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Table of Contents

   Also See for Kawasaki KX250F

   Summary of Contents for Kawasaki KX250F

  • Page 1 This manual is brought to you by: www.magnamaniac.com Here you can find Service Manuals for over 200 different motorcycles http://manuals.magnamaniac.com...
  • Page 2 KX250F Motorcycle Service Manual http://manuals.magnamaniac.com...
  • Page 3 http://manuals.magnamaniac.com...
  • Page 4 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 http://manuals.magnamaniac.com...
  • Page 6 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. http://manuals.magnamaniac.com © 2003 Kawasaki Heavy Industries, Ltd. Second Edition (1) : Jan. 16 2004 (K)
  • Page 7 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 8: How To Use This Manual

    Be alert for problems and non-scheduled Always follow safe operating and maintenance maintenance. practices. • Use proper tools and genuine Kawasaki Mo- WARNING torcycle parts. Special tools, gauges, and testers that are necessary when servicing This warning symbol identifies special...
  • Page 9 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 10 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-10 http://manuals.magnamaniac.com...
  • Page 11: 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 12 Replacement Parts Replacement Parts must be KAWASAKI genuine or rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 13 1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.
  • Page 14 GENERAL INFORMATION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
  • Page 15: General Information

    1-6 GENERAL INFORMATION Before Servicing Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color. http://manuals.magnamaniac.com...
  • Page 16: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KX250–N1 Left Side View KX250–N1 Right Side View http://manuals.magnamaniac.com...
  • Page 17: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KX250–N1 Dimensions: Overall length 2 170 mm (85.43 in.) Overall width 840 mm (33.1 in.) Overall height 1 270 mm (50 in.) Wheelbase 1 475 mm (8.07 in.) Road clearance 340 mm (13.4 in.) Seat height 960 mm (37.8 in.) Dry mass...
  • Page 18 GENERAL INFORMATION 1-9 General Specifications Items KX250–N1 Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.142 (30/14) 1.785 (25/14) 1.444 (26/18) 1.200 (24/20) 1.052 (20/19) Final drive system: Type Chain drive Reduction ratio 3.692 (48/13) Overall drive ratio 13.020 @ Top gear Frame: Type Tubular, semi-double cradle...
  • Page 19: Unit Conversion Table

    1-10 GENERAL INFORMATION 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: micro µ...
  • Page 20: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Tires Inspection......2-29 Torque and Locking Agent....Spoke Tightness Inspection ..2-29 Specifications ........Rim Runout Inspection....2-30 Special Tools ........2-10 Wheel Bearing Inspection .... 2-30 Periodic Maintenance Procedures..2-11 Final Drive........
  • Page 21: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Each Every 3 Every 6 Every 12 See OPERATION race races races races Page • Spark plug –...
  • Page 22 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 See OPERATION race races races races Page • Front fork – inspect and clean 2-44 • Front fork oil – change 2-44 • Rear shock oil – replace 2-46 •...
  • Page 23: 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 24 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Bolt M6 104 in·lb Exhaust Pipe Cover Screws 104 in·lb Exhaust Pipe Holder Nuts Muffler Mounting Bolts Engine Right Side: Primary Gear Nut Shift Drum Cam Bolt Clutch Spring Bolts 87 in·lb Clutch Hub Nut...
  • Page 25 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb 0.25 22 in·lb Piston Oil Nozzle Crankcase Bolts 87 in·lb Engine Oil Drain Plug (for crank room oil sump) 61 in·lb (for transmission room oil sump) Output Shaft Bearing Retaining Screw 0.65 56 in·lb Drive Shaft Bearing Retaining Screw...
  • Page 26 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Push Rod Nut 2.85 20.6 Swingarm Pivot Shaft Nut Rear Shock Absorber Mounting Nuts: (Upper) (Lower) Air Bleed Bolt 0.65 56 in·lb Tie-Rod Mounting Nut (Front, Rear) Rocker Arm Pivot Nut Steering: Steering Stem Head Nut...
  • Page 27: Specifications

    2-8 PERIODIC MAINTENANCE 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 start lever free play Air cleaner element oil High quality foam air filter oil - - -...
  • Page 28 PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Wheels/Tires: Rim Runout: Axial Under 1.0 mm (0.039 in.) 2 mm (0.08 in.) Radial Under 1.0 mm (0.039 in.) 2 mm (0.08 in.) Front and rear tires air pressure 100 kPa (1.0 kgf/cm², 14 psi) Standard tire: Front: Size...
  • Page 29: Special Tools

    2-10 PERIODIC MAINTENANCE Special Tools Valve Spring Compressor Assembly : Fork Oil Level Gauge : 57001–241 57001–1290 Steering Stem Nut Wrench : Pilot Screw Adjuster, C : 57001–1100 57001–1292 Valve Spring Compressor Adapter, 20 : Pilot Screw Adjuster Adapter, 4 : 57001–1154 57001–1371 Jack :...
  • Page 30: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-11 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 31: Hot Start Lever Free Play Inspection

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the throttle grip free play cannot be adjusted with the adjusters at the upper end of the throttle cables, use the cable adjusters [A] at the carburetor. • Make the necessary free play adjustment at the lower ca- ble adjusters, tighten the locknuts [B].
  • Page 32: Idle Speed Adjustment

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures • Check the idle speed, using the engine revolution tester [A] for high accuracy. If the idle speed is out of specified range, adjust it. Idle Speed: Standard: 2 000 ± 50 r/min (rpm) Idle Speed Adjustment •...
  • Page 33 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Seat (see Frame chapter) Wing Bolt [A] Air Cleaner Element [B] • Stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor. • Wipe out the inside of the air cleaner housing with a clean damp towel.
  • Page 34: Cooling System

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Apply grease to all connections and screw holes in the air cleaner housing and intake tract. • Install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a compete seal.
  • Page 35: Coolant Deterioration Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the coolant level. The coolant level [A] should be at the bottom of the filler neck [B]. If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap. Recommended coolant: Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor...
  • Page 36: Engine Top End

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Engine Top End chapter) Timing Inspection Cap [A] Flywheel Cap [B] •...
  • Page 37 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions. • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A].
  • Page 38: Cylinder Head Warp Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 39: Cylinder Wear Inspection

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Wear Inspection NOTE ○ Measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • Visually Inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly worn, replace it with a new one.
  • Page 40: Exhaust System

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Exhaust System • 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 41: Engine Right Side

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply silicone sealant to the circumference [A] of the si- lencer pipe. • Install the muffler (see Engine Top End chapter). Engine Right Side WARNING To avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment.
  • Page 42: Friction And Steel Plates Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Slide the adjuster cover [A] back. • If it cannot be done, loosen the locknut [B] at the middle of the clutch cable, and turn the adjusting nut [C] so that clutch lever has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play. •...
  • Page 43: Oil Filter Change

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely. Drain Plug (for crank room oil sump) [A] Drain Plug (for transmission oil sump) [B] NOTE ○...
  • Page 44 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Using the pry point [A], remove the water pump cover [B]. • Remove the oil filter [A]. • Replace the oil filter with a new one. • Apply grease to the grommet. • Be sure to install the filter with the grommet [A] facing inside as shown.
  • Page 45: Oil Screen Cleaning

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Screen Cleaning • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the oil screen [A]. • Clean the oil screens with a high-flash point solvent and remove any particles stuck to them. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near...
  • Page 46 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Connecting Rod Big End Side Clearance • Measure the connecting rod big end side clearance [A]. Connecting Rod Big End Side Clearance 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.) Standard: Service Limit: 0.55 mm (0.0217 in.) If the clearance exceeds the service limit, replace the crankshaft assembly.
  • Page 47: Wheel/tires

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • 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. CAUTION Do not hammer the crank half at the point [B]. If flywheel misalignment cannot be corrected by the above method, replace the crankpin or the crankshaft itself.
  • Page 48: Tires Inspection

    PERIODIC MAINTENANCE 2-29 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 49: Rim Runout Inspection

    2-30 PERIODIC MAINTENANCE 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 50: Final Drive

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Final Drive Drive Chain Wear Inspection • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.
  • Page 51: Sprocket Wear Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures • If a special lubricant is not available, a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings.
  • Page 52: Brakes

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brakes Brake Lever and Pedal Adjustment WARNING Always maintain proper brake adjustment. If ad- justment is improper, the brake could drag and overheat. This could damage the brake assembly and possibly lock the wheel resulting in loss of control.
  • Page 53: Brake Fluid Level Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check the brake fluid level in the front or rear brake reser- voir [A]. NOTE ○ Hold the reservoir horizontal when checking brake fluid level. • The front or rear reservoir must be kept above the lower level line [B].
  • Page 54: Brake Fluid Change

    PERIODIC MAINTENANCE 2-35 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 55 2-36 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 screw [A], reservoir cap [B] and diaphragm [C].
  • Page 56: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-37 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 (0.8 kgf·m, 69 in·lb) Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) •...
  • Page 57: Brake Master Cylinder Cup And Dust Seal Replacement

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Master Cylinder Dust Seal Replacement • Remove the front master cylinder (see Brake chapter). • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • Unscrew the locknut and pivot bolt, and remove the brake lever.
  • Page 58: Caliper Piston Seal And Dust Seal Replacement

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Apply brake fluid to the removed parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Apply silicone grease (ex. PBC grease). Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact (Rear)
  • Page 59 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Pull out the piston [A] by hand. • Remove the dust seals [B] and fluid seals [C]. NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper.
  • Page 60 PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Replace the fluid seal(s) [A] with new ones. ○ Apply brake fluid to the fluid seal(s), and install them into the cylinders by hand. • Replace the dust seal(s) [B] with new ones. ○...
  • Page 61: Brake Hose And Connection Check

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • 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 62 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Remove each banjo bolts [A] and washers [B]. • Replace the washers with new ones. For Front Brake • Remove Bolts [A] Brake Hose Clamps [B] For Rear Brake • Remove: Master Cylinder [A] Hose Clamps [B] Caliper Cover [C] •...
  • Page 63: Suspension

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Inspection • Holding the brake lever, pump the front fork back and forth manually to check for smooth operation. • Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube [A]. If necessary, repair any damage.
  • Page 64 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Use wrenches [A] on the rod nut [B] and the top plug [C] to loosen the top plug. • Remove the top plug from the push rod. • Lift the fork spring [D] and its top spring seat [E] out of the outer tube.
  • Page 65: Rear Shock Absorber Oil Change

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Purge the air from the fork cylinder by gently moving the piston rod [A] up and down ten times. • Purge the air from between the inner and outer tubes by pumping the outer tube [A] up and down. •...
  • Page 66 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures WARNING Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure. An oil mist is often released with the nitrogen. Always release nitrogen gas pressure before disassem- bling the rear shock absorber to prevent explosive separation of parts.
  • Page 67 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm (0.39 in.) down. • Remove the circlip [A].
  • Page 68 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Push the bladder into the gas reservoir slowly until it just clears the circlip groove. Wipe out any spilled oil. CAUTION Ensure that no air remains in the system. • Check the circlip for weakening, deformity and flaws. If necessary, replace it with a new one.
  • Page 69 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the rear shock body to 55 mm (1.77 in.) [A] from the lower end of the rear shock body [B]. • Insert the piston end [A] of the piston rod assembly into the rear shock body [C] slowly.
  • Page 70: Swingarm And Uni-trak Linkage Inspection

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Install the suitable oil cup [A] to the air bleeder bolt hole, and fill the specified oil into the cup. • Purge the air from between the gas reservoir [B] and rear shock body [C] by slowly pumping the push rod [D] in and out.
  • Page 71: Steering

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Using the jack, raise the front wheel off the ground. Special Tool - Jack : 57001–1238 • With the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 72 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Loosen the front fork upper clamp bolts [A], and remove the steering stem head nut [B] and steering stem head [C]. • Turn the steering stem locknut [A] with the steering stem nut wrench [B] to obtain the proper adjustment. If the steering is too tight, loosen the stem locknut a frac- tion of a turn;...
  • Page 73: Stem Bearing Lubrication

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the handlebar clamp [A] so that the cut side [B] on the clamp points at the front. • Tighten the handlebar clamp bolts [C]. Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) ○...
  • Page 74: Cable Inspection

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Remove the spark plug [A], using the spark plug wrench [B]. Special Tool - Spark Plug Wrench: 57001–1262 Owner’s Tool - Spark Plug Wrench, 16 mm: 92110–0002 • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles.
  • Page 75 2-56 PERIODIC MAINTENANCE 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 Start Cable •...
  • Page 76: Inspection

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Inspection Tightness Inspection • Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition.
  • Page 77 http://manuals.magnamaniac.com...
  • Page 78 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable Replacement ..................... Throttle Cable Lubrication....................Throttle Cable Inspection ....................Hot Start Cable Removal ....................3-10 Hot Start Cable Installation ....................
  • Page 79: Exploded View

    3-2 FUEL SYSTEM Exploded View http://manuals.magnamaniac.com...
  • Page 80 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle pulley cover bolt 30 in·lb Throttle cable locknut 61 in·lb Hot start plunger cap bolt 10 in·lb 4. Throttle Cables 5. Throttle Grip 6. Carburetor Cap 7. Throttle Valve Plate 8.
  • Page 81 3-4 FUEL SYSTEM Exploded View http://manuals.magnamaniac.com...
  • Page 82 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear frame mounting bolts Air cleaner duct clamp screw 17 in·lb Fuel tap plate mounting screws 0.08 7 in·lb 4. Fuel Tank Cap 5. Fuel Tank 6. Fuel Tap 7.
  • Page 83: Specifications

    3-6 FUEL SYSTEM Specifications Standard Item Service Limit KX250-N1 Carburetor: Make/Type KEIHIN FCR37 - - - Starter Jet - - - Leak Jet - - - Main jet #178 - - - Throttle valve cutaway #1.5 - - - Jet needle OBEKS - - - Jet needle clip position...
  • Page 84: Special Tools

    FUEL SYSTEM 3-7 Special Tools Fuel Level Gauge, M18 × 1.0 : 57001-122 http://manuals.magnamaniac.com...
  • Page 85: 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 86: Throttle Cable Lubrication

    FUEL SYSTEM 3-9 Throttle Grip and Cable • Remove the rear frame assy (see Frame chapter). • Remove the carburetor and move it to the right side of the frame. • Unscrew the bolt [A]. • Remove the throttle pulley cover [B]. •...
  • Page 87: Hot Start Cable Removal

    3-10 FUEL SYSTEM Throttle Grip and Cable Hot Start Cable Removal • Remove: Dust Cover [A] (Slide out) Locknut [B] (Loosen) • Turn in the adjuster [C] fully. • Remove the cable end [D] from the hot start lever [E]. •...
  • Page 88: Hot Start Lever Free Play Inspection

    FUEL SYSTEM 3-11 Throttle Grip and Cable Hot Start Lever Free Play Inspection • Refer to the Hot Start Lever Free Play Inspection in Peri- odic Maintenance Hot Start Lever Free Play Adjustment • Refer to the Hot Start Lever Free Play Inspection in Peri- odic Maintenance Hot Start Cable Lubrication •...
  • Page 89: 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 90: Service Fuel Level Adjustment

    FUEL SYSTEM 3-13 Carburetor • Hold the gauge vertically against the side of the carbure- tor body so that the "zero" line [C] is several millimeters higher than the bottom edge [D] of the carburetor body. • Turn the fuel tap to the ON position to feed fuel to the carburetor.
  • Page 91: Carburetor Removal

    3-14 FUEL SYSTEM Carburetor • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 8 ± 1 mm (0.315 ± 0.039 in.) NOTE ○...
  • Page 92 FUEL SYSTEM 3-15 Carburetor • Disconnect the throttle sensor connector [A]. • Loosen the clamp screws [A], and remove the carburetor from the carburetor holder [B] and then pull it out of the end of the air cleaner duct [C]. If necessary, do the following procedure.
  • Page 93: Carburetor Installation

    3-16 FUEL SYSTEM Carburetor • Loosen the locknut [A]. • Pull out the end of the throttle cables [B]. • Free the tips [C]. • Remove the carburetor right side of the frame. • Drain the fuel from the float bowl by removing the drain plug.
  • Page 94: Fuel Inspection

    FUEL SYSTEM 3-17 Carburetor • Route the air vent and overflow hoses properly (see Ap- pendix chapter). CAUTION Always keep the hoses free of obstruction, and make sure they do not get pinched by the chain or shock absorber. • Connect the throttle sensor connector.
  • Page 95 3-18 FUEL SYSTEM Carburetor • Unscrew the screw [A]. • Pull out the fuel hose fitting [B]. • Unscrew the carburetor cap bolts [A]. • Remove the carburetor cap [B]. • Unscrew the throttle valve link screw [A]. • Pull out the throttle valve assembly [B]. •...
  • Page 96 FUEL SYSTEM 3-19 Carburetor • Remove the throttle pulley shaft [A] with the spring [B], steel washer [C], plastic washer [D] and throttle valve link [E]. ○ Turn the throttle pulley shaft [A] clockwise while holding down the acceleration pump lever [B] and clear the idle stop screw [C] to the stopper [D] of the pulley.
  • Page 97 3-20 FUEL SYSTEM Carburetor • Remove the following parts from the carburetor body. [A] Idle Adjusting Screw [B] Screws [C] Clamps [D] Float Bowl [E] Leak Jet [F] O-ring [G] Pin [H] Float [I] Main Jet [J] Needle Jet [K] Starter Jet [L] Pilot Jet [M] Pilot Air Jet [N] Stopper Screw...
  • Page 98: Carburetor Cleaning

    FUEL SYSTEM 3-21 Carburetor • 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. Carburetor Cleaning WARNING Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere...
  • Page 99: Carburetor Inspection

    3-22 FUEL SYSTEM Carburetor Carburetor Inspection 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 100: Carburetor Assembly

    FUEL SYSTEM 3-23 Carburetor • Remove the starter jet. • Check the slow jet for any damage. If the slow jet is damaged, replace it with a new one. • Remove the throttle valve and jet needle. • Inspect the outside of the throttle valve and plate for scratches and abnormal wear.
  • Page 101 3-24 FUEL SYSTEM Carburetor • Install the acceleration pump lever assembly to the car- buretor body. ○ Fit the end [B] of the return spring into the recess [A] on the carburetor body. • Install: Washer [A] E-clip [B] • Apply thin coat silicone grease to the shaft.
  • Page 102 FUEL SYSTEM 3-25 Carburetor • 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]. • Install the push rod [A] into the push rod holder [B]. •...
  • Page 103 3-26 FUEL SYSTEM Carburetor • Install: O-ring [A] Carburetor Cap [B] Bolts (tighten) • Install: Starter Jet [A] Pilot Jet [B] Baffle Plate [C] Needle Jet [D] Main Jet [E] • Replace the O-ring with new one. • Install: Pilot Air Screw [A] Spring [B] Washer [C] O-ring [D]...
  • Page 104 FUEL SYSTEM 3-27 Carburetor • Install: Float Bowl • Tighten the bolts with hose clamps [A] and cable holder [B] as shown. • Replace the O-rings with new ones. • Fit the O-rings [A]. • Install: Diaphragm [B] Spring [C] Acceleration Pump Cover ○...
  • Page 105 3-28 FUEL SYSTEM Carburetor • If turn the adjusting screw of the acceleration pump, follow the procedure 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. Throttle Valve Height –...
  • Page 106: Air Cleaner

    FUEL SYSTEM 3-29 Air Cleaner Air Cleaner Housing Removal • Remove: Side Covers (see Frame chapter) Seat (see Frame chapter) Silencer (see Engine Top End chapter) Bolts and Rear Fender [A] (see Frame chapter) Screws and Rear Flap [B] (see Frame chapter) Rear Frame Bolts [C] •...
  • Page 107: Element Cleaning And Inspection

    3-30 FUEL SYSTEM Air Cleaner • Install the element so that its tab [A] faces upward and fit the element projections [B] to the holes of the housing [C]. • Tighten the wing bolt [D]. • Install the seat (see Frame chapter). Element Cleaning and Inspection •...
  • Page 108: Fuel Tank

    FUEL SYSTEM 3-31 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 109: Fuel Tap Removal

    3-32 FUEL SYSTEM Fuel Tank Fuel Tap Removal • Remove the fuel tank and drain it. • Remove the mounting bolts [A] and take out the fuel tap [B]. Fuel Tap Installation • Be sure the O-ring is in good condition to prevent leaks. •...
  • Page 110 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Water Pump..........................
  • Page 111: Exploded View

    4-2 COOLING SYSTEM Exploded View http://manuals.magnamaniac.com...
  • Page 112 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water pump cover bolts 87 in·lb L (1) Water pump cover bolts (with washer) 61 in·lb L (1) Coolant drain plug 61 in·lb Water pump impeller bolt 61 in·lb Right engine cover bolts 87 in·lb Cooling hose clamp screws...
  • Page 113: Specifications

    4-4 COOLING SYSTEM Specifications Item Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50%, antifreeze 50% Freezing point -35°C (-31°F) Total amount 1.2 L (1.27 US qt.) Radiator 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi) Cap relief pressure http://manuals.magnamaniac.com...
  • Page 114: Special Tool

    COOLING SYSTEM 4-5 Special Tool Bearing Driver Set : 57001–1129 http://manuals.magnamaniac.com...
  • Page 115: Coolant

    4-6 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 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 116: Coolant Filling

    COOLING SYSTEM 4-7 Coolant Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system.
  • Page 117: Cooling System Pressure Testing

    4-8 COOLING SYSTEM Coolant Cooling System Pressure Testing CAUTION During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapter [B] on the radiator filler neck [C].
  • Page 118: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal • Drain the engine oil from the oil filter oil chamber. ○ Unscrew the drain plug [A] • Drain the coolant (see Coolant Draining). ○ Unscrew the drain bolt [B]. • Unscrew the water pipe bolt [A], and disconnect the water pipe [B].
  • Page 119: Impeller Removal

    4-10 COOLING SYSTEM Water Pump • Fill the cooling system (see Coolant Filling). • Bleed the air from the cooling system. • Check the engine oil level and add the engine oil. Impeller Removal • Drain: Coolant (see Coolant Draining) Engine Oil (see above) Water Pump Cover •...
  • Page 120: Water Pump Gear Removal

    COOLING SYSTEM 4-11 Water Pump Water Pump Gear Removal • Remove: Water Pump Cover (see this chapter) Impeller (see this chapter) Right Engine Cover (see Engine Right Side chapter) • Pull out the water pump shaft [A] toward inside of the right engine cover.
  • Page 121 4-12 COOLING SYSTEM Water Pump • Apply plenty of high temperature grease to the oil seal lips. • Press in the oil seals direction as shown. ○ Press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the right engine cover.
  • Page 122: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator Removal • Drain the coolant (see Coolant Draining) • Drain the engine oil from the oil filter oil chamber (see Water Pump Removal) • Remove: Radiator Shrouds (see Fuel System chapter) Fuel Tank (see Fuel System chapter) •...
  • Page 123: Radiator Installation

    4-14 COOLING SYSTEM Radiator • Remove: Bolts with Clamps [A] Left Radiator with Hoses [B] Radiator Installation • Hold the clutch cable with clamps. • Fit the projections [A] of the screen in the holes [B] of the radiator. Torque - Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Radiator Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 124: Radiator Cap Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Cap Inspection • Check the condition of the valve seals [A], and the top and bottom valve spring [B] of the radiator cap. If any one of them shows visible damage, replace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks.
  • Page 125 http://manuals.magnamaniac.com...
  • Page 126 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Installation ......5-22 Specifications ........Valve Guide Removal ....5-23 Special Tools & Sealants ....Valve Guide Installation ....5-23 Cylinder Head Cover ......5-11 Valve/Valve Guide Clearance Cylinder Head Cover Removal ..
  • Page 127: Exploded View

    5-2 ENGINE TOP END Exploded View http://manuals.magnamaniac.com...
  • Page 128 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Auto decompressor bolt 104 in·lb Cylinder head cover bolts 87 in·lb Cylinder head bolts M6 104 in·lb Camshaft cap bolts 104 in·lb Carburetor holder clamp screws 17 in·lb Plug Lower camshaft chain guide bolt 87 in·lb...
  • Page 129 5-4 ENGINE TOP END Exploded View http://manuals.magnamaniac.com...
  • Page 130 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain tensioner mounting bolts 87 in·lb Chain tensioner cap 14.5 Cylinder head bolts M6 104 in·lb Cylinder bolt M6 104 in·lb Exhaust pipe cover screws 104 in·lb Exhaust pipe holder nuts Muffler mounting bolts 8.
  • Page 131: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts: Cam Height: 33.941 ∼ 34.057 mm Exhaust 33.84 mm (1.3363 ∼ 1.3408 in.) (1.3322 in.) 34.642 ∼ 34.758 mm Inlet 34.54 mm (1.3639 ∼ 1.3684 in.) (1.3598 in.) 0.020 ∼ 0.062 mm Camshaft Journal Clearance 0.15 mm (0.0008 ∼...
  • Page 132 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Valve Seat Surface Outside Diameter: 24.62 ∼ 24.82 mm Exhaust - - - (0.9693 ∼ 0.9772 in.) 30.62 ∼ 30.82 mm Inlet - - - (1.2055 ∼ 1.2134 in.) Valve Seat Surface Width: 0.5 ∼...
  • Page 133 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] http://manuals.magnamaniac.com...
  • Page 134: Special Tools & Sealants

    ENGINE TOP END 5-9 Special Tools & Sealants Compression Gauge, 20 kgf/cm² : Valve Seat Cutter, 32° – 28 : 57001–221 57001–1119 Valve Spring Compressor Assembly : Valve Seat Cutter, 32° – 33 : 57001–241 57001–1199 Piston Ring Compressor Grip : Valve Seat Cutter, 60°...
  • Page 135 5-10 ENGINE TOP END Special Tools & Sealants Valve Seat Cutter, 45° – 35 : Valve Guide Arbor, 4.5 : 57001–1116 57001–1331 Valve Seat Cutter, 60° – 28 : Valve Guide Reamer, 4.5 : 57001–1328 57001–1333 Spark Plug Wrench, Hex 16 : Valve Guide Driver, 4.5 : 57001–1262 57001–1564...
  • Page 136: Cylinder Head Cover

    ENGINE TOP END 5-11 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel System chapter) Spark Plug Cap [A] • Remove the cylinder head cover bolts [B] and remove the cylinder head cover [C]. Cylinder Head Cover Installation •...
  • Page 137: Camshaft Chain Tensioner

    5-12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION 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 138: Camshaft

    ENGINE TOP END 5-13 Camshaft Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Flywheel Cap [B] • First, bring the piston to the TDC (of either the compres- sion or exhaust stroke). ○...
  • Page 139: Camshaft Installation

    5-14 ENGINE TOP END Camshaft • Remove: Bolt [A] Auto Decompressor [B] Spring Camshaft Installation • Install: Spring [A] Auto Decompressor [B] Bolt [C] Torque - Auto Decompressor Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) • Apply molybdenum disulfide oil to the ball bearing, all cam and journal surfaces of the camshaft.
  • Page 140 ENGINE TOP END 5-15 Camshaft 1st Pin [A] Punch Marks (exhaust) [D] 2nd Pin [B] Punch Marks (inlet) [E] 28th Pin [C] Upper Cylinder Head Surface [F] • Be sure to install the positioning rings [A] and dowel pins [B]. •...
  • Page 141: Camshaft And Camshaft Cap Wear

    5-16 ENGINE TOP END Camshaft • Uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ Bolts [A] are long. ○ Following the sequence numbers on the camshaft caps, tighten the cap bolts [1 ∼ 4]. Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 142: Camshaft Chain Removal

    ENGINE TOP END 5-17 Camshaft Camshaft Chain Removal • Remove: Camshaft (see Camshaft Removal) Magneto Flywheel (see Electrical System) Lower Camshaft Chain Guide Bolt [A] Lower Chain Guide [B] • Remove the camshaft chain [C] from the crankshaft sprocket. Camshaft Chain Installation •...
  • Page 143: Cylinder Head

    5-18 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 144: Cylinder Head Removal

    ENGINE TOP END 5-19 Cylinder Head Cylinder Head Removal • Remove: Fuel Tank (see Fuel System chapter) Camshaft Chain Tensioner (see Camshaft Chain Ten- sioner Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft (see Camshaft Removal) Nut [A] Bolt [B] (loosen) Exhaust Pipe [C] Clamp Screw [D]...
  • Page 145: Cylinder Head Installation

    5-20 ENGINE TOP END Cylinder Head • Remove the 10 mm cylinder head bolts [A]. • Tap lightly up with a plastic mallet [A] to separate the cylin- der head [B] from the cylinder. • Move back the carburetor [A] and hold it. •...
  • Page 146: Cylinder Head Cleaning

    ENGINE TOP END 5-21 Cylinder Head • Replace all the 10 mm cylinder head bolt washers with new ones. ○ The 10 mm cylinder head bolt washers are copper-plated, and they could leak oil if reused. • Apply molybdenum disulfide oil to the following areas. 10 mm Cylinder Head Bolt Washer, both sides [A] •...
  • Page 147: Valves

    5-22 ENGINE TOP END Valves Valve Clearance Inspection ○ Refer to the Engine Top End 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 148: Valve Guide Removal

    ENGINE TOP END 5-23 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). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 149: Valve/valve Guide Clearance

    5-24 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, 4.5: 57001–1333 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 150: Valve Seat Inspection

    ENGINE TOP END 5-25 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 151 5-26 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 152 ENGINE TOP END 5-27 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 153 5-28 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 154: Valve Seat Repair

    ENGINE TOP END 5-29 Valves Valve Seat Repair http://manuals.magnamaniac.com...
  • Page 155: Cylinder And Piston

    5-30 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 156 ENGINE TOP END 5-31 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 157: Cylinder Wear

    5-32 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 Tool - Piston Ring Compressor Grip: 57001–1095 Piston Ring Compressor Belt, 67 to...
  • Page 158: Piston Ring Thickness

    ENGINE TOP END 5-33 Cylinder and Piston Piston Ring Thickness • Measure the thickness at several points around ring with a micrometer. Piston Ring Thickness (Top) 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Standard: Service Limit: 0.70 mm (0.0276 in.) If any of the measurements is less than the service limit on either of the rings, replace the rings as a set.
  • Page 159: Carburetor Holder

    5-34 ENGINE TOP END 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 Screw: 2.0 N·m (0.2 kgf·m, 104 in·lb) •...
  • Page 160: Muffler

    ENGINE TOP END 5-35 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • Loosen the muffler clamp bolt [A]. • Remove the exhaust pip holder nut [B]. •...
  • Page 161 http://manuals.magnamaniac.com...
  • Page 162 ENGINE RIGHT SIDE 6-1 Engine Right Side Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Lever Installation....................Clutch Cable Removal ...................... Clutch Cable Installation ....................
  • Page 163: 6-2 Engine Right Side

    6-2 ENGINE RIGHT SIDE Exploded View http://manuals.magnamaniac.com...
  • Page 164 ENGINE RIGHT SIDE 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Primary gear nut Clutch cover bolts 87 in·lb L (1) Clutch cover bolt (with washer) 61 in·lb Right engine cover bolts 87 in·lb Clutch spring bolts 87 in·lb Clutch hub nut 7.
  • Page 165 6-4 ENGINE RIGHT SIDE Exploded View http://manuals.magnamaniac.com...
  • Page 166 ENGINE RIGHT SIDE 6-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Ratchet guide bolt 78 in·lb Kick pedal bolt Shift pedal bolt 87 in·lb Ratchet plate mounting bolt 87 in·lb Ratchet plate mounting screw 0.65 56 in·lb Gear set lever nut 78 in·lb Shift drum cam bolt Gear set lever pivot stud...
  • Page 167: Specifications

    6-6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play - - - Clutch: 2.72 ∼ 2.88 mm Friction Plate Thickness 2.62 mm (0.1031 in.) (0.107 ∼ 0.113 in.) 1.5 ∼...
  • Page 168: Special Tool

    ENGINE RIGHT SIDE 6-7 Special Tool Clutch Holder : Gear Holder : 57001–1243 57001–1557 http://manuals.magnamaniac.com...
  • Page 169: 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 To avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment.
  • Page 170: Clutch Cable Installation

    ENGINE RIGHT SIDE 6-9 Clutch Lever and Cable • Free the cable from the cable holder [A]. • Free the clutch inner cable tip [B] from the clutch release lever [C]. CAUTION Do not remove the clutch release shaft unless it is absolutely necessary.
  • Page 171: 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 Periodic Maintenance chapter). • Set the stand attached. • Remove the brake pedal (see Brakes chapter). • Remove the clutch cover bolts [A] and remove the clutch cover [B].
  • Page 172: Release Shaft Removal

    ENGINE RIGHT SIDE 6-11 Clutch Cover and Right Engine Cover • When installing the cover doesn’t go well, the cover is installed according to the following procedures. ○ The cover is installed while turning [A] the impeller [B]. • Install: Water Pump Cover (see Cooling System chapter) •...
  • Page 173: Clutch

    6-12 ENGINE RIGHT SIDE Clutch Clutch Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove the clutch spring bolts [A], spring, and clutch pressure plate [B]. • Remove the push rod holder assy [A], friction plates [B] and steel plates [C].
  • Page 174 ENGINE RIGHT SIDE 6-13 Clutch • Install the toothed washer [A]. • Tighten the clutch hub nut [B]. Torque - Clutch Hub Nut: 98 N·m (10 kgf·m, 72 ft·lb) NOTE ○ Use the clutch holder [C] to prevent the clutch hub from rotating.
  • Page 175: Friction And Steel Plates Wear, Damage Inspection

    6-14 ENGINE RIGHT SIDE Clutch • Check the release shaft lever positions [A]. ○ Pushing [B] the release shaft lever [C] lightly frontward measure the distance between the lever and cable bracket [D]. Release Shaft Lever Position 36.7 ∼ 44.5 mm Standard: If the lever position is not within the standard, select the correct thickness of adjusting washer(s) according to the...
  • Page 176: Clutch Housing Finger Damage

    ENGINE RIGHT SIDE 6-15 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 it the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as well.
  • Page 177: Primary Gear

    6-16 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal • Remove: Right Engine Cover • Remove the clutch (see Clutch Removal). • Temporarily install the clutch housing [A]. • Using the gear holder [B], secure the primary gear. Special Tool - Gear Holder: 57001–1557 •...
  • Page 178: External Shift Mechanism

    ENGINE RIGHT SIDE 6-17 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] • Remove: Right Engine Cover (see this chapter) Clutch Housing (see this chapter) • Pull out the shift shaft [A]. •...
  • Page 179: External Shift Mechanism Inspection

    6-18 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] Crankcase Side [E] • Then install the ratchet assembly [A] to the ratchet plate [B] as shown in the figure.
  • Page 180 ENGINE RIGHT SIDE 6-19 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 181: Kickstarter

    6-20 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. 14 ∼ 24 mm [B] • Apply a non-permanent locking agent to the mounting bolt.
  • Page 182: Idle Gear Installation

    ENGINE RIGHT SIDE 6-21 Kickstarter Idle Gear Installation • Apply engine oil to the inside of the idle gear. • Install the washer [A]. • Fit the idle gear [B] with the boss [C] facing toward the engine side. Kickshaft Removal •...
  • Page 183: Kickstarter Assembly Disassembly/assembly

    6-22 ENGINE RIGHT SIDE Kickstarter Kickstarter Assembly Disassembly/Assembly • The kickstarter assembly consists of the following parts. • Check the kickstarter assembly parts for damage. Any damaged parts should be replaced with new ones. A. Kick Gear E. Ratchet Gear B.
  • Page 184 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 Removal ......................Oil Screen Installation .......................
  • Page 185: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View http://manuals.magnamaniac.com...
  • Page 186 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine oil drain plug M10 (for transmission room oil sump) Engine oil drain plug M6 (for crank room oil sump) 61 in·lb Engine oil drain plug M6 (for oil filter oil chamber) 61 in·lb Oil Pump mounting bolts 61 in·lb...
  • Page 187: Lubrication System Chart

    7-4 ENGINE LUBRICATION SYSTEM Lubrication System Chart http://manuals.magnamaniac.com...
  • Page 188 ENGINE LUBRICATION SYSTEM 7-5 Lubrication System Chart 1. Oil Screen (scavenging) 2. Oil Screen (feed) 3. Oil Pump (scavenging) 4. Oil Pump (feed) 5. Right Crankcase Oil Passage (from Scavenging Oil Pump to Transmission Oil Shower Passage) 6. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil Filter Oil Chamber) 7.
  • Page 189: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Grade Castrol “R4 Superbike” 5W-40 API SH or SJ with JASO MA Viscosity SAE 10W-30, 10W-40, or 10W-50 Capacity Oil change – when filter is not removed 1.3 L (1.4 US qt) Oil change –...
  • Page 190: Special Tools

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools Oil Pressure Gauge, 5 kgf/cm² : Gear Holder : 57001–125 57001–1557 Outside Circlip Pliers : Oil Pressure Gauge Adapter, M6 × 1.0 : 57001–144 57001–1579 http://manuals.magnamaniac.com...
  • Page 191: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM 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. The engine oil level indicated in the clutch cover oil level gauge is very sensitive to the motorcycle’s position and en- gine rpm at time of shut down.
  • Page 192: Oil Filter Change

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Change ○ Refer to the Engine Lubrication System in the Periodic Maintenance chapter. Oil Screen Removal • Separate the crankcase (see Crankshaft/Transmission chapter). • Remove the oil screens [A] from the crankcase. Oil Screen Installation •...
  • Page 193: Oil Pump

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain: Engine Oil (see Periodic Maintenance chapter) Coolant (see Periodic Maintenance chapter) • Remove: Brake Pedal (see Brakes chapter) Kick Pedal (see Engine Right Side chapter) Water Pipe Bolt [A] Water Pipe [B] (pull out) Water Pump Cover [C] Right Engine Cover Bolts [D]...
  • Page 194: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump • Remove the inner [A] and outer [B] rotors of the scaveng- ing oil pump. • Disassembly the feed oil pump assembly. Oil Pump Cover [A] Inner Rotor [B] Outer Rotor [C] Pin [D] Oil Pump Body [E] Oil Pump Gear [F] Oil Pump Installation...
  • Page 195: Oil Pump Inspection

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Install the outer rotor [A]. • Install the dowel pin [B] and dowel pin [C]. • Install the scavenging and feed oil pump assemblies [D]. • Apply a non-permanent locking agent to the oil pump mounting bolts.
  • Page 196: Oil Pressure

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Oil Pressure Measurement • Remove the oil drain plug (for oil filter oil chamber) [A]. • Attach the oil pressure gauge adapter [A]. • Attach the oil pressure gauge [B]. Special Tools - Oil Pressure Gauge Adapter: 57001–1579 Oil Pressure Gauge: 57001–125 •...
  • Page 197 http://manuals.magnamaniac.com...
  • Page 198 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................http://manuals.magnamaniac.com...
  • Page 199: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View http://manuals.magnamaniac.com...
  • Page 200 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper engine mounting bolt, nut (M10) Middle engine mounting bolt, nut (M10) Lower engine mounting bolt, nut (M10) Upper engine bracket bolts, nuts (M8) Middle engine bracket bolts (M8) Swingarm pivot nut http://manuals.magnamaniac.com...
  • Page 201: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001–1238 http://manuals.magnamaniac.com...
  • Page 202: 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 For engine removal, the swingarm pivot shaft must be pulled out, causing the swingarm and rear wheel assembly to become detached.
  • Page 203 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Loosen: Carburetor Clamp Bolts [A] • Remove: Inlet Duct [B] with Rear Frame (see Frame chapter) Carburetor [C] (hanging it) Clutch Cable Lower End [D] (see Engine Right Side chapter) Drive Chain [E] (cut out) •...
  • Page 204: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Pull out the carburetor hoses [A] and breather hose [B] from the clamp [C]. • Remove the swing arm pivot shaft [D]. ○ Pull out the swing arm pivot shaft half way from right side to free the engine.
  • Page 205 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the removed parts (see Appropriate chapter). • Run the cables, hoses, and leads according to the Cable, Wire and Hose Routing section of the Appendix chapter. • Fill: Engine Oil (see Periodic Maintenance chapter) Coolant (see Periodic Maintenance chapter) •...
  • Page 206 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Crankcase ..........................Crankcase Disassembly ....................Crankcase Assembly ......................Crankshaft ..........................9-13 Crankshaft Removal ......................9-13 Crankshaft Installation ...................... 9-13 Crankshaft Disassembly ....................9-13 Crankshaft Assembly ......................9-14 Connecting Rod Bend.......................
  • Page 207: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View http://manuals.magnamaniac.com...
  • Page 208 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Crankcase bolts 87 in·lb 2 Gear set lever nut 78 in·lb 3 Neutral switch 104 in·lb 4 Engine oil drain plug (for crank room oil sump) 61 in·lb 5 Engine oil drain plug (for transmission room oil sump) 6 Shift drum cam bolt 7 Piston oil nozzle 0.25...
  • Page 209: Specifications

    9-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Connecting Rods: 0.002 ∼ 0.014 mm Connecting rod big end radial clearance 0.06 mm (0.0024 in.) (0.00008 ∼ 0.0006 in.) 0.25 ∼ 0.35 mm Connecting rod big end side clearance 0.55 mm (0.0217 in.) (0.0098 ∼...
  • Page 210: Special Tools

    CRANKSHAFT/TRANSMISSION 9-5 Special Tools Bearing Puller : Crankshaft Jig : 57001–135 57001–1174 Outside Circlip Pliers : Crankcase Splitting Tool Assembly : 57001–144 57001–1362 Bearing Driver Set : Kawasaki Bond (Liquid Gasket – Gray) : 57001–1129 92104–1063 http://manuals.magnamaniac.com...
  • Page 211: Crankcase

    9-6 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Re- moval/Installation chapter) • Set the engine on clean surface while parts are being re- moved. • Remove: Magneto Cover (see Electrical System chapter) Cylinder Head Cover (see Engine Top End chapter) Camshaft Chain Tensioner (see Engine Top End chap- ter) Cylinder Head (see Engine Top End chapter)
  • Page 212 CRANKSHAFT/TRANSMISSION 9-7 Crankcase • Remove the crankcase bolts [A]. • Install the jig [A] between the crankshaft flywheels [B]. Special Tool - Crankshaft Jig: 57001–1174 • Attach the crankcase splitting tool [A] to the left crankcase. ○ Adjust the gap between the splitting tool arm and bolt, using the collar or nut [B].
  • Page 213: Crankcase Assembly

    9-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set. • Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high–flash point solvent.
  • Page 214 CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Press the new drive shaft bearing [A] in the left and right crankcase half, so that the sealed side [B] faces outside of the engine. • Press the new output shaft bearings [A] in the left and right crankcase half [B], so that the stepped side [C] faces inside of the engine.
  • Page 215 Special Tool - Crankshaft Jig: 57001–1174 • Apply liquid gasket to the mating surface [A] of the left crankshaft half. Sealant - Kawasaki Bond (Liquid Gasket – Gray): 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 216 CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Using a plastic hammer [A], press [B] the rear portion of the crankcase, and tap [C] the area around the crank- shaft of the left crankcase. While maintaining the mating surfaces of the right and left crankcase halves constantly parallel, mate the crankcase halves evenly.
  • Page 217 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Install the gear set lever [A]. ○ Fit each end of the spring [B] or original positions. ○ Do not forget to install the colar and washer [C]. • Tighten the gear set lever nut [D]. Torque - Gear Set Lever Nut: 8.8 N·m (0.9 kgf·m, 78 in·lb) •...
  • Page 218: Crankshaft

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft Crankshaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Remove the transmission shaft (see this chapter). • Using the hand press [A], remove the crankshaft [B] from the right crankcase [C]. If the bearing stay on the crankshaft when splitting the crankcase, or removing the crankshaft from the right re- move the bearings from the crankshaft with a bearing puller.
  • Page 219: Crankshaft Assembly

    9-14 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crank- shaft can only be done by a shop having the necessary tools and equipment. • Reassemble the crankshaft according to the standard tol- erances in Specifications.
  • Page 220: Transmission

    CRANKSHAFT/TRANSMISSION 9-15 Transmission Transmission Shaft Removal • Disassemble the crankcase halves (see Crankcase Dis- assembly). • Pull out the oil screens. Crank Room Side Oil Screen [A] Transmission Room Side Oil Screen [B] • Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B].
  • Page 221: Transmission Shaft Disassembly

    9-16 CRANKSHAFT/TRANSMISSION Transmission • Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear. • The shift forks can be identified by their shape or mark. Install them noting the direction shown.
  • Page 222 CRANKSHAFT/TRANSMISSION 9-17 Transmission • The output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 5th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and washers are properly in place.
  • Page 223: Shift Fork Bending

    9-18 CRANKSHAFT/TRANSMISSION Transmission • Check each gear spins or slides freely on the transmission shaft without binding after assembly. Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power.
  • Page 224: Bearings/oil Seals

    CRANKSHAFT/TRANSMISSION 9-19 Bearings/Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • Remove the ball bearing and/or needle bearing outer race using a press or puller. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- proximately 93°C (200 °F) max, and tapping the bearing in or out.
  • Page 225: Oil Seal Inspection

    9-20 CRANKSHAFT/TRANSMISSION Bearings/Oil Seals • Check the needle bearing. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a needle bear- ing, replace it.
  • Page 226 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..................... 10-8 Wheels Inspection......................10-9 Spoke Tightness Inspection ....................
  • Page 227: Exploded View

    10-2 WHEELS/TIRES Exploded View http://manuals.magnamaniac.com...
  • Page 228 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spoke Nipple 0.22 19 in·lb Front Axle Nut Front Axle Clamp Bolts 14.5 Rear Axle Nut 11.0 5. Spokes 6. Front Tire 7. Rims 8. Front Axle 9. Swingarm 10. Rear Tire 11.
  • Page 229: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial 1.0 mm (0.039 in.) or less 2 mm (0.08 in.) Radial 1.0 mm (0.039 in.) or less 2 mm (0.08 in.) Axle runout/ 100 mm 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) Tires Air Pressure: Front and Rear...
  • Page 230: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers : Bearing Driver Set : 57001–143 57001–1129 Rim Protector : Jack : 57001–1063 57001–1238 Bead Breaker Assembly : 57001–1072 http://manuals.magnamaniac.com...
  • Page 231: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special Tools - Jack: 57001–1238 • Loosen the left and right axle clamp bolts [A]. • Unscrew the axle nut [B]. •...
  • Page 232: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Remove the jack. • Before tightening the clamp bolts on the right fork leg, pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle. NOTE ○...
  • Page 233: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove Cotter Pin [A] Axle Nut [B] • Pull out the axle [C]. • Move the rear wheel back with the rear caliper installed. • Take off the collar and cap from the each side of the rear hub.
  • Page 234: Wheels Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Check the drive chain slack (see Final Drive chapter). • Tighten the axle nut. Torque - Rear Axle Nut: 110 N·m (11 kg·m, 80 ft·lb) • Install the new cotter pin [A] and spread its end. NOTE ○...
  • Page 235: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.937 in.) [A] apart, and set a dial gauge on the axle at a point halfway between the blocks.
  • Page 236: Tires

    WHEELS/TIRES 10-11 Tires Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • Remove the wheel from the motorcycle (see Wheels Re- moval).
  • Page 237: Installation

    10-12 WHEELS/TIRES Tires • Step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B]. Special Tools - Rim Protector: 57001–1063 Bead Breaker Assembly: 57001–1072 CAUTION Take care not to inset the tire irons so deeply that...
  • Page 238: Hub Bearings

    WHEELS/TIRES 10-13 Hub Bearings Hub Bearing Removal • Remove the wheel (see Wheel Removal). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 239 http://manuals.magnamaniac.com...
  • Page 240 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection ..................... 11-7 Wheel Alignment Adjustment.................... 11-7 Drive Chain Wear Inspection ....................
  • Page 241: Exploded View

    11-2 FINAL DRIVE Exploded View http://manuals.magnamaniac.com...
  • Page 242 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Sprocket Nuts Engine Sprocket Cover Bolts 87 in·lb 3. Engine Sprocket 4. Output Shaft 5. Chain Slipper 6. Swingarm 7. Chain Guide 8. Locknut 9. Adjusting Bolt 10. Chain Adjuster 11.
  • Page 243: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain: 52 ∼ 62 mm (2.05 ∼ 2.44 in.) Chain slack - - - 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Chain 20-link length 323 mm (12.72 in.) Standard Chain: Make: DAIDO - - -...
  • Page 244: Special Tools

    FINAL DRIVE 11-5 Special Tools Outside Circlip Pliers : Jack : 57001–144 57001–1238 http://manuals.magnamaniac.com...
  • Page 245: Drive Chain

    11-6 FINAL DRIVE Drive Chain 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), and adjust it if necessary (see Wheel Alignment Ad- justment).
  • Page 246: Wheel Alignment Inspection

    FINAL DRIVE 11-7 Drive Chain 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. ○ It should be within 30 degree.
  • Page 247: Drive Chain Removal

    11-8 FINAL DRIVE Drive Chain Drive Chain Removal • Remove the clip [A] from the master link using pliers, and free the drive chain from the rear sprocket. • Remove the drive chain from the chassis. Drive Chain Installation • Fit the drive chain back onto the sprockets with the ends at the rear sprocket.
  • Page 248: Sprockets

    FINAL DRIVE 11-9 Sprockets Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Remove: Drive Chain [A] (free of engine sprocket) • Remove the circlip [B], and pull off the engine sprocket [C].
  • Page 249: Rear Sprocket Warp Inspection

    11-10 FINAL DRIVE Sprockets Rear Sprocket Warp Inspection • Refer to the Rear Sprocket Wrap Inspection in Periodic Maintenance chapter. http://manuals.magnamaniac.com...
  • Page 250 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tools .......................... 12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Play Adjustment.................... 12-8 Brake Pedal Position/Pedal Play Adjustment ..............12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................12-8 Brake Fluid ..........................
  • Page 251: Exploded View

    12-2 BRAKES Exploded View http://manuals.magnamaniac.com...
  • Page 252 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front master cylinder clamp bolts 78 in·lb Brake hose banjo bolts Brake pad bolt Caliper bleed valve 69 in·lb Caliper mounting bolts Brake disc mounting bolts 87 in·lb Brake lever pivot bolt locknut 52 in·lb Brake reservoir cap screws 0.15...
  • Page 253 12-4 BRAKES Exploded View http://manuals.magnamaniac.com...
  • Page 254 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake hose banjo bolts Rear master cylinder mounting bolts 87 in·lb Rear master cylinder push rod locknut Caliper bleed valve 69 in·lb Brake pad bolt Rear brake pad bolt plug 0.25 22 in·lb Caliper holder shaft...
  • Page 255: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake adjustment: Lever play - - - Adjustable (to suit rider) Brake Fluid: Recommended disc brake fluid: - - - Type Front DOT3 or DOT4 - - - Rear DOT4 Brake Pads: Lining thickness: Front 3.8 mm (0.150 in.) 1 mm (0.04 in.)
  • Page 256: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers : Jack : 57001–143 57001–1238 http://manuals.magnamaniac.com...
  • Page 257: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Play Adjustment • Refer to the Brake Lever Play Adjustment in Periodic Maintenance chapter. Brake Pedal Position/Pedal Play Adjustment • Refer to Brake Pedal Position/Pedal Play Adjustment in Periodic Maintenance chapter. Brake Pedal Removal •...
  • Page 258: Brake Fluid

    BRAKES 12-9 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 259: Bleeding The Brake Line

    12-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air.
  • Page 260 BRAKES 12-11 Brake Fluid • Check the fluid level. • After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage. WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc.
  • Page 261: Caliper

    12-12 BRAKES Caliper Caliper Removal Front Brake: • Loosen the banjo bolt [A] so as not to spill brake fluid. • Remove the caliper mounting bolts [B]. • Remove the banjo bolt and take off the brake hose from the caliper [C]. •...
  • Page 262: Caliper Installation

    BRAKES 12-13 Caliper Caliper Installation • Tighten the brake pad bolts if it was removed. Torque - Brake Pad Bolts: 18 N·m (1.8 kgf·m, 13 ft·lb) Front Brake: • Install the caliper and tighten the bolts. Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18.0 ft·lb) Rear Brake: •...
  • Page 263: Caliper Holder Shaft Wear

    12-14 BRAKES Caliper Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts. 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 264: Brake Pad Installation

    BRAKES 12-15 Caliper Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. • Install the piston side pad first, and then another pad. ○ Fit the pad end [A] into the groove [B] of the anti-rattle spring securely.
  • Page 265: Master Cylinder

    12-16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wished up immediately. Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the upper brake hose [B] from the master cylinder [C]. •...
  • Page 266: Rear Master Cylinder Removal

    BRAKES 12-17 Master Cylinder Rear Master Cylinder Removal • Remove the cotter pin [A]. • Pull off the joint pin [B] with washer. NOTE ○ Pull off the joint pin while pressing down the brake pedal. • Unscrew the master cylinder mounting bolts [C], and re- move the master cylinder [D].
  • Page 267: Master Cylinder Inspection (visual Inspection)

    12-18 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B].
  • Page 268: Brake Disk

    BRAKES 12-19 Brake Disk Brake Disc Inspection • Visually inspect the disc [A]. If it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the point [B] where it has worn the most. Replace the disc if it has worn past the service limit. Thickness Front Rear...
  • Page 269: Brake Hose

    12-20 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in Periodic Main- tenance chapter. Brake Hose Inspection • Refer to the Brake Hose and Connection Check in Peri- odic Maintenance chapter. http://manuals.magnamaniac.com...
  • Page 270 SUSPENSION 13-1 Suspension Table of Contents Exploded View........13-2 Spring Replacement ....13-24 Specifications ........13-6 Rear Shock Absorber Special Tools ........13-7 Disassembly (Oil Change) ..13-24 Front Fork .......... 13-9 Rear Shock Absorber Assembly .. 13-24 Air Pressure ......... 13-9 Rear Shock Absorber Scrapping .
  • Page 271: Exploded View

    13-2 SUSPENSION Exploded View http://manuals.magnamaniac.com...
  • Page 272 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front fork top plug Lower front fork clamp bolts 14.5 Upper front fork bolts 14.5 Steering stem head nut Push rod nut 2.85 20.6 Front axle clamp bolts 14.5 Front fork cylinder valve assembly 8.
  • Page 273 13-4 SUSPENSION Exploded View http://manuals.magnamaniac.com...
  • Page 274 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 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 0.65 56 in·lb 7.
  • Page 275: Specifications

    13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork: Air pressure Atmospheric pressure - – – Rebound damping adjustment (Adjustable Range) 11 clicks counterclockwise 16 clicks (from the seated position adjuster turned fully clockwise) 12 clicks counterclockwise (EU) Compression damping adjustment (Adjustable Range) 8 clicks counterclockwise 16 clicks...
  • Page 276: Special Tools

    SUSPENSION 13-7 Special Tools Oil Seal & Bearing Remover : Jack : 57001–1058 57001–1238 Steering Stem Nut Wrench : Bearing Remover Shaft, 9 : 57001–1100 57001–1265 Hook Wrench : Bearing Remover Head, 15 × 17 : 57001–1101 57001–1267 Bearing Driver Set : Fork Oil Level Gauge : 57001–1129 57001–1290...
  • Page 277 13-8 SUSPENSION Special Tools Fork Cylinder Holder : 57001–1573 http://manuals.magnamaniac.com...
  • Page 278: Front Fork

    SUSPENSION 13-9 Front Fork Air Pressure The standard air pressure in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during opera- tion. Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap.
  • Page 279: Fork Oil Level Adjustment (simplify)

    13-10 SUSPENSION Front Fork Seated positions adjuster turned fully clockwise [A]. Compression Damping Adjuster Setting Standard: 8 clicks [B] 11 clicks (European Model) [C] Softer (Counterclockwise) [D] Harder (Clockwise) [E] *: Number of turns counterclockwise usable range – 16 clicks or more. Counterclockwise from the fully seated position.
  • Page 280 SUSPENSION 13-11 Front Fork • Place a stand or other suitable support [A] under the front wheel. • While holding the push rod nut with a 19 mm wrench, loosen the front fork top plug [A] from the top of the push rod.
  • Page 281: Oil Change/oil Level Adjustment (each Fork Leg)

    13-12 SUSPENSION Front Fork • Hold the push rod with your hand fully up. • Insert the fork spring [A] into the fork tube. • Install the fork spring seat [A] on the fork spring [B]. • Check both top plug O-ring [C] for damage and replace them if necessary.
  • Page 282 SUSPENSION 13-13 Front Fork • Remove: Front wheel (see Wheels/Tires chapter) Bolts [A] • Remove the caliper [B] from the fork leg to be removed, and rest the caliper on some kind of stand so that it doesn’t dangle. • Loosen the upper [A], and lower fork clamp bolts [B].
  • Page 283: Front Fork Installation

    13-14 SUSPENSION Front Fork Front Fork Installation • If the fork leg was disassembled, check the fork oil level. • Install the fork so that the distance [B] between the top end [A] of the outer tube and the upper surface [C] of the steering stem head is specified dimension.
  • Page 284 SUSPENSION 13-15 Front Fork • Use wrenches [A] on the rod nut [B] and top plug [C] loosen the push rod nut. • Remove the top plug from the push rod. • Lift the fork spring [D] and its top spring seat [E] out of the outer tube.
  • Page 285 13-16 SUSPENSION Front Fork • Remove: Circlip [A] O-ring [B] Nut [C] Collar [D] Holder [E] • Clean the bottom of the inner tube. • Remove the cap on the bottom of the inner tube. • Hold the front fork horizontally in a vise. •...
  • Page 286: Front Fork Assembly

    SUSPENSION 13-17 Front Fork • Separate the inner tube [A] from the outer tube [B] as follows: ○ Slide up the spring band [C]. ○ Slide up the dust seal [D]. ○ Remove the retaining ring [B] from the outer tube [A]. ○...
  • Page 287 13-18 SUSPENSION Front Fork • When assembling the new outer tube guide bush [A], hold the washer against the new one, and tap the washer with the fork oil seal driver [B] until it stops. Special Tool - Fork Oil Seal Driver, 48: 57001–1509 •...
  • Page 288 SUSPENSION 13-19 Front Fork • Fit the circlips [A] onto the groove of the push rod [B]. • Install the Collar [C], Holder [D], and Nut [E] • Replace the O-ring [F] with a new one. • Install the spring guide [A] so that the thinner portion end [B] is down.
  • Page 289: Inner Tube Inspection

    13-20 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect the inner tube [A], repair any damage. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube.
  • Page 290: Rear Suspension (uni-trak)

    SUSPENSION 13-21 Rear Suspension (Uni-Trak) Rear Shock Absorber: The rear suspension system of this motorcycle is New Uni-trak. It consists of a rear shock absorber, swing arm, tie-rod and rocker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one.
  • Page 291 13-22 SUSPENSION Rear Suspension (Uni-Trak) Seated position : adjuster turned fully clockwise [A]. Rebound Damping Adjuster Setting Standard: 11 clicks [B] Softer (Counterclockwise) [C] Harder (Clockwise) [D] *: Number of turns counterclockwise usable range – 16 clicks or more. Counterclockwise from the fully seated position. NOTE ○...
  • Page 292: Spring Preload Adjustment

    SUSPENSION 13-23 Rear Suspension (Uni-Trak) Spring Preload Adjustment (Adjusting nut position at the lower surface [A] from the center of the mounting hole) Standard: 113 mm (4.45 in.) Adjustable Range 109 ∼ 129.5 mm (4.29 ∼ 5.098 in.) • Tighten the locknut securely. •...
  • Page 293: Spring Replacement

    13-24 SUSPENSION Rear Suspension (Uni-Trak) Spring Replacement In addition to the standard spring, heavy and light springs are available. If the standard spring is improper for your purpose, select a proper one according to the rider’s weight or course conditions. •...
  • Page 294: Rear Shock Absorber Scrapping

    SUSPENSION 13-25 Rear Suspension (Uni-Trak) Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas, do not incinerate the reser- voir tank without first releasing the gas or it may explode. • Remove the shock absorber (see Rear Shock Absorber Removal).
  • Page 295: Swingarm

    13-26 SUSPENSION Swingarm Swingarm Removal • Place the jack [A] under the frame so that the rear wheel is off the ground. Special Tool - Jack : 57001–1238 • Remove Rear Wheel (see Wheels/Tires chapter) Clamps [B] Brake Pedal [C] (see Brakes chapter) Caps [D] Disc Protector [E] •...
  • Page 296: Swingarm Installation

    SUSPENSION 13-27 Swingarm Swingarm Installation • Apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • Tighten the following: Torque - Swingarm Pivot Shaft Nut: 98 N·m (10.0 kgf·m, 72 ft·lb) Rocker Arm Mounting Nut: 83 N·m (8.5 kgf·m, 61 ft·lb) •...
  • Page 297: Swingarm Bearing, Sleeve Inspection

    13-28 SUSPENSION Swingarm • Visually inspect the chain slipper [A] on the swingarm [B] and replace it if worn or damaged. • Visually inspect the upper and lower chain guide rollers [A] and replace them if excessively worn or damaged. Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection.
  • Page 298: Tie-rod, Rocker Arm

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Tie-Rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 • Unscrew the nut [A] and remove the guide roller [B]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly.
  • Page 299: Rocker Arm Installation

    13-30 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve. • Be sure seated the washers. • Tighten the following: Torque - Rear Shock Absorber Lower Mounting Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Rocker Arm Pivot Nut: 83 N·m (8.5 kgf·m, 61 ft·lb)
  • Page 300: Needle Bearing Inspection

    SUSPENSION 13-31 Tie-Rod, Rocker Arm • Install the needle bearings [A], [B], grease seals [C], and oil seals [D] position as shown. ○ The installation procedure is the same as the counter side. Front [E] Rear Shock Absorber [H] Right Side [F] Tie-rod [I] Left Side [G] Rocker Arm [J]...
  • Page 301: Uni-trak Maintenance

    13-32 SUSPENSION Uni-Trak Maintenance Uni-Trak Linkage Inspection • Refer to the Uni-Trak Linkage Inspection in Periodic Main- tenance chapter. Tie-Rod and Rocker Arm Sleeve Wear • Pull out the sleeves [A] of the tie-rod and rocker arm. • Measure the outside diameter of the sleeve. If the sleeve is worn past the service limit, replace the sleeve.
  • Page 302 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem, Stem Bearing Removal ................14-5 Steering Stem, Stem Bearing Installation ................. 14-6 Steering Maintenance......................14-9 Stem Bearing Lubrication....................
  • Page 303: Exploded View

    14-2 STEERING Exploded View http://manuals.magnamaniac.com...
  • Page 304 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar clamp bolts 18.0 Steering stem head nut Steering stem locknut 43 in·lb Upper front fork clamp bolts 14.5 Lower front fork clamp bolts 14.5 6. Handlebar Clamp 7. Handlebar 8.
  • Page 305: Special Tools

    14-4 STEERING Special Tools Bearing Puller : Head Pipe Outer Race Driver : 57001–135 57001–1077 Steering Stem Bearing Driver : Steering Stem Nut Wrench : 57001–137 57001–1100 Steering Stem Bearing Driver Adapter : Head Pipe Outer Race Remover : 57001–1074 57001–1107 Head Pipe Outer Race Press Shaft : Jack :...
  • Page 306: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in Periodic Maintenance chapter. Steering Adjustment • Refer to the Steering Adjustment in Periodic Maintenance chapter. Steering Stem, Stem Bearing Removal • Remove: Front Wheel (see Wheels/Tires chapter) Front Fork (see Suspension chapter) Front Fender Bolts [A] Front Fender [B] •...
  • Page 307: Steering Stem, Stem Bearing Installation

    14-6 STEERING Steering • Take off the upper stem bearing inner race (tapered roller bearing) [A]. • 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 308 STEERING 14-7 Steering • Replace the lower inner races with new ones. ○ Apply grease to the lower tapered roller bearing [A], and drive it onto the stem using the steering stem bearing driver [B] and adapter [C]. Special Tool - Steering Stem Bearing Driver : 57001–137 Steering Stem Bearing Driver Adapter: 57001–1074 •...
  • Page 309 14-8 STEERING Steering • Install the parts removed (see the appropriate chapter). WARNING Do not impede the handlebar turning by routing the cables, wires and hoses improperly (see the Gen- eral Information chapter). • Check and Adjust : Steering Front Brake Clutch Cable Throttle Cable http://manuals.magnamaniac.com...
  • Page 310: Steering Maintenance

    STEERING 14-9 Steering Maintenance Stem Bearing Lubrication • Refer to the Stem Bearing Lubrication in Periodic Mainte- nance chapter. Stem Bearing Wear, Damage • Using a high flash-point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 311: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove : Clutch Holder [A] (see Clutch chapter) Engine Stop Switch [B] Clamp [C] (Discard) Left Handlebar Grip [D] • Remove: Throttle Grip Assy [A] (see Fuel System chapter) Master Cylinder [B] (see Brakes chapter) •...
  • Page 312 STEERING 14-11 Handlebar • Apply grease to the throttle cable upper end and clutch cable upper end. • Apply a 2 stroke oil to the throttle grip inner wall [A]. • Install the throttle grip assy so that the grip [A] is in as far as it will go.
  • Page 313 http://manuals.magnamaniac.com...
  • Page 314 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Frame ............................. 15-4 Frame Inspection ......................15-4 Rear Frame Removal......................15-4 Rear Frame Installation..................... 15-4 Engine Guard Installation....................15-4 Seat ............................15-5 Seat Removal ........................15-5 Seat Installation ........................ 15-5 Side Cover..........................15-6 Side Cover Removal ......................
  • Page 315: Exploded View

    15-2 FRAME Exploded View http://manuals.magnamaniac.com...
  • Page 316 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper rear frame mounting bolt Lower rear frame mounting bolts G: Apply grease. R: Replacement Parts http://manuals.magnamaniac.com...
  • Page 317: Frame Inspection

    15-4 FRAME Frame Frame Inspection • Refer to the Frame Inspection in Periodic Maintenance chapter. Rear Frame Removal • Remove: Seat (see Seat Removal) Right & Left Side Cover (see Side Cover Removal) Silencer (see Engine Top End chapter) Rear Fender (see Fender Removal) Rear Flap (see Flap Removal) •...
  • Page 318: Seat

    FRAME 15-5 Seat Seat Removal • Unscrew the bolts [A]. • Pull the seat [B] out from the back. Seat Installation • Fit the hooks [A] of the seat under the flange collar [B] and brackets [C]. http://manuals.magnamaniac.com...
  • Page 319: Side Cover

    15-6 FRAME Side Cover Side Cover Removal • Unscrew the bolts [A] and remove the side cover. Side Cover Installation • Stick the pads [A] on the inside of the right side cover [B]. ○ Bend this parts [C] and stick it to the upper surface of the rib.
  • Page 320: Fender

    FRAME 15-7 Fender Front Fender Removal • Unscrew the bolts [A] and remove the front fender [B]. Rear Fender Removal • Remove: Seat • Unscrew the bolts [A] and remove the rear fender [B]. Rear Flap Removal • Unscrew the screws [A] and remove the rear flap [B]. http://manuals.magnamaniac.com...
  • Page 321 http://manuals.magnamaniac.com...
  • Page 322 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-2 Specifications ......................... 16-4 Special Tools .......................... 16-5 Wiring Diagram........................16-6 Precautions..........................16-7 Electrical Wiring........................16-8 Wiring Inspection ......................16-8 Flywheel Magneto ........................16-9 Magneto Cover Removal ....................16-9 Magneto Cover Installation ....................16-9 Flywheel Magneto Removal....................
  • Page 323: Exploded View

    16-2 ELECTRICAL SYSTEM Exploded View http://manuals.magnamaniac.com...
  • Page 324 ELECTRICAL SYSTEM 16-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Neutral switch 104 in·lb Flywheel nut Stator bolts 61 in·lb Spark plug 115 in·lb Magneto cover bolts L35 87 in·lb Magneto cover bolts L30 87 in·lb Neutral lead terminal screw 0.13 12 in·lb Timing inspection cap...
  • Page 325: Specifications

    16-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto: 80 ∼ 120 Ω Crankshaft sensor resistance: Magneto output voltage: in the text Stator coil resistance: in the text Ignition System: Ignition timing: (Disconnect the throttle sensor lead) 8° BTDC @ 2 000r/min (rpm) Ignition coil: 3 needle arcing distance 7 mm (0.26 in.) or more...
  • Page 326: Special Tools

    ELECTRICAL SYSTEM 16-5 Special Tools Timing Light : Needle Adapter Set : 57001–1241 57001–1457 Spark Plug Wrench, Hex 16 : Rotor Puller : 57001–1262 57001–1565 Hand Tester : Rotor Holder : 57001–1394 57001–1567 Throttle Sensor Setting Adapter : 57001–1400 http://manuals.magnamaniac.com...
  • Page 327: Wiring Diagram

    16-6 ELECTRICAL SYSTEM Wiring Diagram http://manuals.magnamaniac.com...
  • Page 328: Precautions

    ELECTRICAL SYSTEM 16-7 Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 329: Electrical Wiring

    16-8 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 330: Flywheel Magneto

    ELECTRICAL SYSTEM 16-9 Flywheel Magneto Magneto Cover Removal • Drain the engine oil from the crank room oil sump (see Periodic Maintenance chapter). • Push down the stopper [A]. • Remove the magneto lead connector [B]. • Disconnect the magneto lead connector with neutral switch lead connector [C] from the main harness.
  • Page 331: Flywheel Magneto Installation

    16-10 ELECTRICAL SYSTEM Flywheel Magneto • Screw the rotor puller [A] into the flywheel. • Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer, while holding the puller body steady. There is a woodruff key in the crankshaft tapered portion.
  • Page 332: Stator Installation

    ELECTRICAL SYSTEM 16-11 Flywheel Magneto Stator Installation • Route the wires according to the Cable, Wiring, and Hose Routing section in the Appendix chapter. • Install the stator and tighten it. Torque - Stator Bolts: 7.0 N·m (0.7 kgf·m, 61 in·lb) •...
  • Page 333 16-12 ELECTRICAL SYSTEM Flywheel Magneto Table 2 Stator Coil Resistance Connections Tester Reading Range Tester (+) to Tester (–) to Red/White lead 27.2 ∼ 40.8 Ω Black/Red lead × 1Ω 1.76 ∼ 2.64 Ω Yellow/White lead Yellow lead If there is more resistance than shown in the table, or no hand tester reading (infinity) the stator has an open lead and must be replaced.
  • Page 334: Ignition Timing

    ELECTRICAL SYSTEM 16-13 Ignition Timing Ignition Timing Inspection • Remove the timing inspection cap [A]. • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer. Special Tool - Timing Light: 57001–1241 • Start the engine and aim the timing light at the ignition timing mark [B] on the flywheel.
  • Page 335: Ignition System

    16-14 ELECTRICAL SYSTEM Ignition System Safety Instructions: WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, high tension coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. Ignition Coil Removal •...
  • Page 336: Spark Plug Cleaning And Inspection

    ELECTRICAL SYSTEM 16-15 Ignition System Measuring Coil Resistance: If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.
  • Page 337: C.d.i Unit Inspection

    16-16 ELECTRICAL SYSTEM Ignition System • Disconnect the main harness connector [A]. • Unscrew the mounting bolts [B] and remove the C.D.I Unit [C]. C.D.I Unit Inspection CAUTION When inspecting the C.D.I. unit observe the follow- ing to avoid damage to the C.D.I. unit. Do not disconnect the C.D.I.
  • Page 338 ELECTRICAL SYSTEM 16-17 Ignition System • Shift the gear to the neutral position, then free the engine stop switch. • Crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil. Peak Voltage 176 V or above WARNING Do not touch the metal portion of the probe in case of measuring the voltage, or you may receive a se-...
  • Page 339 16-18 ELECTRICAL SYSTEM Ignition System http://manuals.magnamaniac.com...
  • Page 340 ELECTRICAL SYSTEM 16-19 Ignition System Crankshaft Sensor Peak Voltage Check: • To check the peak voltage, do the following procedures. ○ Disconnect the connector of the magneto lead connector from the main harness. NOTE ○ Measure the voltage with each lead connected cor- rectly.
  • Page 341 16-20 ELECTRICAL SYSTEM Ignition System Exciter Coil Peak Voltage Check: • Disconnect the connector of the magneto lead connector from the main harness. • To check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor- rectly.
  • Page 342: Throttle Sensor Output/input Voltage Check

    ELECTRICAL SYSTEM 16-21 Ignition System Throttle Sensor Output/Input Voltage Check • Remove the carburetor lead connector [A]. • Connect the throttle sensor setting adapter [A] between carburetor lead connector [B] and main harness connec- tor [C]. Special Tool - Throttle Sensor Setting Adapter...
  • Page 343: Engine Stop Switch Electric Current Check

    16-22 ELECTRICAL SYSTEM Ignition System Engine Stop Switch Electric Current Check: • Open the clamp [A]. • Disconnect the engine stop switch lead connector [B]. • Start the engine. • Ground the stop switch black/white lead of the main har- ness side while the engine is running.
  • Page 344: Throttle Sensor

    ELECTRICAL SYSTEM 16-23 Throttle Sensor Throttle Sensor Inspection NOTE ○ If the variable rheostat is not available, refer to throttle sensor output/input voltage check in the C.D.I Unit in- spection. ○ When inspecting the throttle sensor the throttle valve of the carburetor shall be completely closed and remain the throttle cable connected.
  • Page 345: Neutral Switch

    16-24 ELECTRICAL SYSTEM Neutral Switch Neutral Switch Inspection • Slide out the dust cover [A]. • Disconnect the connector [B]. ○ Unscrew the screw. • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms).
  • Page 346 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-8 http://manuals.magnamaniac.com...
  • Page 347 17-2 APPENDIX Cable, Wire, and Hose Routing http://manuals.magnamaniac.com...
  • Page 348 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clamp 3. Engine Stop Switch Lead 4. Hot Start Cable 5. Clutch Cable 6. Main Harness 7. C.D.I. Unit 8. Throttle Cable (accelerator cable) 9. Throttle Cable (decelerator cable) 10.
  • Page 349 17-4 APPENDIX Cable, Wire, and Hose Routing 1. Clutch Cable 9. Clamp (Hold the hot start cable, engine 2. C.D.I. Unit stop switch lead, and main harness.) 3. Main Harness 10. Clamp (Run the hot start cable and main 4. Clamps (Run the clutch cable.) harness.) 5.
  • Page 350 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch Cable 11. Clamp (Run the hot start cable and main 2. C.D.I. Unit harness.) 3. Main Harness 12. Clamp (Hold the hot start cable and throt- 4. Bolt (together with ground lead terminal) tle sensor lead.) 5.
  • Page 351 17-6 APPENDIX Cable, Wire, and Hose Routing 1. Radiator Overflow Hose 10. Right Radiator 2. Clamp 11. Radiator Hose (to cylinder head) 3. Hot Start Cable 12. Radiator Hose (to water pump) 4. Fuel Hose 13. Radiator Hose (to water pump) 5.
  • Page 352 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Brake Lever 10. Rear Brake Master Cylinder 2. Front Brake Master Cylinder 11. Rear Brake Hose 3. Front Brake Hose 12. Clamps 4. Clamp 13. Rear Brake Caliper 5. Viewed 14. Rear Brake Caliper Guard 6.
  • Page 353: Troubleshooting Guide

    17-8 APPENDIX Troubleshooting Guide This is not an exhaustive list, giving every Cylinder head not sufficiently tightened possible cause for each problem listed. it is down meant simply as a rough guide to assist the No valve clearance troubleshooting for some of the more common Cylinder, piston worn difficulties.
  • Page 354: Engine Overheating

    APPENDIX 17-9 Troubleshooting Guide Valve not seating properly (valve bent, de- Valve not seating properly (valve bent, de- formed, worn, or carbon accumulation on formed, worn, carbon accumulation on the seating surface) the seating surface.) Decompression trouble Decompression trouble Other: Knocking: Faulty CDI unit Carbon built up in combustion chamber...
  • Page 355: Gear Shifting Faulty

    17-10 APPENDIX Troubleshooting Guide Clutch inner cable sticking Valve noise: Friction plate worn or warped Valve clearance incorrect Steel plate worn or warped Valve spring broken or weak Clutch spring broken or weak Camshaft bearing or cam face worn Clutch release function trouble Valve lifter worn Clutch hub or housing unevenly worn Other noise:...
  • Page 356 APPENDIX 17-11 Troubleshooting Guide Master cylinder damaged Wheel bearing worn Other noise: Handlebar clamp bolt loose Bracket, nut, bolt, etc., not properly Steering stem head bolt loose mounted or tightened Front, rear axle runout excessive Handlebar pulls to one side: Abnormal Exhaust Color: Frame bent Rear wheel misalignment...
  • Page 357 MODEL APPLICATION Year Model Beginning Frame No. □ JKAKXMNC 4A000001 or 2004 KX250–N1 JKAKX250NNA000001 □ :This digit in the frame number changes from one machine to another. http://manuals.magnamaniac.com Part No.99924-1324-02 Printed in Japan...

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