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) Ω 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(0.08∼ 0.12 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(0.04∼ 0.08 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(0.08∼ 0.12 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.