Kawasaki ER5 (2004) User Manual [ru]

Quick Reference Guide

General Information 1 j

Fuel System 2 j

Cooling System 3 j

Engine Top End 4 j

Clutch 5 j

Engine Lubrication System 6 j

Engine Removal/Installation 7 j

Crankshaft/Transmission 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.

Wheels/Tires 9 j

Final Drive 10 j

Brakes 11 j

Suspension 12 j

Steering 13 j

Frame 14 j

Electrical System 15 j

Appendix 16 j

ER-5

Motorcycle

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 Motorcycle 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.

© 2000 Kawasaki Heavy Industries, Ltd. 4th Edition (1): Aug. 5, 2004 (K)

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC alternating current min minute(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center Pa pascal(s)

BDC

BTDC before top dead center

°C degree(s) Celsius

DC direct current rpm revolution(s) per minute

F farad(s) TDC top dead center

°F degree(s) Fahrenheit TIR total indicator reading

ft foot, feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

bottom dead center

PS

psi

r revolution

horsepower

pound(s) per square inch

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 United States Environmental Protection Agency and California Air Resources Board. Addi­tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.

1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors

are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the carburetion system.

2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust

of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-

stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

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.

TAMPERING WITH N OISE 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.

Among those acts presumed to constitute tampering are the acts listed below:

Replacement of the original exhaust system or muffler with a component not in compliance

•

with Federal regulations.

Removal of the muffler(s) or any internal portion of the muffler(s).

•

Removal of the air box or air box cover.

•

Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such

•

modifications result in increased noise levels.

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 Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Special Tool Catalog or Manual. 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 i s 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

Periodic Maintenance Chart ................................................................................................... 1-9

Torque and Locking Agent...................................................................................................... 1-11

Special Tools and Sealants .................................................................................................... 1-16

Cable, Wire, and Hose Routing .............................................................................................. 1-23

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 part, 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

(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

ER500-C1, D1 Left Side View

GENERAL INFORMATION 1-5

ER500-C1, D1 Right Side View

1-6 GENERAL INFORMATION

General Specifications

Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1

Dimensions

Overall Length 2 070 mm (81.5 in.) ← ←

Overall Width 730 mm (28.74 in.) ← ←

Overall Height 1 070 mm (42.13 in.) ← ←

Wheelbase 1 430 mm (56.3 in.) ← ←

Road Clearance 125 mm (4.92 in.) ← ←

Seat Height 800 mm (31.5 in.)

Dry Weight

Curb Weight:

Front 92 kg (203 lb.) ← ←

Rear 107 kg (236 lb.) ← ←

Fuel tank Capacity 17 L (4.5 US gal.) ← ←

Performance

Minimum Turning Radius 2.5 m (8.2 ft.) ← ←

Engine

Type 4-stroke, DOHC, 2-cylinder ← ←

Cooling System Liquid-cooled ← ←

Bore and Stroke 74.0 × 58.0 mm (2.91 × 2.28 in.) ← ←

Displacement 498 mL (30.39 cu in.) ← ←

Compression Ratio 9.8:1 ← ←

Maximum Horsepower 37 kW (50.3 PS) @9 000 r/min (rpm) ← 25 kW (34

Maximum Torque 45 N·m (4.6 kgf·m, 33 ft·lb) @7 200

Carburetion System Carburetors, Keihin CVK34 × 2 ← ←

Starting System Electric starter ← ←

Ignition System Battery and coil (transistorized) ← ←

Timing Advance Electronically Advanced (digital) ← ←

Ignition Timing

Spark Plugs NGK DR9EA or ND X27ESR-U ← ←

Cylinder Numbering Method Left to right, 1-2 ← ←

Firing Order 1-2 ← ←

Valve Timing:

Inlet

Open 31° BTDC ← ←

Close 51° ABDC ← ←

DuRation 262° ← ←

Exhaust

Open 56° BBDC ← ←

Close 26° ATDC ← ←

DuRation 262° ← ←

179 kg (395 lb.)

r/min (rpm)

From 10° BTDC @1 200 r/min (rpm)
to 37.5° BTDC @10 000 r/min (rpm)

← ←

← ←

PS) @8 000

r/min (rpm)

← 37 N·m (3.8

kgf·m, 27

ft·lb) @4 500

r/min (rpm)

← ←

GENERAL INFORMATION 1-7

General Specifications

Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1

Lubrication System Forced lubrication ← ←

Engine Oil:

Grade API SE, SF, SG or

API SH or SJ with JASO MA

Viscosity

Capacity 3.4 L (3.6 us at)

Drive Train

Primary Reduction System:

Type Chain ← ←

Reduction Ratio

Clutch Type

Transmission:

Type 6-speed constant mesh, return shift ← ←

Gear Ratios:

1st 2.571 (36/14) ← ←

2nd

3rd

4th

5th 0.961 (25/26) ← ←

6th 0.851 (23/27) ← ←

Final Drive System:

Type Chain drive ← ←

Reduction Ratio 2.470 (42/17) ← ←

Overall Drive Ratio 5.581 @Top gear ← ←

Frame

Type Tubular, double cradle ← ←

Caster (rake angle) 27° ← ←

Trail

Front Tire:

Type Tubeless ← ←

Size 110/70-17 54H 110/70-17

Rear Tire:

Type Tubeless ← ←

Size 130/70-17 62H 130/70-17

Front Suspension:

Type Telescopic fork ← ←

Wheel Travel 125 mm (4.92 in.) ← ←

Rear Suspension:

Type Swingarm ← ←

Wheel Travel 114 mm (4.49 in.) ← ←

Brake Type:

Front Single disc ← ←

Rear Drum ← ←

SAE10W-40

2.652 (61/23)

Wet multi disc ← ←

1.722 (31/18)

1.333 (28/21)

1.125 (27/24)

102 mm (4.02 in.)

← ←

← ←

← ←

← ←

← ←

← ←

← ←

← ←

M/C 54H

M/C 62H

110/70-17

54H

130/70-17

62H

1-8 GENERAL INFORMATION

General Specifications

Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1

Electrical Equipment

Battery 12 V 10 Ah ← ←

Headlight:

Type Semi-sealed beam ← ←

Bulb 12 V 60/55 W (quartz-halogen) ← ←

Tail/brake Light 12 V 5/21 W × 2 ← ←

Alternator:

Type Three-phase AC ← ←

Rated output 17 A × 14 V @6 000 r/min (rpm) ← ←

Specifications subject to change without notice, and may not apply to every country.

GENERAL INFORMATION 1-9

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in

good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)

Throttle cable - inspect †

Idle speed - inspect †

Carburetor synchronization ­inspect †

Air cleaner element - clean† #

Fuel hoses, connections - inspect
†

Coolant filter - clean years

Radiator hoses, connections ­inspect †

Air suction valve - inspect †

• • • •

• • • •

• • •

• • •

• • • • • •

•

• • • • • •

* O DOMETER READING

• • •

Valve clearance - inspect †

•

× 1 000 km

(× 1 000 mile)

Remarks

before 2005

model

after 2005

model

Clutch adjust - inspect †

Tire wear - inspect †

Drive chain wear - inspect †#

Drive chain - lubricate # 600 km

Drive chain slack - inspect †# 1000 km

Brake Play - inspect †#

Brake fluid level - inspect † month

Brake hoses, connections ­inspect †

Brake lining or pad wear - inspect
†#

Brake light switch - inspect †

Front fork oil leak - inspect †

Rear shock absorber oil leak ­inspect †

Swingarm pivot - lubricate

Steering - inspect †

Steering stem bearing - lubricate 2 years

Spark plug - clean and gap †

General lubrication - perform

Nut, bolts, and fasteners tightness

- inspect †

• • • • • • •

• • • • • •

• • • • • •

• • • • • • •

• • • • • • •

• • • • • •

• • • • • •

• • • • • • •

• • •

• • •

• • •

• • • • • • •

•

• • • • • •

• • •

• • • •

Coolant - change 2 years

•

1-10 GENERAL INFORMATION

Periodic Maintenance Chart

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)

Engine oil - change # year

Oil filter - replace

Brake fluid - change 2 years

Brake master cylinder cup and
dust seal - replace

Caliper piston seal and dust seal

- replace

Front Fork oil - change 2 years

#: Service m ore frequently when operating in severe c onditions; dusty, wet, muddy, high speed,

or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

†: Replace, add, adjust, clean, or torque if necessary.

4 years

4 years

• • • • • • •

• • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

Remarks

•

•

GENERAL INFORMATION 1-11

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently
tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle
and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal
thread, or break and then fall out. The following table lists the tightening torque for the major bolts
and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten it to the specified torque.

Letters used in the "Remarks" column mean:

L: Apply a non-permanent locking agent to the threads.

LG: Apply liquid gasket to the threads.

Lh: Left-hand threads.

M: Apply molybdenum disulfide grease.
O: Apply an oil to the threads and seating surface.

R: Replacement parts.
S: Tighten the fasteners following the specified sequence.

SS: Apply silicone sealant to the threads.

St: Stake the fasteners to prevent loosening.

The table relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. 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 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240

Fastener

Fuel System

Fuel Tap Plate Screws

Fuel Tap Diaphragm Chamber S crews 1.0 0.10 9in·lb

Fuel Tap Mounting Bolts 2.5 0.25 22 in·lb

Fuel Level Sensor Bolts

Cooling System

Radiator Hose Clamp Screws 2.5 0.25 22 in·lb

Fan Switch 18 1.8 13

Thermostat Housing Bolts 11 1.1 95 in·lb

Water Temperature Sensor 7.8 0.8 69 in·lb SS

Water Pump Cover Bolts 11 1.1 95 in·lb

Water Pump Shaft 25 2.5 18 Lh

Water P ump Impeller 9.8 1.0 87 in·lb Lh

N·m kgf·m ft·lb

0.8 0.08 7in·lb

6.9 0.7 61 in·lb

Torque

Remarks

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Water Pipe Bolts 9.8 1.0 87 in·lb L

Cylinder Head Jacket Plug 9.8 1.0 87 in·lb L

Air Suction Valve Cover Bolts 11 1.1 95 in·lb

Coolant Drain Plug

Engine Top End

Spark Plugs 14 1.4 10

Cylinder Head Cover Bolts

Camshaft Cap Bolts 12 1.2 8.5 S

Rocker Shafts 39 4.0 29

Valve Adjuster Locknuts 25 2.5 18

Camshaft Sprocket Bolts 15 1.5 11 L

Cylinder Head Bolts (10 mm) 51 5.2 38 S

Cylinder Head Bolts (6 mm) 9.8 1.0 87 in·lb S

Cam Chain Tensioner Mounting Bolts 11 1.1 95 in·lb

Cam Chain Tensioner Cap Bolt 13 1.3 9.5

Main Oil Pipe Upper Banjo Bolts M8

Main Oil Pipe Lower Banjo Bolt M10 20 2.0 14.5

Water Pipe Bolts 9.8 1.0 87 in·lb L

Oil Pipe Bolts (in the cylinder head)

Oil Pipe Mounting Bolt 11 1.1 95 in·lb

Clutch

Oil Filler Plug 1.5 0.15 13 in·lb

Clutch Hub Nut 132 13.5 98

Clutch Spring Bolts 9.3 0.95 82 in·lb

Clutch Cable Holder Bolt

Clutch Cover Bolts 11 1.1 95 in·lb

Engine Lubrication System

Oil Filler Plug 1.5 0.15 13 in·lb

Oil Passage Plug 18 1.8 13

Oil Filter Mounting Stud 25 2.5 18 L

Oil Filter (Cartridge Type) 17 1.75 12.5

Oil Pipe for Balancer Shaft Banjo Bolt

Oil Pipe for Drive Shaft Upper Banjo Bolt M6 7.8 0.8 69 in·lb

Oil Pipe for Drive Shaft Lower Banjo Bolt M8 12 1.2 8.5

Oil Pipe for Output Shaft Upper Banjo Bolt M6 7.8 0.8 69 in·lb

Oil Pipe for Output Shaft Lower Banjo Bolt M8 12 1.2 8.5

Oil Pipe for Output Shaft Mounting Bolt 11 1.1 95 in·lb L

Oil Pump Pipe Mounting Bolts

Relief Valve 15 1.5 11 L

Oil Pressure Switch Terminal Bolt 15 0.15 13 in·lb

Oil Pressure Switch 15 1.5 11 SS

N·m kgf·m ft·lb

11 1.1 95 in·lb

9.8 1.0 87 in·lb

12 1.2 8.5

11 1.1 95 in·lb

11 1.1 95 in·lb

20 2.0 14.5

11 1.1 95 in·lb L

Torque

Remarks

(Planted

side)

Torque and Locking Agent

GENERAL INFORMATION 1-13

Fastener

Engine Oil Drain Plug 29 3.0 22

Oil Pan Mounting Bolts 11 1.1 95 in·lb

Oil Pump Mounting Bolts 11 1.1 95 in·lb

Breather Body Bolt 5.9 0.6 52 in·lb

Engine Removal/Installation

Downtube Bolts 44 4.5 33

Engine Mounting Bolts and Nuts 44 4.5 33

Engine Mounting Bracket Bolts 25 2.5 18

Crankshaft/Transmission

Crankcase Bolts (8 mm)

Crankcase Bolts (6 mm) 12 1.2 8.5 S

Upper Primary Chain Guide Mounting Nut 11 1.1 95 in·lb L

Lower Primary Chain Guide Mounting Bolt 11 1.1 95 in·lb L

Connecting Rod Big End Nuts 36 3.7 27

Return Spring Pin 20 2.0 14.5 L

Gear Positioning Lever Pivot Stud

Gear Positioning Lever Nut

Shift Pedal Mounting Bolt 12 1.2 8.5

Shift Drum Bearing Holder Bolts 11 1.1 95 in·lb L

Shift Drum Cam Pin Plate Screw – – – L

Engine Sprocket Nut 127 13 94 O

External Shift Mechanism Cover Bolts 11 1.1 95 in·lb

Neutral Switch

Wheels/Tires

Front Axle Nut 88 9.0 65

Front Axle Clamp Bolt

Rear Axle Nut 98 10 72

Final Drive

Torque Link Nuts 34 3.5 25

Engine Sprocket Nut 127 13 94 O

Rear Sprocket Nuts 59 6.0 43

Rear Coupling Studs – – – L

Engine Axle Nut 98 10 72

Drive Chain Guide Bolts 11 1.1 95 in·lb

Brakes

Brake Hose Banjo Bolts 25 2.5 18

Reservoir Cap Screws 1.5 0.15 13 in·lb

Brake Lever Pivot Bolt 1.0 0.10 9in·lb

Brake Lever Pivot Locknut 5.9 0.60 52 in·lb

Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S

N·m kgf·m ft·lb

27 2.8 20

– – – L

11 1.1 95 in·lb

15 1.5 11

20 2.0 14.5

Torque

Remarks

S

(planted

side)

(planted

side)

1-14 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Front Brake Light Switch Mounting Screw

Caliper Mounting Bolts 34 3.5 25

Caliper Bleed Valves 7.8 0.8 69 in·lb

Brake Disc Mounting Bolts 27 2.8 20 L

Brake Pedal Bolt 8.8 0.9 78 in·lb

Torque Link Nuts 34 3.5 25

Brake Cam Lever Bolt 19 1.9 13.5

Suspension

Front Fork Upper Clamp Allen Bolts 20 2.0 14.5

Front Fork Lower Clamp Allen Bolts

Front Fork Bottom Allen Bolt 20 2.0 14.5 L

Front Axle Clamp Bolt 20 2.0 14.5

Rear Shock Absorber Bolts and Nuts

Swing Arm Pivot Nut 88 9.0 65

Steering

Handlebar Clamp Bolts 25 2.5 18 S

Handlebar Weight Allen Bolts – – – L

Handlebar Switch Housing Screws 3.4 0.35 30 in·lb

Steering Stem Head Bolt 44 4.5 33

Steering Stem Nut Hand

Frame

Tail Grip Bolts 25 2.5 18

Footpeg Bracket Bolts 34 3.5 25

Sidestand Bolt and Nut 44 4.5 33

Center Stand Bolt and Nut 44 4.5 33

Electrical System

Pickup Coil Mounting Allen Bolts 8.3 0.85 74 in·lb L

Timing Inspection Plug 2.5 0.25 22 in·lb

Alternator Rotor Bolt Plug 1.5 0.15 13 in·lb

Alternator Cover Bolts 11 1.1 95 in·lb

Alternator Cover Allen Bolt 13 1.3 9.5

Alternator Lead Clamp S crews 2.9 0.30 26 in·lb

Spark Plug 14 1.4 10

Alternator Stator Allen Bolts

Alternator Rotor Bolt 69 7.0 51

Starter Motor Mounting Bolts 11 1.1 95 in·lb

Starter Chain Guide Screws

Starter Motor Through Bolts 6.9 0.7 65 in·lb

Starter Motor Terminal Nut 4.9 0.5 43 in·lb

Starter Motor Lead Clamp Nut 4.9 0.5 43 in·lb

N·m kgf·m ft·lb

1.2 0.12 10 in·lb

35 3.6 26

34 3.5 25

-Tighten

(about 4.9) (about 0.5) (about 43

12 1.2 8.5

4.9 0.5 43 in·lb L

Torque

Hand

-Tighten

Hand

-Tighten

in·lb)

Remarks

Torque and Locking Agent

GENERAL INFORMATION 1-15

Fastener

Starter Clutch Allen Bolts 34 3.5 25 L

Sidestand Switch Mounting Screw 3.9 0.4 35 in·lb L

Sidestand Mounting Bolt 44 4.5 33

Starter Motor Terminal Locknut

Starter Relay Terminal Bolt 4.9 0.50 43 in·lb

Headlight Body Screws 2.9 0.30 26 in·lb

Handlebar Switch Housing Screws 3.4 0.35 30 in·lb

Radiator Fan Switch 18 1.8 13

Meter Reset Knob Screw – – – L

Water Temperature Switch

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Oil Pressure Switch 15 1.5 11 SS

Neutral Switch 15 1.5 11

Tail Light Mounting Nut 5.9 0.6 52 in·lb

N·m kgf·m ft·lb

6.9 0.70 61 in·lb

7.8 0.80 69 in·lb

Torque

Remarks

SS

1-16 GENERAL INFORMATION

Special Tools and Sealants

Piston Ring Pliers:
57001-115

Oil Pressure Gauge, 5 kgf/cm²:
57001-125

Bearing Puller:
57001-135

Inside Circlip Pliers:
57001-143

Outside Circlip Pliers:
57001-144

Bearing Puller:
57001-158

Bearing Puller Adapter:
57001-136

Steering Stem Bearing Driver:
57001-137

Fork Cylinder Holder Handle:
57001-183

Compression Gauge, 20 kgf/cm²:
57001-221

Special Tools and Sealants

GENERAL INFORMATION 1-17

Valve Spring Compressor Assembly:
57001-241

Bearing Puller Adapter:
57001-317

Bearing Driver, 32:
57001-382

Valve Guide Arbor, 5.5:
57001-1021

Spark Plug Wrench, Hex 18:
57001-1024

Fork Cylinder Holder Adapter:
57001-1057

Piston Pin Puller A ssembly:
57001-910

Fuel Level Gauge:
57001-1017

Oil Seal & Bearing Remover:
57001-1058

Rim Protector:
57001-1063

1-18 GENERAL INFORMATION

Special Tools and Sealants

Bead Breaker Assembly:
57001-1072

Steering Stem Bearing Dri ve r Adapter, 34.5:
57001-1074

Head Pipe Outer Race Press Shaft:
57001-1075

Piston Ring Compressor Grip:
57001-1095

Piston Ring Compressor Belt, 67 ∼ 79:

57001-1097

Steering Stem Nut Wrench:
57001-1100

Head Pipe Outer Race Driver, 51.5:
57001-1076

Valve Guide Reamer, 5.5:
57001-1079

Head Pipe Outer Race Driver, 46.5:
57001-1106

Valve Seat Cutter, 45° - 24.5:
57001-1113

Special Tools and Sealants

GENERAL INFORMATION 1-19

Valve Seat Cutter, 32° - 25:
57001-1118

Valve Seat Cutter, 32° - 30:
57001-1120

Valve Seat Cutter, 60° - 30:
57001-1123

Bearing Driver Set:
57001-1129

Compression Gauge Adapter, M12 × 1.25:
57001-1183

Valve Seat Cutter, 45° - 30:
57001-1187

Valve Seat Cutter Holder, 5.5:
57001-1125

Valve Seat Cutter Holder Bar:
57001-1128

Valve Spring Compressor Adapter, 22:
57001-1202

Oil Pressure Gauge Adapter, M14 × 1.5:
57001-1209

1-20 GENERAL INFORMATION

Special Tools and Sealants

Rotor Puller, M16/M18/M20/M22 × 1.5:
57001-1216

Fork Outer Tube Weight:
57001-1218

Front Fork Oil Seal Driver:
57001-1219

Clutch Holder:
57001-1243

Oil Filter Wrench:
57001-1249

Bearing Remover Head, 15 × 17:
57001-1267

Jack:
57001-1238

Timing Light:
57001-1241

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

Fork Oil Level Gauge:
57001-1290

Pilot Screw Adjuster, C:
57001-1292

Special Tools and Sealants

GENERAL INFORMATION 1-21

Valve Seat Cutter, 60° - 25:
57001-1328

Pilot Screw Adjuster Adapter, 5:
57001-1372

Pilot Screw Ad juster Driver:
57001-1373

Harness Adapter #1:
57001-1381

Hand Tester:
57001-1394

Flywheel Holder:
57001-1410

Bearing Remover Shaft, 13:
57001-1377

Igniter Checker Assembly:
57001-1378

Peak Voltage Adapter:
57001-1415

Needle Adapter Set:
57001-1457

1-22 GENERAL INFORMATION

Special Tools and Sealants

Kawasaki Bond (Silicone Sealant):
56019-120

Kawasaki Bond (Liquid Gasket - Black) TB1105:
92104-1003

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-23

1. Vacuum Hose

2. Air Hose

3. Fuel Hose

4. Throttle and Choke Cables

5. Fuel Filters

6. Fuel Tap

7. To the air suction valve.

8. To the vacuum switch valve.

9. Clamp

10. To the fuel tap.

11. To the left carburetor.

12. To the right carburetor.

1-24 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Throttle Cables

2. Choke Cable

3. Right Handlebar Switch Leads

4. Horn

5. Clutch Cable

6. Left Handlebar Switch Leads

7. Brake Hose

8. Speedometer Cable

9. Run the cables outside.

10. Run the clutch cable inside the cross pipe.

11. Bands

12. Run the ignition switch lead behind and
then under the choke cable and above
the clutch cable into the right hole of the
headlight housing.

13. Run the main harness outside.

14. Run the meter cable inside the clamp

15. Clamp

16. Holders

17. Run the throttle cables through inside of
the bracket.

18. Drain Hose

19. Run the drain hose above the throttle ca­ble and choke cable at the fuel tank instal­lation.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-25

1. Handlebar Switch Harness

2. Main Harness

3. Radiator Fan Switch

4. Alternator Connector

5. Pickup Coil Connector

6. Neutral Switch Lead

7. Sidestand Switch Lead

8. Battery Negative Lead

9. Battery Positive Lead

10. Rear Brake Light Switch Connector

11. Starter Lead

12. Starter Circuit Relay

13. Turn Signal Relay

14. Regulator/rectifier Connector

15. Starter Relay

16. Bands

17. Run the leads inside the cross pipe.

18. Run the harness inside the frame.

19. Clamps

20. Run the lead under the starter lead.

21. Oil Pressure Switch Lead

22. Clamp

23. Radiator Reservoir Tank Hose

24. 5 mm (0.2 in.) or less

25. Run the harness over the cooling hose.

26. Run the regulator lead between the starter
circuit relay lead and turn signal relay lead.

27. Cooling Hose

1-26 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Radiator

2. Thermostat Housing

3. Coolant Filter

4. Carburetor

5. Reserve Tank

6. Coolant Valve

7. Reserve Tank Overflow Hose

8. Air Cleaner Drain Hose

9. Cross Pipe

10. Damper

11. Radiator Cover

12. Face the white mark upward and to the
radiator.

13. Face the head of the clamp screw up­ward.

14. Place the clamp tab as shown.

15. Run the hose above the engine.

16. Face the head of the clamp screw as
shown.

17. Clamp

18. About 20°

19. Run the hose inside of the frame.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-27

1. Reserve Tank

2. Reserve Tank Overflow Hose

3. Clamps

1-28 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Starter Motor

2. Positive Lead

3. Negative Lead

4. Plate

5. Pickup Coil

6. Pickup Coil Mounting Bolts

7. Tighten the starter motor negative lead terminal with the rear starter mounting bolt.

8. To the battery negative terminal.

9. To the starter relay.

10. Hold the lead with the plate.

11. Bend and run the lead as shown so it does not touch the alternator rotor.

Cable, Wire, and Hose Routing

GENERAL INFORMATION 1-29

1. #1 Ignition Coil Connectors

2. Radiator Fan Switch Connector

3. Left Handlebar Switch Connectors

4. Water Temperature Switch Ground Termi­nal

5. Water Temperature Switch

6. Battery Negative Lead

7. Igniter Connectors

8. #2 Ignition Coil Connectors

9. Radiator Fan Connector

10. White Tape (position here)

11. Right Handlebar Switch Connectors

12. Battery Positive Lead

13. Ground Terminal

14. Fuse Box Lead

15. Fit the bands into gusset.

16. Bands

1-30 GENERAL INFORMATION

Cable, Wire, and Hose Routing

1. Fuel Tank

2. Fuel Tank Upper Drain Hose

3. Catch Tank

4. Reserve Tank Hose

5. Main Harness

6. Fuel Tank Lower Drain Hose

7. Plug

8. Reserve Tank Overflow Hose

9. Air Cleaner Drain Hose

10. Bind the edge of the hose bend

11. About 70 mm

12. Frame Corner

13. Clips

14. Band

15. Bolt

16. Holder

17. Bolt (Bind [4],[5],[6])

FUEL SYSTEM 2-1

Fuel System

Table of Contents

Exploded View........................................................................................................................ 2-2

Specifications ......................................................................................................................... 2-4

Throttle Grip and Cables ........................................................................................................ 2-5

Throttle Cable Inspection .................................................................................................. 2-5

Throttle Cable Lubrication................................................................................................. 2-6

Choke Cable........................................................................................................................... 2-7

Free Play Inspection ......................................................................................................... 2-7

Free Play Adjustment........................................................................................................ 2-7

Cable Installation .............................................................................................................. 2-7

Cable Lubrication.............................................................................................................. 2-7

Carburetors............................................................................................................................. 2-8

Idle Speed Inspection ....................................................................................................... 2-8

Carburetor Synchronization Inspection............................................................................. 2-8

Carburetor Removal.......................................................................................................... 2-9

Carburetor Installation....................................................................................................... 2-9

Service Fuel Level Inspection........................................................................................... 2-10

Service Fuel Level Adjustment ......................................................................................... 2-11

Fuel System Cleanliness Inspection ................................................................................. 2-12

Carburetor Disassembly/Assembly................................................................................... 2-12

Carburetor Separation/Assembly...................................................................................... 2-14

Carburetor Cleaning.......................................................................................................... 2-14

Carburetor Inspection ....................................................................................................... 2-15

Coolant Filter Cleaning ..................................................................................................... 2-16

Coolant Valve Inspection .................................................................................................. 2-16

Air Cleaner.............................................................................................................................. 2-17

Element Removal.............................................................................................................. 2-17

Element Cleaning and Inspection ..................................................................................... 2-17

Housing Removal.............................................................................................................. 2-17

Air Cleaner Draining ......................................................................................................... 2-18

Fuel Tank ................................................................................................................................ 2-19

Fuel Tank Removal ........................................................................................................... 2-19

Fuel Tank Installation ........................................................................................................ 2-20

Fuel Tap Removal ............................................................................................................. 2-20

Fuel Tap Installation .......................................................................................................... 2-20

Fuel Tank and Tap Cleaning ............................................................................................. 2-21

Fuel Tap Inspection........................................................................................................... 2-21

Fuel Tank and Cap Inspection .......................................................................................... 2-21

Fuel Hose ............................................................................................................................... 2-22

Fuel Hose and Connection Inspection.............................................................................. 2-22

2

2-2 FUEL SYSTEM

Exploded View

1. Throttle Cable (accelerator)

2. Throttle Cable (decelerator)

3. Choke Cable

4. Pilot Screw

5. Pilot (Slow) Jet

6. Needle Jet

7. Needle Jet Holder

8. Main Jet

9. Jet Needle

CL: Apply cable lubricant.

G: Apply grease.

Exploded View

FUEL SYSTEM 2-3

1. Vacuum Switch Valve

2. Air Cleaner Housing

3. Air Cleaner Element

T1: 0.8 N·m (0.08 kgf·m, 7 in·lb)
T2: 1.0 N·m (0.10 kgf·m, 9 in·lb)
T3: 6.9 N·m (0.7 kgf·m, 61 in·lb)
T4: 2.5 N·m (0.25 kgf·m, 22 in·lb)

2-4 FUEL SYSTEM

Specifications

Item Standard

Throttle Grip Free Play 2 ∼ 3mm(0.08∼ 0.12 in.)
Choke Cable Free Play 2 ∼ 3mm(0.08∼ 0.12 in.)

Carburetors

Mark, Type KEIHIN CVK34

Idle Speed 1 200 ±50 r/min (rpm)

Pilot Screw (Turns Out) (1 1/4 ±1/4 for reference)

Synchronization Vacuum

Service Fuel Level 0.5 mm (0.02 in.) below ∼ 1.5 mm (0.06 in.) above the float

Float Height

Main Jet #102

Main Air Jet #100

Needle Jet –

Needle Jet Holder –

Jet Needle Mark N4BE, (ER500D) N96R

Pilot Jet (Slow Jet) #35

Pilot Air Jet (Slow Air Jet) #130

Starter Jet #55

Throttle Valve Angle 11°

2.7 kPa (2 cmHg) or less difference between two
carburetors

bowl mating surface

17 ±2 mm (0.67 ±0.08 in.)

Special Tools - Pilot Screw Adjuster, C: 57001-1292

Pilot Screw Adjuster Adapter,
Pilot Screw Adjuster Driver: 57001-1373
Carburetor Drain Plug Wrench, Hex 3: 57001-1269
Fuel Level Gauge: 57001-1017

5: 57001-1372

Pilot Screw [A]
Pilot Jet [B]
Jet Needle [C]
Needle Jet [D]
Pilot Air Jet [E]
Main Air Jet [F]
Valve Seat [G]
Float Valve [H]
Needle Jet Holder [I]
Main Jet [J]

Throttle Grip and Cables

Throttle Cable Inspection

Throttle Grip Free Play Inspection

Check throttle grip play [A] by lightly turning the throttle

•

grip back and forth.
If the free play is improper, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Check that the throttle grip 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 grip does not return properly, check the throt­tle cable routing, grip 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 increase, check the throttle cable free
play and the cable routing.

FUEL SYSTEM 2-5

Throttle Grip Free Play Adjustment

If the free play is incorrect, loosen the locknut [A] and turn
the adjuster [B] of the accelerator cable until the proper
amount of throttle grip play is obtained.
Tighten the locknut against the adjuster securely.

•

Check that the throttle pulley [A] stops against the idle

•

adjusting screw [B] with the throttle grip closed.

If the play can not be adjusted by using the adjuster at the
throttle grip, use the adjusting nuts [A] at the carburetors.
Screw in the adjuster fully at the throttle grip and tighten

•

the locknut.
Remove the fuel tank (see this chapter).

•

Make the necessary free play adjustment at the lower ca-

○

ble end.

2-6 FUEL SYSTEM

Throttle Grip and Cables

Check that the throttle pulley [A] stops against the idle

•

adjusting screw [B], w ith the throttle grip released and
stops against the carburetor stopper with the throttle grip
opened.
Turn the handlebar from side to side while idling the en-

•

gine.
If idle speed varies, the cable may be poorly routed or
damaged.

WARNING

Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.

Throttle Cable Inspection

Remove both ends of the throttle cables.

•

With the throttle cable disconnected at both ends, the ca-

•

ble 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.

Throttle Cable Lubrication

Whenever the throttle cables are removed, lubricate the

throttle cables as follows:

Apply a thin coating of grease to the throttle cable lower

•

ends [A].

Lubricate the throttle cable with a penetrating rust in-

•

hibitor.

Choke Cable

Free Play Inspection

Push the choke lever [A] all the way to the front.

•

Check choke cable free play [B].

•

Determine the amount of choke cable play at the choke

○

lever. Pull the choke lever until the starter plunger lever
[C] at the carburetor touches the starter plunger [D]; the
amount of choke lever lower end travel is the amount of
choke cable play.
If the free play is incorrect, adjust the choke cable.

Choke Cable Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

FUEL SYSTEM 2-7

Free Play Adjustment

Loosen the locknut [A], and turn the adjuster [B] until the

•

cable has the proper amount of free play.
Tighten the locknut securely.

•

Cable Installation

Install the choke cable in accordance with Cable Routing

•

section in General Information chapter.
After installation, adjust the cable free play properly.

•

WARNING

Operation with an incorrectly routed or improperly
adjusted cable could result in an unsafe riding con­dition.

Cable Lubrication

Whenever the choke cable is removed, lubricate the

choke cable as follows:

Apply a thin coating of grease to the cable upper end.

•

Lubricate the cable with a penetrating rust inhibitor.

•

Check that the choke inner cable slides smoothly by mov-

•

ing the choke lever to the front and rear.
If there is any irregularity, check the choke cable and rout­ing.

2-8 FUEL SYSTEM

Carburetors

Idle Speed Inspection

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides.

•

If handlebar movement changes the idle speed, the throt­tle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding.

WARNING

Operation with improperly adjusted, incorrectly
routed, or damaged cables could result in an un­safe riding condition.

Check idle speed.

•

If the idle speed is out of the specified range, adjust it.

Idle Speed

1300±50r/min(rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

Turn the adjusting screw [A] until idle speed is correct.

•

Open and close the throttle a few times to make sure that

○

the idle speed is within the specified range. Readjust if
necessary.

Carburetor Synchronization Inspection

Synchronization Inspection

Situate the motorcycle so that it is perpendicular to the

•

ground.
Warm up the engine.

•

Check idle speed and adjust if necessary.

•

Pull the vacuum hoses off, and attach vacuum gauge [A]

•

to the vacuum hose fittings on the carburetors.

Synchronization Adjustment

The pilot screw is set at the factory and should not be

○

removed. But if necessary, check the pilot screw opening
as follows.
Turn in the pilot screw and count the number of turns until

•

it seats fully but not tightly, and then remove the screw.
This is to set the screw to its original (correct) position
when assembling.

Special Tool - Pilot Screw Adjuster, C [A]: 57001-1292

NOTE

Each carburetor has different opening of the pilot screw.

○

When setting the pilot screw, do not refer to the specifi­cations which show mean opening of the pilot screws.

Carburetors

Carburetor Removal

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.

Remove:

•

Fuel Tank (see this chapter)
Throttle Cable Lower Ends
Choke Cable Lower End
Battery Cover [A]
Fuel Tank Bracket [B]
Vacuum Switch Valve Hose
Air Cleaner Element

FUEL SYSTEM 2-9

Loosen:

•

Carburetor Clamp Screws [A]
Air Cleaner Housing Clamp Screws [B]

Move back the air cleaner housing [A] and the carburetor

•

[B], and remove the carburetor.

Carburetor Installation

Installation is the reverse of removal.

•

Install the carburetor holders with the projection [A] facing

•

upwards.

2-10 FUEL SYSTEM

Carburetors

Install the holder clamps [A] as shown being careful of the

•

screw position and the screw head [B] direction.

WARNING

Install the clamp screws horizontally as shown.
Otherwise the screws could come in contact with
the vacuum adjusting screws, resulting in an un­safe riding condition.

[C] Top
[D] Bottom

Check fuel leakage from the carburetors.

•

WARNING

Fuel spilled from the carburetors is hazardous.

Adjust the following items if necessary.

•

Idle Speed
Vacuum Synchronization
Throttle Cables

Service Fuel Level 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

Situate the motorcycle so that it is perpendicular to the

•

ground.
Connect a suitable rubber hose (5 mm inside diameter

•

and about 300 mm long) to the fitting at the bottom of
each carburetor float bowl.

Carburetors

Connect fuel level gauge [A] to the rubber hose.

•

Special Tool - Fuel Level Gauge: 57001-1017

Hold the gauge vertically against the side of the carburetor

•

body so that the "middle" line [B] is several millimeters
higher than the bottom edge [D] of the carburetor body.
Turn the fuel tap to the PRI position to feed fuel to the

•

carburetor, then turn out the carburetor drain plug [C] a
few turns.
Wait until the fuel level [E] in the gauge settles.

•

Keeping the gauge vertical, slowly lower the gauge until

•

the "middle" line is even with the bottom edge of the car­buretor body.

NOTE

Do not lower the "middle" line below the bottom edge of

○

the carburetor body. If the gauge is lowered and then
raised again, the fuel level measured shows somewhat
higher than the actual fuel level. If the gauge is lowered
too far, dump the fuel out of it into a suitable container
and start the procedure over again.

FUEL SYSTEM 2-11

Read the fuel level in the gauge and compare it to the

•

specification.
Screw in the carburetor drain plug.

•

Fuel Level

1.5 mm (0.06 in.) above ∼ 0.5 mm (0.02 in.) below the

bottom edge of carburetor body

Turn the fuel tap to the ON position and remove the fuel

•

level gauge.
Inspect the fuel level in another carburetor in the same

•

manner.
If the fuel level is incorrect, adjust it (see Service Fuel
Level Adjustment).

Service Fuel Level Adjustment

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.

Remove the carburetor, and drain the fuel into a suitable

•

container.
Remove the float bowl by taking out the screws with lock-

•

washers.
Slide out the pivot pin [A] and remove the float [B].

•

2-12 FUEL SYSTEM

Carburetors

Bend the tang [A] on the float arm very slightly to change

•

the float height. Increasing the float height lowers the fuel
level and decreasing the float height raises the fuel level.

Float Height

17.0 ±2.0 mm (0.6 7 ±0.08 in.)

NOTE

Do not push the needle rod [A] in during the float height

○

measurement [B].

Assemble the carburetor, and recheck the fuel level.

•

If the fuel level cannot be adjusted by this method, the
float or the float valve [C] is damaged.

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

Connect a suitable hose [A] to the fitting at the bottom of

•

each carburetor float bowl.
Run the lower ends of the hoses into a suitable container.

•

Turn the fuel tap to the PRI position.

•

Turn out each drain plug [B] a few turns and drain the fuel

•

from the float bowls.
Check to see if water or dirt comes out.

•

If any water or dirt appears during the above inspection,
clean the fuel system (see Carburetor Cleaning and Fuel
Tank Cleaning).
Tighten the drain plugs and turn the fuel tap to the ON

•

position.

Carburetor Disassembly/Assembly

Read the WARNINGS in the Carburetor Removal.

•

Check the throttle bores at the butterfly valves and around

•

them for carbon deposits by opening the valves.
Punch a hole in the plug and pry it out with an awl or other

○

suitable tool

Carburetors

Turn in the pilot screw and count the number of turns until

•

it seats fully but not tightly, and then remove the screw.
This is to set the screw to its original position when as­sembling.
After installing the upper chamber cover, check that the

•

vacuum piston slides up and down smoothly without bind­ing in the carburetor bore.

CAUTION

During carburetor disassembly, be careful not to
damage the diaphragm. Never use a sharp edge to
remove the diaphragm.

Turn in the pilot screw [A] fully but not tightly, and then

•

back it out the same number of turns counted during dis­assembly.

FUEL SYSTEM 2-13

Turn the carburetor body upside-down, and drop the nee-

•

dle jet [A] into place so that the smaller diameter end [B]
of the jet goes in first.

Carefully screw in the needle jet holder. It will seat against

•

the needle jet, pushing the end of the jet into the carbu­retor bore.

CAUTION

Do not force the needle jet holder [A] and main jet
[B] or overtighten them. The needle jet or the car­buretor body could be damaged requiring replace­ment.

2-14 FUEL SYSTEM

Carburetors

Slip the jet needle through the hole in the center of the

•

vacuum piston, and put the spring seat [A] on the top of
the needle. Turn the seat so that it does not block the hole
[B] at the bottom of the vacuum piston.

Carburetor Separation/Assembly

Read the WARNINGS in the Carburetor Removal.

•

The center lines of the carburetor bores must be parallel

•

both horizontally and vertically. If they are not, loosen
the mounting screws and align the carburetors on a flat
surface. Retighten the mounting screws.
After assembling the choke mechanism, check to see that

•

the starter plunger lever slides from side to side smoothly
without abnormal friction.

CAUTION

Fuel mixture trouble could result if the starter
plunger does not seat properly in its rest position
after the choke lever is returned.

Visually synchronize the throttle (butterfly) valves.

•

Check to see that the throttle valves open and close

○

smoothly without binding when turning the pulley.
Visually check the clearance [A] between the throttle

○

valve and the carburetor bore in each carburetor.
If there is a difference between the throttle valves, turn the
balance adjusting screw [B] to obtain the same clearance.
Do not remove the atmospheric pressure hose.

Carburetor Cleaning

WARNING

Clean the carburetors in a well-ventilated area, and
take care that there is no spark 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 low flash

-point solvents to clean the carburetors.

Carburetors

CAUTION

Do not use compressed air on an assembled car­buretor, or the floats may be crushed by the pres­sure, and the vacuum piston diaphragms may be
damaged. Remove as many rubber or plastic parts
from the carburetor as possible before cleaning the
carburetor with a cleaning solution. This will pre­vent damage to or deterioration of the parts. The
carburetor body has plastic parts that cannot be re­moved. Do not use a strong carburetor cleaning so­lution which could attack these parts; instead, use
a mild, high flash-point cleaning solution safe for
plastic parts. Do not use wire or any other hard in­strument to clean carburetor parts, especially jets,
as they may be damaged.

Disassemble the carburetors.

•

Immerse all the metal parts in a carburetor cleaning solu-

•

tion.
Rinse the parts in water.

•

When the parts are clean, dry them with compressed air.

•

Blow through the air and fuel passages with compressed

•

air.
Assemble the carburetors.

•

FUEL SYSTEM 2-15

Carburetor 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.

Remove the carburetors.

•

Before disassembling the carburetors, check the fuel level

•

(see Fuel Level Inspection).

If the fuel level is incorrect, inspect the rest of the carbu­retor before correcting it.
Move the starter plunger lever from side to side to check

•

that the starter plungers move smoothly without abnormal
friction.
If the starter plungers do not work properly, replace the
carburetors.
Turn the throttle cable bracket to check that the throttle

•

butterfly valves [A] move smoothly and return with spring
tension.
If the throttle valves do not move smoothly, replace the
carburetors.

2-16 FUEL SYSTEM

Carburetors

Disassemble the carburetors.

•

Clean the carburetors.

•

Check that the O-rings on the float bowl and drain plug

•

and the diaphragm on the vacuum piston are in good con­dition.
If any of the O-rings or diaphragms are not in good con­dition, replace them.
Check the plastic tip [A] of the float valve needle [B]. It

•

should be smooth, without any grooves, scratches, or
tears.
If the plastic tip is damaged [C], replace the needle.
Push in the rod [D] in the other end of the float valve nee-

•

dle.
If it does not spring out, replace the needle.

[E] Push and release

Coolant Filter Cleaning

Before winter season starts, clean the coolant filter [A] in

○

the carburetor system.
Drain the coolant (see Cooling System chapter).

•

Remove the coolant filter from the cooling hoses in the

•

carburetor system.
Blow dirt and sediment off the filter with compressed air.

•

Coolant Valve Inspection

Drain the coolant (see Cooling System chapter).

•

Remove the coolant valve on the engine right side.

•

Inspect the coolant valve [A] at room temperature.

•

If the valve is closed, replace the valve with a new one.
To check valve opening, just blow through the valve.

○

Valve Closing Temperature (for reference)

Standard: 70°C (158°F) or more at 25 kPa (0.25

kgf/cm², 3.6 psi)

Air Cleaner

Element Removal

Remove:

•

Left Side Cover (see Frame chapter)
Screws [A]
Nut [B]
Inlet Pipe [C]

Remove the element [A].

•

Push a clean, lint-free towel into the carburetor intake to

•

keep dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident.

FUEL SYSTEM 2-17

CAUTION

If dirt gets through into the engine, excessive en­gine wear and possibly engine damage will occur.

Element Cleaning and Inspection

NOTE

In dusty areas, the element should be cleaned more

○

frequently than the recommended interval.
After riding through rain or on muddy roads, the element

○

should be cleaned immediately.

Remove the air cleaner element (see Element Removal).

•

Clean the element tapping it lightly to loosen dust.

•

Blow away the remaining dust by applying compressed

•

air [A] from the outside to the inside (from the clean side
to the dirty side).
Visually check the element for tears or breaks and check

•

the sponge gasket [B] also.
If the element or gasket has any tears or breaks, replace
the element.

Housing Removal

Remove:

•

Air Cleaner Element (see this chapter)

Remove the air cleaner housing [A].

•

2-18 FUEL SYSTEM

Air Cleaner

Air Cleaner Draining

A drain hose [A] is provided beneath the air cleaner hos­ing, and catches the water or oil from the bottom of the hose.
Usually water or oil does not collect at the bottom of the
hose. In the event that rain water is drawn in through the
air cleaner, or if engine oil is blown back, drain the housing.

Check the drain hose.

•

If any water or oil accumulates in the hose, drain it by

taking off the drain plug [B] at the lower end of the drain

hose.

Be sure to install the plug firmly, or the air will be drawn

•

in through it.

WARNING

Be sure to install the plug in the drain hose after

draining. Oil could drain from the open hose and

get on the tires which could cause an accident and

injury.

Fuel Tank

Fuel Tank Removal

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.

Remove the seat (see Frame chapter).

•

Remove the screws [A] and the side covers [B] on both

•

sides.

FUEL SYSTEM 2-19

Turn the fuel tap to the On or RES position.

•

Pull the hoses off the tap.

•

Remove the fuel tank bolt [A].

•

Remove the fuel tap bolts.

•

Pull the fuel tap outlet hose [A] and vacuum hose [B] off

•

the tap.

Disconnect the fuel level sensor lead connector [A].

•

Pull the overflow drain hose [B] off the fuel level sensor

•

assembly.
Pull the upper drain hose off the fuel tank.

•

2-20 FUEL SYSTEM

Fuel Tank

Remove the fuel tank [A].

•

Drain the fuel tank.

•

Place a suitable container under the fuel tank.

○

Turn the fuel tap to the PRI position to drain the fuel into

○

the container.

Fuel Tank Installation

Read the WARNING in the Fuel Tank Removal s ection.

•

Check the rubber dampers [A].

•

If the dampers are damaged or deteriorated, replace

them.

Route the hoses correctly (see General Information chap-

•

ter).

Be sure the hoses are clamped to the fuel tap to prevent

•

leakage.

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; this includes any appliance with a pilot

light.

Remove the fuel hose and drain the fuel into a suitable

○

container.

Remove the bolts [A] and take out the fuel tap [B].

•

Fuel Tap Installation

Fuel tap installation is the reverse of removal. Note the

•

following.

Torque - Fuel Tap Mounting Bolts: 2.5 N·m (0.25 kgf·m, 22

in·lb)

Be sure to clamp the fuel hose to the tap to prevent leaks.

•

Fuel Tank

Fuel Tank and Tap Cleaning

Remove the fuel tank and drain it.

•

Pour some high flash-point solvent into the fuel tank and

•

shake the tank to remove dirt and fuel deposits.

WARNING

Clean the tank 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 low flash

-point solvents to clean the tank.

Pour the solvent out of the tank.

•

Remove the fuel tap from the tank by taking out the bolts

•

with nylon washers.
Clean the fuel tap filter screens in a high flash-point sol-

•

vent.
Pour high flash-point solvent through the tap in all lever

•

position.
Dry the tank and tap with compressed air.

•

Install the tap in the tank.

•

Install the fuel tank.

•

FUEL SYSTEM 2-21

Fuel Tap Inspection

Remove the fuel tap.

•

Check the fuel tap filter screens [A] for any breaks or de-

•

terioration.
If the fuel tap screens have any breaks or are deterio­rated, they may allow dirt to reach the carburetor, causing
poor running. Replace the fuel tap.
If the fuel tap leaks, or allows fuel to flow when it is at
ON or RES without engine running, replace the damaged
gasket [B] or O-ring [C].

Fuel Tank and Cap Inspection

Open the tank cap.

•

Visually inspect the gaskets [A] on the tank cap for any

•

damage.
Replace the gaskets if they are damaged.
Remove the drain pipes and check to see if the pipes in

•

the tank do not clogged up. Check the tank cap breather
also.
If they are clogged, remove the tank and drain it, and then
blow the breather free with compressed air.

CAUTION

Do not apply compressed air to the air vent holes
[B] in the tank cap. This could cause damage and
clogging of the labyrinth in the cap.

2-22 FUEL SYSTEM

Fuel Hose

Fuel Hose and Connection Inspection

Check the fuel hose periodically in accordance with the

○

Periodic Maintenance Chart, and if the motorcycle is not

properly handled, the inside the fuel line can cause fuel

to leak [A] or the hose to burst. Remove the fuel tank and

check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

Check that the hoses are securely connected and clamps

•

are tightened correctly.

When installing, route the hoses according to Cable,

•

Wire, and Hose Routing section in the Appendix chapter.

When installing the fuel hoses, avoid sharp bending, kink-

•

ing, flattening or twisting, and route the fuel hoses with a

minimum of bending so that the fuel flow will not be ob-

structed.

Replace the hose if it has been sharply bent or kinked.

COOLING SYSTEM 3-1

Cooling System

Table of Contents

Exploded View........................................................................................................................ 3-2

Specifications ......................................................................................................................... 3-3

Coolant Flow Chart................................................................................................................. 3-4

Coolant ................................................................................................................................... 3-5

Coolant Deterioration Inspection....................................................................................... 3-5

Coolant Level Inspection................................................................................................... 3-5

Coolant Draining ............................................................................................................... 3-5

Coolant Filling ................................................................................................................... 3-6

Visual Leak Inspection ...................................................................................................... 3-7

Cooling System Pressure Testing ..................................................................................... 3-7

Flushing ............................................................................................................................ 3-8

Coolant Filter Cleaning ..................................................................................................... 3-8

Water Pump............................................................................................................................ 3-9

Water Pump Removal....................................................................................................... 3-9

Water Pump Installation.................................................................................................... 3-9

Mechanical Seal Inspection .............................................................................................. 3-10

Water Pump Housing Disassembly .................................................................................. 3-10

Water Pump Housing Assembly ....................................................................................... 3-10

Impeller Assembly............................................................................................................. 3-11

Pump Impeller Inspection ................................................................................................. 3-11

Radiator, Radiator Fan ........................................................................................................... 3-12

Radiator Removal ............................................................................................................. 3-12

Radiator Inspection........................................................................................................... 3-12

Filler Neck Inspection........................................................................................................ 3-13

Radiator Cap Inspection ................................................................................................... 3-13

Radiator Hose and Connection Inspection ....................................................................... 3-14

Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installation ............................ 3-14

Thermostat ............................................................................................................................. 3-15

Thermostat Removal......................................................................................................... 3-15

Thermostat Installation...................................................................................................... 3-15

Thermostat Inspection ...................................................................................................... 3-15

Radiator Fan Switch, Water Temperature Switch................................................................... 3-16

Radiator Fan Switch Removal .......................................................................................... 3-16

Water Temperature Switch Removal ................................................................................ 3-16

Radiator Fan Switch, Water Temperature Switch Installation ........................................... 3-16

Radiator Fan Switch, Water Temperature Switch Inspection ............................................ 3-16

3

3-2 COOLING SYSTEM

Exploded View

1. Radiator Fan Switch

2. Water Temperature Switch

3. Thermostat

4. Coolant Drain Plug
T1: 2.5 N·m (0.25 kgf·m, 22 in·lb)
T2: 7.8 N·m (0.8 kgf·m, 69 in·lb)
T3: 11 N·m (1.1 kgf·m, 95 in·lb)
T4: 9.8 N·m (1.0 kgf·m, 7.0 ft·lb)
T5: 18 N·m (1.8 kgf·m, 13.0 ft·lb)
T6: 25 N·m (2.5 kgf·m, 18.0 ft·lb)

G: Apply high temperature grease.

L: Apply a non-permanent locking agent.

Lh: Left-hand Threads

SS: Apply silicone sealant.

COOLING SYSTEM 3-3

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 A mount

Radiator Cap

Relief Pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18 psi)

Thermostat

Valve Opening Temperature 80.5 ∼ 83.5°C (177 ∼ 182°F)

Valve Full Opening Lift 8 mm (0.31 in.) or more @95°C (203°F)

Special Tool - Bearing Driver Set: 57001-1129

1.7L(1.8USqt)

(reserve tank full level including radiator and engine)

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

3-4 COOLING SYSTEM

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.

When the engine starts, the water pump turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The

thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.

When coolant temperature is below 80.5 ∼ 83.5°C (177 ∼ 182°F), the thermostat closes so that the

coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.

When coolant temperature is more than 80.5 ∼ 83.5°C, the thermostat opens and the coolant flows.

When the coolant temperature goes up beyond 93 ∼ 103°C (199 ∼ 217°F), the radiator fan switch

conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there
is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator.

When the temperature is below 91°C (196°F) ∼ temperature less than ON temperature, the fan switch

opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine op-

erates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles

which can cause engine overheating. As the engine warms up, the coolant in the radiator and the
water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank
to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and
the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system

when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18

psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure

escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18 psi).

When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant
cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the
coolant from the reserve tank to enter the radiator.

1. Water Pump (driven by balancer shaft)

2. Cylinder Jacket

3. Cylinder Head Jacket

4. Water Temperature Switch

5. Air Bleeder Hole

6. Thermostat

7. Reserve Tank

8. Radiator Cap

9. Radiator

10. Radiator Fan

11. Radiator Fan Switch

Coolant

Coolant Deterioration Inspe ction

Visually inspect the coolant in the reservoir tank.

•

If whitish cotton-like wafts are observed, aluminum parts

○

in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case flush
thecoolingsystem.
If the coolant gives off an abnormal smell, check for a

○

cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.

Coolant Level Inspection

Situate the motorcycle so that it is perpendicular to the

•

ground.
Check the level through the coolant level gauge on the

•

reservoir tank. The coolant level should be between the
"F" (Full) [A] and the "L" (Low) [B] level lines.

NOTE

Check the level when the engine is cold (room or ambi-

○

ent temperature).

COOLING SYSTEM 3-5

If the coolant level is lower than the "L" (Low) level line,
add coolant to the "F" (Full) level line.

CAUTION

For refilling, add the specified mixture of coolant
and soft water. Adding water alone dilutes the
coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum en­gine parts. In an emergency, soft w ater alone can
be added. But the diluted coolant must be returned
to the correct mixture ratio within a few days. If
coolant must be added often, or the reservoir tank
has run completely dry, there is probably leakage
in the cooling system. Check the system for leaks
(see Visual Leak Inspection, and Cooling System
Pressure Testing).

Coolant Draining

The coolant should be changed periodically to ensure

long engine life.

CAUTION

Use coolant containing corrosion inhibitors made
specifically for aluminum engines and radiators in
accordance with the instructions of the manufactur­ers (see Coolant Filling).

3-6 COOLING SYSTEM

Coolant

Coolant Filling

Install the drain plug [A]. Always replace the gasket with

•

a new one, if it is damaged.
Tighten the drain plug.

•

Torque - Coolant Drain Plug: 11 N·m (1.1 kgf·m, 95 in·lb)

Fill [A] the radiator up to the bottom of the radiator filler

•

neck [B] with coolant [C], and install the cap turning it
clockwise about 1/4 turn.

NOTE

Pour in the coolant slowly so that it can expel the air

○

from the engine and radiator.
The radiator cap must be installed in two steps. First

○

turn the cap clockwise to the first stop. Then push down
on it and turn it the rest of the way.

CAUTION

Soft or distilled water must be used with the an­tifreeze (see Specifications in this chapter) in the
cooling system.
If hard water is used in the system, it causes scales
accumulation in the water passages, and consider­ably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water 50%

Coolant 50%

Freezing Point –35°C (–31°F)

Total Amount 1.7 L (1.8 US qt)

NOTE

Choose a suitable mixture ratio by referring to the

○

coolant manufacturer’s directions.

Remove the fuel tank (see Fuel System chapter).

•

Bleed the air from the cooling system while the engine is

•

running.
Start the engine with the radiator cap removed and run it

○

until no more air bubbles [A] can be seen in the coolant.
Tap the radiator hoses to force any air bubbles caught

○

inside.
Stop the engine and add coolant up to the radiator filler

○

neck.
Install the radiator cap.

•

Coolant

Remove the reserve tank cap.

•

Fill the reserve tank up to the F level [A] with coolant and

•

install the cap.

CAUTION

Do not add more coolant above the F level.

Install the fuel tank.

•

Install the seat.

•

Visual Leak Inspection

Any time the system slowly loses water, inspect for leaks.
Check the water pump body drainage outlet passage [A]

•

for coolant leaks.
If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage. Re­place the mechanical seal.
If there are no apparent leaks, pressure test the system.

COOLING SYSTEM 3-7

Cooling System Pressure Testing

CAUTION

During pressure testing, do not exceed the pres­sure for which the system is designed. The maxi­mum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

Remove the fuel tank (see the Fuel System chapter).

•

Remove the radiator cap, and install a cooling system

•

pressure tester [A] on the radiator filler neck.

NOTE

Wet the cap sealing surfaces with water or coolant to

○

prevent pressure leaks.

Builduppressureinthesystemcarefullyuntilthepres-

•

sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
Watch the gauge for at least 6 seconds. If the pressure

•

holds steady, the system is all right.
If the pressure drops and no external source is found,
check for internal leaks. Droplets in the engine oil indicate
internal leakage. Check the cylinder head gasket and the
cylinder liner O-rings.
Remove the pressure tester, replenish the coolant, and

•

install the radiator cap.

3-8 COOLING SYSTEM

Coolant

Flushing

Over a period of time, the cooling system accumulates

rust, scale, and lime in the water jacket and radiator. When
this accumulation is suspected or observed, flush the cool­ing system. If this accumulation is not removed, it will clog
up the water passages and considerably reduce the effi­ciency of the cooling system.

Drain the cooling system.

•

Fill the cooling system with fresh water mixed with a flush-

•

ing compound.

CAUTION

Avoid the use of a flushing compound which is
harmful to the aluminum engine and radiator.
Carefully follow the instructions supplied by the
manufacturer of the cleaning product.

Warm up the engine, and run it at normal operating tem-

•

perature for about ten minutes.
Stop the engine, and drain the cooling system.

•

Fill the system with fresh water.

•

Warm up the engine and drain the system.

•

Repeat the previous two steps once more.

•

Fill the system with a permanent type coolant and bleed

•

the air from the system (see Coolant Filling).

Coolant Filter Cleaning

Refer to the section of c arburetor in Fuel System chapter

•

for the cleaning procedures.

Water Pump

Water Pump R emoval

Drain the coolant.

•

Loosen the clamp and remove the radiator hose [A] from

•

the water pump cover [B].
Remove the four cover bolts [C].

•

With the water pipe [D] attached, remove the water pump

•

cover.

Install the right footpeg assembly.

•

NOTE

The impeller and water pump shaft have a left-handed

○

thread, therefore they must be turned clockwise [A] to
remove.

Shift the transmission into 1st gear.

•

While applying the rear brake, remove the impeller [B].

•

COOLING SYSTEM 3-9

Pull the water pump housing [A] and gasket out of the

•

right crankcase.
Turn the water pump shaft [B] clockwise, and remove it.

•

Water Pump Installation

When installing the water pump shaft or impeller, shift the

•

transmission into 1st gear and apply the rear brake.
Apply silicone sealant to the area [A] where the mating

•

surface of the crankcase contacts the water pump hous­ing gasket.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Apply high temperature grease to the lips of the water

•

pump housing oil seal.
Turn the water pump shaft or impeller counterclockwise,

•

and tighten them.

Torque - Water Pump Shaft: 25 N·m (2.5 kgf·m, 18 ft·lb)

Water Pump Impeller: 9.8 N ·m (1.0 kgf·m, 87 in·lb)

3-10 COOLING SYSTEM

Water Pump

Be sure to install the water pipe O-rings [A], and apply

•

high temperature grease to them.
Install the water pump cover with the water pipe, being

•

careful of the two knock pins [B].

Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95

in·lb)

Mechanical Seal Inspection

Visually inspect the mechanical seal.

•

If any one of the parts is damaged, replace the mechani­cal seal as a unit.
The sealing seat and rubber seal may be removed easily

○

by hand.

[A] Impeller Sealing Seat Surface
[B] Rubber Seal
[C] Mechanical Seal Diaphragm

WaterPumpHousingDisassembly

CAUTION

Be careful not to damage the sealing surface of the
mechanical seal.

Take the oil seal [A] out of the housing [B] with a hook [C].

•

Press the mechanical seal [A] out of the housing w ith a

•

bearing driver [B].

Special Tool - Bearing Driver Set: 5 70 0 1-1129

Water Pump Housing Assembly

Apply a high temperature grease [A] to the oil seal [B].

•

Press the oil seal into the housing with a bearing driver

•

until it stops at the bottom surface of the housing [C].
Press the mechanical seal into the housing with a bearing

•

driver [D] until its flange [E] touches the surface [F] of the
housing.

Special Tool - Bearing Driver Set: 5 70 0 1-1129

Water Pump

Impeller Assembly

Clean the sliding surface of the mechanical seal with a

•

high flash-point solvent, and apply a little coolant to the
sliding surface to give the mechanical seal initial lubrica­tion.
Apply coolant to the surfaces of the rubber seal [A] and

•

sealing seat [B], and install the rubber seal and sealing
seat into the impeller by pressing them by hand until the
seat stops at the bottom of the hole.

Pump Impeller Inspection

Visually check the impeller [A].

•

If the surface is corroded, or if the blades are damaged,
replace the impeller.

COOLING SYSTEM 3-11

3-12 COOLING SYSTEM

Radiator, Radiator Fan

WARNING

The radiator fan is connected directly to the bat­tery. The radiator fan may start even if the ignition
switch is off. NEVER TOUCH THE RADIATOR FAN
UNTIL THE RADIATOR FAN CONNECTOR IS DIS­CONNECTED. TOUCHING THE FAN BEFORE THE
CONNECTOR IS DISCONNECTED COULD CAUSE
INJURY FROM THE FAN BLADES.

Radiator Removal

Drain the coolant.

•

Remove:

•

Both Radiator Cover bolts [A] and Radiator Covers [B]

Remove:

•

Radiator Fan Connector [A]
Radiator Fan Switch Connector [B]
Radiator Hoses [C]

Unscrew the radiator mounting bolts [D] and remove the

•

radiator taking care not to damage the radiator core.

CAUTION

Do not touch the radiator core. This could damage
the radiator fins, resulting in loss of cooling effi­ciency.

Radiator Inspection

Check the radiator core.

•

If there are obstructions to air flow, remove them.
If the corrugated fins [A] are deformed, carefully
straighten then with the blade of a thin screw driver.

CAUTION

Do not tear the radiator tubes while straightening
the fins.

If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparable de­formed fins, replace the radiator with a new one.

Radiator, Radiator Fan

CAUTION

When cleaning the radiator with steam cleaner, be
careful of the following to prevent radiator damage.

1) Keep the steam gun [A] away more than 0.5 m (20
in.) [B] from the radiator core.

2) Hold the steam gun perpendicular to the core sur­face.

3) Run the steam gun horizontally following the core fin
direction. Running it vertically may damage the fin.

Filler Neck Inspection

Remove the fuel tank.

•

Check the radiator filler neck for signs of damage.

•

Check the condition of the top [A] and bottom sealing

•

seats [B] in the filler neck. They must be smooth and
clean for the radiator cap to function properly.

COOLING SYSTEM 3-13

Radiator Cap Inspection

Check the condition of the bottom and top valve seals [A],

•

valve spring [B] of the radiator cap.
If any one of them shows v isible damage, replace the cap
with a new one.

Install the cap [A] on a cooling system pressure tester [B].

•

NOTE

Wet the cap sealing surfaces with water or coolant to

○

prevent pressure leaks.

Watching the pressure gauge, slowly pump the pressure

•

tester to build up the pressure. The relief valve must open
within the relief pressure range as shown below. The
gauge hand must remain at least 6 seconds between the
lowest relief pressure and the valve opened pressure.

Radiator Cap Relief Pressure

Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18

psi)

If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.

3-14 COOLING SYSTEM

Radiator, Radiator Fan

Radiator Hose and Connection Inspection

The high pressure inside the radiator hose can cause

○

coolant to leak [A] or the hose to burst if the line is not
properly maintained. Visually inspect the hoses for signs
of deterioration. Squeeze the hoses. A hose should not
be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C]
are noticed.
Check that the hoses are securely connected and clamps

•

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m,

22 in·lb)

Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank
Hose Installation

Install the radiator hoses. Avoid sharp bending, kinking,

•

flattening, or twisting.
Tighten the hose clamps securely.

•

Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m,

22 in·lb)

Route the air vent hose, radiator hoses, pipes and reser-

•

voir tank hose (see General Information chapter).

Thermostat

Thermostat Removal

Remove:

•

Coolant (Draining)
Seat (see Frame chapter)
Fuel Tank (see Fuel System chapter)

Unscrew the thermostat housing bolts [A].

•

Separate the housing from the housing cover [B].

•

Pull out the thermostat [A].

•

COOLING SYSTEM 3-15

Thermostat Installation

Install the thermostat [A] into the thermostat housing so

•

that the thermostat does not touch the water temperature
switch [B] as shown.
Be sure to install the O-ring on the thermostat housing

•

cover.
Fill the radiator with coolant.

•

Thermostat Inspection

Remove the thermostat, and inspect the thermostat valve

•

[A] at room temperature.
If the valve is open, replace the valve with a new one.

To check valve opening temperature, suspend the ther-

•

mostat [A] in a container of water and raise the tempera­ture of the water.

[B] Thermometer
If the measurement is out of the specified range, replace
the thermostat with a new one.

Thermostat Valve Opening Temperature

80 ∼ 84°C (176 ∼ 183°F)

3-16 COOLING SYSTEM

Radiator Fan Switch, Water Temperature Switch

CAUTION

The fan switch or the water temperature switch
should never be allowed to fall on a hard surface.
Such a shock to these parts can damage them.

Radiator Fan Switch Removal

Pull out the cover [A].

•

Disconnect the fan switch connector [B].

•

Remove the radiator fan switch [C].

•

Water Temperature Switch Removal

Drain the coolant.

•

Remove the fuel tank (see Fuel System chapter).

•

Disconnect the lead [A] and remove the water tempera-

•

ture switch [B].

Radiator Fan Switch, Water Temperature Switch Installation

Apply silicone sealant to the threads before mounting the

•

water temperature switch.

Sealant - Kawasaki Bond (Silicone Sealant): 5601 9-1 20

Do not apply silicone sealant to the radiator fan switch on

○

the radiator.
Tighten the water temperature switch and the fan switch.

•

Torque - Water Temperature Switch: 7.8 N·m (0.80 kgf·m,

69 in·lb)

Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13.0 ft·lb)

Radiator Fan Switch, Water Temperature Switch Inspection

Refer to the Electrical System chapter for these inspec-

•

tions.

ENGINE TOP E ND 4-1

Engine Top End

Table of Contents

Exploded View................................... 4-2

Specifications .................................... 4-4

Clean Air System............................... 4-6

Vacuum Switch Valve Removal ... 4-6
Vacuum Switch Valve Installation 4-6

Air Suction Valve Installation........ 4-6

Air Suction Valve Inspection ........ 4-6

Clean Air System Hose

Inspection.................................. 4-7

Vacuum Switch Valve Test ........... 4-7

Cylinder Head Cover ......................... 4-8

Cylinder Head Cover Removal .... 4-8

Cylinder Head Cover Installation . 4-8

Camshaft Chain Tensioner ................ 4-9

Camshaft Chain Tensioner

Removal .................................... 4-9

Camshaft Chain Tensioner

Installation ................................. 4-9

Camshaft, Camshaft Chain ............... 4-10

Camshaft Removal ...................... 4-10

Camshaft Installation ................... 4-10

Camshaft and Sprocket

Assembly................................... 4-11

Camshaft, Camshaft Cap Wear ... 4-12

Camshaft Chain Guide Wear ....... 4-12

Rocker Shaft, Rocker Arm ................. 4-13

Rocker Shaft, Rocker Arm

Removal .................................... 4-13

Rocker Shaft, Rocker Arm

Installation ................................. 4-13

Oil Pipe.............................................. 4-14

Cylinder Head Oil Pipe Removal . 4-14
Cylinder Head Oil Pipe

Installation ................................. 4-14

Main Oil Pipe Removal ................ 4-14

Main Oil Pipe Installation ............. 4-14

Cylinder Head.................................... 4-15

Compression Measurement......... 4-15

Cylinder Head Removal ............... 4-16

Cylinder Head Installation ............ 4-16

Cylinder Head Warp..................... 4-17

Cylinder Head Cleaning ............... 4-17

Valves ................................................ 4-19

Valve Clearance Inspection ......... 4-19

Valve Removal............................. 4-20

Valve Installation .......................... 4-20

Valve Guide Removal .................. 4-21

Valve Guide Installation ............... 4-21

Valve Seat Inspection .................. 4-21

Measuring Valve-to-guide

Clearance (Wobble method) ..... 4-22

Valve Seat Repair ........................ 4-22

Cylinder, Piston.................................. 4-27

Cylinder Removal......................... 4-27

Cylinder Installation...................... 4-27

Piston Removal............................ 4-27

Piston Installation......................... 4-28

Piston Ring, Piston Ring Groove

Wear.......................................... 4-29

Piston Ring End Gap ................... 4-29

Cylinder Inside Diameter.............. 4-29

Piston Diameter ........................... 4-30

Boring, Honing ............................. 4-30

Carburetor Holder.............................. 4-31

Carburetor Holder Installation ...... 4-31

Muffler................................................ 4-32

Muffler Removal........................... 4-32

Muffler Installation........................ 4-32

4

4-2 ENGINE TOP END

Exploded View

1. Closed coil end faces downward.

2. Arrow points to the front (ER500-C1 ∼ C4).

Install the piston so that the circle mark on the top of the piston come to front side of the engine
(ER500-C5).

3. “N” m arked side faces up.

L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
O: Apply engine oil.
R: Replacement Parts

S: Follow the specific tightening sequence.

SS: Apply silicone sealant.

Exploded View

ENGINE TOP E ND 4-3

T1: 13 N·m (1.3 kgf·m, 9.5 ft·lb)
T2: 9.8 N·m (1.0 kgf·m, 87 in·lb)
T3: 11 N·m (1.1 kgf·m, 95 in·lb)
T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb)
T5: 15 N·m (1.5 kgf·m, 11.0 ft·lb)
T6: 20 N·m (2.0 kgf·m, 14.5 ft·lb)
T7: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
T8: 39 N·m (4.0 kgf·m, 29 ft·lb)
T9: 51 N·m (5.2 kgf·m, 38 ft·lb)

T10: 14 N·m (1.4 kgf·m, 10.0 ft·lb)

4-4 ENGINE TOP END

Specifications

Item Standard Service Limit

Clean Air System

Vacuum Switch Valve Closing
Pressure

Camshafts

Cam Height:

Exhaust 35.475 ∼ 35.591 mm (1.3967 ∼ 1.4012 in.) 35.38 mm (1.3929 in.)
Inlet 35.474 ∼ 35.590 mm (1.3966 ∼ 1.4012 in.) 35.37 mm (1.3925 in.)

Camshaft, Camshaft Cap
Clearance

Camshaft Journal Diameter 25.000 ∼ 25.021 mm (0.9843 ∼ 0.9851 in.) 25.08 mm (0.9874 in.)

Camshaft Bearing Inside
Diameter

Camshaft Runout TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.004 in.)

Rocker Arm Inside Diameter 12.500 ∼ 12.518 mm (0.4921 ∼ 0.4928 in.) 12.55 mm (0.4941 in.)
Rocker Shaft Diameter 12.466 ∼ 12.484 mm (0.4908 ∼ 0.4915 in.) 12.44 mm (0.4898 in.)

Cylinder Head

Cylinder Compression (usable range)

Electric Starter 960 ∼ 1 470 kPa (9.8 ∼ 15.0 kgf/cm², 139

Cylinder Head Warp ––– 0.05 mm (0.002 in.)

Valves

Valve Clearance:

Exhaust 0.18 ∼ 0.23 mm (0.0070 ∼ 0.0090 in.) –––
Inlet 0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.) –––

Valve Head Thickness:

Exhaust

Inlet

Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm

Valve Stem Diameter:

Exhaust 5.455 ∼ 5.470 mm (0.2148 ∼ 0.2154 in.) 5.44 mm (0.2142 in.)
Inlet 5.475 ∼ 5.490 mm (0.2156 ∼ 0.2161 in.) 5.46 mm (0.2150 in.)

Valve Guide Inside Diameter:

Exhaust 5.500 ∼ 5.512 mm (0.2165 ∼ 0.2170 in.) 5.58 mm (0.2197 in.)
Inlet 5.500 ∼ 5.512 mm (0.2165 ∼ 0.2170 in.) 5.58 mm (0.2197 in.)

Valve/valve Guide Clearance
(wobble method):

Exhaust 0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.) 0.27 mm (0.0106 in.)
Inlet 0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.) 0.22 mm (0.0087 in.)

Valve Seat Cutting Angle 45°, 32°, 60° –––

Valve Seat Surface:

Width:

Exhaust 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) –––
Inlet 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) –––

Open → Close

57 ∼ 65 kPa (430 ∼ 490 mmHg)

0.030 ∼ 0.071 mm (0.0012 ∼ 0.0028 in.) 0.16 mm (0.006 in.)

24.95 ∼ 24.97 mm (0.9823 ∼ 0.9831 in.) 24.92 mm (0.9811 in.)

∼ 213 psi) @450 r/min (rpm)

0.9 ∼ 1.1 mm (0.0354 ∼ 0.0433 in.) 0.7 mm (0.028 in.)

0.4 ∼ 0.6 mm (0.0157 ∼ 0.0236 in.) 0.25 mm (0.01 in.)

–––

–––

(0.002 in.)

ENGINE TOP END 4-5

Specifications

Item Standard Service Limit

Outside diameter:

Exhaust 24.0 ∼ 24.2 mm (0.945 ∼ 0.953 in.) –––
Inlet 28.3 ∼ 28.5 mm (1.114 ∼ 1.122 in.) –––

Valvespringfreelength:

Inner 36.3 mm (1.429 in.) 35 mm (1.3780 in.)

Outer 40.4 mm (1.591 in.) 39 mm (1.5354 in.)

Cylinder, Piston

Cylinder Inside Diameter 74.000 ∼ 74.012 mm (2.9134 ∼ 2.9139 in.) 74.11 mm (2.9177 in.)

Piston Diameter

Piston/cylinder Clearance 0.043 ∼ 0.070 mm (0.0017 ∼ 0.0028 in.) –––

Oversize Piston and Rings +0.5 mm (0.020 in.) –––

Piston Ring/groove Clearance:

Top 0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.) 0.17 mm (0.0067 in.)
Second 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.) 0.16 mm (0.0063 in.)

Piston Ring Groove Width:

Top 0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) 0.92 mm (0.0362 in.)
Second 1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.) 1.11 mm (0.0437 in.)

Piston Ring Thickness:

Top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.7 mm (0.0276 in.)
Second 0.97 ∼ 0.99 mm (0.0382 ∼ 0.0390 in.) 0.90 mm (0.0354 in.)

Piston Ring End Gap:

Top 0.20 ∼ 0.35 mm (0.0079 ∼ 0.0138 in.) 0.7 mm (0.0276 in.)
Second 0.20 ∼ 0.35 mm (0.0079 ∼ 0.0138 in.) 0.7 mm (0.0276 in.)
Oil 0.2 ∼ 0.7 mm (0.008 ∼ 0.028 in.) 1.0 mm (0.0394 in.)

73.942 ∼ 73.957 mm (2.9111 ∼ 2.9117 in.) 73.79 mm (2.9051 in.)

Special Tools - Piston Ring Pliers: 57001-115

Fork Oil Level Gauge: 57001-1290
Spark Plug Wrench, Hex 18: 57001-1024
Compression Gauge, 20 kgf/cm²: 57001-221
Compression Gauge Adapter, M12 × 1.25: 57001-1183
Valve Spring Compressor Assembly: 57001-241
Valve Spring Compressor Adapter,
Valve Guide Arbor,
Valve Guide Reamer,
Valve Seat Cutter Holder,
Valve Seat Cutter Holder Bar: 57001-1128
Valve Seat Cutter, 45° ­Valve Seat Cutter, 32° ­Valve Seat Cutter, 60° ­Valve Seat Cutter, 45° ­Valve Seat Cutter, 32° ­Valve Seat Cutter, 60° ­Piton Pin Puller Assembly: 57001-910
Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt,

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

5.5: 57001-1021

5.5: 57001-1079

5.5: 57001-1125

30: 57001-1187
30: 57001-1120
30: 57001-1123

24.5: 57001-1113
25: 57001-1118
25: 57001-1328

22: 57001-1202

67 ∼ 79: 57001-1097

4-6 ENGINE TOP END

Clean Air System

Vacuum Switch Valve Removal

Remove:

•

Fuel Tank (see Fuel System chapter)

Remove the clamps [A] and take off the vacuum switch

•

valve [B].

Vacuum Switch Valve Installation

Install the vacuum switch valve so that the air hole [A]

•

faces downwards.

Air Suction Valve Installation

Replace the gasket with a new one.

•

Install the air suction valve [A] so that its wider side [B] of

•

the reed faces the rear [C].

Torque - Air Suction Valve Cap Bolts: 11 N·m (1.1 kgf·m, 95

in·lb)

Air Suction Valve Inspection

The air suction valve is essentially a check valve which
allows fresh air to flow from the air cleaner into the exhaust
port. Any air that has passed the air suction valve is pre­vented from returning to the air cleaner.

Remove the air suction valves.

•

Visually inspect the reeds [A] for cracks, folds, warps,

•

heat damage, or other damage.

If there is any doubt as to the condition of the reed, replace

the air suction valve as an assembly.

Check the reed contact areas [B] of the valve holder for

•

grooves, scratches, any signs of separation from the

holder, or heat damage.

If there is any doubt as to the condition of the reed contact

areas, replace the air suction valve as an assembly.

If any carbon or other foreign particles have accumulated

•

between the reed and the reed contact area, wash the

valve assembly clean with a high flash-point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this

could damage the rubber, requiring replacement of

the suction valve assembly.

Clean Air System

Clean Air System Hose Inspection

Be certain that all the hoses are routed without being flat-

•

tened or kinked, and are connected correctly to the air
cleaner housing, silencer, vacuum switch valve, carbure­tors, and air suction valve covers.
If they are not, correct them. Replace them if they are
damaged.

Vacuum Switch Valve Test

Using the vacuum gauge and a syringe, inspect the vac-

uum switch operation as follows.

Remove a vacuum switch valve.

•

Connect a vacuum gauge [A] and syringe [B] or fork oil

•

level gauge to the vacuum hoses as shown.

Air Flow [C]

Special Tool - Fork Oil Level Gauge: 57001-1290

Gradually raise the vacuum (lower the pressure) applied

•

to the vacuum switch valve, and check the valve opera­tion. When the vacuum is low, the vacuum switch valve
should permit air to flow. When the vacuum raises to the
level shown below, the valve should stop air flow. When
the vacuum is high enough, air cannot flow through the
valve.

Spring [A]
Diaphragm [B]
Valve [C]
Low Vacuum [D]
Secondary Air Flow [E]

ENGINE TOP END 4-7

If the vacuum switch valve does not operate as described,
replace it with a new one.

NOTE

To check air flow through the vacuum switch valve, just

○

blow through the air cleaner hose.

Vacuum Switch Valve Closing Pressure (open → close)

Standard: 57 ∼ 65 kPa (430 ∼ 490 mmHg)

High Vacuum [A]
Secondary air cannot flow [B].

4-8 ENGINE TOP END

Cylinder Head Cover

Cylinder Head Cover Removal

Drain the coolant (see Cooling System chapter).

•

Remove:

•

Fuel Tank (see Fuel System chapter)
Choke Cable Lower End [A]
Throttle Cable Lower Ends [B]
Spark Plug Caps [C]
Vacuum Switch Valve [D]
Thermostat Housing [E]

Unscrew the cylinder head cover bolts [A].

•

Tilt up the right side [A] of the head cover slightly, move

•

the head cover back [B] and upward.

Remove the cylinder head cover.

•

Cylinder Head Cover Installation

Replace the head cover gasket [A] with a new one, if it is

•

damaged.

Stick the gasket to the cover with a liquid gasket [B] for

•

installation convenience.

Be sure to install the knock pins [C].

•

Apply silicone sealant [D] as s hown.

•

Sealant - Kawasaki Bond (Silicone Sealant): 5601 9-1 20

Tighten the cover bolts [E].

•

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Install the removed parts in reverse of removal.

•

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type cam chain tensioner. The
push rod does not return to its original position
once it moves out to take up cam chain slack. Ob­serve all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in "Chain Tensioner Instal­lation".
Do not turn over the crankshaft while the tensioner
is removed. This could upset the cam chain timing,
and damage the valves.

Loosen the cap bolt [A] before tensioner removal for later

•

disassembly convenience.
Unscrew the mounting bolts [B] and remove the camshaft

•

chain tensioner [C].

ENGINE TOP END 4-9

Camshaft Chain Tensioner Installation

Release the stopper [A] and push the rod [B] into the ten-

•

sioner body [C].

Replace the gasket with a new one.

•

Tighten the mounting bolts.

•

Torque - Camshaft Chain Tensioner Mounting Bolts: 11

N·m (1.1 kgf·m, 95 in·lb)

Install the spring [A], washer [B], and tighten the cap bolt

•

[C].

Torque - Camshaft Chain Tensioner Cap Bolt: 13 N·m (1.3

kgf·m, 9.5 ft·lb)

4-10 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft Removal

Remove the cylinder head cover.

•

Position the crankshaft at #2 piston TDC.

•

Using a wrench on the crankshaft rotation bolt turn the

○

crankshaft clockwise until the "C" mark line [A] on the rotor

is aligned with the notch [B] in the edge of the upper hole

in the alternator cover.

Remove:

•

Camshaft Chain Tensioner (see Camshaft Chain Ten­sioner Removal)
Cylinder Head Oil Pipes [A]
TopChainGuide[B]
Camshaft Caps [C]
Camshafts [D]

Stuff a clean cloth into the chain tunnel to keep any parts

•

from dropping into the crankcase.

CAUTION

The crankshaft may be turned while the camshafts

are removed. Always pull the chain taut while turn-

ing the crankshaft. This avoids kinking the chain

on the lower (crankshaft) sprocket. A kinked chain

could damage both the chain and the sprocket.

Camshaft Installation

Apply engine oil to all cam parts and journals.

•

If the camshaft(s) and/or cylinder head are replaced with

•

new ones, apply a thin coat of a molybdenum disulfide

grease on the new cam part surfaces.

NOTE

The Exhaust camshaft has an EX mark [A] and the i nlet

○

camshaft has an IN mark [B]. Be careful not to mix up
these shafts.
Be sure to operate from the engine left side.

○

Position the crankshaft at #2 piston TDC (see Camshaft

•

Removal).

CAUTION

The crankshaft may be turned while the camshafts

are removed. Always pull the chain taut while turn-

ing the crankshaft. This avoids kinking the chain

on the lower (crankshaft) sprocket. A kinked chain

could damage both the chain and the sprocket.

Camshaft, Camshaft Chain

Engage the camshaft chain with the camshaft sprockets.

•

Pull the tension side [A] (inlet side) of the chain taut to

○

install the chain.
The timing marks [B] on the inlet sprocket [C] must be

○

aligned with the cylinder head upper surface [D].
Pull the chain taut and fit it onto the camshaft sprocket.

•

Starting with the punch mark [E] on the top of the inlet

•

sprocket, count to the 24th pin. Feed the inlet camshaft
through the chain and align the 24th pin with the punch
mark [F] on the exhaust camshaft sprocket [G].

Be sure to install the knock pins.

•

Install the camshaft caps and top chain guide in the cor-

•

rect locations as shown. Location alphabets are marked
on the cylinder head and each c ap.

CAUTION

The camshaft caps are machined with the cylinder
head. So, if a cap is installed in a wrong location,
the camshaft may seize because of improper oil
clearance in the bearings.

ENGINE TOP END 4-11

First tighten down the two camshaft cap bolts (#1 and #2

•

bolts in the figure) evenly to seat the camshafts in place,
then tighten all bolts following the specified tightening se­quence.

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 8.5 ft·lb)

Install the head oil pipes.

•

Torque - Oil P ip e Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)

Install the camshaft chain tensioner (see Camshaft Chain

•

Tensioner Installation).
Check the chain timing.

•

Camshaft and Sprocket Assembly

The inlet and exhaust sprockets are identical.

○

Install the sprockets so that the marked [A] ("IN" and "EX")

•

side faces to the left side.

CAUTION

Inlet sprocket must use "l" marked bolt holes.
Exhaust sprocket must use "E" marked bolt holes.

Apply a non-permanent locking agent to the camshaft

•

sprocket bolts and tighten them.

Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11.0

ft·lb)

If a new camshaft is to be used, apply a thin coat of a
molybdenum disulfide grease to the cam surfaces.

4-12 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft, Camshaft Cap Wear

The journal wear is measured using plastigage (press
gauge), which is inserted into the clearance to be mea­sured. The plastigage indicates the clearance by the
amount it is compressed and widened when the parts are
assembled.

Cut strips of plastigage to journal width. Place a strip on

•

each journal parallel to the camshaft with the camshaft in-

stalled in the correct position and so that the plastigage

will be compressed between the journal and camshaft

cap.

[A] Plastigage Strip

Install the camshaft caps, tightening the bolts in the cor-

•

rect sequence.

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 8.5 ft·lb)

NOTE

Do not turn the camshaft when the plastigage is be-

○

tween the journal and camshaft cap.

Remove the camshaft caps again, and measure the plas-

•

tigage width [A] to determine the clearance between each

journal and camshaft cap. Measure the widest portion of

the plastigage.

If any clearance exceeds the service limit, measure the

camshaft journal diameter and the camshaft bearing in-

side diameter.

If any of the measurements is beyond the service limit,

replace the worn part and check the clearance again.

Camshaft Journal, Camshaft Cap Clearance

Standard: 0.030 ∼ 0.071 mm (0.0012 ∼ 0.0028 in.)

Service Limit: 0.16 mm (0.00 6 in.)

Camshaft Chain Guide Wear

Visually inspect the rubber [A] on the guides.

•

If the rubber is damaged or cut, replace the guides.

Rocker Shaft, Rocker Arm

Rocker Shaft, Rocker Arm Removal

Remove the camshafts (see Camshaft Removal).

•

Unscrew the rocker shafts [A] and remove the rocker arms

•

[B] and springs [C].
Mark and record the rocker arm locations so that the

○

rocker arm can be reinstalled in their original positions.

Rocker Shaft, Rocker Arm Installation

Blow the rocker arm oil passage [A] clean with com-

•

pressed air.
Apply engine oil to all the rocker arms and the rocker

•

shafts.

ENGINE TOP END 4-13

Install the retainer spring [A] on each rocker arm so that

•

thespringisplacedtothecamshaftchainside.
Check that the O-rings are in good condition and install

•

the O-rings onto the rocker shafts.
Insert the shaft running it through the cylinder head,

•

rocker arms and springs.
Tighten the rocker shafts.

•

Torque - Rocker Shafts: 39 N·m (4.0 kgf·m, 29 ft·lb)

Install the camshaft (see Camshaft Installation).

•

Check the chain timing.

•

4-14 ENGINE TOP END

Oil Pipe

Cylinder Head Oil Pipe Removal

Remove the oil pipe mounting bolts [A] and pull the oil

•

pipes [B] and O-rings out of the cylinder head.

Cylinder Head Oil Pipe Installation

Flush out the oil pipes with a high flash-point solvent.

•

Check that the O-rings are in good condition.

•

If they are damaged, replace them with new ones.

Apply a small amount of oil to the O-rings.

•

Fix the oil pipes properly into the cylinder head oil pas-

•

sage holes by pushing both ends at the same time.

Install the oil pipe mounting bolts.

•

Main Oil Pipe Removal

Remove:

•

Carburetor (see Fuel System chapter)
Starter Motor (see Electrical chapter)

Unscrew the banjo bolts [A] and mounting bolt [B].

•

Remove the oil pipe [C].

•

Main Oil Pipe Installation

Flush out the oil pipes with a high flash-point solvent.

•

Discard the used gaskets and install new gaskets on each

•

side of the pipe fittings.

Tighten the banjo bolts and mounting bolt to a snug fit,

•

and then tighten them to the specified torque.

Torque - Main Oil Pipe Upper Banjo Bolts: 12 N·m (1.2

kgf·m, 8.5 ft·lb)

Main Oil Pipe Lower Banjo Bolt: 20 N·m (2.0 kgf·m,

14.5 ft·lb)

Main Oil Pipe Mounting Bolt: 11 N·m (1.1 kgf·m, 95

in·lb)

Cylinder Head

Compression Measurement

Remove the seat (see Frame chapter).

•

Thoroughly warm up the engine so that the engine oil be-

•

tween the piston and cylinder wall will help seal compres­sion as it does during normal running.
Stop the engine, remove the fuel tank, ignition coil and

•

spark plugs, and attach the compression gauge firmly into
the spark plug hole.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221

[A]

Compression Ga ug e Adapter, M12 × 1.25:

57001-1183 [B]

Measure the cylinder compression.

•

Using the starter motor, turn the engine over with the throt-

•

tle fully open until the compression gauge stops rising; the
compression is the highest reading obtainable.

NOTE

Be sure the battery is fully charged.

○

Be sure no air leaks out of the cylinder head gasket.

○

ENGINE TOP END 4-15

Cylinder Compression (Usable Range)

960 ∼ 1 470 kPa (9.8 ∼ 15.0 kgf/cm², 139 ∼ 213 psi) @410

r/min (rpm)

Repeat the measurement for the other cylinder.

•

If cylinder compression is higher than the usable range,
check the following:

1. Carbon build-up on the piston head and cylinder
head. - clean off any carbon on the piston head and
cylinder head.

2. Cylinder head gasket, cylinder base gasket - use
only the proper gaskets for the cylinder head and
base. The use of gaskets of the incorrect thickness
will change the compression.

3. Valve stem oil seals and piston rings - rapid carbon
accumulation in the combustion chambers may be
caused by damaged valve stem oil seals and/or dam­aged piston oil rings. This may be indicated by white
exhaust smoke.

If cylinder compression is lower than the usable range,
check the following:

1. Gas leakage around the cylinder head - replace the
damaged gasket and check the cylinder head for
warping.

2. Condition of the valve seating.

3. Valve clearance - if a valve requires an unusually
large adjustment to obtain proper clearance, the valve
may be bent, and not seating completely.

4. Piston/cylinder clearance, piston seizure.

5. Piston ring, piston ring groove.

4-16 ENGINE TOP END

Cylinder Head

Cylinder Head Removal

Remove:

•

Cylinder Head Cover (see Cylinder Head Cover Re­moval)
Exhaust Pipes and Mufflers (see Crankshaft/Transmis­sion chapter)
Cam Chain Tensioner (see Chain Tensioner Removal)
Camshafts (see Camshaft Removal)
Carburetors (see Fuel System chapter)

Remove the main oil pipe banjo bolts [A].

•

Loosen the main oil pipe mounting bolt [B].

•

Remove the rear 6 mm cylinder head bolt [C].

•

Remove the front 6 mm cylinder head bolt [A] first, then

•

remove the 10 mm cylinder head bolts [B] This prevents
excessive stress on the small bolts.

Tap in the places shown with a mallet [A] to remove the

•

cylinder head.

Cylinder Head Installation

Install the rear chain guide [A], knock pins [B] and gasket

•

[C].

Cylinder Head

Install a new cylinder head gasket with "UP" [A] marked

•

side positioning to the right.

NOTE

The camshaft caps are machined with the cylinder head

○

so if a new cylinder head is installed, use the caps that
are supplied with the new head.

Tighten the 10 mm cylinder head bolts following the tight-

•

ening sequence. Tighten them first to about one half of
the specified torque.

Torque - Cylinder Head Bolts 10 mm: 51 N·m (5.2 kgf·m, 38

ft·lb)

Cylinder Head Bolts 6 mm: 9.8 N·m (1.0 kgf·m, 87

in·lb)

ENGINE TOP END 4-17

Tighten the 6 mm cylinder bolts.

•

Install the camshafts, camshaft caps and top chain guide.

•

Install the head oil pipes.

•

Cylinder Head Warp

Clean the cylinder head (see Cylinder Head Cleaning).

•

Lay a straightedge [A] across the lower s urface of the

•

head at several different points, and measure warp by
inserting a thickness gauge [B] between the straightedge
and the head.
If warp exceeds the service limit, repair the mating sur­face. Replace the cylinder head if the mating surface is
badly damaged.

Cylinder Head Warp

Service L imit: 0.05 mm (0.002 in.)

Cylinder Head Cleaning

Remove the cylinder head (see Cylinder Head Removal).

•

Remove the valves (see Valve Removal).

•

Wash the head with a high-flash point solvent.

•

Scrape [A] the carbon out of the combustion chamber and

•

exhaust port with a suitable tool.

4-18 ENGINE TOP END

Cylinder Head

Using compressed air, blow out any particles which may

•

obstruct the oil passage [A] in the cylinder head.
Install the valves (see Valve Installation).

•

Valves

Valve Clearance Inspection

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (room temperature).

Remove the cylinder head cover (see Cylinder Head

•

Cover Removal).
Remove the cylinder head oil pipes (see Cylinder Head

•

Oil Pipe Removal).
Unscrew the upper [A] and lower [B] caps on the alterna-

•

tor cover.

Check the valve clearance when the pistons are at TDC.

•

The pistons are numbered beginning with the engine left

○

side.
Using a wrench on the crankshaft rotation bolt [A], turn

•

the crankshaft clockwise [B] until the "C" mark [C] on the
rotor is aligned with the notch [D] in the edge of the upper
hole in the alternator cover for #2 piston and "T" mark for
#1 piston.

ENGINE TOP END 4-19

Measure the valve clearance of the valves for which the

○

cam lobe is pointing away from the rocker arm.
Each piston has two inlet and two exhaust valves. Mea-

•

sure these two inlet or exhaust valves at the same crank­shaft position.

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #2 piston, and

Exhaust valve clearances of #2 piston

NOTE

Check the valve clearance using this method only.

○

Checking the clearance at any other cam position may
result in improper valve clearance.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke →

Inlet valve clearances of #1 piston, and

Exhaust valve clearances of #1 piston

4-20 ENGINE TOP END

Valves

Measure the clearance of each valve by inserting a thick-

•

ness gauge [A] between the adjusting screw [B] and the
valve stem.

Valve Clearance (when cold)

Inlet

Exhaust

Valve Clearance Adjustment

If the valve clearance is incorrect, loosen the locknut [A]
and turn the adjusting screw [B] until the correct clearance
is obtained.
Tighten the locknut.

•

Torque - Valve Adjuster Locknuts: 25 N·m (2.5 kgf·m, 18

Install the two caps on the alternator cover.

•

0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.)

0.18 ∼ 0.23 mm (0.0070 ∼ 0.0090 in.)

ft·lb)

Valve Removal

Remove the cylinder head (see Cylinder Head Removal).

•

Use a valve spring compressor assembly to press down

•

the valve spring retainer, and remove the split keepers.

Special Tools - Valve Spring Compressor Assembly: 57001

-241 [A]

Valve Spring Compressor Adapter,

57001-1202 [B]

Valve Installation

Check to see that the valve [A] moves smoothly up and

•

down in the guide.
Check to see that the valve seats properly in the valve

•

seat. If it does not, repair the valve seat.
Replace the oil seal [B] with a new one.

•

Apply a thin coat of molybdenum disulfide engine assem-

•

bly grease to the valve stem before valve installation.
Be sure to install the inner [C] and outer [D] spring seats

•

under the inner [E] and outer [F] springs.
Install the springs so that the closed coil end [G] is facing

○

toward the valve seat (downwards).
Install the spring retainer [H], press it down with the valve

•

spring compressor assembly, and fit the split keepers [I]
into place.

Special Tools - Valve Spring Compressor Assembly: 57001

-241

Valve Spring Compressor Adapter,

57001-1202

Install the other removed parts.

•

22:

22:

Valves

Valve Guide Removal

Remove:

•

Valve (see Valve Removal)
Oil Seal
Spring Seats

Heat the area around the valve guide to about 120 ∼

•

150°C (248 ∼ 302°F), and hammer lightly on the valve

guide arbor [A] to remove the guide from the top of the
head.

Special Tool - Valve Guide Arbor, 5.5: 57001-1021

Valve Guide Installatio n

Apply oil to the valve guide outer surface before installa-

•

tion.

Heat the area around the valve guide hole to about 120 ∼

•

150°C (248 ∼ 302°F).

Drive the valve guide in from the top of the head using the

•

valve guide arbor. The flange stops the guide from going
in too far.

Special Tool - Valve Guide Arbor, 5.5: 57001-1021

Ream the valve guide with a valve guide reamer [A] even

•

if the oil guide is reused.

Special Tool - Valve Guide Reamer, 5.5: 57001-1079

ENGINE TOP END 4-21

Valve Seat Inspection

Remove the valve (see Valve Removal).

•

Check the valve seating surface [A] between the valve [B]

•

and valve seat [C].
Coat the valve seat with machinist’s dye.

○

Push the valve into the guide.

○

Rotate the valve against the seat with a lapping tool.

○

Pull the valve out, and check the seating pattern on the

○

valve head. It must be the correct width and even all the
way around.
Measure the outside diameter [D] of the seating pattern

•

on the valve seat.
If the outside diameter of the valve seating pattern is too
large or too small, repair the seat (see Valve Seat Repair).

Valve Seating Surface Outside Diameter

Inlet

Exhaust

The valve stem and guide must be in good condition, or

○

this check will not be valid.

If the valve seating pattern is not correct, repair the seat
(see Valve Seat Repair).
Measure the seat width [E] of the portion where there is

•

no build-up carbon (white portion) of the valve seat with a
vernier caliper.

28.3 ∼ 28.5 mm (1.114 ∼ 1.122 in.)

24.0 ∼ 24.2 mm (0.945 ∼ 0.953 in.)

NOTE

4-22 ENGINE TOP END

Valves

If the width is too wide, too narrow or uneven, repair the
seat (see Valve Seat Repair).

[F] Good
[G] Too Wide
[H] Too Narrow
[J] Uneven

ValveSeatingSurfaceWidth

Inlet

Exhaust

Measuring Valve-to-guide Clearance (Wobble method)

If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method, as indicated below.

Insert a new valve [A] into the guide [B] and set a dial

•

gauge against the stem perpendicular to it as close as

possible to the cylinder head mating surface.

Move the stem back and forth [C] to measure valve/valve

•

guide clearance.

Repeat the measurement in a direction at a right angle to

•

the first.

If the reading exceeds the service limit, replace the guide.

0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.)

NOTE

The reading is not actual valve/valve guide clearance

○

because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard:

Inlet

Exhaust

Service Limit:

Inlet

Exhaust

0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)

0.07 ∼ 0.14 mm (0.0028 ∼ 0.0055 in.)

0.22 mm (0.00 87 in .)

0.27 mm (0.01 06 in .)

Valve Seat Repair

Repair the valve seat with the valve seat cutters.

•

Special Tools -

Inlet Valve

Seat Cu tter 45°-

Seat Cu tter 32°-

Seat Cu tter 60°-

Exhaust Valve

Seat Cu tter 45°-

Seat Cu tter 32°-

Seat Cu tter 60°-

Valve Seat Cutter Holder -

Valve Seat Cutter Holders Bar 57001-1128

30.0

30.0

30.0

24.5 57001-1113

25.0 57001-1118

25.0 57001-1328

5.5 57001-1125

57001-1187

57001-1120

57001-1123

If the manufacturer’s instructions are not available, use

the following procedure.