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Table of Contents
KLX450R
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KLX450R

   Summary of Contents for Kawasaki KLX450R

  • Page 1 KLX450R Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side 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...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. Fourth Edition (0) : March 12, 2010...
  • 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: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency.
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled which will help you distinguish different types maintenance. of information. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and NOTE ○ testers that are necessary when servicing This note symbol indicates points of par-...
  • Page 10 instructions indicating which parts require spec- agent during assembly. ified tightening torque, oil, grease or a locking...
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...
  • Page 12: 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 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 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 15 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 16 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 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLX450A8F Left Side View KLX450A8F Right Side View Frame Number Engine Number...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications KLX450A8F ∼ ABF Items Dimensions Overall Length 2 180 mm (85.83 in.), (AU) (EUR) 2 175 mm (85.63 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 255 mm (49.41 in.), (AU) (EUR) 1 250 mm (49.21 in.) Wheelbase 1 480 mm (58.27 in.) Road Clearance...
  • Page 19 GENERAL INFORMATION 1-9 General Specifications KLX450A8F ∼ ABF Items Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.167 (26/12) 1.533 (23/15) 1.188 (19/16) 0.950 (19/20) 0.810 (17/21) Final Drive System: Type Chain drive Reduction Ratio 3.846 (50/13) Overall Drive Ratio 8.492 @Top gear Frame Type...
  • Page 20 1-10 GENERAL INFORMATION General Specifications KLX450A8F ∼ ABF Items Tail Light Magneto: Rated Output 2.0 A/14 V Specifications subject to change without notice, and may not apply to every country.
  • Page 21: 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 milli × 0.001 Units of Torque: µ...
  • Page 23 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Air Pressure Inspection/Adjust- Torque and Locking Agent....ment .......... 2-29 Specifications ........Tires Inspection......2-30 Special Tools ........2-11 Spoke Tightness Inspection ..2-30 Periodic Maintenance Procedures..2-12 Rim Runout Inspection....
  • Page 24: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Periodic Inspection FREQUENCY Traveled Distance km (mi) Every Every Every Every Every 1 000 1 500 2 000 (60) (300)
  • Page 25 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Traveled Distance km (mi) Every Every Every Every Every 1 000 1 500 2 000 (60) (300) (600) (900) (1 200) Page or 2.5 or 7.5 or 15 or 30 or 60 OPERATION •...
  • Page 26: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
  • Page 27 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Vacuum Hose Fitting 0.90 78 in·lb Cylinder Head Pipe Mounting Bolt 87 in·lb Exhaust Pipe Cover Bolts 106 in·lb Rear Muffler Mounting Bolt Front Muffler Mounting Bolt (First) 87 in·lb Front Muffler Mounting Bolt (Final) Exhaust Pipe Holder Nuts...
  • Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Gear Set Lever Nut 0.90 78 in·lb Engine Oil Drain Plug (M6)(Sub) 0.71 62 in·lb Engine Oil Drain Plug (M10)(Main) Shift Drum Cam Bolt Piston Oil Nozzle 0.41 35 in·lb Bearing Retaining Screws...
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Locknut/Adjuster Assembly Adjuster Assembly Front Axle Clamp Bolts Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut Tie-rod Mounting Nut (Front, Rear) Rear Shock Absorber Mounting Nut (Upper) Rear Shock Absorber Mounting Nut (Lower) Air Bleed Bolt...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Basic Torque for General Fasteners Threads dia. Torque (mm) N·m kgf·m ft·lb 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 14 ∼ 19 1.4 ∼...
  • Page 31: Specifications

    PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) Hot Starter Lever Free Play – – – Air Cleaner Element Oil High quality foam air filter oil –...
  • Page 32 2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Standard Tire: Front: Size 80/100-21 51M – – – (AU) (EUR) 80/100-21 M/C 51P – – – Make BRIDGESTONE – – – Type D401, Tube – – – (AU) (EUR) ED03, Tube –...
  • Page 33: Special Tools

    PERIODIC MAINTENANCE 2-11 Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001-143 57001-1262 Steering Stem Nut Wrench: Filler Cap Driver: 57001-1100 57001-1454 Jack: Top Plug Wrench, 49 mm: 57001-1238 57001-1653...
  • Page 34: Periodic Maintenance Procedures

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 35: Hot Starter Lever Free Play Inspection

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures WARNING Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an un- safe riding Condition. Follow the service manual to make sure to correct any of these conditions. Hot Starter Lever Free Play Inspection •...
  • Page 36: Idle Speed Adjustment

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged.
  • Page 37 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well ventilated area, and take care that there is no spark or flame any- where near the working areas.
  • Page 38: Fuel Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Squeeze it dry in a clean towel [A]. Do not wring the ele- ment or blow it dry; the element can be damaged. • Check all the parts of the element for visible damage. If any of the parts of the element are damaged, replace them.
  • Page 39: Fuel Tank, Filter And Tap Cleaning

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Turn the fuel tap to the OFF position. • Place a suitable container beneath the carburetor drain hose [B]. • Loosen the drain plug [A] from the bottom of the float bowl and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor, fuel filter, fuel tap and fuel tank.
  • Page 40: Coolant Level Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Lean the motorcycle slightly to the left until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator.
  • Page 41: Radiator Hoses And Connections Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Radiator Hoses and Connections Inspection ○ The high pressure inside the radiator hoses and water hoses [A] can cause coolant to leak [B] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 42: Valve Clearance Inspection

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the vacuum switch valve does not operate as described, replace it with a new one. NOTE ○ To check air flow through the vacuum switch valve, just blow through the air cleaner hose. Vacuum Switch Valve Closing Pressure (open →...
  • Page 43: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Valve Clearance Adjustment • Remove the camshaft caps [A] (see Camshaft Removal in the Engine Top End chapter). • Remove the camshafts [B] (see Camshaft Removal in the Engine Top End chapter). • Remove the valve lifters [C] of the applicable valve. •...
  • Page 44: Periodic Maintenance Procedures

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment shims Thick- Thick- P/No. Mark P/No. Mark ness ness 2.00 92025-1870 2.55 92025-1881 2.05 92025-1871 2.575 92025-1985 2.10 92025-1872 2.60 92025-1882 2.15 92025-1873 2.625 92180-1059 2.20 92025-1874 2.65 92025-1883 2.25 92025-1875 2.675 92180-1194 2.30 92025-1876 2.70...
  • Page 45: Cylinder Head Warp Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Cylinder Head Warp Inspection • Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter). • Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge between the straightedge and the head.
  • Page 46: Piston/cylinder Clearance

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston/Cylinder Clearance The piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced. If only a piston is replaced, the clearance may exceed the standard slightly.
  • Page 47: Engine Right Side

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Remove: Spark Arrester Mounting Bolts [A] Spark Arrester [B] • With a wire brush, remove the carbon off the inside of the spark arrester [A] and muffler. • Inspect the spark arrester. If the spark arrester is damaged, replace it with a new one.
  • Page 48: Clutch Lever Free Play Adjustment

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Lever Free Play Adjustment • Slide the clutch lever dust cover out of place. • Turn the adjuster [A] so that the clutch lever will have 8 ∼ 13 mm (0.3 ∼ 0.5 in.) of play. NOTE ○...
  • Page 49: Oil Filter Change

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely. Drain Plug (Sub) [A] Drain Plug (Main) [B] NOTE ○ Hold the motorcycle upright so that the oil may drain completely.
  • Page 50: Breather Hose Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the Oil Filter [A]. • Install the spring [A] to the right engine cover. • Apply grease to the grommet [B]. • Be sure to install the filter with the grommet facing outside as shown.
  • Page 51: Crankshaft/transmission

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Crankshaft/Transmission Crankshaft Inspection Connecting Rod Big End Side Clearance • Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter). • Remove the cylinder (see Cylinder Removal in the Engine Top End chapter).
  • Page 52: Tires Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection As the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from the tread. • Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage.
  • Page 53: Rim Runout Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Rim Runout Inspection • Place the jack under the frame so that the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warp- ing.
  • Page 54: Final Drive

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection • Raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • Check the wheel alignment (see Wheel Alignment Inspec- tion in the Final Drive chapter), and adjust it if necessary (see Drive Chain Slack Adjustment).
  • Page 55: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment. ○...
  • Page 56: Drive Chain Lubrication

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before each ride.
  • Page 57: Rear Sprocket Warp Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Rear Sprocket Warp Inspection • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 58: Brake Fluid Level Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Loosen the push rod locknut [A]. ○ Replace the cotter pin with a new one. ○ Remove: Cotter Pin [B] Washer Joint Pin [C] ○ Turn the bracket [D] to obtain the specified length. ○...
  • Page 59: Brake Fluid Change

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed.
  • Page 60 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. • Remove the screws [A], reservoir cap [B] and diaphragm [C].
  • Page 61: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Remove the clear plastic hose. • Tighten the bleed valves, and install the rubber caps. Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) •...
  • Page 62 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Do not remove the secondary cup from the piston since removal will damage it. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi- tion adjustment.
  • Page 63: Caliper Piston Seal And Dust Seal Replacement

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Caliper Piston Seal and Dust Seal Replacement • Loosen the brake pad pin [A] and banjo bolt [B], and tighten them loosely. • Remove: Front Caliper Mounting Bolts [C] Banjo Bolt Brake Hose [E] Front Caliper [D] (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Brake Pad Removal in the Brakes...
  • Page 64 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the rear caliper (see Caliper Removal in the Brakes chapter). • Remove the pads (see Brake Pad Removal in the Brakes chapter). • Separate the caliper holder [B] from the caliper [A]. •...
  • Page 65 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Install the anti-rattle spring [A] in the caliper as shown. • Replace the shaft rubber friction boot [A] and dust boot [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistance grease).
  • Page 66: Brake Hose And Connection Check

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Connection Check • 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 67: Suspension

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures For Rear Brake • Remove: Master Cylinder [A] Hose Clamps [B] Caliper Cover [C] • When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
  • Page 68 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the fork top plug [A]. Special Tool - Top Plug Wrench, 49 mm [B]: 57001-1653 • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Brake Caliper (see Caliper Removal in the Brakes chapter) Brake Hose Clamps (see Brake Hose Replacement) •...
  • Page 69 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Place a drain pan under the front fork and drain fork oil [A]. NOTE ○ Pump the fork tube several times to discharge the fork oil. • Raise the outer tube and temporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C].
  • Page 70 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the locknut [A] with a wrench [B] and remove the adjuster assembly [C]. • Remove the push rod [A]. • With the outer tube compressed by hands, remove the top plug wrench [A]. NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal.
  • Page 71 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Holding the top plug wrench [A] with a vise, loosen the base valve assembly [B] on the subtank [C]. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 • Remove the base valve assembly [A] from the subtank [B].
  • Page 72 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the piston rod in fully compressed position, pour the specified amount of fork oil [A]. Recommended Oil: KHL15-10 (KAYABA01) or equivalent Recommended Quantity: 189 ml (6.4 US oz.) NOTE ○ Plug the two oil holes on the subtank [B] with fingers. •...
  • Page 73 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Holding the top plug wrench [A] with a vise. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 • Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C]. Torque - Base Valve Assembly: 28 N·m (2.9 kgf·m, 21 ft·lb) •...
  • Page 74 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Completely wipe of the fork oil from the spring [A], spacer [B] and cylinder unit [C]. • Insert above-mentioned parts into the fork. • Temporarily tighten the fork top plug [A] (subtank) using the top plug wrench.
  • Page 75 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Replace the O-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O-ring. • Turn the locknut [A] counterclockwise until it contacts with the adjuster assembly [B]. •...
  • Page 76: Rear Shock Absorber Inspection

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Shock Absorber Inspection • Bounce [A] the rear of the motorcycle up and down and check for smooth suspension stroke. • Remove the rear frame (see Rear Frame Removal in the Frame chapter). •...
  • Page 77 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Using the suitable tool [A] and press, push the reservoir cap [B] in 10 mm (0.39 in.). • Remove the circlip [C] from the gas reservoir. • Pull the gas reservoir cap [B] out of the gas reservoir using the pliers [A].
  • Page 78 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using the grinder, shave off the stopper portion [A] of the rod. • Remove: Nut [B] Washer [C] Piston [D] • Install the new piston and tighten the locknut. ○ Discard a washer or two. •...
  • Page 79 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Mount the circlip [A] in the groove in the gas reservoir. • Pull up the gas reservoir cap [A] against the circlip. The end of the gas reservoir cap must align [B] with the end of the gas reservoir [C].
  • Page 80 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert the piston end [A] of the piston rod assembly into the rear shock body [C] slowly. Do not insert the seal assembly [B] yet. Pump the piston rod until all the air is forced out of the rear shock body.
  • Page 81: Swingarm And Uni-trak Linkage Inspection

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Swingarm and Uni-Trak Linkage Inspection • Check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 82 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Handlebar Pad [A] Headlight [B] (see Headlight Removal/Installation in the Electrical System chapter) • Remove: Handlebar Clamp Bolts [A] Handlebar Clamps [B] Handlebar [C] (from holder) • Loosen the front fork upper clamp bolts [A], and remove the steering stem head nut [B] and steering stem head [C].
  • Page 83: Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Install the handlebar [B] on the handlebar holder so that the protruded scales of the both side adjust to the same width [A]. • Route the hose according to Cable, Wire, and Hose Rout- ing section in the Appendix chapter.
  • Page 84: Electrical System

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Cleaning and Inspection • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Spark Plug Cap • Clean the plug hole [A], using the compressed air [B]. •...
  • Page 85: Nut, Bolt, And Fastener Tightness Inspection

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Hot Start Inner Cable Upper End Throttle Inner Cable Upper End Cables: Lubricate with Rust Inhibitor. Throttle Cables Clutch Cable Hot Starter Cable •...
  • Page 86 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications. For each fastener, first loosen it by 1/2 turn, then tighten it.
  • Page 87 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable Replacement ..................... Throttle Cable Lubrication....................Throttle Cable Inspection ....................Hot Starter Cable Removal ....................3-10 Hot Starter Cable Installation ....................
  • Page 88: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 89 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Pulley Cover Bolt 0.35 30 in·lb Throttle Cable Mounting Bolts 0.70 61 in·lb 3. Hot Starter Cable 4. Throttle Cables 5. Throttle Grip 6. Carburetor Cap 7. Throttle Valve Plate 8.
  • Page 90 3-4 FUEL SYSTEM Exploded View...
  • Page 91 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Vacuum Switch Valve Bracket Bolts 87 in·lb Fuel Tap Knob Screws 0.80 0.080 7.0 in·lb Rear Frame Mounting Bolts 4. Fuel Tank Cap 5. Fuel Tank 6. Fuel Tap 7.
  • Page 92: Specifications

    3-6 FUEL SYSTEM Specifications Item Standard Throttle Grip and Cable 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) Hot Starter Lever Free Play Carburetor Make/Type KEIHIN FCR-MX40 Starter Jet Leak Jet Main Jet #145...
  • Page 93: Special Tool

    FUEL SYSTEM 3-7 Special Tool Fuel Level Gauge, M18 × 1.0: 57001-122...
  • Page 94: Throttle Grip And Cable

    3-8 FUEL SYSTEM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle.
  • Page 95: Throttle Cable Lubrication

    FUEL SYSTEM 3-9 Throttle Grip and Cable • Remove the exhaust pipe (see Muffler Removal in the Engine Top End chapter). • Unscrew the bolt [A]. • Remove the throttle pulley cover [B]. • Loosen the mounting bolts [A]. • Remove the cables [B] from the carburetor.
  • Page 96: Hot Starter Cable Removal

    3-10 FUEL SYSTEM Throttle Grip and Cable Hot Starter Cable Removal • Slide the clutch lever dust cover [A] back. • Loosen the locknut [B]. • Turn in the adjuster [C] fully. • Remove the cable end [D] from the hot starter lever [E]. •...
  • Page 97: Hot Starter Lever Free Play Adjustment

    FUEL SYSTEM 3-11 Throttle Grip and Cable Hot Starter Lever Free Play Adjustment • Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter. Hot Starter Cable Lubrication • Whenever the hot starter cable is removed or in accor- dance with the Periodic Maintenance Chart, lubricate the these cable (see Lubrication in the Periodic Maintenance chapter).
  • Page 98: Carburetor

    3-12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.
  • Page 99: Service Fuel Level Adjustment

    FUEL SYSTEM 3-13 Carburetor • Read the fuel level in the gauge and compare it to the specification. Service Fuel Level (below the bottom edge of the carb. body) Standard: –6.5 ±1 mm (–0.26 ±0.04 in.) If the fuel level is incorrect, adjust it. •...
  • Page 100: Carburetor Removal

    3-14 FUEL SYSTEM Carburetor NOTE ○ Float height [A] is the distance from the float bowl mat- ing surface [B] of the carburetor body (with the gasket removed) to the top of the float [C]. Measure the height with the carburetor upside down. ○...
  • Page 101 FUEL SYSTEM 3-15 Carburetor • Loosen the clamp screw [A] fully. • Remove: Engine Mounting Bracket Bolts [B] Right Engine Mounting Bracket [C] • Remove: Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Muffler (see Muffler Removal in the Engine Top End chapter)
  • Page 102: Carburetor Installation

    3-16 FUEL SYSTEM Carburetor • Loosen the mounting bolts [A]. • Pull out the end of the throttle cables [B]. • Free the tips [C]. • Remove the carburetor to the right side of the frame. • Drain the fuel from the float bowl by removing the drain plug.
  • Page 103: Fuel Inspection

    FUEL SYSTEM 3-17 Carburetor ○ Adjust the following items if necessary: Throttle Cable (see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter) Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter) Fuel Inspection • Refer to the Fuel Inspection in the Periodic Maintenance chapter.
  • Page 104 3-18 FUEL SYSTEM Carburetor • Disassemble the throttle valve assembly; jet needle holder [A] (unscrew), spring [B], retainer [C], jet needle with circlip [D], O-ring with throttle valve plate [E], and throttle valve [F]. • Remove the choke knob/starter plunger assembly [A] from the carburetor.
  • Page 105 FUEL SYSTEM 3-19 Carburetor • Unscrew the screws [A]. • Remove the acceleration pump cover [B] from the carbu- retor. • Remove the spring [A], diaphragm [B], and the O-rings [C]. • Remove the following parts from the carburetor body. [A] Idle Adjusting Screw [B] Screws [C] Clamps...
  • Page 106: Carburetor Cleaning

    3-20 FUEL SYSTEM Carburetor • Remove: E-clip [A] Washer [B] • Pull out the acceleration pump lever assembly [C] as a set. • Remove the throttle sensor mounting bolt [A]. • Before removing the throttle sensor [B], mark [C] the car- buretor body and sensor so that it can be installed later in the same position.
  • Page 107: Carburetor Inspection

    FUEL SYSTEM 3-21 Carburetor • Immerse all the metal parts in a carburetor cleaning solu- tion. • Rinse the parts in water. • After the parts are cleaned, dry them with compressed air. • Blow through the air and fuel passages with compressed air [A].
  • Page 108: Carburetor Assembly

    3-22 FUEL SYSTEM Carburetor • Remove the float valve needle. • Check the plastic tip [A] of the float valve needle [B] for wear. If the needle is worn as shown right [C], replace the valve needle. • Push the rod [D] in the valve needle, then release it. If the rod does not come out fully by spring tension, re- place the valve needle.
  • Page 109 FUEL SYSTEM 3-23 Carburetor • Install the return spring [A] to the acceleration pump lever [B]. • Install the acceleration pump lever assembly to the car- buretor body. ○ Fit the end [A] of the return spring into the recess [B] on the carburetor body.
  • Page 110 3-24 FUEL SYSTEM Carburetor ○ Fit the end [A] of the return spring into the recess [B] of the carburetor body. • Turn the pulley counterclockwise [A] while holding down the acceleration pump lever [B] and clear the stopper [C] of the pulley from the throttle stop screw head [D].
  • Page 111 FUEL SYSTEM 3-25 Carburetor • Apply a grease to the O-ring [A]. • Fit the stopper [B] of the throttle sensor onto the projection [C] on the throttle cable pulley shaft. ○ Install the throttle sensor so that the marks aligns and check it position (see Throttle Sensor Inspection in the Electrical System chapter).
  • Page 112 3-26 FUEL SYSTEM Carburetor • Install: Leak Jet [A] • Replace the O-ring with new one. • Fit the O-ring [B] onto the groove of the float chamber. • Install: Float Bowl • Tighten the screws with hose clamps [A] and cable holder [B] as shown.
  • Page 113 FUEL SYSTEM 3-27 Carburetor • Install all hoses [A]. • Install the carburetor (see Carburetor Installation). • If turn the adjusting screw of the acceleration pump, follow the procedures below. ○ Adjust the acceleration pump timing. ○ Select an arbor [A] of the same diameter as the throttle valve height [B] and insert it under the throttle valve.
  • Page 114: Air Cleaner

    3-28 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Muffler (see Muffler Removal in the Engine Top End chapter) Rear Fender (see Rear Fender Removal in the Frame chapter) Rear Frame Bolts [A] •...
  • Page 115: Element Installation

    FUEL SYSTEM 3-29 Air Cleaner Element Installation • When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits. •...
  • Page 116: Fuel Tank

    3-30 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 117: Fuel Tank, Filter And Tap Cleaning

    FUEL SYSTEM 3-31 Fuel Tank Fuel Tank, Filter and Tap Cleaning • Refer to the Fuel Tank, Filter and Tap Cleaning in the Periodic Maintenance chapter. Fuel Tap and Filter Inspection • Refer to the Fuel Tap and Filter Inspection in the Periodic Maintenance chapter.
  • Page 119 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tool ..........................Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................4-10 Cooling System Pressure Testing ..................4-11 Cooling System Flushing ....................
  • Page 120: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 121 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 87 in·lb Coolant Drain Plug 0.70 62 in·lb Water Pump Impeller Bolt 87 in·lb Right Engine Cover Bolts 87 in·lb Radiator Hose Clamp Screws 0.30 27 in·lb 6.
  • Page 122: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 123 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator Cap 2. Radiators 3. Reserve Tank Hose 4. Reserve Tank 5. Reserve Tank Over Flow Hose 6. Cylinder Head Jacket 7. Cylinder Jacket 8. Impeller 9. Hot Coolant 10. Cold Coolant 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.
  • Page 124: Specifications

    4-6 COOLING SYSTEM Specifications Item Service Limit Coolant Permanent type antifreeze (soft water and ethylene glycol plus Type 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 1.05 L (1.11 US qt.) Radiator...
  • Page 125: Special Tool

    COOLING SYSTEM 4-7 Special Tool Bearing Driver Set: 57001-1129...
  • Page 126: Coolant

    4-8 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart (see Periodic Maintenance chapter). WARNING Hot engine coolant can cause serious burns. To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot.
  • Page 127: Coolant Filling

    COOLING SYSTEM 4-9 Coolant • Place a container under the coolant drain plug [A], and drain the coolant from the radiator and engine by remov- ing the drain plug on the water pump cover. Immediately wipe or wash out any coolant that spills on the frame, or engine.
  • Page 128: Air Bleeding

    4-10 COOLING SYSTEM Coolant • Fill the radiator up to the bottom of the radiator filler neck [B] with coolant [A], and install the cap, turning it clockwise about 1/4 turn. ○ Lean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is lo- cated uppermost in order to exhaust the air accumulated in the radiator.
  • Page 129: Cooling System Pressure Testing

    COOLING SYSTEM 4-11 Coolant Cooling System Pressure Testing NOTICE During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 141.7 kPa (1.445 kgf/cm², 20.55 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapter [B] on the radiator filler neck [C].
  • Page 130: Reserve Tank Removal

    4-12 COOLING SYSTEM Coolant Reserve Tank Removal • Remove: Seat (see Seat Removal in the Frame chapter) Left Side Cover (see Left Side Cover Removal in the Frame chapter) • Remove: Bolts [A] Cap [B] • Drain the coolant to the suitable container. •...
  • Page 131: Water Pump

    COOLING SYSTEM 4-13 Water Pump Water Pump Cover Removal • Remove engine guard (see Coolant Draining). • Unscrew the drain plug [A], and drain the coolant (see Coolant Draining). • Loosen the clamp screw [B], and remove the water hose [C] from the water pump cover.
  • Page 132: Impeller Removal

    4-14 COOLING SYSTEM Water Pump Impeller Removal • Drain: Coolant (see Coolant Draining) • Remove: Water Pump Cover (see Water Pump Cover Removal) Impeller Bolt [A] Impeller [B] Impeller Installation • Install: Impeller [A] • Tighten: Torque - Water Pump Impeller Bolt [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 133: Oil Seal And Bearing Installation

    COOLING SYSTEM 4-15 Water Pump • Insert a bar [A] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [B] by tapping [C] evenly around the bearing in- ner race. •...
  • Page 134: Radiator

    4-16 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining) • Remove: Radiator Shrouds • Loosen: Clamp Screws [A] Clamps [B] • Remove: Radiator Hoses [C] Bolt [D] Left Radiator Screen [E] • Remove: Bolts [A] Left Radiator [B] •...
  • Page 135: Radiator Installation

    COOLING SYSTEM 4-17 Radiator Radiator Installation • Fit the projections [A] of the screen in the holes [B] of the radiator. Torque - Radiator Hose Clamp Screws: 3.0 N·m (0.30 kgf·m, 27 in·lb) • Route the radiator and breather hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 136: Filler Neck Inspection

    4-18 COOLING SYSTEM Radiator • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • Install the cap [A] on a cooling system pressure tester [B]. • Watching the pressure gauge, slowly pump the pressure tester to build up the pressure.
  • Page 137 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..5-26 Specifications ........Valve Removal ......5-26 Special Tools and Sealant ....Valve Installation ......5-26 Clean Air System (U.S.A., California, Valve Guide Removal ....5-27 and Canada Models) ......
  • Page 138: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 139 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 87 in·lb Cylinder Head Bolts (M10) S, MO Cylinder Head Bolts (M6) 106 in·lb Cylinder Bolt 106 in·lb Camshaft Cap Bolts 87 in·lb S, MO Camshaft Sprocket Bolts 106 in·lb Carburetor Holder Clamp Screws...
  • Page 140 5-4 ENGINE TOP END Exploded View...
  • Page 141 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Pipe Cover Bolts 106 in·lb Rear Muffler Mounting Bolt Front Muffler Mounting Bolt (First) 87 in·lb Front Muffler Mounting Bolt (Final) Exhaust Pipe Holder Nuts Muffler End Mounting Bolts 89 in·lb Spark Arrester Mounting Bolts 89 in·lb...
  • Page 142: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 36.443 ∼ 36.557 mm (1.4348 ∼ 1.4392 in.) Exhaust 36.34 mm (1.431 in.) 37.143 ∼ 37.257 mm (1.4623 ∼ 1.4668 in.) Intake 37.04 mm (1.458 in.) 0.020 ∼ 0.061 mm (0.00079 ∼ 0.0024 in.) Camshaft Journal, Camshaft 0.15 mm (0.0059 in.) Cap Clearance...
  • Page 143 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust: Outer 36.2 mm (1.43 in.) 34.6 mm (1.36 in.) Intake 32.4 mm (1.28 in.) 30.9 mm (1.22 in.) Intake: Outer 39.3 mm (1.55 in.) 37.8 mm (1.49 in.) Inner 36.0 mm (1.42 in.) 34.5 mm (1.36 in.)
  • Page 144 5-8 ENGINE TOP END Specifications Cam Height Camshaft Runout Cam Height [A] Valve Stem Diameter Valve Stem Bend Valve Stem Diameter [A] Dial Gauge [A] 45° [B]...
  • Page 145: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 35: 57001-221 57001-1116 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 35: 57001-241 57001-1121 Valve Guide Arbor, 5.5: Valve Seat Cutter, 32° - 38.5: 57001-1021 57001-1122 Valve Guide Reamer, 5.5:...
  • Page 146 5-10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter, 55° - 35: Filler Cap Driver: 57001-1247 57001-1454 Spark Plug Wrench, Hex 16: Valve Seat Cutter, 45° - 40: 57001-1262 57001-1496 Fork Oil Level Gauge: Valve Seat Cutter, 55° - 38.5: 57001-1290 57001-1497 Compression Gauge Adapter, M10 ×...
  • Page 147 ENGINE TOP END 5-11 Special Tools and Sealant Valve Spring Compressor Adapter, 24: Liquid Gasket, TB1216B: 57001-1586 92104-1064 Valve Guide Driver Attachment D: 57001-1659...
  • Page 148: Clean Air System (u.s.a., California, And Canada Models)

    5-12 ENGINE TOP END Clean Air System (U.S.A., California, and Canada Models) 1. Air Cleaner 2. Carburetor 3. Vacuum Switch Valve 4. View from A 5. Intake Air 6. Exhaust Gas 7. Secondary Air...
  • Page 149: Vacuum Switch Valve Removal

    ENGINE TOP END 5-13 Clean Air System (U.S.A., California, and Canada Models) Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) • Slide out the clamp [A]. • Remove the hose [B] from the cylinder head pipe [C]. •...
  • Page 150: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Spark Plug Cap • Remove the cylinder head cover bolts [A] and remove the cylinder head cover [B]. Cylinder Head Cover Installation •...
  • Page 151: Camshaft Chain Tensioner

    ENGINE TOP END 5-15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 152 5-16 ENGINE TOP END Camshaft Chain Tensioner • Replace the chain tensioner gasket with a new one. • Tighten: Torque - Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Take out the holder plate [B]. • Install the O-ring and tighten the cap bolt.
  • Page 153: Camshaft

    ENGINE TOP END 5-17 Camshaft Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Crankshaft Shaft Cap [B] Special Tool - Filler Cap Driver: 57001-1454 • First, bring the piston to the TDC of the compression stroke.
  • Page 154: Camshaft Installation

    5-18 ENGINE TOP END Camshaft • Remove: Bolts [A] Auto-Decompressor [B] (with the sprocket) • Remove: Circlips [A] Camshaft Installation • Assemble the auto-decompressor weights [A] and spring [B] to install it to the sprocket [C]. • Replace the circlips [D] with new ones, and install them. •...
  • Page 155 ENGINE TOP END 5-19 Camshaft • Engage the camshaft chain with the camshaft sprockets. ○ Pull the tension side (exhaust side) of the chain taut to install the chain. ○ The timing marks on the sprocket must be aligned with the cylinder head upper surface.
  • Page 156: Camshaft Chain Removal

    5-20 ENGINE TOP END Camshaft • Apply grease to the rubber portions of the oil pipes. • Assemble: Camshaft Caps [A] Oil Pipes [B] • While keeping parallel, install them. • Uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts.
  • Page 157: Camshaft And Camshaft Cap Wear

    ENGINE TOP END 5-21 Camshaft Camshaft and Camshaft Cap Wear • Measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [A]. • Install the camshaft caps (see Camshaft Installation). NOTE ○ Do not turn the camshaft when the plastigauge is be- tween the journal and camshaft cap.
  • Page 158: Cylinder Head

    5-22 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. •...
  • Page 159: Cylinder Head Removal

    ENGINE TOP END 5-23 Cylinder Head Problem Diagnosis Remedy (Action) The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression is cylinder head (combustion chamber) is damaged parts if necessary. higher than the suspected due to damaged valve stem usable range or piston oil rings.
  • Page 160: Cylinder Head Installation

    5-24 ENGINE TOP END Cylinder Head • Remove the vacuum switch valve hose [A] and vacuum hose [B] from the cylinder head (equipped models). • Remove the 10 mm cylinder head bolts following the tight- ening sequence [1 ∼ 4] as shown. •...
  • Page 161: Cylinder Head Cleaning

    ENGINE TOP END 5-25 Cylinder Head • Tighten the 10 mm cylinder head bolts in the numbered sequence [1 ∼ 4]. Torque - Cylinder Head Bolts (M10): 59 N·m (6.0 kgf·m, 44 ft·lb) • Tighten: Torque - Cylinder Bolt [A]: 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Head Bolts (M6) [B]: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 162: Valves

    5-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and the shim from the valve. NOTE ○...
  • Page 163: Valve Guide Removal

    ENGINE TOP END 5-27 Valves Valve Guide Removal • Remove: Valve (see Valve Removal) Oil Seal Spring Seat • Heat the area around the valve guide up to 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 164: Valve/valve Guide Clearance

    5-28 ENGINE TOP END Valves • Ream the valve guide with valve guide reamer [A], even if the old guide is reused. Special Tool - Valve Guide Reamer, 5.5: 57001-1079 Valve/Valve Guide Clearance Measurement (Wobble Method) ○ If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below.
  • Page 165: Valve Seat Inspection

    ENGINE TOP END 5-29 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. • Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 166 5-30 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the vale 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 167 ENGINE TOP END 5-31 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 168 5-32 ENGINE TOP END Valves • The seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much;...
  • Page 169 ENGINE TOP END 5-33 Valves Valve Seat Repair...
  • Page 170: Cylinder And Piston

    5-34 ENGINE TOP END Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide [A] Cylinder Bolt [B] • Tap lightly up with a plastic mallet to separate the cylinder from the crankcase. •...
  • Page 171 ENGINE TOP END 5-35 Cylinder and Piston • Install the top ring [A] so that the "R" mark [B] faces up. NOTE ○ If a new piston or cylinder is used, check piston to cylin- der clearance (see Piston/Cylinder Clearance), and use new piston rings.
  • Page 172: Cylinder Wear

    5-36 ENGINE TOP END Cylinder and Piston • Apply engine oil to the cylinder bore. • Determine the position of the piston ring ends. • Install the cylinder while compressing the piston rings with your fingers or the special tool [A]. Special Tools - Piston Ring Compressor Grip: 57001-1095 95 ∼...
  • Page 173: Piston Ring Groove Width

    ENGINE TOP END 5-37 Cylinder and Piston Piston Ring Groove Width • Measure the groove width at several points around the piston with a vernier caliper. Piston Ring Groove Width Standard: 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) Service Limit: 1.13 mm (0.0445 in.) If any of the groove widths exceeds the service limit, re- place the piston.
  • Page 174: Piston, Piston Pin, Connecting Rod Wear Inspection

    5-38 ENGINE TOP END Cylinder and Piston Piston, Piston Pin, Connecting Rod Wear Inspection • Visually inspect the snap rings [A] still fitted in place. If the rings show weakness or deformation, replace the rings. Also if the pin hole groove shows excessive wear, replace the piston.
  • Page 175: Carburetor Holder

    ENGINE TOP END 5-39 Carburetor Holder Carburetor Holder Installation • Install the carburetor holder [A] with the marked [B] side facing toward the cylinder head outside. ○ Install the holder clamp [C] with its screw head [D] facing left side. Torque - Carburetor Holder Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 176: Muffler

    5-40 ENGINE TOP END Muffler WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Removal • Loosen the muffler clamp bolt [A]. • Remove the exhaust pip holder nuts [B].
  • Page 177: Exhaust System Inspection

    ENGINE TOP END 5-41 Muffler Exhaust System Inspection • The exhaust system, in particular the silencer, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If car- bon has built up inside the silencer, exhaust efficiency is reduced, causing engine performance to drop.
  • Page 179 ENGINE RIGHT SIDE 6-1 Engine Right Side Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Lever Installation....................Clutch Cable Removal ...................... Clutch Cable Installation ....................
  • Page 180: Exploded View

    6-2 ENGINE RIGHT SIDE Exploded View...
  • Page 181 ENGINE RIGHT SIDE 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Primary Gear Nut Lh,R Clutch Cover Bolts 87 in·lb Right Engine Cover Bolts 87 in·lb Clutch Spring Bolts 0.90 78 in·lb Clutch Hub Nut 6. Primary Gear 7. Push Rod Holder 8.
  • Page 182 6-4 ENGINE RIGHT SIDE Exploded View...
  • Page 183 ENGINE RIGHT SIDE 6-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Ratchet Guide Bolt 0.90 78 in·lb Kick Pedal Bolt Ratchet Plate Mounting Bolt 87 in·lb Ratchet Plate Mounting Screw 0.65 56 in·lb Gear Set Lever Nut 0.90 78 in·lb Shift Drum Cam Bolt 7.
  • Page 184: Specifications

    6-6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever 8 ∼ 13 mm (0.3 ∼ 0.5 in.) Clutch Lever Free Play (Lever pointed – – – end) Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.6 mm (0.10 in.) Friction Plate Warp 0.15 mm (0.0059 in.) or less...
  • Page 185: Special Tools

    ENGINE RIGHT SIDE 6-7 Special Tools Outside Circlip Pliers: Gear Holder, m2.0: 57001-144 57001-1557 Clutch Holder: 57001-1243...
  • Page 186: Clutch Lever And Cable

    6-8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns.
  • Page 187: Clutch Cable Installation

    ENGINE RIGHT SIDE 6-9 Clutch Lever and Cable • Free the clutch inner cable tip [A] from the pull rod [B]. NOTICE Do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with a new one. •...
  • Page 188: Clutch Cover And Right Engine Cover

    6-10 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the brake pedal (see Brake Pedal Removal in the Brakes chapter). •...
  • Page 189: Right Engine Cover Installation

    ENGINE RIGHT SIDE 6-11 Clutch Cover and Right Engine Cover Right Engine Cover Installation • Three dowel pins [A] are installed at the mating surface between the crankcase and the right engine cover. • Apply grease to the O-rings [B], and install them to the crankcase.
  • Page 190: Release Shaft Installation

    6-12 ENGINE RIGHT SIDE Clutch Cover and Right Engine Cover • Turn the release lever shaft [A] and remove the short ca- ble [B] from the lever. • Pull the lever and shaft assembly [C] out of the crankcase. Release Shaft Installation •...
  • Page 191: Clutch

    ENGINE RIGHT SIDE 6-13 Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove: Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] •...
  • Page 192 6-14 ENGINE RIGHT SIDE Clutch • Install the washer so that stamp mark [A] facing the out- side. • Tighten the clutch hub nut [A] with the clutch holder [B]. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 98 N·m (10 kgf·m, 72 ft·lb) •...
  • Page 193 ENGINE RIGHT SIDE 6-15 Clutch • Tighten: Torque - Clutch Spring Bolts [A]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the clutch cover (see Clutch Cover Installation). • Check the pull rod positions [A]. ○ Pulling [B] the pull rod [C] lightly upward by hand and measure the portion of the pull rod coming out.
  • Page 194: Clutch Plate Assembly Free Play Inspection/adjustment

    6-16 ENGINE RIGHT SIDE Clutch Clutch Plate Assembly Free Play Inspection/Ad- justment • Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Friction Plates [D] Spring Plate [E] Spring [F] Bolts [G] ○ Friction Plates [B] have lining blocks that are wider than other plates.
  • Page 195: Clutch Housing Finger Damage

    ENGINE RIGHT SIDE 6-17 Clutch Clutch Housing Finger Damage • Visually inspect the clutch housing fingers [A] that come in contact with the friction plate tangs. If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as well.
  • Page 196: Primary Gear

    6-18 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch (see Clutch Removal) • Temporarily install the clutch housing [A]. • Using the gear holder [B], secure the primary gear and loosen the primary gear nut.
  • Page 197: External Shift Mechanism

    ENGINE RIGHT SIDE 6-19 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) Circlip [A] Oil Pump Driven Gear [B] •...
  • Page 198: External Shift Mechanism Inspection

    6-20 ENGINE RIGHT SIDE External Shift Mechanism • Set up the shift ratchet assembly as shown in the figure. Ratchet [A] Pawls [B] Pins [C] Springs [D] ○ Assembly the shift ratchet so that groove [E] of the pawl facing the crankcase side [F]. •...
  • Page 199 ENGINE RIGHT SIDE 6-21 External Shift Mechanism • Check the ratchet assembly for damage. If ratchet [A], pawls [B], pins [C] or springs [D] are dam- aged in any way, replace them. • Check the gear set lever [A] and its spring [B] for cracks or distortion.
  • Page 200: Kickstarter

    6-22 ENGINE RIGHT SIDE Kickstarter Kick Pedal Assy Removal • Remove: Mounting Bolt [A] Kick Pedal Assy [B] Kick Pedal Assy Installation • Install the kick pedal assy [A] at the angle shown. 17 ∼ 27 mm (0.67 ∼ 1.1 in.) [B] •...
  • Page 201: Idle Gear Installation

    ENGINE RIGHT SIDE 6-23 Kickstarter Idle Gear Installation • Apply engine oil to the inside of the idle gear. • Replace the circlip [A] with a new one. • Install the idle gear [B] facing embossed letter [C] to the outside.
  • Page 202: Kick Shaft Assembly Disassembly/assembly

    6-24 ENGINE RIGHT SIDE Kickstarter Kick Shaft Assembly Disassembly/Assembly • The kick shaft assembly consists of the following parts. [A] Kick Gear [B] Circlip [C] Washer [D] Spring [E] Ratchet Gear [F] Kick Shaft [G] Kick Spring [H] Spring Guide •...
  • Page 203 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Lubrication System Chart ....................... Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Change ....................... Oil Screen..........................7-10 Oil Screen (Scavenge) Removal..................
  • Page 204: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 205 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug (M10) (Main) Engine Oil Drain Plug (M6) (Sub) 0.71 62 in·lb Oil Pump (Scavenge) Cover Bolts 87 in·lb Oil Pump (Feed) Cover Bolts 87 in·lb Right Engine Cover Bolts 87 in·lb Piston Oil Nozzle...
  • Page 206: Lubrication System Chart

    7-4 ENGINE LUBRICATION SYSTEM Lubrication System Chart...
  • Page 207 ENGINE LUBRICATION SYSTEM 7-5 Lubrication System Chart 1. Oil Screen (feed) 2. Oil Pump (feed) 3. Oil Pressure Relief Valve 4. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil filter) 5. Oil Filter 6. Right Engine Cover Oil Passage (from Oil filter to Crankshaft) 7.
  • Page 208: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity Oil Change - when filter is not removed 1.06 L (1.12 US qt) Oil Change - when filter is removed 1.08 L (1.14 US qt) when engine is completely dry...
  • Page 209: Special Tools

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools Oil Pressure Gauge, 5 kgf/cm²: Oil Pressure Gauge Adapter, M10 × 1.25: 57001-125 57001-1182 Outside Circlip Pliers: Oil Pressure Cap: 57001-144 57001-1656...
  • Page 210: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 211: Oil Filter Change

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Change • Refer to the Oil Filter Change in the Periodic Maintenance chapter.
  • Page 212: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen (Scavenge) Removal • Remove the oil pump (scavenge) cover (see Oil Pump (Scavenge) Removal). • Pull out the oil screen [A] from the crankcase. Oil Screen (Scavenge) Installation • Clean the oil screens thoroughly whenever it is removed for any reason.
  • Page 213: Oil Screen (feed) Removal

    ENGINE LUBRICATION SYSTEM 7-11 Oil Screen Oil Screen (Feed) Removal • Split the crankcase (see Crankcase Disassembly in the Crankshaft/Transmission chapter). • Remove: Bolts [A] Oil Screen [B] Oil Screen (Feed) Installation • Replace the O-ring [A] with a new one. •...
  • Page 214: Oil Screen (feed) Cleaning

    7-12 ENGINE LUBRICATION SYSTEM Oil Screen • Check the screen [A] carefully for any damage, holes, broken wires gasket pulling off. If the screen is damaged, replace it. • Install the oil screen (see Oil Screen (Scavenge) Installa- tion). Oil Screen (Feed) Cleaning •...
  • Page 215: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Right Engine cover (see Right Engine Cover Removal in the Engine Right Side chapter) Clutch (see Clutch Removal in the Engine Right Side chapter) • Remove the oil pressure relief valve [A].
  • Page 216: Oil Pump

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump (Scavenge) Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Draining in the Coolant System chapter) • Remove: Shift Pedal (see External Shift Mechanism in the Engine Right Side chapter) Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter)
  • Page 217: Oil Pump (feed) Removal

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump Oil Pump (Feed) Removal • Remove: Right Engine Cover (Right Engine Cover Removal in the Engine Right Side chapter) Clutch (Clutch Removal in the Engine Right Side chap- ter) Circlip [A] Oil Pump Driven Gear [B] Shaft [C] Oil Pump Idle Gear [D] •...
  • Page 218: Oil Pump Inspection

    7-16 ENGINE LUBRICATION SYSTEM Oil Pump • Apply molybdenum disulfide grease to the oil pump idle gear shaft [A]. • Install the oil pump idle gear [B] facing the stepped side [C] to the outside. • Replace the circlip [D] with a new one. •...
  • Page 219: Oil Pressure

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Oil Pressure Measurement • Remove: Exhaust Pipe (see Muffler Removal in the Engine Top End chapter) Right Engine Cover Bolt [A] Oil Filter Cover Bolt [B] Oil Filter Cover [C] • Install the O-rings to the oil pressure cap. Special Tool - Oil Pressure Cap: 57001–1656 •...
  • Page 221 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 222: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 223 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Mounting Bolts (M10) Middle Engine Mounting Nut (M10) Lower Engine Mounting Nut (M10) Upper Engine Bracket Bolts (M8) Middle Engine Bracket Nuts (M8) Swingarm Pivot Shaft Nut 7.
  • Page 224: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...
  • Page 225: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to support the motor- cycle. Special Tool - Jack: 57001-1238 WARNING When the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor, creating the potential for injury.
  • Page 226 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Radiator (see Radiator Removal in the Cooling System chapter) Muffler (see Muffler Removal in the Engine Top End chapter) Air Cleaner Housing with Rear Frame (see Air Cleaner Housing Removal in the Fuel System chapter) Starter Motor (see Stater Motor Removal in the Electrical System chapter) Carburetor (see Carburetor Removal in the Fuel System...
  • Page 227 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the swingarm pivot shaft nut [A] to pull out the swingarm pivot shaft [B]. ○ Pull out the swingarm pivot shaft half way from right side to free the engine. • Remove the engine from the vehicle to right side. ○...
  • Page 228: Engine Installation

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Install the engine. ○ First, insert the front portion of the engine, and then install the rear portion. • Install the swingarm pivot shaft, all engine bracket and mounting bolts temporarily. ○ Swingarm pivot shaft insert from the right side.
  • Page 229 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation WARNING After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc.
  • Page 231 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase ..........................Crankcase Disassembly ....................Crankcase Assembly ......................Crankshaft/Connecting Rod ....................9-15 Crankshaft Removal ......................9-15 Crankshaft Installation ...................... 9-15 Crankshaft Disassembly ....................9-15 Crankshaft Assembly ......................9-15 Crankshaft Inspection .......................
  • Page 232: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 233 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener marks N·m kgf·m ft·lb 1 Crankcase Bolts (M6) 106 in·lb 2 Crankcase Bolts (M7) 3 Gear Set Lever Nut 0.90 78 in·lb 4 Engine Oil Drain Plug (M6)(Sub) 0.71 62 in·lb 5 Engine Oil Drain Plug (M10)(Main) 6 Shift Drum Cam Bolt 7 Piston Oil Nozzle 0.41...
  • Page 234: Specifications

    9-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Connecting Rods 0.002 ∼ 0.014 mm Connecting Rod Big End Radial 0.06 mm (0.002 in.) (0.00008 ∼ 0.0006 in.) Clearance 0.25 ∼ 0.35 mm Connecting Rod Big End Side 0.6 mm (0.02 in.) (0.0098 ∼...
  • Page 235: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-5 Special Tools and Sealant Outside Circlip Pliers: Crankcase Splitting Tool Assembly: 57001-144 57001-1362 Bearing Driver Set: Liquid Gasket, TB1216: 57001-1129 92104-1063 Crankshaft Jig: 57001-1174...
  • Page 236: Crankcase

    9-6 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on clean surface while parts are being re- moved. • Remove: Magneto Cover (see Magneto Cover Removal in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter)
  • Page 237 CRANKSHAFT/TRANSMISSION 9-7 Crankcase • Remove: Gear Position Switch Finger [A] Spring [B] • Remove: Circlip [A] Balancer Drive Gear [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Circlip [A] Special Tool - Outside Circlip Pliers: 57001-144 • Remove the crankcase bolts [A]. •...
  • Page 238: Crankcase Assembly

    9-8 CRANKSHAFT/TRANSMISSION Crankcase ○ The crankcase may also be split, using the crankcase splitting tool assembly. ○ Install the jig [A] between the crankshaft flywheels. Special Tool - Crankshaft Jig: 57001-1174 ○ Attach the crankcase splitting tool [A] to the left crankcase.
  • Page 239 CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Support the crankcase bearing boss with a suitable re- tainer [A]. • Using a press and the bearing driver set [C], install a new bearing [B] until it bottoms out. Special Tool - Bearing Driver Set: 57001-1129 NOTICE Support the crankcase bearing boss when the bear- ing is pressed, or the crankcase could be damaged.
  • Page 240 9-10 CRANKSHAFT/TRANSMISSION Crankcase • First, press the inside release shaft needle bearing [A] until its top comes 19.5 mm [B] from the surface using the bearing driver set. • Next, press the oil seal [C] until it reach to the inside nee- dle bearing with the bearing driver set.
  • Page 241 CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Apply engine oil to the transmission gears, bearings, shift forks, shift drum and crankshaft bearing. • Install the drive shaft [A] and output shaft [B] in the right crankcase [C] as a set. • Install: Shift Drum [A] (see Transmission Shaft Installation) Shift Rods [B] (see Transmission Shaft Installation) Shift Forks [C] (see Transmission Shaft Installation) •...
  • Page 242 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Apply liquid gasket to the mating surface [A] of the left crankshaft half. Sealant - Liquid Gasket, TB1216: 92104-1063 NOTE ○ Make the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied.
  • Page 243 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Install the gear set lever [A]. ○ Fit each end [B] of the spring or original positions. ○ Do not forget to install the collar and washer [C]. • Tighten the gear set lever nut [D]. Torque - Gear Set Lever Nut: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 244 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Replace the circlip [A] with a new one, and install it to the output shaft.
  • Page 245: Crankshaft/connecting Rod

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft/Connecting Rod Crankshaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Using the hand pull out the crankshaft [A] from the right crankcase [B]. Crankshaft Installation • Apply high-temperature grease to the outer side of the crankshaft bearings and use the bearing driver set [C] to face the stepped side [A] to the engine inside and drive the bearing to the bottom of the crankcase [B].
  • Page 246: Crankshaft Inspection

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rod Crankshaft Inspection Connecting Rod Big End Radial Clearance • Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end. • Push [B] the connecting rod first towards the gauge and then in the opposite direction.
  • Page 247: Connecting Rod Bend

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft/Connecting Rod • Next, correct the vertical misalignment by either driving a wedge [A] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. NOTICE Do not hammer the crank half at the point [B]. If flywheel misalignment cannot be corrected by the above method, replace the crank pin or the crankshaft itself.
  • Page 248: Connecting Rod Twist

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rod Connecting Rod Twist • With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist.
  • Page 249: Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-19 Torque Limiter Torque Limiter Removal/Installation • Remove: Torque Limiter Cover Bolts [A] Torque Limiter Cover [B] Torque Limiter [C] NOTICE Do not disassemble the torque limiter. The torque limiter will not function if this is done. • Install the torque limiter cover so that the arrow mark [A] faces upward.
  • Page 250: Transmission

    9-20 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Disassemble the crankcase halves (see Crankcase Dis- assembly). • Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C]. •...
  • Page 251: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-21 Transmission Transmission Shaft Assembly • Apply engine oil liberally to the transmission shaft, gears and bearings. • Replace any circlips that were removed with new ones. ○ Always install the circlips [A] so that the opening [B] is aligned with a spline groove [C], and install toothed wash- ers.
  • Page 252: Shift Fork Bending

    9-22 CRANKSHAFT/TRANSMISSION Transmission 1. Circlip 7. 5th Gear (21 T) 13. 4th Gear (19 T) 2. Toothed Washer 8. 1st Gear (12 T) 14. 3rd Gear (19 T) 3. 2nd Gear (15 T) 9. Drive Shaft 15. 5th Gear (17 T) 4.
  • Page 253: Shift Fork/gear Groove Wear

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift F