Kawasaki BAYOU 250 (2003) User Manual [ru]

Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Engine Top End 4 j
Engine Right Side 5 j
Recoil Starter 6 j
Engine Lubrication System 7 j
Engine Removal/Installation 8 j
This quick reference guide will assist you in locating a desired topic or pro­cedure.
•Bend the pages back to match the black tab of the desired chapter num­ber with the black tab on the edge at each table of contents page.
•Refer to the sectional table of contents for the exact pages to locate the spe­cific topic required.
Crankshaft/Transmission 9 j
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 17 j
KLF 250
BAYOU 250
Workhorse 250
All Terrain Vehicle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted i n any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to m ake it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication a re intended for reference use only and may not depict actual model component parts.
© 2002 Kawasaki Heavy Industries, Ltd. Third Edition (1) :Apr. 27, 2004 (K)

LIST OF ABBREVIATIONS

A
ABDC after bottom dead center
AC
ATDC after top dead center
BBDC before bottom dead center
BDC
BTDC before top dead center
°C degree(s) Celcius
DC
F
°F degree(s) Fahrenheit
ft foot, feet
g
h
L
ampere(s)
alternating current min
bottom dead center
direct current rpm
farad(s) TDC
gram(s)
hour(s) ohm(s)
liter(s)
lb
m
N
Pa
PS
psi
r revolution
TIR total indicator reading
V
W
pounds(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution(s) per minute
top dead center
volt(s)
watt(s)
Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board.
1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow
-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that
consist of a modified carburetor and an ignition system having optimum ignition timing character­istics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum
fuel economy with a suitable air cleaner and exhaust system.
A m aintenance free ignition system provides the most favorable ignition timing and helps main-
tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know­ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow­ing its sale and delivery to the ultimate purchaser..."
NOTE
The phrase "re move or render inoperative any device or e lement of design" has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de ­vices or elements o f design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE TH ESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
PLEASE DO NOT TAMPER W ITH NOISE CONTROL SYSTEM
(US MODEL only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in­formation to make it useful to the owner who de­sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce­dures must be understood in order to carry out maintenance and repair satisfactorily. When­ever the owner has insufficient experience or doubts his ability to do the work, all adjust­ments, maintenance, and repair should be car­ried out only by qualified mechanics.
In order to perform the work efficiently and to avoid costly mistakes, read the text, thor­oughly familiarize yourself with the procedures before starting work, and then do the work care­fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad­versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Vehi-
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Special Tool
Catalog or M anual. Genuine parts provided
as spare parts are listed in the Parts Catalog.
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta­ble of Contents.
For example, if you want ignition coil informa­tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap­ter to find the Ignition Coil section.
Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa­tion.
NOTE
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
done.
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec­ified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1

General Information

Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-6
Unit Conversion Table ............................................................................................................ 1-9
1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera­tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra­tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Disconnect the ground () wire from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if instal­lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assem­bled in the same way. It is preferable to mark and record the locations and routing whenever possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a pat, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com­monly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.
GENERAL INFORMATION 1-3
Before Servicing
(10)Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam­age.
(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally dam­ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks, press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re­moval weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular s hould be used only in certain applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos­itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are removed.
Replacement parts will be damaged or lose their original function once they are removed. There­fore, always replace these parts with new ones every time they are removed. Although the pre­viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Wires
All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed. Unless in­structed otherwise, electrical wires must be connected to wires of the same color.
1-4 GENERAL INFORMATION
Before Servicing
Two-Color Electrical Wire
(19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20)Specifications
Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. "Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
Model Identification

KLF250-A1 Left Side View

GENERAL INFORMATION 1-5

KLF250-A1 Right Side View

1-6 GENERAL INFORMATION
General Specifications
Item KLF250-A1 A3
Dimensions
Overall Length 1 780 mm (70.08 in..)
Overall Width 1 120 mm (44.09 in.),
(US) (CA) 1 020 mm (40.16 in.)
Overall Height 1 040 mm (40.94 in.)
Wheelbase 1 115 mm (43.90 in.)
Ground Clearance 155 mm (6.10 in.)
Seat Height 730 mm (28.74 in.)
Dry Mass 185 kg (408 lb), (US) 183 kg (404 lb),
(CA) 183.5 kg (405 lb)
Curb Mass:
Fuel Tank Capacity 10 L (2.6 US gal)
Performance
Minimum Turning Radius 2.7 m (8.86 ft)
Engine
Type 4-stroke, SOHC, 1-cylinder
Cooling System Air-cooled
Bore and Stroke 69.0 × 61.0 mm (2.72 × 2.40 in.)
Displacement 228 mL (13.9 cu in.)
Compression Ratio 8.9
Maximum Horsepower 12.5 kW (17 PS) @7 000 r/min (rpm), (US) –
Maximum Torque 17.9 N·m (1.83 kgf·m, 13.24 ft·lb)
Carburetion System Carburetor, MIKUNI VM24SS
Starting System Electric starter & Recoil starter
Ignition System CDI
Timing Advance Electronically advanced
Ignition Timing From 10° BTDC @1 800 r/min (rpm)
Spark Plug NGK DR8ES
Valve Timing:
Inlet: Open 35° BTDC
Exhaust: Open 54° BBDC
Lubrication System Forced lubrication (wet sump)
Engine Oil: Type API SF or SG
Front
Rear 106 kg (234 lb), (US) 104.5 kg (230 lb),
Close 57° ABDC
Duration 272°
Close 26° ATDC
Duration 260°
Viscosity SAE 10W-40
Capacity 2.0L(2.11USqt)
89 kg (196 lb), (US) (CA) 88.5 (195 lb)
(CA) 105 kg (232 lb)
@5 500 r/min (rpm)
to 35° BTDC @4 600 r/min (rpm)
API SH or SJ with JASO MA
GENERAL INFORMATION 1-7
General Specifications
Item KLF250-A1 A3
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 3.450 (69/20)
Clutch Type Wet multi disc and centrifugal
Transmission:
Type 5-speed plus reverse, constant mesh, return shift
Gear Ratio: 1st 2.923 (38/13)
2nd 1.684 (32/19)
3rd 1.173 (27/23)
4th
5th 0.785 (22/28)
Reverse 3.115 (27/13 × 33/22)
Final Drive System:
Type Shaft
Reduction Ratio 4.680 (18/15 × 39/10)
Overall Drive Ratio (@Top Gear)
Final Gear Case Oil:
Type Hypoid gear oil
Capacity 0.2L(0.21USqt)
Frame
Type Double tubular
Caster (Rake Angle) 4.0°
Camber 3.0°
King Pin Angle 10°
Trail 17 mm (0.67 in.)
Tread:
Front 764 mm (30.08 in.)
Rear 776 mm (30.55 in.)
Front Tire:
Type Tubeless
Size AT21 × 8 - 9
Rear Tire:
Type Tubeless
Size AT22 × 10 - 10
Suspension:
Front:
Type Independent swing axle
Wheel Travel
Rear:
Type Torque tube-link
Wheel Travel 125 mm (4.92 in.)
0.923 (24/26)
12.686
SAE90 (above 5°C, 41°F) or
SAE80 (below 5°C, 41°F)
115 mm (4.53 in.)
1-8 GENERAL INFORMATION
General Specifications
Item KLF250-A1 A3
Brake type:
Front Drum (Mechanical)
Rear Drum (Mechanical)
Electrical Equipment
Battery 12 V 14 Ah, (US) 12 V 11 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 25/25 W × 2
Tail/brake light 12 V 8/27 W × 2
Alternator:
Type Three - phase AC
Rated Output 13 A, 14 V @8 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country. (CA): Canada Model (US): U.S.A. Model
Unit Conversion Table
GENERAL INFORMATION 1-9

Prefixes fo r Units:

Prefix Symbol Power
mega M ×1000000
kilo k × 1 000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001

Units o f Mass:

kg ×2.205=lb g × 0.03527 = oz

Units of Volume:

L × 0.2642 = L × 0.2200 = L × 1.057 = qt (US) L × 0.8799 = qt (imp) L × 2.113 = pint (US) L × 1.816 = mL × 0.03381 = mL × 0.02816 = mL × 0.06102 = cu in.
gal (US) gal (imp)
pint (imp) oz (US) oz (imp)

Units of Force:

N × 0.1020 = kg N × 0.2248 = lb
kg ×9.807=N kg ×2.205=lb

Units of Length:

km × 0.6214 = mile m × 3.281 = ft mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m N·m × 0.7376 = ft·lb N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m kgf·m kgf·m
×7.233= × 86.80 = in·lb
ft·lb

Units of Pressure:

kPa × 0.01020 = kPa × 0.1450 = psi kPa × 0.7501 = cmHg
kg/cm² kg/cm² × 14.22 = psi cm Hg × 1.333 = kPa
× 98.07 = kPa
kg/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Power:

kW × 1.360 = kW × 1.341 = HP
PS × 0.7355 = kW PS × 0.9863 = HP
PS

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents
Periodic Maintenance Chart .............. 2-2
Torque and Locking Agent................. 2-3
Specifications .................................... 2-6
Periodic Maintenance Procedures..... 2-7
Fuel System.................................... 2-7
Throttle Lever Free Play
Inspection.................................. 2-7
Throttle Lever Free Play
Adjustment ................................ 2-7
Fuel System Cleanliness
Inspection.................................. 2-8
Air Cleaner Element Cleaning and
Inspection.................................. 2-8
Air Cleaner Draining..................... 2-9
Fuel Hose and Connection
Check........................................ 2-9
Fuel Hose Replacement .............. 2-9
Engine Top End .............................. 2-10
Valve Clearance Inspection ......... 2-10
Spark A rrester Cleaning............... 2-10
Clutches.......................................... 2-11
Clutch Adjustment........................ 2-11
Engine Lubrication System ............. 2-12
Engine Oil Change....................... 2-12
Oil Filter Change .......................... 2-12
2
Wheels/Tires................................... 2-13
Tire Inspection ............................. 2-13
Final Drive....................................... 2-14
Final Gear Case Oil Change ........ 2-14
Propeller Shaft Joint Boot
Inspection.................................. 2-14
Brakes............................................. 2-15
Front Brake Adjustment ............... 2-15
Rear (Parking) Brake Lever Free
Play Inspection.......................... 2-16
Brake Pedal Free Play Inspection 2-16 Rear (Parking) Brake Lever and
Pedal Free Play Adjustment...... 2-17
Steering .......................................... 2-18
Steering Inspection ...................... 2-18
Electrical System ............................ 2-18
Battery Inspection ........................ 2-18
Spark Plug Cleaning / Inspection . 2-18
Spark Plug Gap Inspection .......... 2-18
Brake Light Switch Adjustment .... 2-19
General Lubrication ........................ 2-19
Lubrication ................................... 2-19
Bolts and Nuts Tightening............... 2-21
Tightness Inspection .................... 2-21
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The initial maintenance is vitally important and must not be neglected.
FREQUENCY
OPERATION
ENGINE
Air cleaner - service*
Throttle lever play - inspect
Valve clearance - inspect
Fuel system cleanliness - inspect*
Engine oil - change*
Oil filter - replace*
Clutch adjustment*
Spark plug - clean and gap
Spark arrester - clean
Fuel hoses and connections - inspect
Fuel hose - replace 4 years
CHASSIS
First
Service
After 10
hrs. or 100 km (60 mi)
of use
Every 10
days or 200 km
(120 mi)
of use
Every 30
(360 mi)
Regular Service
Every 90 days or 600 km
of use
days or
1 700 km
(1 100 mi)
of use
Every
year of
use
Joint boots - inspect*
Rear brake pedal and lever adjustment - inspect*
Cables adjustment*
Bolts and nuts - tighten
Brake wear - inspect*
Brake light switch - inspect*
Battery - inspect
Steering - inspect
Tire wear - inspect*
Final gear case oil - change
General lubrication*
*: Service more frequently when operated in mud, dust, or other harsh riding conditions.
: Clean, adjust, lubricate, torque, or replace parts as necessary.
PERIODIC MAINTENANCE 2-3
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of
a non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to the threads.
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide
grease in a weight ratio 10 : 1).
S: Tighten the fasteners following the specified sequence.
St: Stake the fasteners to prevent loosening.
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.

Basic Torque for General Fasteners

Threads Torque
dia. (mm) N·m kgf·m ft·lb
5 3.4 4.9 0.35 0.50 30 43 in·lb 6 5.9 7.8 0.60 0.80 52 69 in·lb
8 14 19 1.4 1.9 10.0 13.5 10 25 34 2.6 3.5 19.0 25 12 44 61 4.5 6.2 33 45 14 73 98 7.4 10.0 54 72 16 115 155 11. 5 16.0 83 11 5 18 165 225 17.0 23.0 125 165 20 225 325 23 33 165 240
Fastener
Fuel Sytem
Carburetor Holder Bolts 11 1.1 95 in·lb L
Throttle Lever Bolt 5.9 0.6 52 in·lb
Engine Top End
Cylinder Head Bolts (M10), first torque
Cylinder Head Bolts (M10), final torque
Cylinder Head Bolts (M6), first torque 5.9 0.6 52 in·lb MO, S
Cylinder Head Bolts (M6), final torque 9.8 1.0 87 in·lb S
Valve Adjusting Cap Bolts 8.8 0.9 78 in·lb
Retaining Bolt 4.4 0.45 39 in·lb
Compression Releasing Lever Bolt 8.8 0.9 78 in·lb
Camshaft Sprocket Bolt 34 3.5 25 MO
Rear Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb
Camshaft Chain Tensioner Mounting Bolts
Valve Adjusting Screw Locknuts
Rocker Shaft Retainer Screws 4.4 0.45 39 in·lb
Camshaft Chain Guard Screws 4.4 0.45 39 in·lb
Engine Right Side
Right Engine Cover Bolts 8.8 0.9 78 in·lb
N·m
13 1.3 113 in·lb
34 3.5 25
8.8 0.9 78 in·lb
12 1.2 104 in·lb
Torque
Remarks
kgf·m ft·lb
L(1), MO, S
S
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Clutch Spring Bolts
Primary Clutch Hub Nut 127 13 94 MO
Secondary Clutch Hub Nut 78 8.0 58 MO
Balancer Drive Gear Nut 83 8.5 61 MO
Balancer Gear Nut 118 12 87 MO
Clutch Adjusting Screw Locknut 11 1.1 95 in·lb
Recoil Starter
Recoil Starter Mounting Bolts 8.8 0.9 78 in·lb
Recoil Starter Flange Nut 12 1.2 104 in·lb
Engine Lubrication System
Oil Pipe Banjo Bolts 15 1.5 11
Oil Pump Screws 4.4 0.45 39 in·lb
Engine Drain Plug 29 3.0 22
Oil Filter Cover Bolts 8.8 0.9 78 in·lb
Relief Valve 15 1.5 11 L
Engine Removal/Installation
Engine Bracket Bolts and Nuts 26 2.7 20
Engine Mounting Nuts (M10) 39 4.0 29
Engine Mounting Nut (M8)
Crankshaft/Transmission
Engine Drain Plug 29 3.0 22
Crankcase Bolts
Clutch Release Cam Pin 25 2.5 18 L
Return Spring Pin 25 2.5 18 L
Output Shaft Bearing Position Plate Screws 8.8 0.9 78 in·lb L
Relief Valve 15 1.5 11 L
Bearing Stopper Screws 9.8 1.0 87 in·lb
Positioning Lever Bolt 8.8 0.9 78 in·lb
Neutral and Reverse Switch Screws L
Shift Drum Pin Plate Bolt 12 1.2 104 in·lb
Wheels/Tires
Wheel Nuts 34 3.5 25 S
Rear Axle Nut 147 15 108
Final Drive
Output Bevel Gear Case Bolts (M8) 25 2.5 18 L(1)
Output Bevel Gear Case Bolts (M6) 8.8 0.9 78 in·lb
Oil Seal Housing Nuts
Drive Gear Nut 118 12 87 MO
Cam Damper Mounting Nut 78 8.0 58 MO
Driven Gear Shaft Nut 147 15 108 L
Bearing Retainer 108 11 80 L
Pinion Gear Nut 69 7.0 51 St
Propeller Shaft Housing Nuts 25 2.5 18
N·m kgf·m ft·lb
12 1.2 104 in·lb
29 3.0 22
8.8 0.9 78 in·lb
25 2.5 18
Torque
Remarks
Torque and Locking Agent
PERIODIC MAINTENANCE 2-5
Fastener
Final Gear Case Drain Bolt 20 2.0 14
Speedometer Plug 20 2.0 14
Final Gear Case Filler Cap 15 1.5 11
Ring Gear Cover Bolts
Axle Shaft Pipe Bolts 20 2.0 14
Oil Level Inspection Bolt 7.8 0.8 69 in·lb
Brakes
Front Axle Nut 34 3.5 25
Rear Axle Nut 147 15 108
Front Brake Panel Bolts 25 2.5 18 L
Rear Brake Panel Bolts 29 3.0 22 L
Rear Brake Drum Drain Bolts 29 3.0 22
Suspension
Front Suspension Arm Pivot Bolts 88 9.0 65
Rear Suspension Arm Pivot Bolts and Nuts 34 3.5 25
Shock Absorber Mounting Bolts and Nuts
Steering Knuckle Pivot Nuts 39 4.0 29
Steering
Steering Stem Clamp Allen Bolts 26 2.7 20
Stem Bottom End Nut 29 3.0 22
Tie-rod End Nuts 41 4.2 30
Tie-rod Adjusting Sleeve Locknuts 26 2.7 20
Steering Knuckle Arm Pivot Nuts 39 4.0 29
Handlebar Holder Bolts 20 2.0 14 S
Frame
Rear Carrier Bolts 20 2.0 14
Electrical System
Alternator Cover Bolts
Spark Plug 14 1.4 10
Starter Motor Clutch Bolts 34 3.5 25 L
Ignition Switch Nut 2.9 0.3 26 in·lb
Alternator Rotor Bolt 59 6.0 43
Starter Motor Mounting Bolts 8.8 0.9 78 in·lb
Starter Motor Terminal Nut 4.9 0.5 43 in·lb
Starter Motor Terminal Locknut 6.9 0.7 61 in·lb
Starter Motor Bolts 3.4 0.3 30 in·lb
N·m kgf·m ft·lb
25 2.5 18 L
34 3.5 25
8.8 0.9 78 in·lb
Torque
Remarks
2-6 PERIODIC MAINTENANCE
Specifications
Item Standard Service Limit
Fuel System
Throttle Lever Free Play 2 3mm(0.080.12 in.) ––– Idle Speed 1 300 1 400 r/min (rpm) –––
Air Cleaner Element Oil High-quality foam air filter oil –––
Engine Top End
Valve Clearance:
Exhaust 0.18 0.23 mm (0.0071 0.0091 in.) –––
Inlet
Engine Lubrication System
Engine Oil:
Type API SF or S G –––
Viscosity SAE10W40 –––
Capacity 2.0L(2.11USqt)
Wheels/Tires
Tire Tread Depth:
Front ––– 4 mm (0.16 in.)
Rear –––
Standard Tire:
Front AT 21 X 8-9 –––
Rear AT 22 x 10-10 –––
Final Drive
Final Gear Case:
Gear Case Oil:
Type
Viscosity SAE90 (above 5°C, 41°F) –––
Capacity 0.2 L (0.21 US qt) –––
Brakes
Front Brake Lever Free Play 1 2mm(0.040.08 in.) –––
Rear (Parking) Brake Lever Free Play
Brake Pedal Free Play 25 35 mm (1.0 1.4 in.) ––– Cam Lever angle 80 90° –––
Electrical System
Spark Plug Gap 0.6 0.7 mm (0.024 0.028 in.) –––
Rear Brake Light Switch Timing On after 10 mm (0.4 in.) of pedal travel
0.15 0.20 mm (0.0059 0.0079 in.)
API SH or SJ with JASO MA –––
(When filter is not removed)
2.1 L (2.22 US qt) –––
(When filter is removed)
2.75 L (2.91 US qt) –––
(When engine is completely dry)
4 mm (0.16 in.)
Dunlop, KT856, Tubeless –––
Dunlop, KT857, Tubeless –––
API GL-5 Hypoid gear oil
SAE80 (below 5°C, 41°F) –––
2 3mm(0.080.12 in.) –––
–––
–––
–––
–––
Periodic Maintenance Procedures

Fuel System

Throttle Lever Free Play Inspection
Check that the throttle lever moves smoothly from full
open to close, and the throttle closes quickly and com­pletely in all steering positions by the return spring. If the throttle lever does not return properly, check the throttle cable routing, lever free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle lever free play and the cable routing. Stop the engine and check the throttle lever free play [A].
If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play

Standard: 2 3 mm (0.08 0. 12 in.)
PERIODIC MAINTENANCE 2-7
Throttle Lever Free Play Adjustment
Slide the rubber cover off the adjuster at the throttle case.
Loosen the locknut [A] and turn the throttle cable upper
adjuster [B] until the cable has proper amount of play. Tighten the locknut and reinstall the rubber cover.
If the free play cannot be adjusted by using the upper ca­ble adjuster, pull up the rubber cover [A] at the carburetor. Loosen the locknut [B] and turn the throttle cable lower adjuster [C] to obtain the specified free play. Tighten the locknut and reinstall the rubber cover.
2-8 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be ex­plosive 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; this includes any appliance with a pilot light.
Turn the fuel tap to the OFF position.
Run the lower end of the carburetor drain hose to a suit-
able container. Turn out the carburetor drain plug a few turns and drain
the fuel system. Check to see if water or dirt comes out.
Tighten the drain plug.
If any water or dirt appears during the above inspection, clean the fuel system (carburetor, tank, fuel hose).
Air Cleaner Element Cleaning and Inspection
NOTE
In dusty areas, the element should be cleaned more
frequently than the recommended interval. After riding through rain or muddy terrains, the element
should be cleaned immediately. Since repeated cleaning opens the pores of the ele-
ment, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, if there is a break in the element material or any
other damage to the element, replace the element with a new one.
WARNING
Clean the element 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. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the foam element.
Remove the air cleaner element (see Air Cleaner Element
Removal). Clean the element in a bath of high-flash point solvent
using a soft bristle brush.
Periodic Maintenance Procedures
Squeeze it dry in a clean towel [A]. Do not wring the ele-
ment or blow it dry; the element can be damaged. Inspect the element for damage.
If it is torn, punctured, or hardened, replace it.
NOTE
Replace the element after cleaning it five times or if it is
damaged.
After cleaning, saturate the element with a high-quality
foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element.
Air Cleaner Draining
Two drain tubes [A] are connected to the bottom of the air cleaner housing to drain water or oil accumulated in the housing.
Squeeze open the two drain tubes to expel dust and/or
water accumulated inside.
PERIODIC MAINTENANCE 2-9
Fuel Hose and Connection Check
Turn the fuel tap to the OFF position.
Check the fuel hose [A].
If the fuel hose is frayed, cranked, or bulged, replace the
fuel hose.
Check that the hose is securely c onnected and clamps
are tightened.
If the fuel hose has been sharply bent or kinked, replace
the fuel hose.
If the clamps are loosened or damaged, replace the
clamps.
When installing the fuel hose, avoid sharp bending, kink-
ing, flattening or twisting, and route the fuel hose with a
minimum of bending so that the fuel flow will not be ob-
structed.
Fuel Hose Replacement
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; this includes any appliance with a pilot
light.
Turn the fuel tap to the OFF position.
Remove:
Clamps Fuel Hose
2-10 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fit the fuel hose [A] onto the pipe fully and install the
clamps [B] beyond the raised rib [C].
Engine Top End
Valve Clearance Inspection
NOTE
Check the valve clearance only when the engine is cold
(at room temperature).
Remove:
Front Fender (see Frame chapter) Bolts [A] and Valve Adjusting Caps [B]
Remove:
Recoil Starter (see Recoil Starter chapter) Timing Inspection Plug
Turn the crankshaft counterclockwise with a wrench on
the alternator rotor bolt until the “T” mark [A] on the alter­nator rotor aligns with the slot [B], as shown.
Measure the clearance of each valve between the end of
the valve stem and the adjusting screw on the rocker arm with a thickness gauge [A]. If the valve clearance is not correct, adjust it.

Valve Clearance (when cold)

Exhaust: 0.18 0.23 mm (0.0071 0.0091 in.) Inlet: 0.15 0.20 mm (0.0059 0.0079 in.)
Spark Arrester Cleaning
WARNING
To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run dur­ing this procedure, the muffler will become hot.
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