 Special Tool ........12-7 Front Master Cylinder Installation 12-17 Brake Lever and Brake Pedal.... 12-8 Rear Master Cylinder Removal..12-17 Brake Lever Position Adjustment.
  • Page 208: Exploded View

    12-2 BRAKES Exploded View...
  • Page 209 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Front Reservoir Cap Screws 0.15 13 in·lb 2 Brake Lever Pivot Bolt 0.10 9 in·lb 3 Brake Lever Pivot Locknut 0.60 52 in·lb 4 Front Master Cylinder Clamp Bolts 95 in·lb 5 Front Brake Light Switch Mounting Screw 0.12...
  • Page 210 12-4 BRAKES Exploded View...
  • Page 211 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Reservoir Mounting Bolt 0.60 52 in·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Caliper Bleed-Valve 0.80 69 in·lb Rear Caliper Mounting Bolts Brake Disc Mounting Bolts 16.5 Brake Pedal Bolt B: Apply brake fluid.
  • Page 212: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 4-way adjustable (to suit rider) – – – Brake Pedal Position 30 40 mm (1.2 1.6 in.) below footpeg top – – – Free Play Non-adjustable –...
  • Page 213: Special Tool

    BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001-143...
  • Page 214: Brake Lever And Brake Pedal

    12-8 BRAKES Brake Lever and Brake Pedal Brake Lever Position Adjustment The adjuster has 4 positions so that the brake lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the Arrow mark [B] on the lever holder.
  • Page 215: Brake Pedal And Shaft Installation

    BRAKES 12-9 Brake Lever and Brake Pedal • Remove brake light switch spring [A] and shaft spring [B]. Brake Pedal and Shaft Installation • Install the brake shaft and connect the brake rod and brake shaft with pin. • Install the new cotter pin and bend the end of it surely. •...
  • Page 216: Caliper

    12-10 BRAKES Caliper Front Caliper Removal • Drain the brake fluid. • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. •...
  • Page 217: Rear Caliper Installation

    BRAKES 12-11 Caliper Rear Caliper Installation • Install the caliper and rear side brake hose. ○ Replace the washers that are on each side of hose fitting with new ones. • Tighten the caliper mounting bolts and banjo bolt. Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 218 12-12 BRAKES Caliper Remove: Anti-rattle spring [A] Caliper Mounting Bolts [B] Piston [C] Dust Seal [D] Fluid Seal [E] Front Caliper [F] Rear Caliper [G] • The pistons can be removed by compressed air as fol- lows. ○ Remove the banjo bolt and take off the caliper. ○...
  • Page 219: Caliper Assembly

    BRAKES 12-13 Caliper Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb) •...
  • Page 220: Caliper Fluid Seal And Dust Seal Inspection

    12-14 BRAKES Caliper Caliper Fluid Seal and Dust Seal Inspection Fluid Seal Damage The fluid seal [A] around the piston maintains the proper pad/disc clearance. If this seal is not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature.
  • Page 221: Caliper Holder Shaft Wear

    BRAKES 12-15 Caliper Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 222: Brake Pads

    12-16 BRAKES Brake Pads Brake Pad Removal • Remove the caliper [A] with the hose installed. • Remove the pads pushing the caliper holder at both side holding the caliper body, so, the inner pad can be re- moved first and then outer pad. •...
  • Page 223: Master Cylinder

    BRAKES 12-17 Master Cylinder Front Master Cylinder Removal • Disconnect the front brake switch connectors [A]. • Remove the banjo bolt [B] to disconnect the upper brake hose end from the master cylinder [C]. There is a flat washer on each side of the hose fitting. •...
  • Page 224: Rear Master Cylinder Installation

    12-18 BRAKES Master Cylinder • Pull out the cotter pin [A] from the pin [B] fixing the pin so that it does not turn, and remove the pin. • Remove the reservoir mounting bolt [A]. • Remove the brake hose banjo bolt [B]. •...
  • Page 225: Rear Master Cylinder Disassembly

    BRAKES 12-19 Master Cylinder Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi- tion adjustment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal). •...
  • Page 226: Master Cylinder Inspection (visual Inspection)

    12-20 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the master cylinder (see Front/Rear Master Cylinder Disassembly). • Check that there are no scratches, rust or pitting on the inner wall of the master cylinder [A] and on the outside of the piston [B].
  • Page 227: Brake Disc

    BRAKES 12-21 Brake Disc Brake Disc Removal • Remove the wheel (see Front Wheel Rear Wheel Re- moval in the Wheels/Tires chapter). • Unscrew the mounting Allen bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 228: Brake Fluid

    12-22 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Brake Line •...
  • Page 229: Brake Hose

    BRAKES 12-23 Brake Hose Brake Hoses and Connections Inspection • Refer to the Brakes Hoses and Connections in the Peri- odic Maintenance chapter. Brake Hose Replacement • Refer to the Brakes Hoses Replacement in the Periodic Maintenance chapter. Front Brake Hose Removal •...
  • Page 231 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools and Sealant ...................... 13-7 Front Fork ..........................13-8 Front Fork Oil Change ...................... 13-8 Front Fork Removal ......................13-9 Front Fork Installation ....................... 13-9 Front Fork Disassembly ....................13-10 Front Fork Assembly......................
  • Page 232: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 233 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts 16.5 Front Fork Top Bolts Front Fork Bottom Allen Bolts FO: Apply front oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specific tightening sequence.
  • Page 234 13-4 SUSPENSION Exploded View...
  • Page 235 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Upper Mounting Nut Rear Shock Absorber Lower Mounting Nut Rocker Arm Pivot Nut Tie-rod Mounting Nuts Swingarm Pivot Nut 6. Needle Bearings: Face the mark side of it to outside. G: Apply grease.
  • Page 236: Specifications

    13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork (per one unit) Fork Inner Tube Diameter 41 mm (1.61 in.) – – – Fork Spring Setting Non-adjustable – – – Air Pressure 0 kPa (Adjustable) – – – Rebound Damper Setting Non-adjustable –...
  • Page 237: Special Tools And Sealant

    SUSPENSION 13-7 Special Tools and Sealant Fork Cylinder Holder Handle: Fork Outer Tube Weight: 57001-183 57001-1218 Fork Cylinder Holder Adapter: Front Fork Oil Seal Driver: 57001-1057 57001-1219 Oil Seal & Bearing Remover: Jack: 57001-1058 57001-1238 Hook Wrench R37.5, R42: Fork Oil Level Gauge: 57001-1101 57001-1290 Bearing Driver Set:...
  • Page 238: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Oil Change • Remove the front fork (see Front Fork Removal). • Remove the fork boot from the front fork. • Hold the outer tube vertically in a vise. • Remove: Top Bolt [A] and O-ring [B] Spacer [C] Fork Spring Seat [D] Fork Spring [E]...
  • Page 239: Front Fork Removal

    SUSPENSION 13-9 Front Fork Front Fork Removal • Remove: Brake Hose Clamps (Left Front Fork only) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Brake Caliper Mounting Bolts Front Brake Hose Clamp Mounting Bolt Speedometer Cable Clamp Mounting Bolt •...
  • Page 240: Front Fork Disassembly

    13-10 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Front Fork Oil Change). ○ The following parts are removed during draining the fork oil. Top Bolt and O-ring Spacer Fork Spring Seat Fork Spring...
  • Page 241: Front Fork Assembly

    SUSPENSION 13-11 Front Fork Front Fork Assembly • Replace the following parts with new ones after removal. Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Bottom Allen Bolt Gasket [F] • Put the cylinder unit [A] with the spring into the inner tube [B] protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit.
  • Page 242: Inner Tube, Outer Tube Inspection

    13-12 SUSPENSION Front Fork • Pour in the specified type of oil and install the parts re- moved (see Front Fork Oil Change). Fork Oil Viscosity: KAYABA KHL34-G10 or equivalent Fork Oil Capacity (completely dry): 530 ±4 mL (17.91 ±0.14 US oz.) Inner Tube, Outer Tube Inspection •...
  • Page 243: Rear Shock Absorber

    SUSPENSION 13-13 Rear Shock Absorber Spring Preload Adjustment The spring preload adjuster on the rear shock absorber has 5 positions so that the spring tension can be adjusted for different road and loading conditions. • Using the hook wrench [A], turn the adjuster to adjust the spring tension.
  • Page 244: Rear Shock Absorber Installation

    13-14 SUSPENSION Rear Shock Absorber • Remove the upper tie-rod bolt [A] and nut. • Remove the mounting bolts [B] and pull off the rear shock absorber [C]. Rear Shock Absorber Installation • Tighten the mounting bolts. Torque - Rear Shock Absorber Upper Mounting Nut: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Lower Mounting Nut: 98 N·m (10 kgf·m, 72 ft·lb)
  • Page 245: Swingarm

    SUSPENSION 13-15 Swingarm CAUTION Do not tap the swingarm pivot shaft when removing or installing. Push or pull the pivot shaft while turn- ing the shaft. Tapping on the shaft could damage the needle bearings in the swingarm. Swingarm Removal •...
  • Page 246: Swingarm Installation

    13-16 SUSPENSION Swingarm Swingarm Installation • Installation is the reverse of removal. NOTE ○ Loosen the rocker arm pivot nut while installing the pivot shaft. • Tighten the pivot shaft nut. Torque - Swingarm Pivot Nut: 118 N·m (12 kgf·m, 87 ft·lb) •...
  • Page 247: Tie-rod, Rocker Arm

    SUSPENSION 13-17 Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Remove the upper tie-rod bolt [A] pushing the rocker arm sleeve and swingarm sleeve for upper tie-rod a little in after removing the nut.
  • Page 248: Rocker Arm Installation

    13-18 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the needle bearings grease seals. • Tighten: Torque - Rocker Arm Pivot Nut: 98 N·m (10 kg·m, 72 ft·lb) Tie-Rod Nut: 98 N·m (10 kg·m, 72 ft·lb) Rear Shock Absorber Lower Mounting Nut: 98 N·m (10 kg·m, 72 ft·lb) Front Footpeg Brackets Bolts: 34 N·m (3.5 kgf·m,...
  • Page 249 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Handlebar ..........................14-6 Handlebar Removal ......................14-6 Handlebar Installation ....................... 14-6 Rear View Mirror Removal....................14-7 Rear View Mirrors (Left and Right) Installation ..............14-7 Steering ..........................14-8 Steering Play Inspection ....................
  • Page 250: Exploded View

    14-2 STEERING Exploded View...
  • Page 251 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering Stem Head Nut Hand Tighten Hand Tighten Hand Tighten Steering Stem Locknut (about 4.9) (about 0.5) (about 43 in ·lb) Front Fork Upper Clamp Allen Bolts Front Fork Lower Clamp Bolts 16.5 Handlebar Clamp Bolts AD: Apply adhesive.
  • Page 252: Special Tools

    14-4 STEERING Special Tools Steering Stem Bearing Driver: Head Pipe Outer Race Driver, 51.5: 57001-137 57001-1076 Bearing Puller: Steering Stem Nut Wrench: 57001-158 57001-1100 Bearing Puller Adapter: Head Pipe Outer Race Driver, 46.5: 57001-317 57001-1106 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID >...
  • Page 253 STEERING 14-5 Special Tools Bearing Puller: 57001-1575...
  • Page 254: Handlebar

    14-6 STEERING Handlebar Handlebar Removal • Remove: Plugs Clutch Lever (see Clutch Lever Removal in the Clutch chapter) Right and Left Handlebar Switch Housing Throttle Grip Front Brake Master Cylinder (see Front Brake Master Cylinder Removal in the Brakes chapter) •...
  • Page 255: Rear View Mirror Removal

    STEERING 14-7 Handlebar Rear View Mirror Removal • Slide the rubber cap [A] up. • Loosen the adapter nut [B] for tightening to remove the rear view mirror from the holder. Rear View Mirrors (Left and Right) Installation • Screw the rear view mirror into the holder all the way, and tighten the adapter nut securely.
  • Page 256: Steering Play Inspection

    14-8 STEERING Steering Steering Play Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter.
  • Page 257: Steering Stem

    STEERING 14-9 Steering Stem Steering Stem Removal • Remove the handlebar [A] (see Handlebar Removal). • Loosen the stem head nut [B]. • Remove the front fork [C] (see Front Fork Removal in the Suspension chapter). • Remove: Front Brake Hose and Speedometer Cable Clamp Mounting Bolt [A] •...
  • Page 258 14-10 STEERING Steering Stem • Install the oil seals [A] and tapered roller bearing inner races [B] to the upper and lower head pipe. • Install the stem through the head pipe, and hand tighten the stem nut [C]. Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb, for reference) NOTE ○...
  • Page 259: Steering Stem Warp

    STEERING 14-11 Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem shaft [A] is bent, replace the steering stem.
  • Page 260: Steering Stem Bearing

    14-12 STEERING Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see Steering Stem Removal). • Drive out the bearing outer races from the head pipe. ○ Remove the outer races pressed into the head pipe using the head pipe outer race remover [A], and hammer the head pipe outer race remover to drive it out.
  • Page 261: Stem Bearing Lubrication

    STEERING 14-13 Steering Stem Bearing • Apply grease to the upper [A] and lower [B] bearings. • Apply grease to the upper inner race, and install it in the head pipe. • Install the steering stem through the head pipe and upper bearing, and hand tighten the stem nut [A] while pushing up the steering stem.
  • Page 263 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Specifications ........................15-5 Seat ............................15-6 Seat Removal ........................15-6 Seat Installation ....................... 15-6 Fairing............................. 15-7 Lower Fairings Removal ....................15-7 Lower Fairings Installation ....................15-7 Upper Fairing Removal ..................... 15-7 Air Duct Removal ......................
  • Page 264: Exploded View

    15-2 FRAME Exploded View...
  • Page 265 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Frame Down Tube Mounting Bolts Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Bolt and Nut EO: Apply engine oil. G: Apply grease.
  • Page 266 15-4 FRAME Exploded View...
  • Page 267: Specifications

    FRAME 15-5 Specifications Jack: 57001-1238...
  • Page 268: Seat

    15-6 FRAME Seat Seat Removal • Remove the side covers (see Side Cover Removal). • Remove the seat mounting bolts [A]. Seat Installation • Slip the hook [A] of the seat under the brace [B] on the fuel tank. • Install the seat mounting bolts.
  • Page 269: Fairing

    FRAME 15-7 Fairing Lower Fairings Removal • Remove the fairing mounting screws [A] in both side. • Pull the rear side [A] of the fairing a little to outside to clear the stoppers [B] and then remove the fairing pushing [C] it to forward.
  • Page 270: Side Covers

    15-8 FRAME Side Covers Right Side Cover Removal • Insert the ignition switch key [A] into the seat lock. • Turn the ignition switch key clockwise and pull the front of side cover outward to clear the stopper [B]. • Remove the right side cover [C] pulling it forward.
  • Page 271: Fenders

    FRAME 15-9 Fenders Front Fender Removal • Remove the speedometer clamp from front fender. • Remove the bolts [A] and take off the front fender [B] up- ward from rearward. Rear Fender Removal • Remove: Side Covers (see Side Cover Removal) Seat (see Seat Removal) Carrier (see Carrier Removal) •...
  • Page 272: Fender Installation Note

    15-10 FRAME Fenders • Remove the fender mounting bolts [A], and remove the rear fender front [B] backward. Fender Installation Note • Fender installation is the reverse of removal. • Connect the tail/brake light leads and licence light lead correctly.
  • Page 273: Frame

    FRAME 15-11 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 274: Guard, Carrier

    15-12 FRAME Guard, Carrier Engine Guard Removal • Remove the engine guard mounting bolts [A], and remove the engine guard [B]. Carrier Removal • Remove the seat (see Seat Removal). • Disconnect the turn signal connectors [A]. • Remove the carrier mounting bolts [B], and remove the carrier [C] with the turn signals installed to the carrier stays [D].
  • Page 275 16-4 Brush Inspection ......16-46 Specifications ........16-10 Brush Spring Inspection....16-46 Special Tools and Sealant ....16-12 Commutator Cleaning and KLE500-B1 Wiring Diagram ....16-14 Inspection........16-46 Precautions........16-16 Armature Inspection..... 16-47 Electrical Wiring......... 16-18 Brush Plate Inspection ....
  • Page 276 16-2 ELECTRICAL SYSTEM Starter Circuit/Headlight Relay 30 A Main Fuse Removal..... 16-65 Inspection........16-62 Junction Box Fuse Removal ..16-65 Diode Circuit Inspection ....16-63 Junction Box Fuse Installation ..16-65 Fuses..........16-65 Fuse Inspection......16-65...
  • Page 277: Parts Location

    ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch 13. Sidestand Switch 2. Radiator Fan 14. Horn 3. Radiator Fan Switch 15. Spark Plugs 4. #1 Ignition Coil 16. Water Temperature Switch 5. Starter Motor 17. Regulator/Rectifier 6. Sealed Battery 18.
  • Page 278: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 279 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Rotor Bolt Alternator Stator Allen Bolts 104 in·lb Crankshaft Sensor Mounting Screws 0.85 74 in·lb Spark Plugs Starter Clutch Allen Bolts Starter Chain Guide Bolts 43 in·lb Starter Motor Terminal Nut 43 in·lb Starter Motor Mounting Bolts 95 in·lb...
  • Page 280 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 281 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tail Light Mounting Nuts 52 in·lb 2. Rectifier 3. Turn Signal Relay 4. Junction Box...
  • Page 282 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 283 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Side Stand Switch Mounting Screw 35 in·lb 2. Ignition Switch 3. Rear Brake Light Switch 4. Front Brake Light Switch 5. Starter Lockout Switch 6. City Light L: Apply a non-permanent locking agent.
  • Page 284: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery – – – Capacity 12 V 10 Ah – – – Voltage 12.8 V or more – – – Charging System Alternator Type Three-phase AC – – – DC Battery Charging Voltage 15 V @4 000 r/min (rpm) –...
  • Page 285 ELECTRICAL SYSTEM 16-11 Specifications Item Standard Service Limit Falling Temperature From ON to OFF @108°C (226°F) – – – temperature less than ON ON: Less than 0.5 Ω OFF: More than 1 MΩ...
  • Page 286: Special Tools And Sealant

    16-12 ELECTRICAL SYSTEM Special Tools and Sealant Outside Circlip Pliers: Harness Adapter #1: 57001-144 57001-1381 Spark Plug Wrench, Hex 18: Hand Tester: 57001-1024 57001-1394 Rotor Puller, M16/M18/M20/M22 × 1.5: Flywheel Holder: 57001-1216 57001-1410 Timing Light: Peak Voltage Adapter: 57001-1241 57001-1415 Igniter Checker Assembly: Filler Cap Driver: 57001-1378...
  • Page 287 ELECTRICAL SYSTEM 16-13 Special Tools and Sealant Needle Adapter Set: Kawasaki Bond (Liquid Gasket - Gray): 57001-1457 92104-1063 Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 288: Kle500-b1 Wiring Diagram

    16-14 ELECTRICAL SYSTEM KLE500-B1 Wiring Diagram...
  • Page 289 ELECTRICAL SYSTEM 16-15 KLE500-B1 Wiring Diagram...
  • Page 290: Precautions

    16-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○...
  • Page 291 ELECTRICAL SYSTEM 16-17 Precautions Male Connectors [B]...
  • Page 292: Electrical Wiring

    16-18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is in poor condition, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 293: Battery

    ELECTRICAL SYSTEM 16-19 Battery Battery Removal/Installation • Remove: Seat (see Seat Removal in the Frame Chapter) • Remove the rubber IC igniter cover [A] with the igniter connected. • Remove the battery pusher [B] by taking off the bolt [C] and nut [D].
  • Page 294 16-20 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • Place the battery on a level surface. •...
  • Page 295: Precautions

    1.2 A × 5 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 296: Interchange

    16-22 ELECTRICAL SYSTEM Battery When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced noticeably if charged under condi- tions other than given above.
  • Page 297: Refreshing Charge

    ELECTRICAL SYSTEM 16-23 Battery Refreshing Charge • Disconnect the battery terminals (see Charging Condition Inspection). • Remove the battery [A]. • Do refresh-charge by following method according to the battery terminal voltage. WARNING This battery is sealed type. Never remove seal cap [B] even at charging.
  • Page 298: Charging System

    16-24 ELECTRICAL SYSTEM Charging System Alternator Rotor/Starter Clutch Removal • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Remove the engine guard (see Engine Guard Removal in the Frame chapter). • Remove the shift pedal. •...
  • Page 299: Starter Clutch Sprocket Removal

    ELECTRICAL SYSTEM 16-25 Charging System • Remove the rollers [A], springs [B], and spring caps [C] from the starter clutch [D]. • Holding the rotor [A] steady, remove the Allen bolts [B] to separate the rotor and starter clutch [C]. Starter Clutch Sprocket Removal •...
  • Page 300: Alternator Rotor/starter Clutch Installation

    Apply silicone sealant to the area [A] where the mating surface ends of the crankcase touch the alternator cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply silicone sealant around the circumference of the wiring grommets before setting it in the notch in the al- ternator cover.
  • Page 301: Alternator Stator Installation

    Apply silicone sealant [A] around the circumference of the wiring grommets before setting them in the notch in the alternator cover. Sealant - Kawasaki Bond (Liquid Gasket): 92104-1063 • Install the grommet for the stator wiring and crankshaft sensor lead in this order.
  • Page 302: Regulator/rectifier Removal

    16-28 ELECTRICAL SYSTEM Charging System Voltage Connectings Tester Reading Range @4 000 rpm Tester (+) to Tester (–) to 250 V AC One yellow lead Another yellow lead About 60 V If the output voltage shows the value in the table 1, the alternator operates properly and the regulator/rectifier is damaged.
  • Page 303: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-29 Charging System • Check that the ignition switch is turned off, and connect the hand tester [A] as shown in the table. Special Tool - Hand Tester:57001-1394 • Start the engine, and note the voltage readings at vari- ous engine speeds with the headlight turned on and then turned off.
  • Page 304 16-30 ELECTRICAL SYSTEM Charging System • Connect the hand tester to the regulator/rectifier as shown in the table, and measure the resistance of the respective diodes in both directions, in the sequence in the table. The measured resistance should be small in one direc- tion and 10 or more times in the other direction.
  • Page 305 ELECTRICAL SYSTEM 16-31 Charging System Regulator Circuit Test-1st Step: • Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. • Check Y1, Y2, and Y3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
  • Page 306 16-32 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load...
  • Page 307: Ignition System

    ELECTRICAL SYSTEM 16-33 Ignition System Ignition System Circuit 1. Ignition Switch 9. Side Stand Switch 2. Engine Stop Switch 10. Neutral Switch 3. Starter Button 11. Main Fuse 30 A 4. Spark Plugs 12. Battery 12 V 10 AH 5. Ignition Coils 13.
  • Page 308: Crankshaft Sensor Removal

    16-34 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running.
  • Page 309: Ignition Coil Removal/installation

    ELECTRICAL SYSTEM 16-35 Ignition System Ignition Coil Removal/Installation • Remove the Lower Fairings (see Lower Fairing Removal in the Frame chapter). • Disconnect the leads and remove the ignition coils. • Install the ignition coils. Note the following. ○ Connect the primary winding leads to the ignition coiled terminals as shown.
  • Page 310: Ignition Timing Inspection

    16-36 ELECTRICAL SYSTEM Ignition System NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Disconnect the primary leads from the coil terminals. • Measure the primary winding resistance [A] as follows: ○...
  • Page 311: Ic Igniter Removal

    ELECTRICAL SYSTEM 16-37 Ignition System IC Igniter Removal • Remove the seat (see Seat Removal in the Frame chap- ter). • Slide the rubber IC igniter cover [A]. • Disconnect the IC igniter connectors [B], and remove the igniter [C]. IC Igniter Inspection CAUTION When inspecting the IC igniter [A], observe the fol-...
  • Page 312 16-38 ELECTRICAL SYSTEM Ignition System • Set the Hand Tester [A] to the × 25 V DC range, and connect it to the connector come from harness side as follows. Tester (+) terminal [B] → BR/W lead Tester (–) terminal [C] → BK/Y lead Special Tool - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 •...
  • Page 313 [B] to the tester [A], and connect the adapter terminals to the respective terminals of the ignition coil [C]. ○ Keep the terminals connected. Special Tool - Kawasaki Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connect Adapter’s positive (+) → terminal black wire terminal [D] Adapter’s negative (–)
  • Page 314 16-40 ELECTRICAL SYSTEM Ignition System Troubleshooting...
  • Page 315: Diodes Inspection

    ○ Connect the peak voltage adapter [A] to the tester, and connect the adapter terminal to the crankshaft sensor connector [B] terminal. Special Tool - Kawasaki Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connect Adapter’s positive (+) terminal →...
  • Page 316 16-42 ELECTRICAL SYSTEM Ignition System NOTE ○ The actual meter reading varies with the meter used and the individual diode, but, generally speaking, the lower reading should be from zero to one half the scale.
  • Page 317: Electric Starter System

    ELECTRICAL SYSTEM 16-43 Electric Starter System Electric Starter Circuit 1. Ignition Switch 7. Ignition Fuse 10 A 2. Engine Stop Switch 8. Starter Lockout Switch 3. Starter Button 9. Neutral Switch 4. Junction Box 10. Starter Motor 5. Diode 11. Starter Relay 6.
  • Page 318: Starter Motor Removal

    16-44 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove the alternator cover (see Alternator Cover Re- moval). • Remove the starter chain guide bolts [A] and remove the starter chain guide [B]. • Disconnect the starter motor lead [A] and negative lead [B].
  • Page 319: Starter Motor Assembly

    ELECTRICAL SYSTEM 16-45 Electric Starter System • Remove the terminal nut [A], and take the brush plate [B] off the end cover [C]. Starter Motor Assembly • Replace any O-ring removed with a new one. • Install the terminal bolt. •...
  • Page 320: Brush Inspection

    16-46 ELECTRICAL SYSTEM Electric Starter System • Make sure that the marks [A] on the covers and yoke housing align with each other. • Tighten the through bolts. Torque - Starter Motor Through Bolts: 6.9 N·m (0.7 kgf·m, 65 in·lb) Brush Inspection •...
  • Page 321: Armature Inspection

    ELECTRICAL SYSTEM 16-47 Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 322: Starter Relay Inspection

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Relay Inspection • Remove the left side cover (see Side Cover Removal in the Frame chapter). • Remove the starter relay. • Connect a hand tester [A] and one 12 V battery [B] to the starter relay [C] as shown.
  • Page 323: Lighting System

    ELECTRICAL SYSTEM 16-49 Lighting System Headlight Circuit 1. Ignition Switch 2. Junction Box 3. Diode 4. Headlight Relay 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight (High Beam) 8. Headlight (Low Beam) 9. Dimmer Switch 10. Alternator 11.
  • Page 324: Headlight Bulb Replacement

    16-50 ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement • Remove the headlight unit with upper fairing (see Head- light Unit/Housing Removal). • Remove the dust cover. • Remove the screw [A] and remove the retaining spring [B]. • Remove the headlight bulb [C] and replace it. CAUTION When handling the quartz-hologen bulb, never touch the glass portion with bare hands.
  • Page 325: Headlight Unit/housing Installation

    ELECTRICAL SYSTEM 16-51 Lighting System • Disconnect the headlight lead couplers [A], city light lead connector [B], and free the headlight unit/housing [C] and upper fairings [D] assembly. • Remove the 4-bolts [A] and two-screws [B], and separate the headlight unit/housing [C] and upper fairings [D]. Headlight Unit/Housing Installation •...
  • Page 326: Tail/brake Light Lens Removal/installation

    16-52 ELECTRICAL SYSTEM Lighting System • Insert the new bulb by aligning the pins [A] with the grooves [B] in the walls of the socket so that the pin closest to the bulb base is to the upper right. • Turn the bulb clockwise pushing it into the bulb base.
  • Page 327 ELECTRICAL SYSTEM 16-53 Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Light 2. Front Right Turn Signal Light 3. Front Left Turn Signal Light 4. Turn Signal Relay 10 W 5. Turn Signal Fuse 10 A 6. Junction Box 7.
  • Page 328: Radiator Fan System

    16-54 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Disconnect the connector from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch connector.
  • Page 329: Meter Unit

    ELECTRICAL SYSTEM 16-55 Meter Unit Meter Unit Removal • Remove the headlight unit and housing (see Headlight Unit/Housing Removal). • Remove the speedometer cable upper end [A] and the mounting nuts [B]. • Disconnect the meter connectors [C] and take off the me- ter unit [D].
  • Page 330: Tachometer Inspection

    16-56 ELECTRICAL SYSTEM Meter Unit • Remove the screws [A] for removal of each unit. Tachometer [B] Speedometer [C] Speedometer Gear [D] NOTE ○ Turns out the trip knob counterclockwise before remov- ing the speedometer mounting screws. Tachometer Inspection • Check the tachometer circuit wiring (see Wiring Inspec- tion).
  • Page 331: Water Temperature Warning System Inspection

    ELECTRICAL SYSTEM 16-57 Meter Unit Tachometer Circuit 1. Tachometer 2. Junction Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Main Fuse 30 A 6. Battery 12 V 10 AH 7. IC Igniter Water Temperature Warning System Inspection The water temperature warning light goes on when the ignition switch is turned on and goes off soon after the en- gine starts running (oil pressure switch off) to ensure that its circuit functions properly.
  • Page 332 16-58 ELECTRICAL SYSTEM Meter Unit Water Temperature Warning System 1. Ignition Switch 2. Junction Box 3. Ignition Fuse 10 A 4. Starter Relay 5. Main Fuse 30 A 6. Water Temperature Warning Light 7. Oil Pressure Warning Light 8. Rectifier 9.
  • Page 333: Switches And Sensors

    ELECTRICAL SYSTEM 16-59 Switches and Sensors Brake Light Switch Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection • Using the hand tester, check to see that only connections shown in the table have continuity (about zero ohm). ○...
  • Page 334: Radiator Fan Switch Inspection

    16-60 ELECTRICAL SYSTEM Switches and Sensors Radiator Fan Switch Inspection • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the fan switch (see Radiator Fan Switch Re- moval in the Cooling System chapter). •...
  • Page 335: Water Temperature Switch Inspection

    ELECTRICAL SYSTEM 16-61 Switches and Sensors Water Temperature Switch Inspection • Remove the water temperature switch (see Water Tem- perature Switch Removal in the Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.
  • Page 336: Junction Box

    16-62 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the left side cover (see Side Cover Removal in the Frame chapter). •...
  • Page 337: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-63 Junction Box Relay Circuit Inspection (with the battery disconnected) Tester Tester Reading Tester Tester Reading (Ω) Connection (Ω) Connection ∞ 9 -11 ∞ ∞ ∞ Headlight 7-13 Starter Circuit 12 -13 Relay Relay (+) (–) (+) (–) 13 -9 Not ∞...
  • Page 338 16-64 ELECTRICAL SYSTEM Junction Box Junction Box Internal Circuit A: Accessory Fuse 10 A B: Radiator Fan Fuse 10 A C: Turn Signal Relay Fuse 10 A D: Horn Fuse 10 A E: Ignition Fuse 10 A F: Headlight Fuse 10 A G: Headlight Relay H: Headlight Diodes I: Starter Diode...
  • Page 339: Junction Box Fuse Installation

    ELECTRICAL SYSTEM 16-65 Fuses 30 A Main Fuse Removal • Remove the right side cover (see Side Cover Removal in the Frame chapter). • Unlock the hook to lift up the lids of the main fuse cover [A]. • Pull up the main fuse cover with the starter relay connec- tor.
  • Page 341 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-16...
  • Page 342 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 343 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Headlight Lead Connector (High Beam) 2. Headlight Lead Connector (Low Beam) 3. City Light Lead Connector 4. Meter Assembly Connector 5. Rectifier Lead Connector 6. Front Right Turn Signal Light Lead Connector 7.
  • Page 344 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 345 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Headlight Lead Connector (High Beam) 2. Headlight Lead Connector (Low Beam) 3. City Light Lead Connector 4. Meter Assembly 5. Diode Lead Connector 6. Front Right Turn Signal Light Lead Connector 7. Radiator Fan Motor Lead Connector 8.
  • Page 346 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 347 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Front Brake Hose 2. Choke Cable 3. Handlebar Switch Lead (Left) 4. Frame Ground Lead Terminal 5. Band 6. Ignition Coil (Left) 7. Radiator Fan Switch 8. Front Left Turn Signal Light Lead Connector 9.
  • Page 348 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 349 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Choke Cable 2. Route the choke cable and throttle cables under the main harness. 3. Run the choke cable under the throttle cables. 4. Throttle Cables 5. Band 6. Rear Brake Light Switch 7.
  • Page 350 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 351 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Diode 2. Headlight Lead Connector (High Beam) 3. Clamp 4. City Light 5. Headlight Lead Connector (Low Beam) 6. Starter Relay 7. Band 8. Throttle Cables 9. Clutch Cable 10. Handlebar Switch Lead Connector (Right) 11.
  • Page 352 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 353 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Ignition Switch Lead 2. Handlebar Switch Lead (Right) 3. Handlebar Switch Lead (Left) 4. Fix the connector with bracket (5). 5. Bracket 6. Meter Leads 7. Insert the connector to arrow direction. 8.
  • Page 354 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 355 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Ignition Switch 3. Clutch Cable 4. Route the speedometer cable through the clamp (5). 5. Clamp 6. Front Brake Hose 7. Band 8. Clamp 9. Choke Cable 10. Band (Fix the choke cable, clutch cable, left handlebar switch lead and ignition switch leads with the band) 11.
  • Page 356: Troubleshooting Guide

    17-16 APPENDIX Troubleshooting Guide NOTE Crankshaft sensor trouble ○ This is not an exhaustive list, giving every Ignition coil trouble possible cause for each problem listed. It Ignition or engine stop switch shorted is meant simply as a rough guide to assist Wiring shorted or open the troubleshooting for some of the more Fuse blown...
  • Page 357 APPENDIX 17-17 Troubleshooting Guide Cylinder, piston worn No valve clearance Piston ring bad (worn, weak, broken, or Cylinder, piston worn sticking) Piston ring bad (worn, weak, broken, or Piston ring/groove clearance excessive sticking) Cylinder head warped Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head gasket damaged Valve spring broken or weak...
  • Page 358: Abnormal Engine Noise

    17-18 APPENDIX Troubleshooting Guide Coolant incorrect: Shift drum groove worn Coolant level too low Gear positioning lever spring weak or bro- Coolant deteriorated Cooling system component incorrect: Shift fork pin worn Radiator fin damaged Drive shaft, output shaft, and/or gear Radiator clogged splines worn Thermostat trouble...
  • Page 359: Abnormal Frame Noise

    APPENDIX 17-19 Troubleshooting Guide Clutch housing gear worn Brown smoke: Transmission noise: Main jet too small Bearings worn Fuel level in carburetor float bowl too low Transmission gears worn or chipped Air cleaner duct loose Metal chips jammed in gear teeth Air cleaner O-ring damaged Engine oil insufficient Air cleaner poorly sealed or missing...
  • Page 360 17-20 APPENDIX Troubleshooting Guide Primary or secondary cup damaged in mas- Load excessive (e.g., bulb of excessive ter cylinder wattage) Master cylinder scratched inside Ignition switch trouble Alternator trouble Battery Trouble: Wiring faulty Regulator/rectifier trouble Battery discharged: Battery overcharged: Battery faulty (e.g., plates sulphated, Regulator/rectifier trouble shorted through sedimentation, elec-...
  • Page 361 MODEL APPLICATION Year Model Beginning Frame No. 2005 KLE500-B1 JKALE500ABA085001 Part No .999 24-1352-01 Printed in Japan...

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  • Alex Apr 19, 2016 05:23:
    Manual kle 500

    Servi​ce kawasaki kle 500