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