Kawasaki KLE500 (2004) User Manual [ru]

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System 3 j

Cooling System 4 j

Engine Top End 5 j

Clutch 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

This quick reference guide will assist
you in locating a desired topic or pro­cedure.

•Bend the pages back to match the
black tab of the desired chapter num­ber with the black tab on the edge at
each table of contents page.

•Refer to the sectional table of contents
for the exact pages to locate the spe­cific topic required.

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

KLE500

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 Division/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.

© 2004 Kawasaki Heavy Industries, Ltd. First Edition (1): Dec. 10, 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.

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 t he 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................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion Table ............................................................................................................ 1-11

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:

Battery Ground

Before completing any service on the motorcycle, discon­nect the battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the negative wire
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (–) wire to the neg­ative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into s ealed areas during ve­hicle disassembly can cause excessive wear and decrease
performance of the vehicle.

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

GENERAL INFORMATION 1-3

Inspection

Reuse of worn or damaged parts may lead to serious ac­cident. Visually inspect removed parts for corrosion, discol­oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be­yond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, Oil seals,
Grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassem­bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified se­quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar­ter turn and them remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.

Force

Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam­age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per­formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling.

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains be­fore applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil pas­sages and cause serious damage.

Before Servicing

Press

For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con­tact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

GENERAL INFORMATION 1-5

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to lip of seal before installing the
seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri­cation points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Eng ine Rotation

When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro­tate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires

A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

Model Identification

KLE500-B1 Left Side View

GENERAL INFORMATION 1-7

KLE500-B1 Right Side View

1-8 GENERAL INFORMATION

General Specifications

Items KLE500-B1

Dimensions

Overall Length 2 215 mm (87.2 in.)

Overall Width 880 mm (34.6 in.)

Overall Height 1 270 mm (50.0 in.)

Wheelbase 1 500 mm (59.0 in.)

Road Clearance 180 mm (7.09 in.)

Seat Height 850 mm (33.5 in.)

Dry Weight 181 kg (399 lb.)

Curb Weight:

Front 95 kg (209 lb.)

Rear 105 kg (232 lb.)

Fuel tank Capacity 15 L (4.0 US gal.)

Performance

Minimum Turning Radius

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

Compression Ratio

Maximum Horsepower

Maximum Torque 41 N·m (4.2 kgf·m, 30 ft·lb) @7 500 r/min (rpm)

Carburetion System Carburetors, Keihin CVK34 × 2

Starting System Electric starter

Ignition System Battery and coil (transistorized)

Timing Advance Electronically Advanced (digital)

Ignition Timing From 10° BTDC @1 300 r/min (rpm) to 35° BTDC

Spark Plugs NGK DR9EA or ND X27ESR-U

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Valve Timing:

Inlet

Open 27° BTDC

Close 47° ABDC

Duration 254°

Exhaust

Open 52° BBDC

Close 22° ATDC

Duration 254°

Lubrication System Forced lubrication

2.4 m (7.9 ft.)

498 mL (30.39 cu in.)

9.8:1

33 kW (44.9 PS) @8 300 r/min (rpm)

@5 000 r/min (rpm)

GENERAL INFORMATION 1-9

General Specifications

Items KLE500-B1

Engine Oil:

Grade API SE, SF, SG or

API SH or SJ with JASO MA

Viscosity SAE10W-40

Capacity 3.4 L (3.6 US qt)

Drive Train

Primary Reduction System:

Type Chain

Reduction Ratio 2.652 (61/23)

Clutch Type Wet multi disc

Transmission:

Type

Gear Ratios:

1st 2.571 (36/14)

2nd 1.722 (31/18)

3rd 1.333 (28/21)

4th 1.125 (27/24)

5th 0.961 (25/26)

6th 0.851 (23/27)

Final Drive System:

Type Chain drive

Reduction Ratio

Overall Drive Ratio 5.847 @Top gear

Frame

Type Tubular, double cradle

Caster (rake angle) 27°

Trail 105 mm (4.13 in.)

Front Tire:

Type Tubeless

Size 90/90-21 M/C 54S

Rear Tire:

Type Tubeless

Size 130/80-17 M/C 65S

Front Suspension:

Type

Wheel Travel

Rear Suspension:

Type Swingarm

Wheel Travel 200 mm (7.87 in.)

Brake Type:

Front

Rear

6-speed constant mesh, return shift

2.588 (44/17)

Telescopic fork

220 mm (8.66 in.)

Single disc

Single disc

1-10 GENERAL INFORMATION

General Specifications

Items KLE500-B1

Electrical Equipment

Battery 12 V 10 Ah

Headlight:

Type Semi-sealed beam

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

Tail/brake Light 12 V 5/21 W

Alternator:

Type

Rated output

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

Three-phase AC

17 A × 14 V @6 000 r/min (rpm)

Unit Conversion Table

GENERAL INFORMATION 1-11

Prefixes fo r Units:

Prefix Symbol Power

mega M ×1000000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units o f Mass:

kg ×2.205=lb

g × 0.03527 = oz

Units of Volume:

L × 0.2642 = gal (US)

L × 0.2200 =

L × 1.057 =

L × 0.8799 = qt (imp)

L × 2.113 = pint (US)

L × 1.816 = pint (imp)

mL × 0.03381 = oz (US)

mL × 0.02816 =

mL × 0.06102 = cu in

gal (imp)

qt (US)

oz (imp)

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kgf·m

kgf·m

kgf·m

× 9.807 = N·m

×7.233=

× 86.80 = in·lb

ft·lb

Units of Pressure:

kPa × 0.01020 =

kPa × 0.1450 = psi

kPa × 0.7501 = cm Hg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cm Hg × 1.333 = k Pa

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature:

Units of Power:

kW × 1.360 =

kW × 1.341 = HP

PS × 0.7355 = kW

PS × 0.9863 = HP

PS

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-6

Specifications ......................................................................................................................... 2-11

Special Tools .......................................................................................................................... 2-13

Maintenance Procedure ......................................................................................................... 2-14

Fuel System......................................................................................................................... 2-14

Throttle Cable Inspection .................................................................................................. 2-14

Idle Speed Inspection ....................................................................................................... 2-15

Carburetor Synchronization Inspection............................................................................. 2-16

Coolant Filter Cleaning ..................................................................................................... 2-17

Fuel Hoses and Connections Check ................................................................................. 2-17

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

Cooling System.................................................................................................................... 2-18

Coolant Level Inspection................................................................................................... 2-18

Radiator Hoses and Connections Inspection.................................................................... 2-19

Engine Top End ................................................................................................................... 2-19

Air Suction Valve Inspection ............................................................................................. 2-19

Valve Clearance Inspection .............................................................................................. 2-19

Clutch................................................................................................................................... 2-21

Clutch Operation Inspection.............................................................................................. 2-21

Wheels/Tires........................................................................................................................ 2-22

Air Pressure Inspection/Adjustment.................................................................................. 2-22

Tire Tread Wear Inspection............................................................................................... 2-22

Wheel/Tire Damage Inspection......................................................................................... 2-23

Wheel Bearing Damage Inspection .................................................................................. 2-24

Spoke Tightness and Rim Runout Inspection................................................................... 2-24

Final Drive............................................................................................................................ 2-25

Drive Chain Slack Inspection ............................................................................................ 2-25

Drive Chain Wear Inspection ............................................................................................ 2-26

Drive Chain Lubrication..................................................................................................... 2-27

Brakes.................................................................................................................................. 2-27

Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-27

Brake Hose Damage and Installation Condition Inspection.............................................. 2-28

Brake Operation Inspection .............................................................................................. 2-28

Brake Fluid Level Inspection ............................................................................................. 2-28

Brake Pad Wear Inspection .............................................................................................. 2-29

Brake Light Switch Operation Inspection.......................................................................... 2-30

Suspension.......................................................................................................................... 2-30

Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-30

Front Fork Oil Leak Inspection.......................................................................................... 2-31

Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-31

Rocker Arm Operation Inspection..................................................................................... 2-31

Rocker Arm Bearings and Sleeves Lubrication ................................................................ 2-31

Tie-rod Operation Inspection ............................................................................................ 2-32

Swingarm N eedle Bearing Lubrication.............................................................................. 2-32

Steering ............................................................................................................................... 2-32

2

2-2 PERIODIC MAINTENANCE

Steering P lay Inspection ................................................................................................... 2-32

Steering S tem Bearing Lubrication ................................................................................... 2-33

Electrical System ................................................................................................................. 2-34

Spark Plug Gap Inspection ............................................................................................... 2-34

Lights and Switches Operation Inspection ........................................................................ 2-34

Headlight Aiming Inspection ............................................................................................. 2-36

Side Stand Switch Operation Inspection........................................................................... 2-37

Engine Stop Switch Operation Inspection......................................................................... 2-38

Others.................................................................................................................................. 2-38

Chassis Parts Lubrication ................................................................................................. 2-38

Bolts, Nuts and Fastener Tightness Inspection ................................................................ 2-39

Replacement P arts .............................................................................................................. 2-40

Fuel Hose Replacement ................................................................................................... 2-40

Air Cleaner Element Replacement.................................................................................... 2-41

Coolant Change ................................................................................................................ 2-41

Radiator Hoses and O-ring Replacement......................................................................... 2-44

Engine Oil Change............................................................................................................ 2-44

Oil Filter Replacement ...................................................................................................... 2-45

Brake Hose Replacement ................................................................................................. 2-45

Brake Fluid Change .......................................................................................................... 2-46

Bleeding the Brake Line.................................................................................................... 2-47

Caliper Rubber Parts Replacement .................................................................................. 2-48

Master Cylinder Rubber Parts Replacement .................................................................... 2-48

Spark Plug Replacement .................................................................................................. 2-49

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

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

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

FREQUENCY

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

Fuel System

Throttle cable-inspect year

Idle speed-inspect

Carburetor synchronization-inspect

Coolant filter-clean year 2-17

Air cleaner element-clean #

Fuel hoses and connections-inspect year

Cooling System

Coolant level-inspect

Radiator hose and connection-inspect year

Engine Top End

Air suction valve-inspect

Valve clearance-inspect

Clutch

Clutch operation (play, disengagement,
engagement)-inspect

Wheels and Tires

Whichever

comes first

1 6 12 18 24 30 36

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

* ODOMETER READING

× 1000 km

(× 1000 mile)

• • •

• • •

• • •

•

See

Page

2-14

2-15

2-16

2-17

2-17

2-18

2-19

2-19

2-19

2-21

Tire air pressure-inspect

Tire tread wear-inspect

Wheel/tire damage-inspect

Wheel bearing damage-inspect year

Spoke tightness and rim runout-inspect

Final Drive

Drive chain slack-inspect # Every 1 000 km (600 mile) 2-25

Drive chain wear-inspect # Every 6 000 km (4 000 mile) 2-26

Drive chain lubrication condition-inspect # Every 600 km (400 mile) 2-27

Drive chain guide wear-inspect Every 12 000 km (7 500 mile) –

Brake System

Brake fluid leak (brake hose and
pipe)-inspect

Brake hose damage-inspect year

Brake hose installation condition-inspect year

Brake operation (effectiveness, play, no
drag)-inspect

Brake fluid level-inspect 6 months

Brake pad wear-inspect #

Brake light switch operation-inspect

year

year

• • • • • •

• • •

• • •

• • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • • •

• • • • • •

• • • • • • •

2-22

2-22

2-23

2-24

2-24

2-27

2-28

2-28

2-28

2-28

2-29

2-30

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

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

Suspensions

Front forks/rear shock absorber operation
(damping and smooth stroke)-inspect

Front forks/rear shock absorber oil
leak-inspect

Rocker arm operation-inspect

Rocker arm bearings and sleeves

-lubricate

Tie-rods operation-inspect

Swingarm pivot-lubricate

Steering System

Steering play-inspect year

Steering stem bearings-lubricate 2 years

Electrical System

Whichever

comes first

1 6 12 18 24 30 36

year

• • • •

* ODOMETER READING

× 1000 km

(× 1000 mile)

• • •

• • •

• • •

•

• • •

•

•

See

Page

2-30

2-31

2-31

2-31

2-32

2-32

2-32

2-33

Spark plug condition-inspect

Lights and switches operation-inspect year

Headlight aiming-inspect year

Side stand switch operation-inspect

Engine stop switch operation-inspect year

Others

Chassis parts-lubricate year

Bolts, nuts and fasteners tightness-inspect

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or

frequent starting/stopping.

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

year

• • • •

• • •

• • •

• • •

• • •

• • •

• • •

2-34

2-34

2-36

2-37

2-38

2-38

2-39

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

come

first

1 12 18 24 36 48

CHANGE/REPLACEMENT Every (0.6) (7.5) (12) (15) (24) (30)

* ODOMETER READING

× 1000 km

(× 1000 mile)

See

Page

Fuel hose 4 years

Air cleaner element 2 years 2-40

Coolant 3 years

Radiator hose and O-ring 3 years

Engine oil #

Oil filter year

Brake hose 4 years

Brake fluid 2 years

Master Cylinder/Caliper Rubber Parts 4 years

#: Service more frequently when operating in severe conditions; dusty, wet, m uddy, high speed or

frequent starting/stopping.

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

year

• • • • •

• • • • •

•

•

• •

2-40

•

2-40

2-43

2-43

2-44

2-44

•

2-45

2-47

•

2-6 PERIODIC MAINTENANCE

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:

EO: Apply engine oil to the threads and seating surface.

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

LG: Apply l iquid gasket to the threads.

Lh: Left-hand threads.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in

a weight ratio 10 : 1)
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.

Fastener

Fuel System

Fuel Tap Cover Screws 0.8 0.08 7in·lb

Fuel Tap Mounting Bolts 5.0 0.51 44 in·lb

Air Cut Valve Cover Screws 1.0 0.10 9in·lb

Cooling System

Radiator Hose Clamp Screws 2.5 0.25 22 in·lb

Radiator 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 C over Bolts 11 1.1 95 in·lb

Water Pump Shaft

Water Pump Impeller 9.8 1.0 87 in·lb Lh

Water Pipe Bolts 9.8 1.0 87 in·lb L

Cylinder Head Jacket Plug 9.8 1.0 87 in·lb L

Radiator Cap Holder Mounting Bolts 11 1.1 95 in·lb

Coolant Drain Plug 11 1.1 95 in·lb

Engine Top End

Air Suction Valve Cover Bolts 11 1.1 95 in·lb

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb S

Camshaft Cap Bolts

Rocker Shafts 39 4.0 29 EO

Valve Adjuster Locknuts 25 2.5 18

Camshaft Sprocket Bolts

Cylinder Head Bolts (10 mm) 51 5.2 38 S

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

Camshaft Chain Tensioner Mounting Bolts 11 1.1 95 in·lb

Camshaft Chain Tensioner Cap Bolt 13 1.3 9.5

N·m kgf·m ft·lb

25 2.5 18 Lh

12 1.2 104 in·lb

15 1.5 11 L

Torque

Remarks

S

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Main Oil Pipe Upper Banjo Bolts M8 12 1.2 104 in·lb

Main Oil Pipe Lower Banjo Bolt M10 20 2.0 14.5

Water Jacket Plug 9.8 1.0 87 in·lb L

Oil Pipe Bolts (in the cylinder head) 11 1.1 95 in·lb

Main Oil Pipe Mounting Bolt 11 1.1 95 in·lb

Clutch

Oil Filler Plug

Clutch Hub Nut 132 13.5 98

Clutch Spring Bolts 9.3 0.95 82 in·lb

Clutch Cable Holder Bolt 11 1.1 95 in·lb

Clutch Cover Bolts 11 1.1 95 in·lb

Engine Lubrication System

Oil Filler Plug

Oil Passage Plug 18 1.8 13

Oil Filter Mounting Stud

Oil Filter (Cartridge Type) 17 1.7 12.5

Oil Pipe for Balancer Shaft Banjo Bolt 20 2.0 14.5

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

Oil Pipe for Drive Shaft Lower Banjo Bolt M 8 12 1.2 104 in·lb

Oil Pipe for Output Shaft Upper Banjo Bolt M6

Oil Pipe for Output Shaft Lower Banjo Bolt M8 12 1.2 104 in·lb

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

Oil Pump Outer Oil Pipe Bolts 11 1.1 95 in·lb L

Relief Valve 15 1.5 11 L

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

Oil Pressure Switch

Main Oil Pipe Mounting Bolt 11 1.1 95 in·lb

Main Oil Pipe Upper Banjo Bolts 12 1.2 104 in·lb

Main Oil Pipe Lower Banjo Bolt 20 2.0 14.5

Rocker Shafts 39 4.0 29

Engine Oil Drain Plug 29 3.0 22

Oil Pan Mounting Bolts

Oil Pump Mounting Bolts 11 1.1 95 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

Breather Body Bolt 5.9 0.6 52 in·lb

Crankcase Bolts (8 mm) 27 2.8 20 S

Crankcase Bolts (6 mm) 12 1.2 104 in·lb S

N·m kgf·m ft·lb

1.5 0.15 13 in·lb

1.5 0.15 13 in·lb

25 2.5 18 L

7.8 0.8 69 in·lb

15 1.5 11

11 1.1 95 in·lb

Torque

Remarks

(Planted

side)

SS

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Upper Primary Chain Guide Mounting Bolt

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 – – – L

Gear Positioning Lever Nut 11 1.1 95 in·lb

Shift Pedal Link Lever Mounting Bolt 12 1.2 104 in·lb

Shift Drum Bearing Holder Bolts

Shift Drum Cam Pin Plate Screw – – – L

Engine Sprocket Nut 127 13 94 EO

External Shift Mechanism Cover Bolts 11 1.1 95 in·lb

Neutral Switch 15 1.5 11

Wheels/Tires

Spoke Nipple

Front Axle Nut 88 9.0 65

Rear Sprocket Nut 33 3.4 24

Rear Axle Nut 108 11 80

Final Drive

Engine Sprocket Nut 127 13 94 EO

Rear Sprocket Nuts 33 3.4 24

Rear Coupling Studs – – – L

Rear Axle Nut 108 11 80

Drive Chain Guide Bolts 11 1.1 95 in·lb

Brakes

Brake Hose Banjo Bolts 34 3.5 25

Front 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

Front Master Cylinder Clamp Bolts 11 1.1 95 in·lb S

Front Brake Light Switch Mounting Screw 1.2 0.12 10 in·lb

Front Caliper Mounting Bolts 34 3.5 25

Rear Caliper Mounting Bolts 25 2.5 18

Caliper Bleed Valves

Brake Disc Mounting Bolts 23 2.3 16.5 L

Brake Pedal Bolt 25 2.5 18

Rear Reservoir Mounting Bolt 5.9 0.60 52 in·lb

Rear Master Cylinder Mounting Bolts 25 2.5 18

Suspension

Front Fork Upper Clamp Allen Bolts 25 2.5 18 S

Front Fork Lower Clamp Bolts 23 2.3 16.5 S

N·m kgf·m ft·lb

11 1.1 95 in·lb L

11 1.1 95 in·lb L

2.0 ∼ 3.9 0.2 ∼ 0.4 17 ∼ 35 in·lb

7.8 0.8 69 in·lb

Torque

Remarks

(planted

(planted

side)

side)

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Front Fork Top Bolts 30 3.1 22

Front Fork Bottom Allen Bolt 30 3.1 22 L

Rear Shock Absorber Upper Mounting Nut 59 6.0 43

Rear Shock Absorber Lower Mounting Nut

Swingarm Pivot Nut 118 12 87

Rocker Arm Pivot Nut 98 10 72

Tie-Rod Mounting Nuts 98 10 72

Steering

Handlebar Clamp Bolts 25 2.5 18 S

Handlebar Weight Allen Bolts – – – L

Front Fork Upper Clamp Allen Bolts 25 2.5 18 S

Front Fork Lower Clamp Bolts 23 2.3 16.5 S

Steering Stem Head Nut

Steering Stem Locknut

Frame

Tail Grip Bolts

Front Footpeg Bracket Bolts 34 3.5 25

Sidestand Bolt and Nut 44 4.5 33

Rear Footpeg Bracket Bolts 25 2.5 18

Carrier Stay Mounting Bolts 25 2.5 18

Electrical System

Crankshaft Sensor Mounting Screws

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 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 Lh

Starter Motor Mounting Bolts 11 1.1 95 in·lb

Starter Chain Guide Bolts

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

Starter Clutch Allen Bolts 34 3.5 25 L

Sidestand Switch Mounting Screw 3.9 0.4 35 in·lb L

Sidestand Bolt and Nut

Radiator Fan Switch 18 1.8 13

Water Temperature Switch 7.8 0.80 69 in·lb SS

Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb

N·m kgf·m ft·lb

98 10 72

39 4.0 29

Hand

-Tighten

(about 4.9) (about 0.5) (about 43

25 2.5 18

8.3 0.85 74 in·lb L

12 1.2 104 in·lb

4.9 0.5 43 in·lb L

44 4.5 33

Torque

Hand

-Tighten

Remarks

Hand

-Tighten

in·lb)

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Oil Pressure Switch

Neutral Switch 15 1.5 11

Tail Light Mounting Nut 5.9 0.6 52 in·lb

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.

N·m kgf·m ft·lb

15 1.5 11

Torque

Remarks

SS

Basic Torque for General Fasteners

Threads Torque

dia. (mm)

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 11 5 ∼ 155 11. 5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240

N·m

kgf·m ft·lb

PERIODIC MAINTENANCE 2-11

Specifications

Item Standard Service Limit

Fuel System

ThrottleGripFreePlay 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Idle Speed 1 200 ±50 r/min (rpm) –––

Engine Top End

Valve Clearance

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

Clutch

Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Wheels/Tires

Air Pressure

Front 150 kPa (1.5 kgf/cm², 21 psi) –––

Rear 225 kPa (2.25 kgf/cm², 32 psi) –––

Tread Depth

Front

Dunlop 6.9 mm (0.27 in.) 1 mm (0.04 in.)

Bridgestone 6.0 mm (0.24 in.)

Rear

Dunlop

Bridgestone 8.5 mm (0.33 in.) 3 mm (0.12 in.)

Rim Runout

Axial

Radial

Final Drive

Drive Chain Slack 2 ∼ 12 mm (0.08 ∼ 0.47 in.)
Drive Chain Wear (20-link l ength) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)

Brakes

Brake Fluid Grade DOT4

Pad Lining Thickness

Brake Light Timing

Front

Rear

Electrical System

Spark Plug Gap 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) –––

Replacement Parts

Coolant Capacity 1.7 L (1.8 US qt) –––

Engine Oil

Grade API SE, SF, SG or

Viscosity SAE10W-40 –––

8.8 mm (0.35 in.) 2 mm (0.08 in.)

(Over to 130 km/h

0.5 mm (0.02 in.) 1.5 mm (0.06 in.)

0.8 mm (0.03 in.) 1.5 mm (0.06 in.)

5.5 mm (0.203 in.) 1 mm (0.04 in.)

ON after 10 mm (0.39 in.) lever travel

ON after 15 mm (0.59 in.) pedal travel –––

API SH or SJ with JASO MA

–––

(Up to 130 km/h

(80 mph))

(80 mph))

–––

–––

–––

–––

2-12 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Capacity

when filter is not removed 2.8L(3.0USqt) –––

when filter is removed 3.0L(3.2USqt) –––

when engine is completely dry 3.4L(3.6USqt) –––

Special Tools

PERIODIC MAINTENANCE 2-13

Steering Stem Nut Wrench:
57001-1100

Jack:
57001-1238

Pilot Screw Adjuster, A:
57001-1239

Oil Filter Wrench:
57001-1249

Vacuum Gauge:
57001-1369

Filler Cap Driver:
57001-1454

2-14 PERIODIC MAINTENANCE

Maintenance Procedure

Fuel System

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.

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 2 ∼3mm
(0.08 ∼ 0.12 in.) 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.

Maintenance Procedure

If the play can not be adjusted by using the adjuster at the
throttle grip, use the adjuster [A] of the decelerator cable
under the fuel tank.
Screw in the adjuster fully at the throttle grip and tighten

•

the locknut.
Remove the fuel tank (see Fuel Tank Removal in the Fuel

•

System chapter).
Make the necessary free play adjustment at the lower ca-

○

ble end.

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

•

adjusting screw [B], with 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.

PERIODIC MAINTENANCE 2-15

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.

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

1 200 ±50 r/min (rpm)

2-16 PERIODIC MAINTENANCE

Maintenance Procedure

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.
Remove the fuel tank and connect the auxiliary fuel tank

•

to supply the fuel.
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.

Special Tool - Vacuum Gauge: 57001-1369

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]: 57001-1239

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.

Maintenance Procedure

Coolant Filter Cleaning

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

○

the carburetor system.
Drain the coolant (see Coolant Draining).

•

Remove the coolant filter from the cooling hoses in the

•

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

•

Fuel Hoses and Connections Check

The fuel hoses are designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the
motorcycle is not properly handled, the high pressure in­side the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel Tank Removal in
the Fuel System chapter) 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 General Informa­tion 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 ob­structed.
Replace the hose if it has been sharply bent or kinked.

PERIODIC MAINTENANCE 2-17

Air Cleaner Element Cleaning and Inspection

NOTE

In dusty areas, the element should be cleaned more

○

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

○

should be cleaned immediately.

WARNING

Clean the element in a well-ventilated area, and
make sure that there are no sparks or flame any­where near the working area. Because of the
danger of highly flammable liquids, do not use
gasoline or a low-flash point solvent to clean the
element.

2-18 PERIODIC MAINTENANCE

Maintenance Procedure

Remove the element assembly from the air cleaner hous-

•

ing (see Air Cleaner Element Removal in the Fuel System
chapter).
Separate the element [A] from the element holders [B].

•

Clean the element in a bath of high-flash point solvent,

•

and then dry it with compressed air or by shaking it.
Visually check the element for tear or breaks.

•

If any of the parts of the element are damaged, replace
them with a new one.

After cleaning of the element, saturate it with high quality

•

form air filter oil and squeeze out excess oil.
Wrap the element [A] in a clean rag [B] and squeeze it as

•

dry as possible.
Assemble the element with the holders, and install them

•

into the air cleaner housing.

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 [C]. The coolant level should be between
the "H" (High) [A] and the "L" (Low) [B] level lines.

NOTE

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

○

ent temperature).

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 water 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 reserve 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).

Maintenance Procedure

Radiator Hoses and Connections 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 C lamp Screws: 2.5 N·m (0.25 kgf·m,

22 in·lb)

Engine Top End

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.

PERIODIC MAINTENANCE 2-19

CAUTION

Do not scrape off the deposits with a scraper as this

could damage the rubber, requiring replacement of

the suction valve assembly.

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 in the Engine Top End chapter).

Remove the cylinder head oil pipes (see Cylinder Head

•

Oil Pipe Removal in the Engine Top End chapter).

2-20 PERIODIC MAINTENANCE

Maintenance Procedure

Unscrew the upper [A] and lower [B] caps on the alterna-

•

tor cover.

Special Tool - Filler Cap Driver: 57001-1454

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.

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

Maintenance Procedure

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)

PERIODIC MAINTENANCE 2-21

Clutch

WARNING

To avoid a serious burn, never touch the engine or

exhaust pipe during clutch adjustment.

Clutch Operation Inspection

Clutch Operation Inspection

With the engine idling, make sure that there is no noise

•

or abnormally heavy feeling when pulling [A] in the clutch

lever fully. Also, make sure that the shift lever operates

smoothly.

When moving off the motorcycle by releasing the clutch

•

lever gradually, make sure that the clutch does not slip

and that the clutch engages smoothly.

If the clutch operation is insufficiency, inspect the clutch

system.

WARNING

When inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

Clutch Lever Free Play Inspection

Pull the clutch lever just enough to take up the free play

•

[A].

Measure the gap between the lever and the lever holder.

•

If the gap is too wide, the clutch may not release fully. If

the gap is too narrow, the clutch may not engage fully. In

either case, adjust the clutch.

Clutch Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

2-22 PERIODIC MAINTENANCE

Maintenance Procedure

Clutch Lever Free Play Adjustment

Slide back the dust cover [A].

•

Loosen both adjuster nuts [B] at the right hand crankcase

•

as far as they will go.

Loosen the knurled locknut [A] at the clutch lever.

•

Turn the adjuster [B] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [C]

•

of threads are visible.

WARNING

Be sure that the outer cable end at the clutch lever
is fully seated in the adjuster at the clutch lever, or
it could slip into the place later, creating enough
cable play to prevent clutch disengagement.

After the adjustment is made, start the engine and check

•

that the clutch does not slip and that it releases properly.

Wheels/Tires

Air Pressure Inspection/Adjustment

Measure the tire air pressure with an air pressure gauge

•

[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
Adjust the tire air pressure according to the specifications
if necessary.

Air Pressure (when cold)

Front

Rear

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more sus­ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.

Measure the tread depth at the center of the tread with a

•

depth gauge [A]. Since the tire may wear unevenly, take

measurement at several places.

150 kPa (1.5 kgf/cm², 21 psi)

225kPa(2.25kgf/cm²,32psi)

Maintenance Procedure

Wear Indicator [A]
Wear Indicator Position Mark [B]

If any measurement is less than the service limit, replace
the tire.

Tread Depth

Front

Standard 6.9 mm (0.27 in.) 6.0 mm (0.24 in.)

Service Limit 1 mm (0.04 in.)

Rear

Standard 8.8 mm (0.35 in.) 8.5 mm (0.33 in.)

Service Limit 2 mm (0.08 in.)(Up to 130 km/h (80 mph))

DUNLOP BRIDGESTONE

DUNLOP BRIDGESTONE

3 mm (0.12 in.)(Ove r 130 km/h (80 mph ))

PERIODIC MAINTENANCE 2-23

WARNING

To ensure safe handling and stability, use only the
recommended standard tires for replacement, in­flated to the standard pressure.
Use the same manufacturer’s tires on both front and
rear wheels.

NOTE

Check and balance the wheel when a tire is replaced

○

with a new one.

Wheel/Tire Damage Inspection

Remove any imbedded stones [D], nail [C] or other foreign

•

particles from the tread.

Wear Indicator [E]

Visually inspect the tire for cracks [A] and cuts [B], and re-

•

place the tire if necessary. Swelling or high spots indicate
internal damage, requiring tire replacement.
Visually inspect the wheel for cracks, cuts and dents dam-

•

age.
If any damage is found, replace the wheel if necessary.

2-24 PERIODIC MAINTENANCE

Maintenance Procedure

Wheel Bearing Damage Inspection

Using a jack and attachment, raise the front wheel off the

•

ground (see Wheels/Tires chapter).

Turn the handlebar all the way to the right or left.

•

Inspect the roughness of the front wheel bearing by push-

•

ing and pulling [A] the wheel.

Spin [B] the front wheel lightly, and check for smoothly

•

turn, roughness, binding or noise.

If roughness, binding or noise is found, remove the front

wheel and inspect the wheel bearing (see Hub Bearing

Inspection in the Wheels/Tires chapter).

Spoke Tightness and Rim Runout Inspection

Spoke Tightness Inspection

Check whether all the spokes are uniformly tightened.

•

Uniformly tighten the spokes if any spoke is loose or un-

evenly tightened.

Torque - Spoke Nipple: 3.0 N·m (0.3 kgf·m, 26 in·lb)

(On and after EJ650-A3/C3): 5.1 N·m (0.52 kgf·m,

45 in·lb)

Inspect the rims.

•

WARNING

If any spoke brakes, it should be replaced immedi-

ately. A missing spoke places an additional load on

the other spokes, which will eventually cause other

spokes to break.

Rim Runout Inspection

Raise the front/rear wheel of the ground.

•

Special Tool - Jack: 57001-1238

Check the rim for damage or warpage.

•

If there is any damage to the rim, replace the rim.

Measure the radial [A] and axial [B] rim runout by placing a

•

dial gauge against the sides and the outer circumference

of the rim, and slowly rotating the wheel.

Rim Runout (with tire installed)

Standard:

Axial Runout

Radial Runout

Service Limit:

Axial Runout

Radial Runout

0.5 mm (0.02 in.)

0.8 mm (0.03 in.)

1.5 mm (0.06 in.)

1.5 mm (0.06 in.)

If rim runout exceeds the service limit, inspect the hub

bearings. If the problem is not due to the bearings,

retighten the spokes.

WARNING

Never attempt to repair a damaged wheel part. If

the wheel part is damaged, it must be replaced with

a new part.

Maintenance Procedure

Final Drive

Drive Chain Slack Inspection

Drive Chain Slack Inspection

NOTE

Check the slack with the motorcycle setting on its side

○

stand.
Clean the chain if it is dirty, and lubricate it if it appears

○

dry.

Check the wheel alignment (see Wheel Alignment Inspec-

•

tion/Adjustment).
Rotate the rear wheel to find the position where the chain

•

is tightest.
Measure the vertical movement (chain slack) [A] m idway

•

between the sprockets.
If the chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 35 ∼ 45 mm (1.4 ∼ 1.8 in.)

PERIODIC MAINTENANCE 2-25

Drive Chain Slack Adjustment

Remove:

•

Cotter Pin [A]

Loosen:

•

Axle Nut [B]
Chain Adjuster Locknuts [F] (both sides)

Turn the chain adjusting nuts [C] forward or rearward un-

•

til the drive chain has the correct amount of chain slack.
To keep the chain and wheel properly aligned, the left ad­juster mark [D] position should align with the same grad­uation that the right adjuster mark [E] position aligns with.

WARNING

Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.

Tighten both chain adjuster locknuts securely.

•

Tighten the axle nut (see Front/Rear Wheel Installation in

•

the Wheels/Tires chapter).

Torque - Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

Insert a the new cotter pin [A].

•

NOTE

When inserting the cotter pin, if the slots in the nut do

○

not align with the cotter pin hole in the axle shaft, tighten
the nut clockwise [A] up to next alignment.
It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past

○

the nearest hole.

2-26 PERIODIC MAINTENANCE

Maintenance Procedure

Bend the cotter pin [A] over the nut.

•

Turn the wheel, measure the chain slack again at the tight-

•

est position, and readjust if necessary.

Check the rear brake.

•

Wheel Alignment Inspection/Adjustment

Check that the left adjuster mark [A] position should align

•

with the same graduation [B] that the right adjuster mark

position aligns with.

If they do not, adjust the chain slack and align the wheel

alignment.

NOTE

Wheel alignment can also be checked using the

○

straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal

wear, and may result in an unsafe riding condition.

Drive Chain Wear Inspection

Remove:

•

Chain Cover

Rotate the rear wheel to inspect the drive chain for dam-

•

aged rollers, loose pins and links.

If there is any irregularity, replace the drive chain.

Lubricate the drive chain if it appears dry.

Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)

•

weight [A] on the chain.

Measure the length of 20 links [B] on the straight part [C] of

•

the chain from the pin center of the 1st pin to the pin center

of the 21st pin. Since the chain may wear unevenly, take

measurements at several places.

If any measurements exceed the service limit, replace the

chain. Also, replace the front and rear sprockets when the

drive chain is replaced.

Drive C hain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit: 323 mm (12.7 in.)

Maintenance Procedure

WARNING

If the drive chain wear exceeds the service limit, re­place the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprock­ets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
For safely, use only the standard chain. It is an end­less type and should not be cut for installation.

Drive Chain Lubrication

If a special lubricant is not available, a heavy oil such as

•

SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
If the chain appears especially dirty, clean it before lubri-

•

cation.

[A] Apply oil

PERIODIC MAINTENANCE 2-27

CAUTION

The O-rings between the side plates seal in the lu­bricant between the pin and the bushing. To avoid
damaging the O-rings and resultant loss of lubri­cant, observe the following rules:
Use only kerosene or diesel oil for cleaning an O

-ring drive chain.
Any other cleaning solution such as gasoline
or trichloroethylene will cause deterioration and
swelling of the O-ring.
Blow the chain dry with compressed air immedi­ately after cleaning.
Complete cleaning and drying the chain within 10
minutes.

Apply oil to the sides of the rollers so that oil will penetrate

•

to the rollers and bushings. Apply the oil to the O-rings so
that the O-rings will be coated with oil.
Wipe off any excess oil.

•

Brakes

Brake Fluid Leak (Brake Hose and Pipe) Inspection

Apply the brake lever or pedal and inspect the brake fluid

•

leak from the brake hoses [A] and fittings.
If the brake fluid leaked from any position, inspect or re­place the problem part.

2-28 PERIODIC MAINTENANCE

Maintenance Procedure

Brake Hose Damage and Installation Condition Inspection

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage.

The high pressure inside the brake line can cause fluid to

○

leak [A] or the hose to burst if the line is not properly main-

tained. Bend and twist the rubber hose while examining

it.

Replace the hose if any cracks [B] or bulges [C] are no-

ticed.

Tighten any loose fittings and any banjo bolts.

Torque - Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Inspect the brake hose routing.

•

If any brake hose routing is incorrect, route the brake hose

according to Cable, Wire and Hose Routing Section in the

Appendix chapter.

Brake Operation Inspection

Inspect the operation of the front and rear brake by run-

•

ning the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake

system.

WARNING

When inspecting by running the vehicle, note a

surrounding traffic situation enough in the place of

safety.

Brake Fluid Level Inspection

Check that the brake fluid level in the front/rear brake

•

reservoirs [A] is above the lower level line [B].

NOTE

Hold the reservoirs horizontal by raising the motorcycle

○

perpendicular to the ground when checking brake fluid
level.

Special Tool - Jack: 57001-1238

Remove the right side cover.

•

Maintenance Procedure

If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [A] in the reservoir [B].

WARNING

Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that is already in the reser­voir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

PERIODIC MAINTENANCE 2-29

If the rear brake reservoir cap is open to fill the brake fluid,
follow the procedure below to install the cap correctly.
First, tighten the brake fluid reservoir cap [B] clockwise

○

[C] by hand until the resistance is felt fully; then, tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir [A] body.

Brake Pad Wear Inspection

In accordance with the Periodic Maintenance Chart, in-

spect the brake pads for wear.

Remove the pads.

•

Check the lining thickness [A] of the pads in the caliper.

•

If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.

Stepped Portion [C]

Pad Lining Thickness

Standard: 5.15 mm (0.203 in.)

Service Limit: 1 mm (0.04 in.)

2-30 PERIODIC MAINTENANCE

Maintenance Procedure

Brake Light Switch Operation Inspection

Front Brake Light Timing Inspection

Turn on the ignition switch.

•

The brake light should go on when the brake lever is ap-

•

plied or after the tip of brake lever moves about 10 mm

(0.39 in.) [A].

Rear Brake Light Timing Inspection

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by de-

•

pressing the brake pedal. The brake light should go on

as specified.

If it does not, adjust the brake light timing.

Brake Light Timing

Standard: On after about 15 mm (0.59 in.) pedal

travel [A]

Rear Brake Light Timing Adjustment

Brake light timing is adjusted by changing the position of
the rear brake light switch [A].

Adjust the position of the switch so that the brake light

•

goes on after the specified pedal travel by turning the ad-

justing nut [B].

[C] Lights sooner.
[D] Lights later.

CAUTION

To avoid damaging the electrical connections in-

side the switch, be sure that the switch body does

not turn during adjustment.

Suspension

Front Forks/Rear Shock Absorber Opera tion Inspection

Pump the forks down and up [A] 4 or 5 times, and inspect

•

the smooth stroke.

If the forks do not smoothly or noise is found, inspect the

fork oil level or fork clamps (see Front Fork Oil Change in

the Suspension chapter).

Maintenance Procedure

Pump the seat down and up [A] 4 or 5 times, and inspect

•

the smooth stroke.
If the shock absorber does not smoothly stroke or noise
is found, inspect the oil leak (see Rear Shock Absorber
Oil Leak Inspection) or shock absorber clamps.

Front Fork Oil Leak Inspection

Visually inspect the front forks for oil leakage [A].

•

If the oil leakage is found on it, replace or repair any de­fective parts.

PERIODIC MAINTENANCE 2-31

Rear Shock Absorber Oil Leak Inspection

Visually inspect the shock absorber for oil leakage [A].

•

If the oil leakage is found on it, replace the shock absorber
with a new one.

Rocker Arm Operation Inspection

Remove the lower fairings (see Fairing Removal in the

•

Frame chapter).
Pump the seat down and up 4 or 5 times, and inspect the

•

smooth stroke.
If the rocker arm [A] does not smoothly stroke or noise
is found, inspect the fasteners and bearings (see Rocker
Arm Bearing, Sleeve Inspection in the Suspension chap­ter).

Rocker Arm Bearings and Sleeves Lubrication

Remove the rocker arm (see Rocker Arm Removal in the

•

Suspension chapter).
Using a high flash-point solvent, wash the sleeves and

•

bearings, and dry them.
Apply molybdenum disulfide grease to the inner surface

•

of the needle bearings and outer circumference of the
sleeves.
Apply a thin coat of grease to the lips of the grease seal

•

[A].

2-32 PERIODIC MAINTENANCE

Maintenance Procedure

Tie-rod Operation Inspection

Remove the lower fairings (see Fairing Removal in the

•

Frame chapter).

Pump the seat down and up 4 or 5 times, and inspect the

•

smooth stroke.

If the tie-rods [A] do not smoothly stroke or noise is

found, inspect the fasteners and rocker arm bearings

(see Rocker Arm Bearing and Sleeve Inspection in the

Suspension chapter).

Swingarm Needle Bearing Lubrication

Remove the swingarm (see Swingarm Removal in the

•

Suspension chapter).

Apply a thin coat of the grease to the inner surfaces [A] of

•

the needle bearings.

Steering

Steering Play Inspection

Steering Play Inspection

Check the steering.

•

Lift the front wheel off the ground using the jack.

○

Special Tool - Jack: 57001-1238

With the front wheel pointing straight ahead, alternately

○

tap each end of the handlebar. The front wheel should

swing fully left and right from the force of gravity until the

fork hits the stop.

If the wheel binds or catches before the stop, the steering

is too tight.

Stand in front of the motorcycle and grasp the lower ends

•

of fork near the axle.

Feel for steering looseness by pushing [A] and pulling [B]

•

the forks.

If you feel looseness, the steering is too loose.

NOTE

The cables and wiring will have some effect on the mo-

○

tion of the fork which must be taken into account. Be
sure the wires and cables are properly routed.
The bearings must be in good condition and properly

○

lubricated in order for any test to be valid.

Steering Play Adjustment

Adjust the steering if necessary.

Remove:

•

Handlebar (see Handlebar Removal in the Steering
chapter)
Side Cover (see Side Cover Removal in the Frame chap­ter)
Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal i n the Fuel System
chapter)

Maintenance Procedure

Loosen:

•

Both Fork Lower Clamp Bolts [A].
Steering Stem Head Nut [B].

Adjust the steering.

•

If the steering is too tight, loosen the stem nut [A] a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.

Special Tool - Steering Stem Nut Wrench: 57001-1100 [B].

NOTE

Turn the stem nut 1/8 turn at a time maximum.

○

PERIODIC MAINTENANCE 2-33

Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb,

for reference)

Tighten the steering stem head nut [B] and fork lower

•

clamp bolts [A].

Torque - Steering Stem H ead Nut: 39 N·m (4.0 kgf·m, 29

ft·lb)

Fork Lower Clamp Bolts: 23 N·m (2.3 kgf·m, 17

ft·lb)

Check the steering again.

•

If the steering is still too tight or too loose, repeat the ad­justment.

Steering Stem Bearing Lubrication

Remove the steering stem (see Steering Stem Removal

•

in the Steering chapter).
Using a high-flash-point solvent, wash the upper and

•

lower tapered rollers in the cages, and wipe the upper
and lower outer races, which are press-fitted into the
frame head pipe, clean off grease and dirt.
Visually check the outer races and the rollers.

•

Replace the bearing assemblies if they show wear or
damage.

2-34 PERIODIC MAINTENANCE

Maintenance Procedure

Pack the upper and lower tapered roller bearings [A] in

•

the cages with grease, and apply a light coat of grease to

the upper and lower outer races.

Install the steering stem, and adjust the steering (see

•

Steering Play Inspection).

Electrical System

Spark Plug Gap Inspection

Measure the gap [A] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode

•

[B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.)

Lights and Switches Operation Inspectio n

First Step

Turn on the ignition switch.

•

The following lights should go on according to below table.

•

City Light [A]

Taillight [B]

Neutral Indicator LED [C]

Oil Pressure Warning Indicator LED [D]

Water Temperature Warning Indicator LED [E]

If the light does not go on, inspect or replace the following

item.

Battery (see Battery Activation in the Electrical System
chapter)
Applicable Bulb (see Lighting System in the Electrical
System chapter)
Meter Unit for Meter Panel Light (see Meter Unit in the
Electrical System chapter)
Meter Unit for Neutral Indicator Light (see Motor Unit in
the Electrical System chapter)
Meter Unit for Oil Pressure Warning Indicator Light (see
Meter Unit in the Electrical System chapter)
Meter Unit for Water Temperature Warning Indicator
Light (see Meter Unit in the Electrical System chapter)
Main Fuse 30 A and Taillight Fuse 10 A (see Fuses in
the Electrical System chapter)

goes on

goes on

goes on

goes on

goes on

Maintenance Procedure

Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Turn off the ignition switch.

•

The all lights should go off (see Switch Inspection in the

•

Electrical System chapter).
If the light does not go off, replace the ignition switch.

Second Step

Turn the ignition switch to P (Park) position.

•

The city light and taillight should go on.

•

If the light does not go on, inspect or replace the following
item.

Ignition Switch (see Switch Inspection in the Electrical
System chapter)

Third Step

Turn on the turn signal switch [A] (left or right position).

•

The left or right turn signal lights [B] (front and rear) ac-

•

cording to the switch position should flash.
The turn signal indicator LED [C] in the meter unit should

•

flash.
If the each light does not flash, inspect or replace the
following item.

Turn Signal Light Bulb (see Lighting System in the Elec­trical System chapter)
Meter Unit for Turn Signal Light Indicator LED (see Meter
Unit in the Electrical System chapter)
Turn Signal Relay Fuse 10 A (see Fuses in the Electrical
System chapter)
Turn Signal Switch (see Lighting System in the Electrical
System chapter)
Turn Signal Relay (see Lighting System in the Electrical
System chapter)
Harness (see Wiring Inspection in Electrical System
chapter)

Push the turn signal switch.

•

The turn signal lights and indicator LED should go off.

•

If the light does not go off, inspect or replace the following
item.

Turn Signal Switch (see Lighting System in the Electrical
System chapter)
Turn Signal Relay (see Lighting System in the Electrical
System chapter)

PERIODIC MAINTENANCE 2-35

2-36 PERIODIC MAINTENANCE

Maintenance Procedure

Fourth Step

Set the dimmer switch [A] to low beam position.

•

Start the engine.

•

The low beam headlight and license plate light should go

•

on.

If the low beam headlight and license plate light do not go

on, inspect or replace the following item.

Headlight Low Beam Bulb (see Lighting System in the
Electrical System chapter)
License Plate Light Bulb
Headlight Fuse 10 A (see Fuses in the Electrical System
chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)

Set the dimmer switch to high beam position.

•

The low beam [A] and high beam [B] headlights, and li-

•

cense plate light [C] should go on.

The high beam indicator LED [D] should go on.

•

If the high beam headlight and/or high beam indicator

LED, and license plate light do not go on, inspect or re-

place the following item.

Headlight High Beam Bulb (see Lighting System in the
Electrical System chapter)
License Plate Light Bulb
Dimmer Switch (see Switch Inspection Electrical System
chapter)

Turn off the engine stop switch.

•

The low beam and high beam headlights, and license

•

plate light should stay going on.

If the headlights, license plate light and high beam indica-

tor LED go off, inspect or replace the following item.

Headlights or Indicator Light (see Lighting System in the
Electrical System chapter)
License Plate Light Bulb

Turn off the ignition switch.

•

The headlights, license plate light and high beam indicator

•

LED should go off.

Headlight Aiming Inspectio n

Inspect the headlight beam for aiming.

•

If the headlight beam points to one side rather than

straight ahead, adjust the horizontal beam.

Maintenance Procedure

Headlight Beam Horizontal Adjustment

Insert the conventional screwdriver into the adjuster from

•

underside of the headlight, turn the horizontal adjuster [A]
on the headlight housing in or out until the beam points
straight ahead. Turning the adjuster clockwise m oves the
headlight beam to the left.

Headlight Beam Vertical Adjustment

Insert the conventional screwdriver into the adjuster from

•

the slit of the meter cover, turn the vertical adjuster [B]
on the headlight housing in or out to adjust the headlight
vertically.

NOTE

On high beam, the brightest point should be slightly be-

○

low horizontal with the motorcycle on its wheels and
rider seated. Adjust the headlight to the proper angle
according to local regulations.

Side Stand Switch Operation Inspection

Inspect the side stand switch [A] operation in accordance

•

to below table.

PERIODIC MAINTENANCE 2-37

Sidestand Switch Operation

Side Stand

Up Neutral Released

Up Neutral Pulled in

Up

Up

Down Neutral Released

Down Neutral Pulled in

Down In Gear Released

Down

Gear

Position

In Gear

In Gear

In Gear

Clutch

Lever

Released

Pulled in

Pulled in

Engine

Start

Starts

Starts

Doesn’t

start

Starts

Starts

Starts

Doesn’t

start

Doesn’t

start

Engine

Run

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Continue

running

Stops

Stops

If the side stand switch operation does not work, inspect
or replace the following item.

Battery (see Battery Activation in the Electrical System
chapter)
Main Fuse 30 A (see Fuses in the Electrical System
chapter)
Ignition Fuse 10 A (see Fuses in the Electrical System
chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Side Stand Switch (see Switch Inspection in the Electri­cal System chapter)

2-38 PERIODIC MAINTENANCE

Maintenance Procedure

Engine Stop Switch (see Switch Inspection in the Elec­trical System chapter)
Starter Button (see Switch Inspection in the Electrical
System chapter)
Starter Relay (see Starter Relay Inspection in the Elec­trical System chapter)
Junction Box (see Junction Box Inspection in the Elec­trical System chapter)
Harness (see Wiring Inspection in Electrical System
chapter)

If the all parts are good condition, replace the IC igniter.

Engine Stop Switch Operation I nspectio n

First Step

Turn on the ignition switch.

•

Set the neutral position.

•

Turn the engine stop switch to stop position [A].

•

Push the starter button.

•

The engine does not start.

•

If the engine starts, inspect or replace the following item.

Engine Stop Switch (see Switch Inspection in the Elec­trical System chapter)

Second Step

Turn on the ignition switch.

•

Set the neutral position.

•

Turn the engine stop switch to run position [B].

•

Push the s tarter button and run the engine.

•

Turn the engine stop switch to stop position.

•

Immediately the engine should be stop.

•

If the engine does not stop, inspect or replace the follow-

ing item.

Engine Stop Switch (see Switch Inspection in the Elec-

trical System chapter)
If the engine stop switch is good condition, replace the IC
Igniter.

Others

Chassis Parts Lubrication

Before lubricating each part, clean off any rusty spots w ith

•

rust remover and wipe off any grease, oil, dirt, or grime.
Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubri­cation.

Pivots: Lubricate with Motor Oil.

Rear Brake Rod Joint

Maintenance Procedure

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]
Throttle Inner Cable Upper and Lower Ends
Fast Idle Inner Cable Upper and Lower end
Clutch Lever Pivot (Apply silicone grease)
Brake Lever Pivot (Apply silicone grease)
Brake Pedal Pivot
Side Stand
Tie-Rod Pivot
Rocker Arm Pivot
Speedometer Gear Housing

Cables: Lubricate with Cable Lubricant.

Fast Idle Cable
Throttle Cables
Clutch Cable
Lubricate the cables by seeping the oil between the cable

•

and housing.
The cable may be lubricated by using a commercially

○

available pressure cable lubricator with an aerosol cable
lubricant.

PERIODIC MAINTENANCE 2-39

With the cable disconnected at both ends, the cable

•

should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.

Bolts, Nuts and Fastener Tightness Inspection

Check the tightness of the bolts and nuts listed here. Also,

•

check to see that each cotter pin is in place and in good
condition.

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

If there are loose fasteners, retorque them to the spec­ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.

2-40 PERIODIC MAINTENANCE

Maintenance Procedure

Nut, Bolt and Fastener to be checked

Wheels:

Front Axle Nut
Front Axle Clamp Bolt
Rear Axle Nut
Rear Axle Nut Clip

Brakes:

Master Cylinder Clamp Bolts
Brake Lever Pivot Nut
Caliper Mounting Bolts
Brake Pedal Lever Clamp Bolt
Cam Lever Clamp Bolt
Brake Rod Joint Cotter Pin
Torque Link Nuts
Torque Link Nut Clips

Suspension:

Front Fork Clamp Allen Bolts
Front Fender Mounting Bolts
Rear Shock Absorber Mounting Bolts
Swingarm Pivot Shaft Nut

Steering:

Stem Head Nut
Handlebar Mounting Nuts

Engine:

Engine Mounting Bolts and Nuts
Shift Pedal Bolt
Muffler Mounting Bolts and Nuts
Exhaust Pipe Holder Nuts
Muffler Connecting Clamp Bolt
Clutch Lever Holder Clamp Bolt
Clutch Lever Pivot Nut

Others:

Side Stand Pivot Nut
Front Footpeg Bracket Mounting Bolts
Rear Frame Mounting Bolts

Replacement Parts

Fuel Hose Replacement

Remove the fuel tank (see Fuel Tank Removal in the Fuel

•

System).
Slide the clamps of both hose end of fuel tame and car-

•

buretor.
Replace the fuel hose with a new one.

•

Clamp the hose securely with clamps.

•

Maintenance Procedure

Air Cleaner Element Replacement

NOTE

Since repeated cleaning opens the pores of the foam

○

element, replace it with a new one periodically. Also,
if there is a brake in the element material or any other
damage to the element, replace the element with a new
one.

WARNING

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

CAUTION

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

Coolant Change

Coolant Draining

The coolant should be changed periodically to ensure

long engine life.

PERIODIC MAINTENANCE 2-41

CAUTION

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

WARNING

To avoid burns do not remove the radiator cap or try
to change the coolant when the engine is still hot.
Wait until it cools down.
Coolant on tires will make them slippery and can
cause an accident and injury. Immediately wipe up
or wash away any coolant that spills on the frame,
engine, or other painted parts.
Since coolant is harmful to the human body, do not
use for drinking.

Situate the motorcycle so that it is perpendicular to the

•

ground.
Remove the engine guard (see engine Guard Removal in

•

the Frame chapter).
Place a container under the water pump [A].

•

Remove the drain plug [B], and drain the coolant.

•

Remove the left lower fairing (see Lower Fairing Removal

•

in the Frame chapter).

2-42 PERIODIC MAINTENANCE

Maintenance Procedure

Remove the radiator cap [A] in two steps. First turn the

•

cap counterclockwise to the first stop and wait there for a
few seconds. Then push down and turn it further in the
same direction and remove the c ap.
The coolant will drain from the radiator and engine.

○

Remove the left side cover (see Side Covers Removal in

•

the Frame chapter).
Pull off the air vent hose [A], unscrew the bolts [B] and

•

remove the reserve tank [C] with the lower hose attached.
Unscrew the cap [D] and pour the coolant into a container.

•

Inspect the old coolant for color and smell (mentioned

•

above).

Coolant Filling

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

•

a new one.
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 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.

Maintenance Procedure

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.

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.

•

PERIODIC MAINTENANCE 2-43

Remove the reserve tank cap.

•

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

•

install the cap.

CAUTION

Do not add more coolant above the F level.

Install:

•

Engine Guard
Left Side Cover
Left Lower Fairing

2-44 PERIODIC MAINTENANCE

Maintenance Procedure

Radiator Hoses and O-ring Replacement

Drain the coolant (see Coolant Draining).

•

Remove:

•

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Spark Plug Caps

Thermostat Housing Cover [A]

Pipe [B]

Hoses [C]

O-rings [D]

To Cylinder Head [E]

To Carburetor [F]

To Cylinder [G]
Apply grease to the new O-rings and install them.

•

Install the hoses and tighten the clamps securely.

•

Fill the coolant (see Coolant Filling).

•

Check the cooling system for leaks.

•

Engine Oil Change

Warm up the engine so that the oil will pick up any sedi-

•

ment and drain easily. Then stop the engine.
Support the motorcycle perpendicular to the ground, and

•

place an oil pan beneath the engine.
Remove the engine oil drain plug [A], and let the oil drain

•

completely.
If the oil filter is to be changed, replace it with a new one.

•

Check the gasket at the drain plug for damage.

•

Replace the gasket with a new one if it is damaged.
After the oil has completely drained out, install the drain

•

plug with the gasket, and tighten it.

Torque - Engine Oil Drain Plug: 29 N·m (3.0 kgf·m, 22 ft·lb)

Maintenance Procedure

Fill the engine with a good quality motor oil specified in

•

the table.

Torque - Oil Fill er Plug: 1.5 N·m (0.15 kgf·m, 13 in·lb)

Check the oil level.

•

Engine Oil

Grade: API SE, SF, SG or

API SH or SJ with JASO MA

Viscosity:

Capacity: 2.8 L (When filter is not removed)

Although 10W-40 engine oil is the recommended oil

○

for most conditions, the oil viscosity may need to be
changed to accommodate atmospheric conditions in
your riding area.

SAE 10W40

3.0 L (When filter is remove d)

3.4 L (When engine is completely dry)

NOTE

PERIODIC MAINTENANCE 2-45

Oil Filter Replacement

Support the motorcycle perpendicular to the ground.

•

Remove the engine guard.

•

Drain the engine oil (see Engine Oil Change).

•

Using an oil filter wrench [A] on the oil filter [B], unscrew

•

it.

Special Tool - Oil Filter Wrench: 57001-1249

Replace the oil filter with a new one.

•

Apply engine oil to the gasket before screwing on.

•

Tighten the oil filter with an oil filter wrench or tighten it with

•

hands about 3/4 turns after gasket touches the mounting
surface of the engine.

Torque - Oil Filter: 17 N·m (1.7 kgf·m, 12.5 ft·lb)

Pour in the specified type and amount of oil (see Engine

•

Oil Change).
Thoroughly warm up the engine and check for oil leakage.

•

Brake Hose Replacement

CAUTION

Brake fluid quickly ruins painted or plastic sur­faces; any spilled fluid should be completely wiped
up immediately with wet cloth.

When removing the brake hose, take care not to spill the

•

brake fluid on the painted or plastic parts.
When removing the brake hose, temporarily secure the

•

end of the brake hose to some high place to keep fluid
loss to a minimum.
There are washers on each side of the brake hose fitting.

•

Replace them with new ones when installing.

2-46 PERIODIC MAINTENANCE

Maintenance Procedure

When installing the hose, avoid sharp bending, kinking,

•

flattening or twisting, and route the hose according to Ca­ble, Wire and Hose Routing in the Appendix chapter.
Tighten the banjo bolts to the specified torque.

•

Torque - Brake Hose Banjo bolts: 34 N·m (3.5 kgf·m, 25

ft·lb)

Bleed the brake line after installing the brake hose.

•

Brake Fluid Change

Level the brake fluid reservoir.

•

Remove the reservoir cap.

•

Remove the rubber cap from the bleed valve [A] on the

•

caliper.
Attach a clear plastic hose [B] to the bleed valve, and run

•

the other end of the hose into a container.
Fill the reservoir with fresh specified brake fluid.

•

Change the brake fluid as follows:

•

Repeat this operation until fresh brake fluid comes out

•

from the plastic hose or the color of the fluid changes.

NOTE

The fluid level must be checked often during the chang-

○

ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.

1. Open the bleed valve [A].

2. Apply the brake and hold it [B].

3. Close the bleed valve [C].

4. Release the brake [D].

Remove the clear plastic hose.

•

Tighten the bleed valve to the specified torque, and install

•

the rubber cap.

Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)

Follow the procedure below to install the brake fluid reser-

○

voir cap correctly.
First, tighten the brake fluid reservoir cap [B] clockwise

○

[C] by hand until the resistance is felt fully; then, tighten
the cap an additional 1/6 turn [D] while holding the brake
fluid reservoir [A] body.
After changing the fluid, check the brake for good braking

•

power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.

Maintenance Procedure

Bleeding the Brake Line

The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever is transmit­ted directly to the caliper for braking action. Air, however, is
easily compressed. When air enters the brake line, brake
lever movement will be partially used in compressing the
air. This will make the lever feel spongy, and it will be a loss
in braking power.

WARNING

Be sure to bleed the air from the brake line when-

ever brake lever action feels soft or spongy, a fter

the brake fluid is changed, or whenever a brake line

fitting has been loosened for any reason.

Remove the reservoir cap, and fill the reservoir with fresh

•

brake fluid to the upper level line in the reservoir.

With the reservoir cap off, slowly pump the brake lever

•

several times until no air bubbles can be seen rising up

through the fluid from the holes at the bottom of the reser-

voir.

Bleed the air completely from the master cylinder by this

○

operation.

PERIODIC MAINTENANCE 2-47

NOTE

The fluid level must be checked often during the bleed-

○

ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs almost out
any time during bleeding operation, the bleeding opera­tion must be done over again from the beginning since
air will have entered the line.
Tap the brake hose lightly from the caliper to the reser-

○

voir for easier bleeding.

2-48 PERIODIC MAINTENANCE

Maintenance Procedure

Install the reservoir cap.

•

Remove the rubber cap from the bleed valve on the

•

caliper.
Attach a clear plastic hose to the bleed valve on the

•

caliper, and run the other end of the hose into a con­tainer.
Bleed the air from the caliper as follows:

•

Repeat this operation until no more air can be seen com-

•

ing out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold­ing the brake applied.

3. Release the brake [C].

Detach the clear plastic hose from the bleed valve.

•

Tighten the bleed valve to the specified torque, and install

•

the rubber cap.

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Check the fluid level.

•

After bleeding is done, check the brake for good braking

•

power, no brake drag, and no fluid leakage.

Caliper Rubber Parts Rep lacement

Disassembly the calipers (see Brakes chapter).

•

Replace the fluid seal [A] under any of the following con-

•

ditions.
Fluid leakage around the pad.

○

Brakes overheat.

○

There is a large difference in left and right pad wear.

○

The seal is stuck to the piston.

○

If the fluid seal is replaced, replace the dust seal as well.
After finishing the replacement, check the brake effective-

•

ness.
Replace the dust seal [B] when it is cracked, worm,

•

swollen and otherwise damaged.

Master Cylinder Rubber Parts Replacement

Remove the master cylinders (see Master Cylinder Re-

•

moval in the Brakes chapter).
Disassemble the master cylinder (see Master Cylinder

•

Disassembly in the Brake System).
Replace the piston assembly to renew the primary and

•

secondary cups.
After finishing the replacement, check the brake effective-

•

ness.

Maintenance Procedure

Spark Plug Replacement

Remove:

•

Lower Fairings (see Lower Fairings Removal in the Fuel
chapter)

Carefully pull the spark plug caps from the spark plugs

•

and unscrew the spark plug using an owner’s tool [A].

Replace the spark plugs and tighten them with specified

•

torque.

Torque - Spark Plugs: 14 N·m (1.4 kgf·m, 10 ft·lb)

Fit the plug caps securely.

•

PERIODIC MAINTENANCE 2-49

FUEL SYSTEM 3-1

Fuel System

Table of Contents

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

Specifications ......................................................................................................................... 3-6

Special Tools .......................................................................................................................... 3-7

Throttle Grip and Cables ........................................................................................................ 3-8

Throttle Cable Inspection .................................................................................................. 3-8

Throttle Cable Lubrication................................................................................................. 3-8

Throttle Cable Removal .................................................................................................... 3-8

Throttle Cable Installation ................................................................................................. 3-8

Choke Cable........................................................................................................................... 3-9

Choke Cable Free Play Inspection ................................................................................... 3-9

Choke Cable Free Play Adjustment.................................................................................. 3-9

Choke Cable Installation ................................................................................................... 3-9

Choke Cable Lubrication................................................................................................... 3-9

Carburetors............................................................................................................................. 3-10

Carburetor Removal.......................................................................................................... 3-10

Carburetor Installation....................................................................................................... 3-10

Service Fuel Level Inspection........................................................................................... 3-11

Service Fuel Level Adjustment ......................................................................................... 3-12

Fuel System Cleanliness Inspection ................................................................................. 3-13

Carburetor Disassembly/Assembly................................................................................... 3-14

Carburetor Separation/Assembly...................................................................................... 3-15

Carburetor Cleaning.......................................................................................................... 3-17

Carburetor Inspection ....................................................................................................... 3-18

Coolant Filter Cleaning ..................................................................................................... 3-18

Air Cleaner.............................................................................................................................. 3-19

Air Cleaner Element Removal........................................................................................... 3-19

Air Cleaner Element Installation........................................................................................ 3-19

Air Cleaner Element Cleaning and Inspection .................................................................. 3-19

Air Cleaner Housing Removal........................................................................................... 3-19

Air Cleaner Housing Installation........................................................................................ 3-20

Air Cleaner Draining ......................................................................................................... 3-20

Fuel Tank ................................................................................................................................ 3-21

Fuel Tank Removal ........................................................................................................... 3-21

Fuel Tank Installation ........................................................................................................ 3-22

Fuel Tap Removal ............................................................................................................. 3-22

Fuel Tap Installation .......................................................................................................... 3-22

Fuel Tank and Tap Cleaning ............................................................................................. 3-22

Fuel Tap Inspection........................................................................................................... 3-23

Fuel Tank and Cap Inspection .......................................................................................... 3-23

Fuel Hose ............................................................................................................................... 3-24

Fuel Hose and Connection Inspection.............................................................................. 3-24

3

3-2 FUEL SYSTEM

Exploded View

Exploded View

1. Throttle Cable (Accelerator)

2. Throttle Cable (Decelerator)

3. Choke Cable

4. Pilot (Slow) Jet

5. Pilot (Slow) Air Screw

6. Float Valve

7. Jet Needle

8. Needle Jet

9. Needle Jet Holder

10. Main Jet

11. Float

CL: Apply c able lubricant.

G: Apply grease.

FUEL SYSTEM 3-3

3-4 FUEL SYSTEM

Exploded View

Exploded View

FUEL SYSTEM 3-5

No. Fastener

Torque

N·m kgf·m ft·lb

1 Fuel Tap Mounting Bolts 5.0 0.51 44 in·lb

2 Fuel Tap Cover Screws 0.8 0.08 7in·lb

3 Air Cut Valve Cover Screws 1.0 0.10 9in·lb

4. Vacuum Switch Valve

5. Air Cleaner Housing

6. Air Cleaner Element

Remarks

3-6 FUEL SYSTEM

Specifications

Item Standard

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

Carburetors

Mark, Type KEIHIN CVK34

Idle Speed 1 200 ±50 r/min (rpm)

Pilot Screw (Turns Out) 1 3/4 ±1/4

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

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

mating surface

Float Height 17 ±2 mm (0.67 ±0.08 in.)

Main Jet Left: #95 Right: #92

Main Air Jet #100

Needle Jet –

Needle Jet Holder –

Jet Needle Mark Left: N60D, Right: N96L

Pilot Jet (Slow J et) #35

Pilot Air Jet (Slow Air Jet) #80

Starter Jet #52

Throttle Valve Angle 11°

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]

Special Tools

FUEL SYSTEM 3-7

Fuel Level Gauge:
57001-1017

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

3-8 FUEL SYSTEM

Throttle Grip and Cables

Throttle Cable Inspection

Throttle Grip Free Play Inspection

Refer to the Throttle Cable Inspection in the Periodic

•

Maintenance chapter.

Throttle Grip Free Play Adjustment

Refer to the Throttle Cable Inspection in the Periodic

•

Maintenance chapter.

Throttle Cable Inspection

Refer to the Throttle Cable Inspection in the Periodic

•

Maintenance chapter.

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.

Throttle Cable Removal

Remove the handlebar cover mounting bolt and nut.

•

Remove the right switch housing screws [A], and split the

•

switch housing [B].
Remove the throttle cable.

•

Throttle Cable Installation

Fit the throttle cables into the right switch housing, assem-

•

ble the switch housing.
Install the switch housing cap aligning the projection [A]

○

with the hole on the handlebar [B].

Choke Cable

Choke Cable Free Play Inspection

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

•

Check the 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 3-9

Choke Cable 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.

•

Choke Cable Installation

Install the choke cable in accordance with Cable, Wire,

•

and Hose Routing in the Appendix 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.

Choke 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.

3-10 FUEL SYSTEM

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:

•

Side Covers (see Side Cover Removal in the Frame
chapter)
Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Throttle Cable Lower Ends [A]
Choke Cable Lower End [B]
Air Cleaner Housing (see Air Cleaner Housing Removal)

Loosen:

•

Carburetor Clamp Screws [A]

Slide up the clamp and pull up the vacuum hose [B].

•

Slide the clamps [A] and remove the left and right coolant

•

hoses [B].
Move back the carburetor [C], and remove the carburetor.

•

Carburetor Installatio n

Installation is the reverse of removal.

•

Tighten the carburetor holders clamps after inserting the

•

carburetor into the holders enoughly.

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

FUEL SYSTEM 3-11

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.

3-12 FUEL SYSTEM

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 s everal 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.

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.) abo ve ∼ 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.

Carburetors

Remove the float bowl by taking out the float chamber

•

screws [A] and water hose fitting screws [B] with lock­washers.

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

•

FUEL SYSTEM 3-13

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 (0.67 ±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

3-14 FUEL SYSTEM

Carburetors

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.

•

Special Tool - Carburetor Drain Plug Wrench, Hex 3:

57001-1269 [C]

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

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.

Carburetors

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.

FUEL SYSTEM 3-15

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 b lock the hole
[B] at the bottom of the vacuum piston.

Install the carburetor top cover.

•

Turn in the pilot screw fully but not tightly, and then back it

•

out the same number of turns counted during disassem­bly.
When removing the coasting enricher system, unscrew

•

the mounting screws [B] and remove the air cut valve
cover [C], spring [D], O-ring [E] and diaphragm [F].

Right Carburetor [A]

Torque - Air Cut valve Cover Screws: 1.0 N·m (0.10 kgf·m,

9in·lb)

Carburetor Separation/Assembly

Read the WARNINGS in the Carburetor Removal.

•

Remove the choke synchronizing stay spring [A].

•

Remove the choke synchronizing stay screws [B] with ny-

•

lon washers, and remove the stay [C].

3-16 FUEL SYSTEM

Carburetors

Remove the upper carburetor mounting screws [A] and

•

stay [B].
Remove the fuel supply pipe connected both carburetors.

○

Remove the vacuum hose [C] connected both carbure-

•

tors.

Remove the lower carburetor mounting screws [A] and

•

stay [B].

Inspect the O-rings [A] of fuel supply pipe.

•

If they are damaged, replace the O-rings.

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.

Carburetors

Visually synchronize the throttle (butterfly) v alves.

•

Check t o 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.

FUEL SYSTEM 3-17

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.

•

3-18 FUEL SYSTEM

Carburetors

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.

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

Refer to the Coolant Filter Cleaning in the Periodic Main-

•

tenance chapter.

Air Cleaner

Air Cleaner Element Removal

Remove:

•

Side Covers (see Side Cover Removal in the Frame
chapter)

Air Cleaner Cover Screws [A]
Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)

Remove the element [A].

•

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

•

keep dirt or other foreign material from entering.

WARNING

FUEL SYSTEM 3-19

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

CAUTION

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

Air Cleaner Element Installation

Insert the air cleaner element into the housing so that the

•

projections [A] on both side of the element holder fit to the
groove [B].

Install:

•

Air Cleaner Element Cover
Fuel Tank
Seat
Side Covers

Air Cleaner Element Cleaning and Inspection

Refer to the Air Cleaner Element Cleaning and Inspection

•

in the Periodic Maintenance chapter.

Air Cleaner Housing Removal

Remove:

•

Side Covers (see Side Cover Removal in the Frame
chapter)
Seat (see Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
chapter)

3-20 FUEL SYSTEM

Air Cleaner

Fuel Tank Bracket [A]
Air Cleaner Ducts
Breather Tube
Air Suction Valve Hose

Remove the air cleaner housing [A].

•

Air Cleaner Ho using Installation

Air cleaner housing i nstallation is the reverse of removal.

•

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

pinching the lower end [B] 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:

•

Side Covers (see Side Covers Removal in the Frame
chapter)
Seat (see Seat Removal in the Frame chapter)

Turn the fuel tap to the ON or RES position.

•

Remove the fuel tank mounting bolts [A].

•

FUEL SYSTEM 3-21

Remove the lower fairing mounting screws [A], stoppers

•

[B] and free the fuel tank from the fairings.

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

•

the tap.
Pull the over flow drain hose [C] off the fuel tank.

•

Remove the fuel tank.

•

Drain the fuel tank.

•

Place a suitable container under the fuel tank.

○

TurnthefueltaptothePRIpositiontodrainthefuelinto

○

the container.

3-22 FUEL SYSTEM

Fuel Tank

Fuel Tank Installation

Read the WARNING in the Fuel Tank Removal section.

•

Check the rubber dampers [A] on the frame and the one

•

pasted under the fuel tank.

If the dampers are damaged or deteriorated, replace

them.

Route the hoses correctly (see Cable, Wire, and Hose

•

Routing in the Appendix chapter).

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 tank (see Fuel Tank Removal).

•

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

•

Fuel Tap Installation

Install the fuel tap with a specified torque.

•

Torque - Fuel Tap Mounting Bolts: 5.0 N·m (0.51 kgf·m, 44

in·lb)

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

•

Install the fuel tank (see Fuel Tank Installation)

•

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.

Fuel 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 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 SYSTEM 3-23

Fuel Tank and Cap Inspection

Open the tank cap.

•

Visually inspect the gasket [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.

3-24 FUEL SYSTEM

Fuel Hose

Fuel Hose and Connection Inspection

Refer to the Fuel Hoses and Connections Inspection in

•

the Periodic Maintenance chapter.

COOLING SYSTEM 4-1

Cooling System

Table of Contents

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

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

Special Tool and Sealant........................................................................................................ 4-5

Coolant Flow Chart................................................................................................................. 4-6

Coolant ................................................................................................................................... 4-8

Coolant Deterioration Inspection....................................................................................... 4-8

Coolant Level Inspection................................................................................................... 4-8

Coolant Draining ............................................................................................................... 4-8

Coolant Filling ................................................................................................................... 4-8

Visual Leak Inspection ...................................................................................................... 4-8

Cooling System Pressure Testing..................................................................................... 4-8

Flushing ............................................................................................................................ 4-9

Coolant Filter Cleaning ..................................................................................................... 4-9

Coolant Valve Inspection .................................................................................................. 4-9

Water Pump............................................................................................................................ 4-10

Water Pump Removal....................................................................................................... 4-10

Water Pump Installation.................................................................................................... 4-10

Mechanical Seal Inspection .............................................................................................. 4-11

Water Pump Housing Disassembly .................................................................................. 4-11

Water Pump Housing Assembly ....................................................................................... 4-11

Impeller Assembly............................................................................................................. 4-12

Pump Impeller Inspection ................................................................................................. 4-12

Radiator, Radiator Fan ........................................................................................................... 4-13

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

Radiator Inspection........................................................................................................... 4-13

Radiator Fan Removal ...................................................................................................... 4-14

Filler Neck Inspection........................................................................................................ 4-14

Radiator Cap Inspection ................................................................................................... 4-14

Radiator Hose and Connection Inspection ....................................................................... 4-15

Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installation ............................ 4-15

Thermostat ............................................................................................................................. 4-16

Thermostat Removal......................................................................................................... 4-16

Thermostat Installation...................................................................................................... 4-16

Thermostat Inspection ...................................................................................................... 4-16

Radiator Fan Switch, Water Temperature Switch................................................................... 4-18

Radiator Fan Switch Removal .......................................................................................... 4-18

Water Temperature Switch Removal ................................................................................ 4-18

Radiator Fan Switch, Water Temperature Switch Installation ........................................... 4-18

Radiator Fan Switch, Water Temperature Switch Inspection ............................................ 4-18

4

4-2 COOLING SYSTEM

Exploded View

Exploded View

COOLING SYSTEM 4-3

No. Fastener

1

Cylinder Head Jacket Plug

2 Thermostat Housing Bolts 11 1.1 95 in·lb

3 Radiator Cap Holder Mounting Bolts 11 1.1 95 in·lb

4

Water Temperature Switch

5 Water Pipe Bolts 9.8 1.0 87 in·lb L

6 Radiator Fan Switch 18 1.8 13

7

Radiator Hose Clamp Screws

8 Water Pump Shaft 25 2.5 18 Lh

9 Water Pump Impeller 9.8 1.0 87 in·lb Lh

10

Water Pump Cover Bolts

11 Coolant Drain Bolt 11 1.1 95 in·lb

12. Thermostat
G: Apply high temperature grease.

L: Apply a non-permanent locking agent.

Lh: Left-hand Thread

SS: Apply s ilicone sealant.

N·m kgf·m ft·lb

9.8 1.0 87 in·lb L

7.8 0.8 69 in·lb

2.5 0.25 22 in·lb

11 1.1 95 in·lb

Torque

Remarks

SS

4-4 COOLING SYSTEM

Specifications

Item Standard

Coolant Provided when Shipping

Type (recommended) Permanent type antifreeze (soft water and ethylene glycol

plus corrosion and rust inhibitor chemicals for aluminum
engines and radiators)

Color Green

Mixed Ratio Soft water 50%, coolant 50%

Freezing Point –35°C (–31°F)

Total Amount 1.7L(1.8USqt)

(reserve tank full level including radiator and engine)

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)

SpecialToolandSealant

COOLING SYSTEM 4-5

Bearing Driver Set:
57001-1129

Kawasaki Bond (Silicone Sealant):
56019-120

4-6 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 96 ∼ 100°C (205 ∼ 212°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 l ess 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.