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   Also See for Kawasaki KLE500

   Summary of Contents for Kawasaki KLE500

  • Page 2 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 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – Throttle Grip Free Play Idle Speed 1 200 ±50 r/min (rpm) – – – Engine Top End Valve Clearance 0.13 ∼...
  • 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 2 ∼...
  • 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) 0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.) Inlet 0.18 ∼...
  • 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 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Choke Cable Free Play Carburetors Mark, Type KEIHIN CVK34 Idle Speed 1 200 ±50 r/min (rpm) Pilot Screw (Turns Out) 1 3/4 ±1/4 Synchronization Vacuum...
  • 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: Service Fuel Level Inspection

    FUEL SYSTEM 3-11 Carburetors • 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 as shown. Otherwise the screws could come in contact with the vacuum adjusting screws, resulting in an un- safe riding condition.
  • Page 82: Service Fuel Level Adjustment

    3-12 FUEL SYSTEM Carburetors • Connect fuel level gauge [A] to the rubber hose. Special Tool - Fuel Level Gauge: 57001-1017 • Hold the gauge vertically against the side of the carburetor body so that the "middle" line [B] is several millimeters higher than the bottom edge [D] of the carburetor body.
  • Page 83: Fuel System Cleanliness Inspection

    FUEL SYSTEM 3-13 Carburetors • Remove the float bowl by taking out the float chamber screws [A] and water hose fitting screws [B] with lock- washers. • Slide out the pivot pin [A] and remove the float [B]. • Bend the tang [A] on the float arm very slightly to change the float height.
  • Page 84: Carburetor Disassembly/assembly

    3-14 FUEL SYSTEM Carburetors • Connect a suitable hose [A] to the fitting at the bottom of each carburetor float bowl. • Run the lower ends of the hoses into a suitable container. • Turn the fuel tap to the PRI position. •...
  • Page 85: Carburetor Separation/assembly

    FUEL SYSTEM 3-15 Carburetors • Turn the carburetor body upside-down, and drop the nee- dle jet [A] into place so that the smaller diameter end [B] of the jet goes in first. • Carefully screw in the needle jet holder. It will seat against the needle jet, pushing the end of the jet into the carbu- retor bore.
  • Page 86 3-16 FUEL SYSTEM Carburetors • Remove the upper carburetor mounting screws [A] and stay [B]. ○ Remove the fuel supply pipe connected both carburetors. • Remove the vacuum hose [C] connected both carbure- tors. • Remove the lower carburetor mounting screws [A] and stay [B].
  • Page 87: Carburetor Cleaning

    FUEL SYSTEM 3-17 Carburetors • Visually synchronize the throttle (butterfly) valves. ○ Check to see that the throttle valves open and close smoothly without binding when turning the pulley. ○ Visually check the clearance [A] between the throttle valve and the carburetor bore in each carburetor. If there is a difference between the throttle valves, turn the balance adjusting screw [B] to obtain the same clearance.
  • Page 88: Carburetor Inspection

    3-18 FUEL SYSTEM Carburetors Carburetor Inspection 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 89: Air Cleaner

    FUEL SYSTEM 3-19 Air Cleaner Air Cleaner Element Removal • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Air Cleaner Cover Screws [A] Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) •...
  • Page 90: Air Cleaner Housing Installation

    3-20 FUEL SYSTEM Air Cleaner Fuel Tank Bracket [A] Air Cleaner Ducts Breather Tube Air Suction Valve Hose • Remove the air cleaner housing [A]. Air Cleaner Housing Installation • Air cleaner housing installation is the reverse of removal. Air Cleaner Draining A drain hose [A] is provided beneath the air cleaner hos- ing, and catches the water or oil from the bottom of the hose.
  • Page 91: 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 92: 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 93: 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 94: 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 95 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 96: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 97 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 98: 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 99: Special Tool And Sealant

    COOLING SYSTEM 4-5 Special Tool and Sealant Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001-1129 56019-120...
  • Page 100: 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 101 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 102: 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 103: 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 104: 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 105: 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 106: 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 107: 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 108: 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 109: 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 110: 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 111 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 112: 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 113 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 114: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 115 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 116 5-4 ENGINE TOP END Exploded View...
  • Page 117 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 118: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Open → Close – – – 45 ∼ 53 kPa (340 ∼ 400 mmHg) Pressure Camshafts Cam Height: 35.416 ∼ 35.530 mm (1.3943 ∼ 1.3988 in.) 35.32 mm (1.3905 in.) Exhaust 35.476 ∼...
  • Page 119 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Outside diameter: 24.0 ∼ 24.2 mm (0.945 ∼ 0.953 in.) Exhaust – – – 28.3 ∼ 28.5 mm (1.114 ∼ 1.122 in.) Inlet – – – Valve spring free length: Inner 36.3 mm (1.429 in.) 35 mm (1.3780 in.) Outer...
  • Page 120: 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 Piston Ring Compressor Belt, 67 ∼ 79: Valve Spring Compressor Assembly: 57001-241 57001-1097 Piston Pin Puller Assembly: Valve Seat Cutter, 45°...
  • Page 121 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 122 5-10 ENGINE TOP END Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 123: 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 124: 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 125: 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 126: 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 127: 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 128: 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 129: 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 130: 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 131: 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 132: 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 133: 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 134: 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 135: 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 136: 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 137: 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 138: 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 139: 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 140 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 141 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 142 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 143 ENGINE TOP END 5-31 Valves...
  • Page 144: 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 145: 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 146: 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 147: 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 148: 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 149: Muffler

    ENGINE TOP END 5-37 Muffler Muffler Removal • Remove the right side cover (see Side Cover Removal in the Frame chapter). • Unscrew the muffler mounting bolt and nut [A]. • Remove the exhaust pipe holder nuts [A]. • Take off the muffler [A]. Muffler Installation •...
  • Page 151 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Position Adjustment ..................Clutch Cable Inspection ....................Clutch Lever Installation....................Cable Lubrication ......................Right Engine Cover ........................ Clutch Cover Removal ...................... Clutch Cover Installation ....................
  • Page 152: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 153 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 154 6-4 CLUTCH Exploded View...
  • Page 155 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 156: Specifications

    6-6 CLUTCH Specifications Item Standard Service Limit Clutch Lever Position Non-adjustable – – – 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.) Friction Plate Thickness 2.75 mm (0.1082 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less...
  • Page 157: Special Tool And Sealant

    CLUTCH 6-7 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 56019-120...
  • Page 158: 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 159: 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 160: Clutch Release Installation

    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 161: Clutch Removal

    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 162: Clutch Plate Wear, Damage Inspection

    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 163: Clutch Spring Free Length Measurement

    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 165 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 166: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 167 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 168 7-4 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 169 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 170: Engine Oil Flow Chart

    7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 171: 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 172: 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 173: 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 174: 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 175: 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 176: 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 177: 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 178: 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 179: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove: Oil Passage Plug WARNING If the oil passage plug is removed while the engine is warm, hot engine oil will drain through the oil pas- sage;...
  • Page 181 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 182: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 183 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Frame Downtube Bolts Engine Mounting Bolts and Nut Engine Mounting Bracket Bolts...
  • Page 184: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Set the motorcycle up on its center stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 185 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Pull off the connectors from the engine and free the wiring from the straps. Crankshaft Sensor Lead Connector [A] Alternator Lead Connector [B] • Remove: Battery Negative Lead [A] Starter Motor Lead [B] • Remove: Oil Pressure Switch Lead [A] Neutral Switch Lead [B]...
  • Page 186: Engine Installation

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Hang the drive chain [A] over the output shaft [B] just be- fore moving the engine into its final position in the frame. • Install the engine sprocket [A] so that the mark side is outward.
  • Page 187 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... 9-10 Crankcase Splitting ......................9-10 Crankcase Assembly ......................9-11 Clutch Housing/Primary Chain ....................9-14 Clutch Housing/Primary Chain Removal................9-14 Clutch Housing/Primary Chain Installation................ 9-14 Primary Chain Guide Wear Inspection................
  • Page 188: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 189 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Body Bolt 52 in·lb Upper Primary Chain Guide Mounting Bolt 95 in·lb Connecting Rod Big End Cap Nuts EO: Apply engine oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. WL: Apply soap water solution or rubber lubricant.
  • Page 190 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 191 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Bearing Holding Bolts 95 in·lb Gear Positioning Lever Nut 95 in·lb External Shift Mechanism Cover Bolts 95 in·lb Lower Primary Chain Guide Mounting Bolt 95 in·lb Neutral Switch Return Spring Pin 14.5 Crank Case Bolts (M6 ×...
  • Page 192: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – 0.2/100 mm (0.0079/4 in.) Connecting Rod Twist – – – 0.2/100 mm 0.0079/4 in.) 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) Connecting Rod Big End Side 0.50 mm Clearance (0.02 in.)
  • Page 193 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 39.000 ∼ 39.016 mm (1.5354 ∼ 1.5361 in.) Crankshaft Main Bearing Bore – – – Diameter Marking: ○ 39.000 ∼ 39.008 mm (1.5354 ∼ 1.5357 in.) – – – 39.009 ∼ 39.016 mm (1.5358 ∼ 1.5361 in.) None –...
  • Page 194 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Balancer Shaft Bearing Insert Selection: Crankcase Balancer Bearing Insert* Bearing Bore Shaft Journal Part Number Diameter Diameter Size Color L. H. R. H. Marking Marking ○ ○ Brown 92028-1497 92028-1692 ○ None Black 92028-1496 92028-1691 ○...
  • Page 195: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Bearing Puller: Bearing Driver, 57001-135 57001-382 Outside Circlip Pliers: Kawasaki Bond (Silicone Sealant): 57001-144 56019-120 Bearing Puller Adapter: Kawasaki Bond (Liquid Gasket - Gray): 57001-317 92104-1063...
  • Page 196: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Shift Pedal Link Lever Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Water Pump (see Water Pump Removal in the Cooling...
  • Page 197: Crankcase Splitting

    • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Gray): 92104 -1063 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and balancer shaft inserts.
  • Page 198 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Fit the lower crankcase half on the upper crankcase half observing the following. ○ Set the shift forks so that the ears [A] of each fork fit into the grooves of the gears. • Tighten the lower crankcase-half bolts using the following 3 steps: ○...
  • Page 199 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Turn the engine over so it is upright. • Put the 8 mm bolts [A], and the 6 mm bolts [B] into the upper crankcase half as shown in the figure, torque the 8 mm bolt first, then the other bolts in the sequence shown. 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)
  • Page 200: Clutch Housing/primary Chain

    9-14 CRANKSHAFT/TRANSMISSION Clutch Housing/Primary Chain Clutch Housing/Primary Chain Removal • Remove the engine. • Remove: Cylinder Head, Cylinder and Pistons (see Cylinder Head, Cylinder and Piston in the Engine Top End chap- ter) Starter Clutch Sprocket (see Starter Clutch Sprocket Re- moval in the Electrical System chapter) Clutch (except the Clutch Housing) •...
  • Page 201: Primary Chain Guide Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-15 Clutch Housing/Primary Chain • Install the spacer [A] onto the drive shaft [B], facing the chamfered side [C] to the ball bearing [D]. • Install the clutch housing in the reverse order of removal. Primary Chain Guide Wear Inspection •...
  • Page 202: Crankshaft/connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the clutch housing and the primary chain. • Remove the crankshaft with the camshaft chain and pri- mary chain. Crankshaft Installation CAUTION If the crankshaft, bearing inserts or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with plastigage before assembling engine to be sure the correct...
  • Page 203: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft/Connecting Rods Connecting Rod Installation CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set. To minimize vibration, the connecting rods should have the same weight mark.
  • Page 204: Connecting Rod Bend/twist

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Connecting Rod Bend/Twist • Measure the connecting rod bend. ○ Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. ○ Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 205: Connecting Rod Big End Bearing Insert/crankpin Clearance

    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 206: Crankshaft Runout

    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 207 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 208: Crankshaft Side Clearance

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankcase Main Bearing Bore Diameter Marks ○ 39.000 ∼ 39.008 mm (1.5354 ∼ 1.5357 in.) 39.009 ∼ 39.016 mm (1.5358 ∼ 1.5361 in.) None: □□ □□ Crankcase Main Bearing Bore Diameter ○ Marks, " " mark or no mark. •...
  • Page 209: Balancer

    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 210 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 211: Transmission

    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 212: External Shift Mechanism Inspection

    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 213: Transmission Shaft Disassembly

    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 214: Drive Shaft Assembly

    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 215: Output Shaft Assembly

    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 216: Shift Drum And Fork Removal

    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 217: Shift Drum And Fork Installation

    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 218: Shift Drum Disassembly

    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 219: Ball And Needle Bearing Wear

    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 221 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 222: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 223 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 2.0 ∼ 3.9 0.2 ∼ 0.4 17 ∼ 35 in·lb Spoke Nipple 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.
  • Page 224: 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 225: 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 226: 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 227: 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 228: 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 229: 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 230: 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 231: 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 232: 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 233: 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 234: 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 235 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 236: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 237 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 238: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 35 ∼ 45 mm (1.4 ∼ 1.8 in.) Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 20-link Length 323 mm (12.7 in.) Standard Chain Make DAIDO KOGYO –...
  • Page 239: Special Tools And Sealants

    FINAL DRIVE 11-5 Special Tools and Sealants Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 240: 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 241: 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 242: 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 243: 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 244: 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 245: 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 246 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 247 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 248: Exploded View

    12-2 BRAKES Exploded View...
  • Page 249 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 250 12-4 BRAKES Exploded View...
  • Page 251 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 252: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 4-way adjustable (to suit rider) – – – 30 ∼ 40 mm (1.2 ∼ 1.6 in.) below footpeg top Brake Pedal Position – – – Free Play Non-adjustable –...
  • Page 253: Special Tool

    BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001-143...
  • Page 254: 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 255: 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 256: 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 257: 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 258 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 259: 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 260: 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 261: 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 262: 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 263: 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 264: 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 265: 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 266: 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 267: 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 268: 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 269: 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 271 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 272: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 273 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 274 13-4 SUSPENSION Exploded View...
  • Page 275 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 276: 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 277: 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 278: 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 279: 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 280: 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 281: 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 282: 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 283: 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 284: 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 285: 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 286: 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 287: 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 288: 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 289 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 290: Exploded View

    14-2 STEERING Exploded View...
  • Page 291 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 292: 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 293 STEERING 14-5 Special Tools Bearing Puller: 57001-1575...
  • Page 294: 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 295: 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 296: Steering Play Inspection

    14-8 STEERING Steering Steering Play Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter.
  • Page 297: 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 298 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 299: 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 300: 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 301: 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 303 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 304: Exploded View

    15-2 FRAME Exploded View...
  • Page 305 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 306 15-4 FRAME Exploded View...
  • Page 307: Specifications

    FRAME 15-5 Specifications Jack: 57001-1238...
  • Page 308: 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 309: 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 310: 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 311: 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 312: Fender Installation Note