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KLR650
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KLR650

   Summary of Contents for Kawasaki KLR650

  • Page 1 KLR650 Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...
  • Page 12: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KL650E8 Left Side View KL650E8 Right Side View Frame Number Engine Number...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications KL650E8 ∼ EC Items Dimensions Overall Length 2 295 mm (90.4 in.) Overall Width 960 mm (37.8 in.) Overall Height 1 350 mm (53.1 in.) Wheelbase 1 480 mm (58.3 in.) Road Clearance 210 mm (8.27 in.) Seat Height 890 mm (35.0 in.) Dry Mass...
  • Page 19 GENERAL INFORMATION 1-9 General Specifications KL650E8 ∼ EC Items Valve Timing: Inlet Open 19° BTDC Close 69° ABDC Duration 268° Exhaust Open 57° BBDC Close 37° ATDC Duration 274° Lubrication System Forced lubrication Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or Viscosity SAE10W-40 Capacity...
  • Page 20 1-10 GENERAL INFORMATION General Specifications KL650E8 ∼ EC Items Frame Type Tubular, double cradle Caster (Rake Angle) 28° Trail 112 mm (4.41 in.) Rim Size: Front 21 × 1.60 Rear 17 M/C × MT2.50 Front Tire: Type Tube Size 90/90-21 M/C 54S Rear Tire: Type Tube...
  • Page 21: Unit Conversion Table

    GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System......................... 2-15 Air Cleaner Element Cleaning................... 2-15 Throttle Control System Inspection................... 2-16 Choke Operation Inspection .....................
  • Page 24 2-2 PERIODIC MAINTENANCE Rear Shock Absorber Oil Leak Inspection ................ 2-38 Rocker Arm Operation Inspection..................2-38 Rocker Arm Bearing Lubrication ..................2-38 Tie-Rod Operation Inspection ................... 2-39 Tie-Rod Bearing Lubrication ..................... 2-39 Swingarm Pivot Lubrication ....................2-39 Steering System ........................2-39 Steering Play Inspection ....................
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Wheels and Tires • • • Tire air pressure - inspect year 2-26 •...
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) Steering stem bearings - • 2 years 2-40 lubricate Electrical System Lights and switches operation •...
  • Page 28: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent.
  • Page 29: Periodic Maintenance

    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Coolant Hose Fitting Bolts 0.90 78 in·lb Cylinder Bolt (M6) 87 in·lb Cylinder Bolt (M8) Cylinder Head Bolts (First) Cylinder Head Bolts (Final) Cylinder Head Cover Bolts (L = 34.5) 0.80 69 in·lb Cylinder Head Cover Bolts (L = 46.5)
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe Banjo Bolts Oil Pipe Bolt 0.90 78 in·lb Oil Pressure Relief Valve Oil Pump Mounting Screws 0.45 39 in·lb Oil Pump Cover Screw 0.43 37 in·lb Engine Removal/Installation Front Engine Bracket Nuts R, S...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Pad Pins Front Caliper Holder Shaft Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts 0.90 78 in·lb...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sidestand Switch Mounting Bolt 78 in·lb Upper Fairings Mounting Bolts 0.09 8 in·lb Upper Left and Right Fairings Mounting Screws 0.04 4 in·lb Upper Rear Frame Bolts Windshieid Mounting Screws 0.04 4 in·lb...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 34: Specifications

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Choke Lever Free Play – – – Idle Speed 1 300 ±100 r/min (rpm) –...
  • Page 35 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive 35 ∼ 45 mm (1.4 ∼ 1.8 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 323 mm (12.7 in.) (KL650E8 ∼...
  • Page 36: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Spark Plug Wrench, Hex 18: Filler Cap Driver: 57001-1024 57001-1454 Steering Stem Nut Wrench: 57001-1100...
  • Page 37: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately. WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe...
  • Page 38: Throttle Control System Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage.
  • Page 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Push the choke lever [A] all the way to the front [B]. • Check the choke lever free play [C]. Choke Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: If the free play is incorrect, adjust the choke cable as fol- lows.
  • Page 40: Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition) ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose burst. •...
  • Page 41: Cooling System

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank with the mo- torcycle held perpendicular (Do not use the sidestand.). If the coolant level is lower than the “LOW”...
  • Page 42: Valve Clearance Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the cylinder head cover (see Cylinder Head Cover Removal in the Engine Top End chapter). • Remove the timing inspection cap [A] and alternator rotor bolt cap [B], using the filler cap driver. Special Tool - Filler Cap Driver: 57001-1454 •...
  • Page 43 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures NOTE ○ Mark and record the locations of the 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. •...
  • Page 44 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 2.00 12037-001 200 or 0200 2.05 12037-002 205 or 0205 2.10 12037-003 210 or 0210 2.15 12037-004 215 or 0215 2.20 12037-005 220 or 0220 2.25 12037-006 225 or 0225 2.30 12037-007 230 or 0230...
  • Page 45: Spark Arrester Cleaning (us And Ca Models)

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures NOTICE 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 46: Air Suction System (other Than Au Model)

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System (Other than AU Model) Air Suction System Damage Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). • Separate the vacuum switch valve hose [A] from the fitting on the frame.
  • Page 47: Crankshaft/transmission

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Slide the dust cover [A] at the clutch cable lower end out of place.
  • Page 48: Wheels/tires

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the engine guard (see Engine Guard Removal in the Frame chapter). • Remove the plug [A], and loosen the idle shaft lever bolt [B] a few turns. • Tighten the idle shaft lever bolt to the specified torque. Torque - Idle Shaft Lever Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 49: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Tread Depth Standard: Front 6.4 mm (0.25 in.) (AU) 6.9 mm (0.27 in.) Rear 8.8 mm (0.35 in.) Service Limit: Front 2 mm (0.08 in.) Rear 2 mm (0.08 in.) WARNING Some replacement tires may adversely affect han- dling and cause an accident resulting in serious in- jury or death.
  • Page 50: Spoke Tightness And Rim Runout Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spoke Tightness and Rim Runout Inspection • Check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 4.0 N·m (0.41 kgf·m, 35 in·lb) •...
  • Page 51: Drive Train

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Train Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 52: Drive Chain Slack Adjustment

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the right and left chain adjusters [D] evenly.
  • Page 53: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Wheel Alignment Inspection • Check that the notch [A] on the right alignment indicator [B] aligns with the same swingarm mark or position [C] that the left alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 54: Drive Chain Wear Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • 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.
  • Page 55: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Chain Guide Wear Inspection • Visually inspect the front chain guide [A], rear chain guide [B] and chain slipper [C]. If the chain guides and chain slipper show any signs of abnormal wear or damage, replace them.
  • Page 56: Brake System

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 57: Brake Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 58: Brake Pad Wear Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an ac-...
  • Page 59: Suspensions

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] NOTICE To avoid damaging the electrical connections in-...
  • Page 60: Front Fork Oil Leak Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Slide the fork boot upward. • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection •...
  • Page 61: Tie-rod Operation Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Tie-Rod Operation Inspection • Pump the tail grip down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen- sion chapter).
  • Page 62: Steering Play Adjustment

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Play Adjustment • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Handlebar (see Handlebar Removal in the Steering chapter) • Loosen: Upper Fork Clamp Bolts (see Front Fork Removal in the Suspension chapter)
  • Page 63: Electrical System

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn the ignition switch ON. • The following lights should go on according to below table. Headlights (High and/or Low) [A] go on Taillight [B] goes on License Plate Light [C] goes on...
  • Page 64 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 65: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light [C] should go on. If the high beam headlight and/or high beam indicator light does not go on, inspect or replace the following item.
  • Page 66: Sidestand Switch Operation Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.
  • Page 67: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Battery Condition in the Electrical System chapter) Main Fuse 20 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Sidestand Switch (see Switch Inspection in the Electrical...
  • Page 68: Battery Electrolyte Level Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Battery Electrolyte Level Inspection • Remove the battery (see Battery Removal in the Electrical System chapter). • Visually check the electrolyte level in the battery. If the electrolyte level in any cell is lower than the lower level line [A] on the battery, unscrew the battery filler caps [B] and add distilled water only to that cell until the level is at the upper level line [C].
  • Page 69 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 70: Bolts, Nuts And Fasteners Tightness Inspection

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 71: Replacement Parts

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly...
  • Page 72: Fuel Hose Replacement

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the frame into the new element. • Install the element and tighten the wring bolt securely. • Fit the tongue [A] of the air cleaner cap into the slot [B] of the air cleaner housing and tighten the screw securely. Fuel Hose Replacement WARNING Gasoline is extremely flammable and can be ex-...
  • Page 73: Coolant Change

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Coolant Change WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts.
  • Page 74 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. NOTICE Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.
  • Page 75: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Water Hose Fitting [A] Water Pump Impeller [B] (see Water Pump Removal in the Cooling System chapter) O-rings [C] Hoses [D] •...
  • Page 76: Oil Filter Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 1.9 L (2.0 US qt) (when filter is not removed) 2.0 L (2.1 US qt) (when filter is removed) 2.1 L (2.2 US qt) (when engine is completely dry) NOTE...
  • Page 77 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Remove the bypass valve [A] from the oil filter [B]. • Replace the oil filter with a new one. • Apply grease to the grommets. • Insert the bypass valve [A] into the oil filter. NOTE ○...
  • Page 78: Brake Hose And Pipe Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 79 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 80: Master Cylinder Rubber Parts Replacement

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap [A] and diaphragm [B], and pour the brake fluid into a container.
  • Page 81: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 82 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 83 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Rear Caliper Disassembly • Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) • Using compressed air, remove the pistons. ○ Cover the piston area with a clean, thick cloth [B].
  • Page 84: Spark Plug Replacement

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the anti-rattle spring [A] in the caliper as shown. • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber friction boot [A] and dust boot [B] if they are damaged.
  • Page 85 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... 3-12 Special Tools .......................... 3-13 Throttle Grip and Cables ......................3-14 Throttle Grip Free Play Inspection ..................3-14 Throttle Grip Free Play Adjustment................... 3-14 Throttle Cable Removal ....................3-14 Throttle Cable Installation ....................
  • Page 86: Exploded View

    3-2 FUEL SYSTEM Exploded View KL650E8 ∼ KL650E9 Models...
  • Page 87: Exploded View

    FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Case Screws 0.39 34 in·lb Carburetor Holder Clamp Screw 0.20 18 in·lb 3. Throttle Cables 4. Choke Cable 5. Pilot Screw 6. Pilot Jet 7. Float Valve 8. Jet Needle 9.
  • Page 88 3-4 FUEL SYSTEM Exploded View KL650EA ∼ EC Model...
  • Page 89 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Case Screws 0.39 34 in·lb Carburetor Holder Clamp Screw 0.20 18 in·lb 3. Throttle Cables 4. Choke Cable 5. Pilot Screw 6. Pilot Jet 7. Float Valve 8. Jet Needle 9.
  • Page 90 3-6 FUEL SYSTEM Exploded View...
  • Page 91 FUEL SYSTEM 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Duct Clamp Screw 0.20 18 in·lb Fuel Tap Diaphragm Cover Screws 0.10 9.0 in·lb Fuel Tap Bolts 0.25 22 in·lb Fuel Tap Lever Plate Screws 0.08 7 in·lb Air Cleaner Housing Bolt 0.90 78 in·lb...
  • Page 92 3-8 FUEL SYSTEM Exploded View CAL Model (KL650E8)
  • Page 93 FUEL SYSTEM 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Separator Bracket Bolts 0.90 78 in·lb Canister Bracket Bolts 0.90 78 in·lb 3. Canister 4. Separator 5. Green Hose 6. Blue Hose 7. Blue Hose 8. Red Hose 9. White Hose...
  • Page 94 3-10 FUEL SYSTEM Exploded View CAL Model (KL650E9 ∼ EC)
  • Page 95 FUEL SYSTEM 3-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Separator Bracket Bolts 0.90 78 in·lb Canister Bracket Bolts 0.90 78 in·lb 3. Canister 4. Separator 5. Green Hose 6. Blue Hose 7. Blue Hose 8. Red Hose 9. White Hose...
  • Page 96: Specifications

    3-12 FUEL SYSTEM Specifications Item Standard Carburetors Mark, Type KEIHIN CVK40 Idle Speed 1 300 ±100 r/min (rpm) Pilot Screw (Turns Out) 1 5/8 (for reference) Service Fuel Level 0.5 ±1 mm (0.02 ±0.04 in.) above the bottom edge of carburetor body Float Height 17.5 ±2 mm (0.69 ±0.08 in.) Main Jet...
  • Page 97: Special Tools

    FUEL SYSTEM 3-13 Special Tools Fuel Level Gauge: Pilot Screw Adjuster, B: 57001-1017 57001-1240...
  • Page 98: Throttle Grip And Cables

    3-14 FUEL SYSTEM Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.
  • Page 99: Throttle Cable Lubrication

    FUEL SYSTEM 3-15 Throttle Grip and Cables Throttle Cable Lubrication • Refer to the Chassis Parts Lubrication Perform in the Pe- riodic Maintenance chapter.
  • Page 100: Choke Cable

    3-16 FUEL SYSTEM Choke Cable Choke Lever Free Play Inspection • Refer to the Choke Operation Inspection in the Periodic Maintenance chapter. Choke Lever Free Play Adjustment • Refer to the Choke Operation Inspection in the Periodic Maintenance chapter. Choke Cable Removal •...
  • Page 101: Carburetor

    FUEL SYSTEM 3-17 Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Pilot Screw Adjustment (AU Model) NOTE ○...
  • Page 102: Float Height Adjustment

    3-18 FUEL SYSTEM Carburetor • Remove the carburetor, and hold it upright on a stand (see Carburetor Removal). • Prepare an auxiliary fuel tank and connect the fuel hose to the carburetor. • Pour the fuel into the carburetor. • Prepare a rubber hose (6 mm (0.24 in.) inside diameter and about 300 mm (11.81 in.) long) and connect it to the fitting at the bottom of float bowl.
  • Page 103: Fuel System Cleanliness Inspection

    FUEL SYSTEM 3-19 Carburetor If the float height is out of the standard range, adjust the float height according to the following procedure. ○ Bend the tang [A] on the float arm very slightly to change the float height. ○ Increasing the float height lowers the fuel level and de- creasing the float height raises the fuel level.
  • Page 104: Carburetor Installation

    3-20 FUEL SYSTEM Carburetor • Remove: Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter) Starter Relay Bracket (see Fuel Hose Replacement in the Periodic Maintenance chapter) • For the other than Australia model, drain the coolant and remove the water hoses from the fitting on the carburetor.
  • Page 105: Carburetor Disassembly

    FUEL SYSTEM 3-21 Carburetor • Insert the air cleaner duct into the carburetor until the stopper [A] attach to the duct end [B]. • Install the duct clamp screw [C] in the direction as shown and tighten it. Torque - Air Cleaner Duct Clamp Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 106 3-22 FUEL SYSTEM Carburetor • Remove: Spring [A] Diaphragm [B] and Vacuum Piston [C] • Remove the jet needle [A] from the vacuum piston [B] along with the spring seat [C]. • Remove: Screws [A] Float Bowl [B] • Remove: Pivot Pin [A] Float [B] and Float Valve Pilot Jet [C]...
  • Page 107: Carburetor Assembly

    FUEL SYSTEM 3-23 Carburetor KL650E8 ∼ E9 Models • Remove: Screws [A] Plate [B] Coasting Enricher Cover [C] • Remove: Spring [A] Diaphragm [B] O-ring [C] KL650EA ∼ EC Model • Remove: Screws [A] Coasting Enricher Cover [B] Spring [C] Diaphragm [D] O-ring [E] Carburetor Assembly...
  • Page 108 3-24 FUEL SYSTEM Carburetor • Install the following on the pilot screw [A]. Spring [B] Spring Seat [C] O-ring [D] • Turn in the pilot screw [A] fully but not tightly, and then back it same number of turns counted during disassem- bly.
  • Page 109 FUEL SYSTEM 3-25 Carburetor • Carefully screw in the pilot jet [A] on the carburetor. • Hook the needle hanger [B] onto the float tangs [C] and install the float valve needle in the valve seat. • Insert the float pivot pin [D]. •...
  • Page 110: Carburetor Cleaning

    3-26 FUEL SYSTEM Carburetor Carburetor Cleaning WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
  • Page 111 FUEL SYSTEM 3-27 Carburetor • Turn the throttle cable pulley [A] to check that the throttle valve [B] moves smoothly and returns by spring force. If the throttle valve does not move smoothly, replace the carburetor. • Disassemble the carburetor (see Carburetor Disassem- bly).
  • Page 112: Air Cleaner

    3-28 FUEL SYSTEM Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Cleaning • Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter. Air Cleaner Element Inspection •...
  • Page 113: Air Cleaner Housing Installation

    FUEL SYSTEM 3-29 Air Cleaner Air Cleaner Housing Installation • Insert the air cleaner duct into the carburetor until the stopper [A] attach to the duct end [B]. • Install the duct clamp screw [C] in the direction as shown and tighten it.
  • Page 114: Fuel Tank

    3-30 FUEL SYSTEM Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 115: Fuel Tank Installation

    FUEL SYSTEM 3-31 Fuel Tank • For the California model, note the following. NOTICE For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.
  • Page 116: Fuel Tank Inspection

    3-32 FUEL SYSTEM Fuel Tank • Be sure that the trim [A] is on the fuel tank as shown. • When installing the fuel tank, fit the stoppers [A] to the dampers [B] on the frame securely. • Be sure the hoses are clamped securely. Fuel Tank Inspection •...
  • Page 117: Fuel Tap Removal

    FUEL SYSTEM 3-33 Fuel Tank Fuel Tap Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 118: Evaporative Emission Control System (cal Model)

    3-34 FUEL SYSTEM Evaporative Emission Control System (CAL Model) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 119: Separator Operation Test

    FUEL SYSTEM 3-35 Evaporative Emission Control System (CAL Model) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch OFF. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 121 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tool and Sealant ......................Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Filter Cleaning (AU Model) ..................
  • Page 122: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 123 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Reserve Tank Bolts 0.90 78 in·lb Reserve Tank Cap – – – Hand-tighten Radiator Bolts 0.90 78 in·lb Radiator Fan Switch Water Hose Fitting Bolts 0.90 78 in·lb Water Temperature Sensor Water Pump Cover Bolts 0.90 78 in·lb...
  • Page 124: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 125 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Radiator Cap 4. Radiator Overflow Hose 5. Reserve Tank 6. Reserve Tank Overflow Hose 7. Outlet Hose 8. Inlet Hose 9. Thermostat 10. Water Pump 11. Cylinder Water Jacket 12.
  • Page 126: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...
  • Page 127: Special Tool And Sealant

    COOLING SYSTEM 4-7 Special Tool and Sealant Bearing Driver Set: Liquid Gasket, TB1211: 57001-1129 56019-120...
  • Page 128: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 129: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 130: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hoses [A] Water Pump Cover Bolts [B] Water Pump Cover [C] • For the Australia model, remove the water hose of the carburetor system.
  • Page 131: Water Pump Inspection

    COOLING SYSTEM 4-11 Water Pump • Install the water hoses [A] and clamps [B] as shown. White Marks [C] • Tighten the water hose clamp screw securely. • Fill the radiator with the coolant (see Coolant Change in the Periodic Maintenance chapter). Water Pump Inspection •...
  • Page 132: Mechanical Seal Replacement

    4-12 COOLING SYSTEM Water Pump Mechanical Seal Replacement • Remove the water pump impeller (see Water Pump Re- moval in this section). • Pry the mechanical seal flange off with a small chisel [A]. • Pull the mechanical seal out of the clutch cover with nee- dle nose pliers.
  • Page 133: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator Fan Removal • Turn the ignition switch OFF. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). • Disconnect the radiator fan lead connector [A]. • Open the clamps [B]. •...
  • Page 134: Radiator Inspection

    4-14 COOLING SYSTEM Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 135: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 136: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hose [A] Thermostat Housing Bolts [B] Thermostat Housing [C] • For the Australia model, remove the following. Water Hose (from carburetor) Thermostat Housing Fitting [A] Washer [B] Gasket [C]...
  • Page 137: Thermostat Inspection

    COOLING SYSTEM 4-17 Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 138: Hose And Pipes

    4-18 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 139: Radiator Fan Switch, Water Temperature Sensor

    COOLING SYSTEM 4-19 Radiator Fan Switch, Water Temperature Sensor Radiator Fan Switch Removal/Installation NOTICE The radiator fan switch should never be allowed to fall on a hard surface. Such a shock to the switch can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 141 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..5-31 Exhaust System Identification ... Valve Removal ......5-31 Specifications ........5-10 Valve Installation ......5-31 Special Tools and Sealant ....5-12 Valve Guide Removal ....5-31 Clean Air System (Other than AU Valve Guide Installation ....
  • Page 142: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 143 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts (L = 34.5) 0.80 69 in·lb Cylinder Head Cover Bolts (L = 46.5) 0.80 69 in·lb Camshaft Cap Bolts 106 in·lb Clean Air System Pipe Bolt (M5) (Other than 0.60 52 in·lb AU Model)
  • Page 144 5-4 ENGINE TOP END Exploded View KL650E8 ∼ E9 Models...
  • Page 145 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Pipe Cover Bolts 0.45 39 in·lb Exhaust Pipe Holder Nuts Exhaust Pipe Holder Clamp Bolt Muffler Joint Clamp Bolt Heat Guard Plate Bolts 0.45 39 in·lb Muffler Body Mounting Bolts (KL650E8) Muffler Body Mounting Bolts (KL650E9) G: Apply grease.
  • Page 146 5-6 ENGINE TOP END Exploded View KL650EA ∼ EC Model...
  • Page 147 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Pipe Cover Bolts 0.45 39 in·lb Exhaust Pipe Holder Nuts Exhaust Pipe Holder Clamp Bolt Muffler Joint Clamp Bolt Heat Guard Plate Bolts 0.45 39 in·lb Muffler Body Mounting Bolts 7.
  • Page 148: Exhaust System Identification

    5-8 ENGINE TOP END Exhaust System Identification Full: Full Power...
  • Page 149 ENGINE TOP END 5-9 Exhaust System Identification Muffler Body Mark Position [A] Pipe Type Catalyst Position [B]...
  • Page 150: Specifications

    5-10 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Open → Close Closing Pressure – – – 42.7 ∼ 53.3 kPa (320 ∼ 400 mmHg) (Other than AU Model) Camshafts Cam Height: 36.243 ∼ 36.357 mm (1.4269 ∼ 1.4314 in.) Exhaust 36.14 mm (1.423 in.) 36.742 ∼...
  • Page 151 ENGINE TOP END 5-11 Specifications Item Standard Service Limit Outside diameter: 31.9 ∼ 32.1 mm (1.256 ∼ 1.264 in.) Exhaust – – – 36.9 ∼ 37.1 mm (1.453 ∼ 1.461 in.) Inlet – – – Valve spring free length: Inner 37.6 mm (1.480 in.) 36.2 mm (1.425 in.) Outer...
  • Page 152: Special Tools And Sealant

    5-12 ENGINE TOP END Special Tools and Sealant Valve Guide Reamer, 7: Spark Plug Wrench, Hex 18: 57001-162 57001-1024 Valve Guide Arbor, 7: Valve Spring Compressor Adapter, 29.5: 57001-163 57001-1078 Compression Gauge, 20 kgf/cm²: Piston Ring Compressor Grip: 57001-221 57001-1095 Valve Spring Compressor Assembly: Valve Seat Cutter, 45°...
  • Page 153 ENGINE TOP END 5-13 Special Tools and Sealant Valve Seat Cutter Holder, 7: Fork Oil Level Gauge: 57001-1126 57001-1290 Piston Ring Compressor Belt, 95 ∼ 108: Valve Seat Cutter Holder Bar: 57001-1128 57001-1358 Compression Gauge Adapter, M12 × 1.25: Filler Cap Driver: 57001-1183 57001-1454 Piston Pin Puller Adapter, 14:...
  • Page 154 5-14 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter, 32°- 44: Valve Guide Driver Attachment H: 57001-1515 57001-1734 Valve Guide Driver: Liquid Gasket, TB1211F: 57001-1564 92104-0004...
  • Page 155: Clean Air System (other Than Au Model)

    ENGINE TOP END 5-15 Clean Air System (Other than AU Model) Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Air Hoses [A] Vacuum Hose [B] Vacuum Switch Valve Bolts [C] and Nuts Vacuum Switch Valve [D] Vacuum Switch Valve Installation •...
  • Page 156: Clean Air System Hose Inspection

    5-16 ENGINE TOP END Clean Air System (Other than AU Model) Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the right air cleaner housing, vacuum switch valve, carbure- tor holder, and air suction valve cover.
  • Page 157: Cylinder Head Cover

    ENGINE TOP END 5-17 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Radiator (see Radiator Removal in the Cooling System chapter) Right Lower Fairing Bracket (see Engine Removal in the Engine Removal/Installation chapter) •...
  • Page 158 5-18 ENGINE TOP END Cylinder Head Cover Other than AU Model • Be sure to install the O-ring [A] to the clean air system pipe. • Install the clean air system pipe [A]. • Tighten: Torque - Clean Air System Pipe Bolt (M5) [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb) Clean Air System Pipe Bolt (M6) [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 159: Camshaft Chain Tensioner

    ENGINE TOP END 5-19 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 160 5-20 ENGINE TOP END Camshaft Chain Tensioner • Tighten: Torque - Camshaft Chain Tensioner Bolts [A]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Replace the gasket [A] with a new one. • Install the spring [B] together with the gasket and cap bolt [C].
  • Page 161: Camshaft

    ENGINE TOP END 5-21 Camshaft Camshaft Removal • Remove: Timing Inspection Cap [A] Alternator Rotor Bolt Cap [B] Special Tool - Filler Cap Driver: 57001-1454 • First, bring the piston to the TDC (of either the compres- sion or exhaust stroke). ○...
  • Page 162: Camshaft Installation

    5-22 ENGINE TOP END Camshaft NOTICE The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crank- shaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could dam- age both the chain and the sprocket.
  • Page 163 ENGINE TOP END 5-23 Camshaft 1st Pin [A] Arrow Mark [D] 2nd Pin [B] Cylinder Head Upper Surface [E] 47th Pin [C] • Be sure to install the dowel pins [A]. • Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase.
  • Page 164: Camshaft Chain Removal

    5-24 ENGINE TOP END Camshaft • Install the camshaft caps [A] and oil pipe [B] so that note the identification mark of the “EX” and “IN”. • Uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 165: Camshaft And Camshaft Cap Wear

    ENGINE TOP END 5-25 Camshaft • Hang the camshaft chain [A] to the crankshaft sprocket. • Install: Front Camshaft Chain Guide [B] Rear Camshaft Chain Guide [C] • Tighten: Torque - Rear Camshaft Chain Guide Bolt [D]: 19 N·m (1.9 kgf·m, 14 ft·lb) •...
  • Page 166: Camshaft Runout

    5-26 ENGINE TOP END Camshaft Camshaft Journal Diameter 22.959 ∼ 22.980 mm (0.90390 ∼ 0.90472 Standard: in.) Service Limit: 22.93 mm (0.9027 in.) If the clearance still remains out of the service limit, re- place the cylinder head unit. Camshaft Runout •...
  • Page 167: Cylinder Head

    ENGINE TOP END 5-27 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged • Thoroughly warm up the engine so that engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. •...
  • Page 168: Cylinder Head Removal

    5-28 ENGINE TOP END Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression is cylinder head (combustion chamber) is damaged parts if necessary.
  • Page 169: Cylinder Head Installation

    ENGINE TOP END 5-29 Cylinder Head • Remove: Cylinder Head Bolts [A] • Loosen the left side front bolt [B] fully. • Tap lightly up with a plastic mallet [A] to separate the cylin- der head [B] from the cylinder. •...
  • Page 170: Cylinder Head Warp Inspection

    5-30 ENGINE TOP END Cylinder Head • Insert the cylinder head left side front bolt [A] to the origi- nal position. • Insert the cylinder head [B] together with the left side front bolt. • Tighten the cylinder head bolts [A] diagonally with the specified torque.
  • Page 171: Valves

    ENGINE TOP END 5-31 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and the shim from the valve. NOTE ○...
  • Page 172: Valve Guide Installation

    5-32 ENGINE TOP END Valves • Hammer lightly on the valve guide arbor [A] to remove the guide. Special Tool - Valve Guide Arbor, 7: 57001-163 Valve Guide Installation • Apply a thin coat of oil to the outer surface of the valve guide.
  • Page 173: Valve/valve Guide Clearance

    ENGINE TOP END 5-33 Valves 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. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 174: Valve Seat Repair

    5-34 ENGINE TOP END Valves Valve Seat Repair • For the instructions on how to use the valve seat cutter [A], follow the operation manual provided by the to man- ufacturer. Special Tools - Valve Seat Cutter Holder, 7: 57001-1126 Valve Seat Cutter Holder Bar: 57001-1128 Exhaust: Valve Seat Cutter, 45°...
  • Page 175 ENGINE TOP END 5-35 Valves Marks Stamped on the Cutter The marks stamped on the back of the cutter [A] represent the following. 60° ......Cutter Angle [B] 37.5 ....... Cutter Outer Diameter [C] Repair Operating Procedures • Clean the seat area carefully. •...
  • Page 176 5-36 ENGINE TOP END Valves If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low.
  • Page 177 ENGINE TOP END 5-37 Valves Valve Seat Repair...
  • Page 178: Cylinder And Piston

    5-38 ENGINE TOP END Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide • Remove: Radiator Hose [A] Cylinder Nuts [B] • Remove: Cylinder Bolt [A] • Tap lightly up with a plastic mallet to separate the cylinder from the crankcase.
  • Page 179: Cylinder And Piston Installation

    ENGINE TOP END 5-39 Cylinder and Piston • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the oil ring in the same procedure. Cylinder and Piston Installation NOTE ○...
  • Page 180 5-40 ENGINE TOP END Cylinder and Piston • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○ When installing the piston pin snap ring, compress it only enough to install it and no more.
  • Page 181: Cylinder Wear Inspection

    ENGINE TOP END 5-41 Cylinder and Piston Cylinder Wear Inspection • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the three locations (total of six measure- ments) shown in the figure.
  • Page 182: Cylinder Boring And Honing

    5-42 ENGINE TOP END Cylinder and Piston Cylinder Boring and Honing ○ There is an oversize piston available. The oversize piston requires oversize rings. Oversize Piston and Rings 0.5 mm Oversize 1.0 mm Oversize • Before boring a cylinder [A], first measure the exact di- ameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the rebore diameter.
  • Page 183: Piston Ring Groove Width Inspection

    ENGINE TOP END 5-43 Cylinder and Piston Piston Ring Groove Width Inspection • Measure the groove width at several points around the piston with a vernier caliper. Piston Ring Groove Width Standard: 1.22 ∼ 1.24 mm (0.0480 ∼ 0.0488 in.) 1.21 ∼...
  • Page 184: Carburetor Holder

    5-44 ENGINE TOP END Carburetor Holder Carburetor Holder Removal • Remove: Carburetor (see Carburetor Removal in the Fuel System chapter) Carburetor Holder Screws [A] Carburetor Holder [B] Carburetor Holder Installation • Install the O-ring [A] to the carburetor holder [B]. •...
  • Page 185: Muffler

    ENGINE TOP END 5-45 Muffler WARNING The exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Exhaust Pipe Removal •...
  • Page 186: Muffler Body Removal

    5-46 ENGINE TOP END Muffler Muffler Body Removal • Loosen the muffler joint clamp bolt (see Exhaust Pipe Re- moval). • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Muffler Body Mounting Bolts [A] and Nut [B] •...
  • Page 187 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................Clutch Lever Installation....................
  • Page 188: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 189 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Spring Bolts (KL650E8 ∼ EA) 87 in·lb Clutch Spring Bolts (KL650EB ∼ EC) 0.93 81 in·lb Clutch Hub Nut Clutch Cable Holder Bolt 0.90 78 in·lb Oil Filler Cap –...
  • Page 190: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.90 ∼ 3.10 mm (0.114 ∼ 0.122 in.) Friction Plate Thickness 2.7 mm (0.106 in.) Friction Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Steel Plate Warp...
  • Page 191: Special Tool

    CLUTCH 6-5 Special Tool Clutch Holder: 57001-1243...
  • Page 192: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 193: Clutch Cover

    CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Water Pump Impeller (see Water Pump Removal in the Cooling System chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Brake Pedal (see Brake Pedal Removal in the Brakes chapter)
  • Page 194: Release Shaft Removal

    6-8 CLUTCH Clutch Cover • Be sure that the dowel pins [A] are in position. • Replace the clutch cover gasket with a new one. • Tighten: Torque - Clutch Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Release Shaft Removal NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary.
  • Page 195: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with bearing) Pusher [C] • Remove: Friction Plates Steel Plates • Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C].
  • Page 196 6-10 CLUTCH Clutch • Install: Clutch Housing [A] Spacer [B] ○ Engage the clutch housing gear with primary gear on the balancer shaft. • Install the clutch hub. • Install the washer so that the OUT SIDE mark [A] faces outward.
  • Page 197: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-11 Clutch • Apply molybdenum disulfide grease to the pusher end [A]. • Install the pusher [B] to the drive shaft direction as shown. • Apply engine oil to the sliding surfaces of the bearing [A]. • Install the bearing on the spring plate [B]. •...
  • Page 198: Clutch Spring Free Length Measurement

    6-12 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 38.7 mm (1.52 in.) Service Limit: 37.2 mm (1.46 in.) Clutch Housing Finger Inspection •...
  • Page 199 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Screen..........................Oil Screen Removal ......................Oil Screen Installation .......................
  • Page 200: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 201 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filter Cap Bolts 0.70 61 in·lb Oil Pressure Relief Valve Oil Filler Cap – – – Hand-tighten Oil Pipe Banjo Bolts Oil Pipe Bolt 0.90 78 in·lb Engine Oil Feed Fitting Bolts 0.90 78 in·lb...
  • Page 202: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 203 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Exhaust Camshaft 2. Inlet Camshaft 3. Oil Pipe (Cylinder Head) 4. Oil Pipe (Main) 5. Oil Pressure Relief Valve 6. Oil Filter 7. Bypass Valve 8. Oil Pump 9. Oil Screen 10.
  • Page 204: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 1.9 L (2.0 US qt.) (when filter is not removed) 2.0 L (2.1 US qt.) (when filter is removed) 2.1 L (2.2 US qt.) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼...
  • Page 205: Special Tools

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools Oil Pressure Gauge, 10 kgf/cm²: Oil Pressure Gauge Adapter, M10 × 1.25: 57001-164 57001-1182...
  • Page 206: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 207: Oil Screen

    ENGINE LUBRICATION SYSTEM 7-9 Oil Screen Oil Screen Removal • Remove: Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Oil Screen [A] Oil Screen Installation NOTE ○ Clean the oil screen thoroughly whenever it is removed for any reason. ○...
  • Page 208: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 209: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Remove: Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Oil Pump Mounting Screws [A] Oil Pump [B] NOTE ○ Do not remove the oil pump cover screw [C]. Oil Pump Installation •...
  • Page 210 7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Fit the hole [A] of the oil pump cover on the dowel pin [B]. • Install the dowel pins [A] onto the oil pump cover tempo- rary. • Apply a non-permanent locking agent to the threads of the oil pump cover screw, and tighten it.
  • Page 211: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Measurement Oil Pressure Measurement • Remove: Engine Guard (see Engine Guard Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, M10 ×...
  • Page 212: Oil Pipe

    7-14 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pipe Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Oil Pipe Banjo Bolt [A] (Right Crankcase Side) Oil Pipe Banjo Bolt [B] (Left Crankcase Side)
  • Page 213 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 214: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 215 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Bracket Nuts R, S Upper Engine Mounting Bolt Front Engine Mounting Nut Front Engine Bracket Nuts R, S Lower Engine Mounting Nut L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 216: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...
  • Page 217: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Place the jack under the frame to raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 WARNING When the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor, creating the potential for injury.
  • Page 218 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Engine Guard (see Engine Guard Removal in the Cool- ing System chapter) Brake Pedal (see Brake Pedal Removal in the Brakes chapter) Clutch Cable Lower End (see Clutch Cable Removal in the Clutch chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Engine Sprocket (see Engine Sprocket Removal in the...
  • Page 219 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Disconnect: Ignition Coil Connectors [A] Horn Connectors [B] • Remove: Ignition Coil Bolt [C] Frame Ground Terminal [D] • Remove: Bolts [A] Ignition Coil Bracket [B] Right Lower Fairing Bracket [C] • Remove: Breather Hose [A] Starter Motor Mounting Bolt [B] Engine Ground Terminal [C] •...
  • Page 220: Engine Removal

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the drive chain from the output shaft. • Remove the engine [A] from the left side of the motorcy- cle. Engine Installation • Replace: Upper Engine Bracket Nuts Front Engine Bracket Nuts • Install: Front Chain Guide [A] Lower Engine Mounting Bolt [B]...
  • Page 221 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Apply non-permanent locking agent to the threads of the upper engine mounting bolt [A]. • Install the bracket so that the hook portion [B] faces right side of the motorcycle. ○ Attach the hook portion to the upper engine bracket. •...
  • Page 223 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase ..........................Crankcase Disassembly ....................Crankcase Assembly ......................9-10 Crankshaft ..........................9-15 Crankshaft Removal ......................9-15 Crankshaft Installation ...................... 9-15 Crankshaft Disassembly ....................9-15 Crankshaft Assembly ......................9-15 Crankshaft Inspection .......................
  • Page 224: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 225 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener marks N·m kgf·m ft·lb 1 Primary Gear Nut 2 Bearing Retaning Screws 0.45 39 in·lb 3 Engine Oil Drain Bolt 4 Engine Oil Feed Fitting Bolts 0.90 78 in·lb 5 Crankcase Bolts (L = 30) 0.90 78 in·lb 6 Crankcase Bolts (L = 50)
  • Page 226 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 227 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener marks N·m kgf·m ft·lb 1 Front Right Balancer Weight Nut 2 Rear Balancer Chain Guide Bolts 0.90 78 in·lb 3 Idle Shaft Lever Bolt 0.90 78 in·lb 4 Shift Drum Cam Bolt 106 in·lb 5 Neutral Switch 6 Shift Pedal Bolt 12.5...
  • Page 228: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm 0.008/3.94 in.) 0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) Connecting Rod Big End Side 0.6 mm Clearance...
  • Page 229: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-7 Special Tools and Sealant Outside Circlip Pliers: Crankcase Splitting Tool Assembly: 57001-144 57001-1362 Bearing Puller Adapter: Gear Holder: 57001-317 57001-1602 Bearing Driver Set: Liquid Gasket, TB1216: 57001-1129 92104-1063 Crankshaft Jig: 57001-1174...
  • Page 230: Crankcase

    9-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on clean surface while parts are being re- moved. • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter)
  • Page 231 CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Remove: Circlip [A] Collar [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove the crankcase bolts [A]. • Install the jig [A] between the crankshaft flywheels. Special Tool - Crankshaft Jig: 57001-1174 • Attach the crankcase splitting tool [B] to the left crankcase.
  • Page 232: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Assembly NOTICE 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 233 CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Apply a non-permanent locking agent to the retaining screws [A]. • Tighten: Torque - Bearing Retaining Screws: 4.4 N·m (0.45 kgf·m, 39 in·lb) • Install the crankshaft. • Apply engine oil to the transmission gears, bearings, shift forks, shift drum and crankshaft bearing.
  • Page 234 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Be sure to install the O-ring [A] on the engine oil feed fitting [B]. • Tighten: Torque - Engine Oil Feed Fitting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install: Dowel Pins [A] • With the connecting rod positioned at the bottom-dead -center, install the crankshaft jig [A].
  • Page 235 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Install the clamp [A]. • Apply a non-parmanent locking agent to the crankcase bolt [B]. • Tighten the crankcase bolts [B] [C], starting with the pe- riphery of the crankshaft, then outward. Torque - Crankcase Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) NOTE ○...
  • Page 236 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Install the collar [A]. • Replace the circlip [B] with a new one, and install it to the output shaft.
  • Page 237: Crankshaft

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft Crankshaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Using the hand, pull out the crankshaft [A] from the right crankcase [B]. Crankshaft Installation • Install the crankshaft to the right crankcase. • Apply engine oil to the connecting rod big end bearing. Crankshaft Disassembly Since assembly of the crankshaft demands exacting tol- erances, the disassembly and reassembly of the crankshaft...
  • Page 238: Crankshaft Inspection

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Inspection Connecting Rod Big End Radial Clearance • Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end. • Push [B] the connecting rod first towards the gauge and then in the opposite direction.
  • Page 239: Connecting Rod Bend

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft • First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer as shown. • Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit. •...
  • Page 240: Connecting Rod Twist

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft • With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend. If connecting rod bend exceeds the service limit, the con- necting rod must be replaced.
  • Page 241: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-19 External Shift Mechanism Shift Pedal Removal • Remove the shift pedal bolt [A]. • Pull out the shift pedal [B]. Shift Pedal Installation • Install the shift pedal so that the top of the shift pedal pad [A] position is lower than the punch mark [B] on the alternator outer cover.
  • Page 242: External Shift Mechanism Inspection

    9-20 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Holding the gear positioning lever [A] with the (–) driver [B] and install the shift dram cam [C] so that the hollow [D] fit to the shift drum pin [E]. • Apply a non-permanent locking agent to the shift drum cam bolt.
  • Page 243: Primary Gear

    CRANKSHAFT/TRANSMISSION 9-21 Primary Gear Primary Gear Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter) • Flatten out the bended washer [A]. • Install the clutch housing temporary (see Clutch Installa- tion in the Clutch chapter).
  • Page 244 9-22 CRANKSHAFT/TRANSMISSION Primary Gear • Install the primary gear [A]. • Align the key groove [B] of the primary gear and the crank- shaft. • Insert the woodruff key [C] into the key groove. • Install the oil pump drive gear [A] while fitting the woodruff key [B] onto the groove [C].
  • Page 245: Transmission

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Transmission Shaft Removal • Disassemble the crankcase halves (see Crankcase Dis- assembly). • Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C]. •...
  • Page 246: Transmission Shaft Disassembly

    9-24 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Disassembly • Remove the transmission shafts. • Remove the circlips, washers, then gears. Special Tool - Outside Circlip Pliers: 57001-144 • Do not reuse the removed circlips. Transmission Shaft Assembly • Apply engine oil liberally to the transmission shaft, gears and bearings.
  • Page 247 CRANKSHAFT/TRANSMISSION 9-25 Transmission 1. Circlip ( 23.5) 9. Washer ( 30 × 25.3) 17. 4th Gear 2. Needle Bearing 10. 5th Gear 18. Washer ( 32 × 25.3) 3. Washer ( 30 × 20.5) 11. Drive Shaft (1st Gear) 19. Washer ( 31) 4.
  • Page 248: Shift Fork Bending

    9-26 CRANKSHAFT/TRANSMISSION Transmission 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. 90° [A] Shift Fork/Gear Groove Wear •...
  • Page 249: Balancer

    CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Removal • Remove: Camshaft Chain (see Camshaft Chain Removal in the Engine Top End chapter) Clutch Cover (see Clutch Cover Removal in the Clutch chapter) Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter) •...
  • Page 250 9-28 CRANKSHAFT/TRANSMISSION Balancer • Install: Spacer (T = 3) [A] Washer (T = 2) [B] • Align the punch mark [C] on the camshaft sprocket and TDC adjusting line [D]. • Engage the balancer chain [A] with the sprockets as shown.
  • Page 251 CRANKSHAFT/TRANSMISSION 9-29 Balancer • Replace the circlips [A] with new ones. • Install: Washer [B] Circlips Special Tool - Outside Circlip Pliers: 57001-144 • Install the rear balancer chain guide [C]. • Apply a non-parmanent locking agent to the rear balancer chain guide bolts [D].
  • Page 252: Bearings/oil Seals

    9-30 CRANKSHAFT/TRANSMISSION Bearings/Oil Seals Bearing Replacement NOTICE 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 253: Oil Seal Inspection

    CRANKSHAFT/TRANSMISSION 9-31 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 255 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......................10-8 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-9 Spoke Inspection ......................
  • Page 256: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 257 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spoke Nipples 0.41 35 in·lb Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut G. Apply grease. HG. Apply high-temperature grease. R. Replacement Parts WL. Apply soap and water solution, or rubber lubricant.
  • Page 258: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 2.0 mm (0.08 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 2.0 mm (0.08 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance...
  • Page 259: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Oil Seal & Bearing Remover: Bearing Remover Head, 15 × 17: 57001-1058 57001-1267 Rim Protector: Bearing Remover Head, 20 × 22: 57001-1063 57001-1293 Bead Breaker Assembly: Bearing Remover Shaft, 13: 57001-1072 57001-1377 Bearing Driver Set:...
  • Page 260: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Loosen the front axle nut [A]. • Remove the speedometer cable lower end [A]. • Loosen the front axle clamp bolts [A]. • Raise the front wheel off the ground wtih jack. Special Tool - Jack: 57001-1238 •...
  • Page 261 WHEELS/TIRES 10-7 Wheels (Rims) • Fit the collar [A] on the wheel hub [B]. • Fit the speedometer gear housing stop [A] to the fork leg projection [B]. • Insert the front axle, and tighten the axle nut. Torque - Front Axle Nut: 88 N·m (9.0 kgf·m, 65 ft·lb) •...
  • Page 262: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Remove: Brake Hose Clamp Bolt [A] Brake Caliper Mounting Bolts [B] Rear Brake Caliper [C] • Remove the cotter pin [A] and loosen the rear axle nut [B]. • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001-1238 •...
  • Page 263: Wheel Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 264: Rim Installation Position

    10-10 WHEELS/TIRES Wheels (Rims) Rim Installation Position • When installing the rim, set the rim following position. ○ The distance [A] from the brake disc seating surface [B] of the front hub [C] to left end of the front rim [D] should be as follows.
  • Page 265: Balance Adjustment

    30 g (1.06 US oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 g (0.35, 0.71 US oz.), and 30 g (1.06 US oz.) sizes. An imbalance of less than 10 grams (0.35 US oz.) will not usually affect running stability.
  • Page 266: Tires

    10-12 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove the wheel (see Front/Rear Wheel Removal). NOTICE Do not lay the front wheel on the ground with the disc facing down.
  • Page 267: Tire Installation

    WHEELS/TIRES 10-13 Tires • Step on the side of the tire opposite air valve, and pry the tire off the rim with the tire iron [B] of the bead breaker protecting the rim with rim protectors [A]. Special Tools - Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 NOTICE Take care not to insert the tire irons so deeply that...
  • Page 268: Hub Bearing

    10-14 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Front Grease Seal [A] Circlip [B] Special Tool - Inside Circlip Pliers: 57001-143 Rear Coupling [A] Collar [B] Circlip [C] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 269: Hub Bearing Installation

    WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Installation • Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. • Replace the bearings with new ones. • Install the front hub bearings in the following sequence.
  • Page 270: Speedometer Gear

    10-16 WHEELS/TIRES Speedometer Gear Disassembly and Assembly NOTE ○ It is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation).
  • Page 271 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/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 272: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 273 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut Engine Sprocket Cover Bolts 0.90 78 in·lb Rear Sprocket Nuts G: Apply grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts...
  • Page 274: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 35 ∼ 45 mm (1.4 ∼ 1.8 in.) Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 20-link Length 323 mm (12.7 in.) Standard Chain: ENUMA (KL650E8 ∼ EA) Make –...
  • Page 275: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Bearing Driver Set: 57001-1129...
  • Page 276: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 277: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Swingarm (see Swingarm Removal in the Suspension chapter). Engine Sprocket Cover (see Engine Sprocket Removal) • Disengage the drive chain [A] from the engine sprocket [B], and pull out the drive chain backward.
  • Page 278 11-8 FINAL DRIVE Drive Chain • Grind [A] the pin head to make it flat. • Set the cutting and riveting pin [B] as shown. • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. •...
  • Page 279 FINAL DRIVE 11-9 Drive Chain • Set the plate holder (a) [A] and plate holder (b) [B] on the body. • Fit the plate holder (a) to link plate. • Turn the pin holder by hand until plate holder (b) touches the other link plate.
  • Page 280: Drive Chain Replacement (kl650eb ~ Ec)

    11-10 FINAL DRIVE Drive Chain • Turn the wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 281 FINAL DRIVE 11-11 Drive Chain • Remove: Body [A] Pin Holder [B] Positioning Pin [C] “U” Holder [D] Plate Holder [E] Cutting and Riveting Pin [F] Part for Riveting [G] Part for Cutting [H] • Grind [A] the heads of the link pin to make it flat. •...
  • Page 282 11-12 FINAL DRIVE Drive Chain • Set the cutting and riveting pin [B] and plate holder [C] on the pin holder [A] as shown in the figure. • Set the “U” holder and body, align the positioning pin [A] with the “A mark” [B]. •...
  • Page 283 FINAL DRIVE 11-13 Drive Chain • After riveting, check the ends of the riveted pins for cracks. • Measure the outside diameter [A] of the link pin and width [B] of the link plates. Link Pin Outside Diameter 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plate Outside Width 17.25 ∼...
  • Page 284: Sprocket, Coupling

    11-14 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 285: Rear Sprocket Removal

    FINAL DRIVE 11-15 Sprocket, Coupling • After tightening the engine sprocket nut, bend [A] the one side of the washer over the nut. • Install the engine sprocket cover. Torque - Engine Sprocket Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 286: Coupling Bearing Removal

    11-16 FINAL DRIVE Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling Collar [A] (from inside) Circlip [B] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing by tapping from the wheel side. Special Tool - Bearing Driver Set [A]: 57001-1129 Coupling Bearing Installation •...
  • Page 287: Coupling Damper Inspection

    FINAL DRIVE 11-17 Sprocket, Coupling Coupling Damper Inspection • Remove the rear wheel coupling, and inspect the rubber dampers [A]. • Replace the damper if it appears damaged or deterio- rated. Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage.
  • Page 289 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 Position Adjustment..................12-8 Brake Pedal Position Inspection ..................12-8 Brake Pedal Position Adjustment..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................
  • Page 290: Exploded View

    12-2 BRAKES Exploded View...
  • Page 291 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Lever Pivot Bolt 0.60 52 in·lb Front Master Cylinder Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Lever Adjusting Bolt Locknut 0.60 52 in·lb Brake Hose Banjo Bolts Front Master Cylinder Clamp Bolts...
  • Page 292 12-4 BRAKES Exploded View...
  • Page 293 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Reservoir Tank 0.70 61 in·lb Mounting Bolt Rear Master Cylinder Push Rod Locknut Rear Caliper Mounting Bolts Bleed Valve 0.80 69 in·lb Brake Pedal Bolt...
  • Page 294: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Free Play Non-adjustable – – – Lever Position Adjust (to suit rider) – – – Brake Pedal Free Play Non-adjustable – – – Pedal Position About 1.1 mm (0.043 in.) below top of –...
  • Page 295: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238...
  • Page 296: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever can be adjusted to suit the operator’s hand by turning the adjusting bolt [A]. ○ Loosen the locknut [B] and turn the bolt to either side. ○ After adjustment, tighten the locknut.
  • Page 297: Brake Pedal Installation

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Rear Brake Light Switch Spring [A] Brake Pedal [B] Shaft [C] Return Spring [D] Brake Pedal Installation • Apply grease to the sliding surface of the shaft [A]. • Install the return spring [B] to the shaft as shown. ○...
  • Page 298: Calipers

    12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the brake hose clamp bolt [B]. • Unscrew the caliper mounting bolts [C], and detach the caliper [D] from the disc.
  • Page 299: Caliper Installation

    BRAKES 12-11 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 300: Caliper Fluid Seal Damage

    12-12 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 301: Caliper Piston And Cylinder Damage

    BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper [C] Rear Caliper [D] Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 302: Brake Pads

    12-14 BRAKES Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove the pad pins. • Remove the pad [A] of the jaw side. •...
  • Page 303: Rear Brake Pad Installation

    BRAKES 12-15 Brake Pads • Remove the rear caliper with the hose installed (see Rear Caliper Removal). • Remove the pad pins. • Remove the pad [A] of the jaw side. • Remove the pad [B] on the piston side. Rear Brake Pad Installation •...
  • Page 304: Master Cylinder

    12-16 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the right handle cover (see Handle Cover Re- moval in the Frame chapter). • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).
  • Page 305: Rear Master Cylinder Removal

    BRAKES 12-17 Master Cylinder • Install the front master cylinder so that the punch mark [A] of the handlebar is aligned with the mating surface [B] of the master cylinder clamp to level the reservoir. • The master cylinder clamp must be installed with the ar- row mark [A] upward.
  • Page 306: Front Master Cylinder Disassembly

    12-18 BRAKES Master Cylinder • Replace the cotter pin [A] with a new one. • Insert the cotter pin and bend the pin ends. • Bleed the brake line (see Brake Line Bleeding). • Check the brake for good braking power, no brake drag, and no fluid leakage.
  • Page 307: Brake Disc

    BRAKES 12-19 Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 308: Brake Fluid

    12-20 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding 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.
  • Page 309 BRAKES 12-21 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 310 12-22 BRAKES 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 311: Brake Hose

    BRAKES 12-23 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
  • Page 313 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal ......................13-8 Front Fork Installation ....................... 13-8 Front Fork Oil Change ...................... 13-9 Front Fork Disassembly ....................13-10 Front Fork Assembly......................
  • Page 314: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 315 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Fork Clamp Bolts Lower Fork Clamp Bolts Front Fork Top Plugs Front Axle Clamp Bolts Front Fork Bottom Allen Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 316 13-4 SUSPENSION Exploded View...
  • Page 317 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Rear Shock Absorber Bolt Swingarm Pivot Shaft Nut Lower Rear Shock Absorber Nut Rocker Arm Nut Tie-rod Nuts G: Apply grease.
  • Page 318: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Fork Spring Setting Non-adjustable Damper Setting Non-adjustable Fork Oil: Type KAYABA KHL34-G10 or equivalent Amount Approx. 500 mL (16.9 US oz.) (when changing oil) 585 ±4 mL (19.8 ±0.14 US oz.) (after disassembly and completely dry) Fork Oil Level:...
  • Page 319: Special Tools

    SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: Jack: 57001-183 57001-1238 Fork Cylinder Holder Adapter: Fork Oil Seal Driver, 41: 57001-1057 57001-1288 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: 57001-1129...
  • Page 320: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Caliper (with the hose installed, see Front Caliper Removal in the Brakes chapter) Reflectors [A] (Other than AU Model) Bolts [B] Speedometer Cable Clamp [C] Brake Hose Clamp [D] Loosen the upper fork clamp bolts [A] and top plug [B]...
  • Page 321: Front Fork Oil Change

    SUSPENSION 13-9 Front Fork Front Fork Oil Change • Remove the front fork (see Front Fork Removal). • Loosen the clamp screw [A], and remove the fork boot [B]. • Remove: Top Plug [A] with O-ring Collar [B] Fork Spring Seat [C] Fork Spring [D] •...
  • Page 322: Front Fork Disassembly

    13-10 SUSPENSION Front Fork • Hold the outer tube vertically in a vise and compress the fork completely. • Wait until the oil level stabilizes. • Use the fork oil level gauge [A] to measure the distance between the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001-1290 ○...
  • Page 323 SUSPENSION 13-11 Front Fork • Remove the cylinder unit [A], washer, and the spring [B] from the inner tube. • Remove the following from the top of the outer tube. Dust Seal [A] Retaining Ring [B] • Separate the inner tube [A] from the outer tube [B]. NOTE ○...
  • Page 324: Front Fork Assembly

    13-12 SUSPENSION Front Fork Front Fork Assembly • Replace the following parts with new ones. Retaining Ring [A] Dust Seal [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Fork Bottom Allen Bolt Gasket [F] • Install the guide bushing on the end of the inner tube. •...
  • Page 325: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-13 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A], and repair any dam- age. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.
  • Page 326: Rear Shock Absorber

    13-14 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting is the 1 turns out from the fully clockwise position.
  • Page 327: Rear Shock Absorber Removal

    SUSPENSION 13-15 Rear Shock Absorber • If the compression of the spring is not suited to the op- erating conditions, adjust it to an appropriate position by referring to the table below. Spring Preload Adjustment Shock Adjuster Damping Road Driving Absorber Load Position...
  • Page 328: Rear Shock Absorber Installation

    13-16 SUSPENSION Rear Shock Absorber Rear Shock Absorber Installation • Install the rear shock absorber so that the spring preload adjusting bolt [A] faces left side of motorcycle. • Tighten: Torque - Upper Rear Shock Absorber Bolt: 59 N·m (6.0 kgf·m, 44 ft·lb) Lower Rear Shock Absorber Nut : 98 N·m (10 kgf·m, 72 ft·lb)
  • Page 329: Swingarm

    SUSPENSION 13-17 Swingarm Swingarm Removal • Remove: Chain Cover (see Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tiers chapter) Bolts [A] Clamps [B] • Remove the upper tie-rod nut and bolt [A]. •...
  • Page 330: Swingarm Bearing Installation

    13-18 SUSPENSION Swingarm • Remove the needle bearings using the oil seal & bearing remover [A]. Special Tool - Oil Seal & Bearing Remover: 57001-1058 Swingarm Bearing Installation • Replace the needle bearings with new ones. • Apply plenty of grease to the new needle bearings. •...
  • Page 331: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-19 Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] installed in the swingarm. ○ The rollers in a bearing normally wear very little, and wear is difficult to measure.
  • Page 332: Tie-rod, Rocker Arm

    13-20 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 • Remove: Upper Tie-Rod Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B] Tie-Rods Tie-Rod Installation...
  • Page 333: Rocker Arm Installation

    SUSPENSION 13-21 Tie-Rod, Rocker Arm • Remove: Plug (Both Sides) Rocker Arm Nut [A] and Bolt [B] • Remove the rocker arm downward. Rocker Arm Installation • Apply plenty of grease to the needle bearings [A]. • Apply grease to the lip of the oil seals [B]. •...
  • Page 334: Tie-rod And Rocker Arm Bearing Installation

    13-22 SUSPENSION Tie-Rod, Rocker Arm ○ Remove the needle bearings, using the oil seal & bearing remover [A]. Special Tool - Oil Seal & Bearing Remover: 57001-1058 Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearings with new ones. •...
  • Page 335: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-23 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 337 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......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Steering Stem, Stem Bearing Installation ................. 14-7 Stem Bearing Lubrication....................14-9 Steering Stem Warp......................
  • Page 338: Exploded View

    14-2 STEERING Exploded View...
  • Page 339 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Case Screws 0.39 34 in·lb Left Switch Housing Screws 0.36 31 in·lb Handlebar Clamp Bolts Upper Fork Clamp Bolts Lower Fork Clamp Bolts Brake Hose Clamp Bolt 0.70 61 in·lb Right Switch Housing Screws 0.36 31 in·lb...
  • Page 340: Special Tools

    14-4 STEERING Special Tools Bearing Puller: Head Pipe Outer Race Driver, 54.5: 57001-135 57001-1077 Steering Stem Bearing Driver: Steering Stem Nut Wrench: 57001-137 57001-1100 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft: Bearing Puller:...
  • Page 341: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 342: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Handlebar (see Handlebar Removal) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter)
  • Page 343: Steering Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the upper stem bearing inner race (tapered roller) [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 344 14-8 STEERING Steering Stem • 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 Tools - Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapter, 34.5: 57001-1074 •...
  • Page 345: Stem Bearing Lubrication

    STEERING 14-9 Steering Stem • Install the stem head. • Install the washer, and tighten the stem head nut tempo- rary. • Install the front forks (see Front Fork Installation in the Suspension chapter). NOTE ○ Tighten the upper fork clamp bolts first, next the stem head nut, last the lower fork clamp bolts.
  • Page 346: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Left Handle Cover [A] (see Handle Cover Removal in the Frame chapter) Left Handlebar Weight [B] Left Handlebar Grip [C] Clutch Cable Upper End (see Clutch Cable Removal in the Clutch chapter) Left Switch Housing [D] Clutch Lever Assembly [E] Clamp [F] •...
  • Page 347 STEERING 14-11 Handlebar • Tighten the front clamp bolts [A] first, and then the rear clamp bolts [B]. ○ There will be a gap [C] at the rear part of the handlebar holder after tightening. Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 348 14-12 STEERING Handlebar • Install the throttle grip [A] and right handlebar weight [B] so that distance [C] between the grip and weight is the 2.5 mm (0.098 in.). • Tighten: Torque - Throttle Case Screws: 3.8 N·m (0.39 kgf·m, 34 in·lb) •...
  • Page 349 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Special Tool ..........................15-6 Seat ............................15-7 Seat Removal ........................15-7 Seat Installation ....................... 15-7 Fairings........................... 15-8 Lower Fairing Removal ..................... 15-8 Lower Fairing Installation ....................15-8 Upper Fairing Removal ..................... 15-8 Upper Fairings Installation ....................
  • Page 350: Exploded View

    15-2 FRAME Exploded View...
  • Page 351 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Bolt and Nut R (1) Sidestand Switch Mounting Bolt 78 in·lb Lower Rear Frame Bolts Upper Rear Frame Bolts Rear Master Cylinder Bracket Bolts 8.
  • Page 352 15-4 FRAME Exploded View...
  • Page 353 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshieid Mounting Screws 0.04 4 in·lb Upper Fairings Mounting Bolts 0.09 8 in·lb Upper Left and Right Fairings Mounting Screws 0.04 4 in·lb Lower Fairing Mounting Bolts 0.90 78 in·lb 5.
  • Page 354: Special Tool

    15-6 FRAME Special Tool Jack: 57001-1238...
  • Page 355: Seat

    FRAME 15-7 Seat Seat Removal • Remove the side covers (see Side Cover Removal). • Remove the seat mounting bolts [A] on both sides. • Pulling up on the rear of seat [B], and pulling the seat backward. Seat Installation •...
  • Page 356: Fairings

    15-8 FRAME Fairings Lower Fairing Removal • Remove the bolt [A]. • Remove: Bolts [A] Screw [B] Lower Fairing [C] ○ When removing the left lower fairing, remove the radiator screen together with lower fairing. Lower Fairing Installation • Before installing the left lower fairing, insert the projec- tions [A] of the radiator screen into the grommets [B] on the radiator.
  • Page 357: Upper Fairings Installation

    FRAME 15-9 Fairings • Remove the upper fairing mounting bolts [A] [B] on both sides. • Clear the turn signal light leads from the clamps of the upper fairing. • Disconnect: Headlight Lead Connectors [A] Turn Signal Light Lead Connectors [B] •...
  • Page 358: Upper Fairing Bracket Installation

    15-10 FRAME Fairings • Remove: Bolts and Nuts [A] Upper Fairing Bracket [B] Upper Fairing Bracket Installation • Installation in the reverse of removal. ○ Run the harness and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 359: Side Covers

    FRAME 15-11 Side Covers Side Cover Removal • Remove: Side Cover Mounting Bolts [A] Side Cover [B] Side Cover Installation • Installation is the reverse of removal. ○ Insert the projection [A] into the grommet [B] on the rear frame.
  • Page 360: Fenders

    15-12 FRAME Fenders Front Fender Removal • Remove the speedometer cable lower end [A]. • Remove the front fender mounting bolts [A], and pull out the front fender [B]. Rear Fender Rear Removal • Remove: Side Covers (see Side Covers Removal) Seat (see Seat Removal) Carrier (see Carrier Removal) •...
  • Page 361: Rear Fender Front Installation

    FRAME 15-13 Fenders Rear Fender Front Installation • Installation is the reverse of removal. ○ Insert the ledges [A] of the rear fender front into the slits [B] of the rear frame securely.
  • Page 362: Rear Frame Removal

    15-14 FRAME Frame Rear Frame Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Battery (see Battery Removal in the Electrical System chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Rear Fender Front (see Rear Fender Front Removal) Flap (see Flap Removal) Canister (CAL Model)
  • Page 363: Frame Inspection

    FRAME 15-15 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warping. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 364: Windshield

    15-16 FRAME Windshield Windshield Removal • Remove the windshield mounting screws [A], and the windshield [B]. Windshield Installation • Tighten: Torque - Windshield Mounting Screws: 0.4 N·m (0.04 kgf·m, 4 in·lb)
  • Page 365: Guard, Carrier

    FRAME 15-17 Guard, Carrier Engine Guard Removal • Remove: Bolts [A] Engine Guard [B] Carrier Removal • Remove the side covers (see Side Covers Removal). • Remove the seat (see Seat Removal). • Disconnect the turn signal light connectors [A], and tail/brake light connector [B].
  • Page 366: Handle Covers

    15-18 FRAME Handle Covers Handle Cover Removal • Remove: Bolt [A] and Nut [B] Handle Cover [C] Handle Cover Installation • Installation is the reverse of removal. ○ Replace the handle cover nut with new one.
  • Page 367: Sidestand

    FRAME 15-19 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Remove: Sidestand Switch Mounting Bolt [A] Sidestand Switch Cover [B] Sidestand Switch [C] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation...
  • Page 368 15-20 FRAME Sidestand • Install the sidestand switch cover [A] as follows. ○ Insert the projections [B] into the holes [C]. • Apply a non-permanent locking agent to the threads of the sidestand switch mounting bolt, and tighten it. Torque - Sidestand Switch Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 369: Rear View Mirrors

    FRAME 15-21 Rear View Mirrors Rear View Mirrors Removal • When removing the rear view mirror of the right side, re- move the handle cover (see Handle Cover Removal). • Slide up the rubber cap [A]. • Loosen the lower adapter nut [B] for tightening to remove the rear view mirror from the holder.
  • Page 371 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ........................16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-12 Wiring Diagram........................16-14 Precautions..........................16-16 Electrical Wiring........................16-17 Wiring Inspection ......................16-17 Battery ............................ 16-18 Precautions.......................... 16-18 Battery Removal .......................
  • Page 372 16-2 ELECTRICAL SYSTEM Electric Starter System ......................16-48 Starter Motor Removal...................... 16-48 Starter Motor Installation....................16-48 Starter Motor Disassembly....................16-49 Starter Motor Assembly ....................16-49 Brush Inspection ....................... 16-51 Commutator Cleaning and Inspection................16-51 Armature Inspection......................16-52 Brush Lead Inspection ...................... 16-52 Brush Plate and Terminal Bolt Inspection .................
  • Page 373: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View This page intentionally left blank.
  • Page 374 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 375 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Mounting Bolts 0.90 78 in·lb Starter Motor Through Bolts 0.50 43 in·lb Starter Relay Terminal Screws 0.45 39 in·lb Starter Motor Terminal Locknut 10.8 96 in·lb Starter Motor Cable Terminal Nut 0.50 43 in·lb Regulator/Rectifier Bolts...
  • Page 376 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 377 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tail/Brake Light Mounting Nuts 0.60 52 in·lb License Plate Light Lens Screws 0.09 8 in·lb License Plate Light Mounting Screws 0.60 52 in·lb Meter Unit Mounting Screws 0.12 11 in·lb...
  • Page 378 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 379 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Right Handlebar Switch Housing Screws 0.36 31 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Handlebar Switch Housing Screws 0.36 31 in·lb Sidestand Switch Mounting Bolt 0.90 78 in·lb Radiator Fan Switch Water Temperature Sensor...
  • Page 380: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Capacity 12 V 14 Ah Electrolyte Level Between upper and lower level lines Specific Gravity 1.280 at 20°C (68°F) Charging System Alternator Type Three-phase AC Alternator Output Voltage 43 V or more at 4 000 r/min (rpm) 0.1 ∼...
  • Page 381: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Rotor Holder, Hex 32: Hand Tester: 57001-1184 57001-1394 Rotor Puller, M16/M18/M20/M22 × 1.5: Peak Voltage Adapter: 57001-1216 57001-1415 Jack: Filler Cap Driver: 57001-1238 57001-1454 Timing Light: Liquid Gasket, TB1211F: 57001-1241 92104-0004...
  • Page 382: Parts Location

    16-12 ELECTRICAL SYSTEM Parts Location...
  • Page 383 ELECTRICAL SYSTEM 16-13 Parts Location 1. IC Igniter 2. Starter Circuit Relay 3. Turn Signal Relay 4. Interlock Diode Unit 5. Meter Unit 6. Ignition Switch 7. Ignition Coil 8. Horn 9. Regulator/Rectifier 10. Water Temperature Sensor 11. Spark Plug 12.
  • Page 384: Wiring Diagram

    16-14 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 385 ELECTRICAL SYSTEM 16-15 Wiring Diagram...
  • Page 386: Precautions

    16-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 387: Electrical Wiring

    ELECTRICAL SYSTEM 16-17 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 388: Battery

    16-18 ELECTRICAL SYSTEM Battery Precautions Following a few simple rules will greatly extend the life of the battery. ○ When the level of the electrolyte in the battery is low, add only distilled water to each cell, until the level is at the upper level line marked on the outside of the battery.
  • Page 389: Battery Installation

    ELECTRICAL SYSTEM 16-19 Battery • Pull the battery [A] out of the air cleaner housing. Battery Installation • Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from sides of the battery. • Insert the battery into the air cleaner housing so that the positive terminal faces right side of the motorcycle.
  • Page 390: Battery Initial Charging

    16-20 ELECTRICAL SYSTEM Battery • Look for sediment and white sulfation inside the cells on the bottom of the plates. Sulfation Here [A] Sediment Here [B] • See the Battery Troubleshooting Guide in Test Charging. If the specific gravity is below 1.200 the battery needs to be charged.
  • Page 391 ELECTRICAL SYSTEM 16-21 Battery NOTE ○ If the electrolyte level drops, add electrolyte to the upper level line before charging. • Leaving the caps off the cells, connect the battery to a charger, set the charging rate at 1/10 the battery capacity, and charge it for 10 hours.
  • Page 392: Ordinary Charging

    16-22 ELECTRICAL SYSTEM Battery Ordinary Charging • Remove the battery from the motorcycle. NOTICE Always remove the battery from the motorcycle for charging. If the battery is charged while still in- stalled, battery electrolyte may spill and corrode the frame or other parts of the motorcycle. •...
  • Page 393 ELECTRICAL SYSTEM 16-23 Battery Charging Rate/Time Table (12 V 14 Ah) NOTICE Do not use a high rate battery charger as is typi- cally employed at automotive service stations, un- less the charging rate can be reduced to the level required.
  • Page 394: Test Charging

    16-24 ELECTRICAL SYSTEM Battery Test Charging • If the battery is suspected of being defective, sulfated, or unable to take a charge, consult the table. • To test charge a battery, perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below.
  • Page 395: Charging System

    ELECTRICAL SYSTEM 16-25 Charging System Alternator Outer Cover Removal • Remove: Engine Guard (see Engine Guard Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Starter Relay Cover (see Starter Relay Inspection) •...
  • Page 396: Alternator Outer Cover Installation

    16-26 ELECTRICAL SYSTEM Charging System Alternator Outer Cover Installation • Apply silicone sealant [A] to the crankshaft sensor lead grommets. Sealant - Liquid Gasket, TB1211F: 92104-0004 • Replace the alternator outer cover gasket with a new one. • Be sure that the dowel pins [A] are in position. •...
  • Page 397: Stator Coil Removal

    ELECTRICAL SYSTEM 16-27 Charging System • Install the idle shaft lever [A]. • Replace the O-ring [B] of the idle shaft lever bolt [C] with a new one. • Apply grease to the O-ring. • Tighten: Torque - Idle Shaft Lever Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) Stator Coil Removal •...
  • Page 398: Alternator Rotor Removal

    16-28 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval) Shaft [A] Starter Idle Gear [B] with needle bearings Torque Limiter [C] ○ There are washers on both sides onto he starter idle gear and torque limiter.
  • Page 399: Alternator Rotor Installation

    ELECTRICAL SYSTEM 16-29 Charging System • Remove the spacers [A]. Alternator Rotor Installation • Install the spacers [A] on the crankshaft. • Apply molybdenum disulfide oil solution to the inner sur- face [B] of the starter motor clutch gear [C]. •...
  • Page 400: Alternator Inspection

    16-30 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to the shafts of the torque limiter [A]. • Apply engine oil to the needle bearings [B], and install them into the starter idle gear [C]. •...
  • Page 401 ELECTRICAL SYSTEM 16-31 Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch OFF. ○ Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 402: Regulator/rectifier Inspection

    16-32 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). • Disconnect the regulator/rectifier connector [A]. • Remove: Bolts [B] Clamp [C] Regulator/Rectifier [D] Rectifier Circuit Check • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection W-Y1, W-Y2,...
  • Page 403 ELECTRICAL SYSTEM 16-33 Charging System • Do the 2nd step regulator circuit test. ○ Connect the test light and the 12 V battery in the same manner as specified in the “Regulator Circuit Test-1st Step”. ○ Apply 12 V to the voltage BR terminal. ○...
  • Page 404: Charging Voltage Inspection

    16-34 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Battery Condition). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seat (see Seat Removal in the Frame chap- ter). • Check that the ignition switch is turned off, and connect the hand tester [A] to the battery terminals [B].
  • Page 405 ELECTRICAL SYSTEM 16-35 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 12 V 14 Ah 5. Main Fuse 20 A 6. Load...
  • Page 406: Ignition System

    16-36 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 407: Crankshaft Sensor Removal

    ELECTRICAL SYSTEM 16-37 Ignition System Crankshaft Sensor Removal • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval) Hold Plate Screws [A] Plates [B] Crankshaft Sensor Lead Grommets [C] Crankshaft Sensor Screws [D] Crankshaft Sensor [E] Crankshaft Sensor Installation •...
  • Page 408: Crankshaft Sensor Peak Voltage Inspection

    16-38 ELECTRICAL SYSTEM Ignition System If there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced. • Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground.
  • Page 409: Ignition Coil Inspection

    ELECTRICAL SYSTEM 16-39 Ignition System Ignition Coil Inspection • Remove the ignition coil (see Ignition Coil Removal). • Measure the arcing distance with a suitable commercially available coil tester [A] to check the condition of the igni- tion coil [B]. •...
  • Page 410: Ignition Coil Primary Peak Voltage Inspection

    16-40 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Inspection • Refer to the IC igniter Inspection. Spark Plug Removal • Refer to the Spark Plug Replacement in the Periodic Maintenance chapter. Spark Plug Installation • Refer to the Spark Plug Replacement in the Periodic Maintenance chapter.
  • Page 411: Interlock Diode Unit Inspection

    ELECTRICAL SYSTEM 16-41 Ignition System 2nd Check • Start the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch ON and push the starter button. ○...
  • Page 412: Ic Igniter Removal

    16-42 ELECTRICAL SYSTEM Ignition System IC Igniter Removal NOTICE Never drop the IC igniter, especially on a hard sur- face. Such a shock to igniter can damage it. • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Connector [A] IC Igniter [B] IC Igniter Inspection...
  • Page 413 ELECTRICAL SYSTEM 16-43 Ignition System • Pull off the spark plug cap from the spark plug (see Igni- tion Coil Removal). ○ Do not remove the spark plug. • Measure the primary peak voltage as follows. ○ Install the new spark plug [A] into the plug cap, and ground it onto the engine.
  • Page 414 16-44 ELECTRICAL SYSTEM Ignition System Check3: Crankshaft Sensor Primary Peak Voltage Check NOTE ○ Be sure the battery is fully charged. ○ Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements.
  • Page 415 ELECTRICAL SYSTEM 16-45 Ignition System...
  • Page 416 16-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Engine Stop Switch 2. Starter Button 3. Ignition Switch 4. Sidestand Switch 5. Interlock Diode Unit 6. Starter Lockout Switch 7. Ignition Coil 8. Spark Plug 9. Neutral Switch 10. Crankshaft Sensor 11.
  • Page 417: Starter Motor Clutch

    ELECTRICAL SYSTEM 16-47 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation. Starter Motor Clutch Inspection • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval) Starter Idle Gear and Torque Limiter (see Alternator Re- moval) •...
  • Page 418: Electric Starter System

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the exhaust pipe (see Exhaust Pipe Removal in the Engine Top End chapter). •...
  • Page 419: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Disassem- bly). • Take off the starter motor through bolts [A] and remove the both end covers [B]. • Pull the armature [A] out of the yoke [B]. •...
  • Page 420 16-50 ELECTRICAL SYSTEM Electric Starter System • Clamp the springs [A] with the suitable plates [B]. • Insert the armature [C] into the yoke [D]. • Remove the suitable plates. • Replace the O-ring [A] with new one and install it. •...
  • Page 421: Brush Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Install the thrust washer(s) [A] to the right-hand end cover [B]. • Align the lines [A] of the yoke and end covers. • Tighten: Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m, 39 in·lb) •...
  • Page 422: Armature Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 423: Starter Relay Inspection

    ELECTRICAL SYSTEM 16-53 Electric Starter System Starter Relay Inspection • Remove the battery negative (–) cable from the battery negative (–) terminal (see Battery Removal). • Remove: Screw [A] Starter Relay Cover [B] • Disconnect the connector [A]. • Remove the starter relay [B] from the bracket [C]. •...
  • Page 424: Starter Circuit Relay Inspection

    16-54 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Connector [A] Starter Circuit Relay [B] • Connect the hand tester [A] and a 12 V battery [B] to the starter circuit relay [C] as shown.
  • Page 425 ELECTRICAL SYSTEM 16-55 Electric Starter System Electric Starter Circuit 1. Engine Stop Switch 2. Starter Button 3. Ignition Switch 4. Sidestand Switch 5. Interlock Diode Unit 6. Starter Circuit Relay 7. Starter Lockout Switch 8. Neutral Switch 9. Starter Motor 10.
  • Page 426: Lighting System

    16-56 ELECTRICAL SYSTEM Lighting System Headlight Beam Horizontal Adjustment • Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Beam Vertical Adjustment • Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Bulb Replacement •...
  • Page 427: Headlight Removal

    ELECTRICAL SYSTEM 16-57 Lighting System • Fit the dust cover [A] with the projection upward onto the bulb [B] firmly as shown. Good [C] Bad [D] Projection [E] • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). ○...
  • Page 428: License Plate Light Bulb Replacement

    16-58 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement • Remove: Screws [A] License Plate Light Cover [B] • Remove: Screws [A] License Plate Light Lens [B] • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 429: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-59 Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 2. Headlight Fuse 15 A 3. Tail/Brake Light 12 V 5/21 W 4. License Plate Light 12 V 5 W 5. Headlight (High) 12 V 55 W 6. Headlight (Low) 12 V 55 W 7.
  • Page 430: Turn Signal Relay Inspection

    16-60 ELECTRICAL SYSTEM Lighting System • Turn the turn signal light lens [A] counterclockwise, and remove it. • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 431 ELECTRICAL SYSTEM 16-61 Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig- nal relay.
  • Page 432: Radiator Fan System

    16-62 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Disconnect the radiator fan switch connector [A]. • Using an auxiliary lead [B], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch (see Radiator Fan Switch Inspection).
  • Page 433: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-63 Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Speed Meter Cable Upper End [A] • Disconnect the connector [B]. • Remove the meter unit by taking off the mounting screws [C] with the washers.
  • Page 434: Meter, Indicator Light Bulb Replacement

    16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Fit the rod [A] into the hole [B] of the RESET button. • Install the sockets and terminals according to the lead color marks of the lower meter cover. Meter, Indicator Light Bulb Replacement •...
  • Page 435: Water Temperature Gauge Inspection

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit • Then the tachometer needle [A] should flick [B]. If the needle does not flick, replace the meter assembly. Tachometer Circuit 1. Tachometer 2. Ignition Switch 3. IC Igniter 4. Main Fuse 20 A 5.
  • Page 436 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Connect the variable rheostat [A] to the Y lead terminal [B] as shown. • Adjust the resistance value to the approximately 30 Ω. • The water temperature gauge [A] indicate the position [B] of the about 100 °C.
  • Page 437: Switches And Sensors

    ELECTRICAL SYSTEM 16-67 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 438: Radiator Fan Switch Inspection

    16-68 ELECTRICAL SYSTEM Switches and Sensors Radiator Fan Switch Inspection • Remove the radiator fan switch (see Radiator Fan Switch Removal in the Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the thread portion is submerged. •...
  • Page 439: Fuse

    ELECTRICAL SYSTEM 16-69 Fuse 20 A Main Fuse Removal • Remove the starter relay cover (see Starter Relay Inspec- tion). • Disconnect the connector [A]. • Pull out the main fuse [A] from the starter relay with needle nose pliers. Fuse Box Fuse Removal •...
  • Page 440: Fuse Inspection

    16-70 ELECTRICAL SYSTEM Fuse Fuse Inspection • Remove the fuse (see 20 A Main/Fuse Box Fuse Re- moval). • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit.
  • Page 441 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-34...
  • Page 442 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 443 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Run the speedometer cable to the inside of the brake hose. 2. Speedometer Cable 3. Throttle Cable (Decelerator) 4. Throttle Cable (Accelerator) 5. Brake Hose 6. Clamp (Run the right switch housing lead in the clamp, and insert the clamp in the handlebar.) 7.
  • Page 444 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 445 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch Cable 2. Choke Cable 3. Damper 4. Main Harness 5. Band (Fix the main harness, alternator lead and crankshaft sensor lead at the frame pipe.) 6. Dampers 7. 97 mm (3.82 in.) 8.
  • Page 446 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 447 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. IC Igniter 2. Starter Circuit Relay 3. Turn Signal Relay 4. Headlight Leads 5. Meter Unit Lead 6. Interlock Diode Unit 7. Fix the main harness at the upper fairing bracket. 8. Bands (Insert the band in the upper fairing bracket and fix the main harness.) 9.
  • Page 448 17-8 APPENDIX Cable, Wire, and Hose Routing KL650E8 ∼ E9 Models...
  • Page 449 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Left Switch Housing Lead 2. Clamps 3. Alternator Lead Connector 4. Ignition Switch Lead 5. Right Switch Housing Lead 6. Frame Ground Lead 7. Clamps (Clamp the main harness.) 8. Main Harness 9.
  • Page 450 17-10 APPENDIX Cable, Wire, and Hose Routing KL650EA ∼ EC Models...
  • Page 451 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Left Switch Housing Lead 2. Clamps 3. Alternator Lead Connector 4. Ignition Switch Lead 5. Right Switch Housing Lead 6. Frame Ground Lead 7. Clamps (Clamp the main harness.) 8. Main Harness 9.
  • Page 452 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 453 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Ignition Coil 2. Clamp 3. Reguretor/Rectifier 4. Viewed from A - A 5. Clamp the ignition coil lead and reguretor/rectifier lead so that they do not touch the regure- tor/rectifier. 6. Spark Plug Lead 7.
  • Page 454 17-14 APPENDIX Cable, Wire, and Hose Routing KL650E8 ∼ E9 Models...
  • Page 455 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Starter Motor Cable 2. Engine Ground Terminal 3. Rear Brake Light Switch 4. Battery Negative Cable 5. Battery Positive Cable 6. Clamp (Clamp the battery cables.) 7. Starter Relay 8. Clamp (Insert the clamp in the starter relay bracket from inside of motorcycle and clamp the alternator lead and crankshaft sensor lead.) 9.
  • Page 456 17-16 APPENDIX Cable, Wire, and Hose Routing KL650EA ∼ EC Models...
  • Page 457 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Starter Motor Cable 2. Engine Ground Terminal 3. Rear Brake Light Switch 4. Battery Negative Cable 5. Band 6. Battery Positive Cable 7. Clamp (Clamp the battery cables.) 8. Starter Relay 9. Clamp (Insert the clamp in the starter relay bracket from inside of motorcycle and clamp the alternator lead and crankshaft sensor lead.) 10.
  • Page 458 17-18 APPENDIX Cable, Wire, and Hose Routing KL650EA ∼ EC Models...
  • Page 459 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Main Harness 2. Ignition Switch Lead 3. Right Switch Housing Lead 4. Band (Clamp the right switch housing lead, ignition switch lead and main harness.) 5. Left Switch Housing Lead Connector 6. Band (Clamp the right switch housing lead connector and ignition switch lead connector.) 7.
  • Page 460 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 461 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Clamp (Clamp the coolant reserve tank overflow hose and main harness.) 2. Clamps 3. Rear Right Turn Signal Lead 4. Tail/Brake Light Lead 5. License Plate Light Lead 6. Rear Left Turn Signal Lead 7.
  • Page 462 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 463 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Radiator Overflow Hose 2. Clamp (Clamp the radiator fan lead and radiator fan switch lead.) 3. Water Hose (To Thermostat Housing) 4. Radiator Fan Lead 5. Radiator Fan Switch Lead 6. Clamp (Clamp the radiator fan switch lead.) 7.
  • Page 464 17-24 APPENDIX Cable, Wire, and Hose Routing...
  • Page 465 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Carburetor 2. Air Vent Hose 3. Run the air vent hose to the right side of motorcycle. 4. Run the air vent hose under the rear frame fitting. 5. Run the air vent hose between rear frame and air cleaner housing. 6.
  • Page 466 17-26 APPENDIX Cable, Wire, and Hose Routing...
  • Page 467 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Front Brake Hose 2. Clamp 3. Viewed from A 4. Clamp Bracket 5. Viewed from A - A 6. Rear View 7. Clamp 8. Clamp 9. Clamp 10. Rear Brake Hose 11. Clamp 12.
  • Page 468 17-28 APPENDIX Cable, Wire, and Hose Routing Other than AU Model...
  • Page 469 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Clamp (Position the pinch head between upper and front (within the range of 90°).) 2. Vacuum Switch Valve Hose (To Clean Air System Pipe) 3. Clamp (Position the pinch head upward.) 4. Vacuum Switch Valve Hose (To Frame Fitting) 5.
  • Page 470 17-30 APPENDIX Cable, Wire, and Hose Routing CAL Model (KL650E8)
  • Page 471 APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Fuel Hose 2. Coolant Reserve Tank Overflow Hose 3. Main Harness 4. Blue Hose 5. Red Hose 6. Run the green hose between rear frame and canister bracket. 7. Green Hose 8. Blue Hose 9.
  • Page 472 17-32 APPENDIX Cable, Wire, and Hose Routing CAL Model (KL650E9 ∼ EC)
  • Page 473 APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Fuel Hose 2. Coolant Reserve Tank Overflow Hose 3. Main Harness 4. Blue Hose 5. Red Hose 6. Run the green hose between rear frame and canister bracket. 7. Green Hose 8. Blue Hose 9.
  • Page 474: Troubleshooting Guide

    17-34 APPENDIX Troubleshooting Guide NOTE IC igniter trouble ○ This is not an exhaustive list, giving every Neutral, starter lockout, sidestand switch or possible cause for each problem listed. It interlock diodes trouble is meant simply as a rough guide to assist Crankshaft sensor trouble the troubleshooting for some of the more Ignition coil trouble...
  • Page 475 APPENDIX 17-35 Troubleshooting Guide Compression low: Fuel line clogged Spark plug loose Compression low: Cylinder head not sufficiently tightened Spark plug loose down Cylinder head not sufficiently tightened No valve clearance down Cylinder, piston worn No valve clearance Piston ring bad (worn, weak, broken, or Cylinder, piston worn sticking) Piston ring bad (worn, weak, broken, or...
  • Page 476: Gear Shifting Faulty

    17-36 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Engine oil level too high Engine oil viscosity too high Doesn’t go into gear; shift pedal doesn’t Drive train trouble return: Brake dragging Clutch not disengaging Lubrication inadequate: Shift fork bent or seized Engine oil level too low Gear stuck on the shaft Engine oil poor quality or incorrect...
  • Page 477: Abnormal Drive Train Noise

    APPENDIX 17-37 Troubleshooting Guide Camshaft chain tensioner trouble Fuel level in carburetor float bowl too low Camshaft chain, sprocket, guide worn Air cleaner duct loose Vacuum switch valve damaged Air cleaner poorly sealed or missing Alternator rotor loose Handling and/or Stability Balancer gear worn or chipped Unsatisfactory: Balancer shaft position maladjusted...
  • Page 478 17-38 APPENDIX Troubleshooting Guide Battery Trouble: Ignition switch trouble Battery discharged: Alternator trouble Battery faulty (e.g., plates sulphated, Wiring faulty shorted through sedimentation, elec- Regulator/rectifier trouble trolyte insufficient) Battery overcharged: Battery leads making poor contact Regulator/rectifier trouble Load excessive (e.g., bulb of excessive Battery faulty wattage)
  • Page 479 MODEL APPLICATION Year Model Beginning Frame No. □ JKAKLEE1 8DA00101, 2008 KL650E8 □ JKAKLEE1 8DA00701 □ JKAKLEE1 9DA15801, 2009 KL650E9 □ JKAKLEE1 9DA16243 □ JKAKLEE1 ADA29521, 2010 KL650EA □ JKAKLEE1 ADA29561 □ 2011 KL650EB JKAKLEE1 BDA34207 □ 2012 KL650EC JKAKLEE1 CDA40279 □...

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