Kawasaki KLE500 (2004) User Manual [ru]

Quick Reference Guide

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.

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
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 in 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 make 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 are 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	bottom dead center	PS	horsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
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)

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 the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

•Follow the Periodic Maintenance Chart in the Service Manual.

•Be alert for problems and non-scheduled maintenance.

•Use proper tools and genuine Kawasaki Motorcycle 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 carefully. Don’t take shortcuts.

•Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use This Manual

In this manual, the product is divided into its major systems and these systems make up the manual’s chapters.

The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the ignition coil section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

WARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage 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 particular interest for more efficient and convenient operation.

•Indicatesdone. a procedural step or work to be ○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 inspection in the procedural step or sub-step it follows.

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	1
Table of Contents
Before Servicing .....................................................................................................................	1-2
Model Identification.................................................................................................................	1-7
General Specifications............................................................................................................	1-8
Unit Conversion Table ............................................................................................................	1-11

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 sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

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.

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.

GENERAL INFORMATION 1-5

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.

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 Engine 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.

GENERAL INFORMATION 1-7

Model Identification

KLE500-B1 Left Side View

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	2.4 m (7.9 ft.)
Engine
Type	4-stroke, DOHC, 2-cylinder
Cooling System	Liquid-cooled
Bore and Stroke	74.0 × 58.0 mm (2.91 × 2.28 in.)
Displacement	498 mL (30.39 cu in.)
Compression Ratio	9.8:1
Maximum Horsepower	33 kW (44.9 PS) @8 300 r/min (rpm)
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
	@5 000 r/min (rpm)
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

	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	6-speed constant mesh, return shift
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	2.588 (44/17)
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	Telescopic fork
Wheel Travel	220 mm (8.66 in.)
Rear Suspension:
Type	Swingarm
Wheel Travel	200 mm (7.87 in.)
Brake Type:
Front	Single disc
Rear	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		Three-phase AC
Rated output		17	A × 14 V @6 000 r/min (rpm)

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

GENERAL INFORMATION 1-11

Unit Conversion Table

Prefixes for Units:

Units of Length:

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

Units of Mass:

kg	×	2.205	=	lb
g	×	0.03527	=	oz

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

Units of Torque:

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

Units of Volume:						Units of Pressure:
						kPa	×	0.01020	=	kgf/cm²
L	×	0.2642	=	gal (US)		kPa	×	0.1450	=	psi
L	×	0.2200	=	gal (imp)		kPa	×	0.7501	=	cm Hg
L	×	1.057	=	qt (US)		kgf/cm²	×	98.07	=	kPa
L	×	0.8799	=	qt (imp)		kgf/cm²	×	14.22	=	psi
L	×	2.113	=	pint (US)		cm Hg	×	1.333	=	kPa
L	×	1.816	=	pint (imp)
mL	×	0.03381	=	oz (US)		Units of Speed:
mL	×	0.02816	=	oz (imp)		km/h	×	0.6214	=	mph
mL	×	0.06102	=	cu in
Units of Force:						Units of Power:
						kW	×	1.360	=	PS
N	×	0.1020	=	kg		kW	×	1.341	=	HP
N	×	0.2248	=	lb
						PS	×	0.7355	=	kW
kg	×	9.807	=	N		PS	×	0.9863	=	HP
kg	×	2.205	=	lb

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents		2
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 Needle Bearing Lubrication..............................................................................	2-32
Steering ...............................................................................................................................	2-32

2-2 PERIODIC MAINTENANCE

Steering Play Inspection ...................................................................................................	2-32
Steering Stem 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 Parts ..............................................................................................................	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

Whichever

* ODOMETER READING

× 1000 km

comes first

See

(× 1000 mile)

Page

1

6

12

18

24

30

36

OPERATION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Fuel System

Throttle cable-inspect

year

•

•

•

•

2-14

Idle speed-inspect

•

•

•

•

2-15

Carburetor synchronization-inspect

•

•

•

2-16

Coolant filter-clean

year

2-17

Air cleaner element-clean #

•

•

•

2-17

Fuel hoses and connections-inspect

year

•

•

•

•

2-17

Cooling System

Coolant level-inspect

•

•

•

•

2-18

Radiator hose and connection-inspect

year

•

•

•

•

2-19

Engine Top End

Air suction valve-inspect

•

•

•

2-19

Valve clearance-inspect

•

2-19

Clutch

Clutch operation (play, disengagement,

•

•

•

•

2-21

engagement)-inspect

Wheels and Tires

Tire air pressure-inspect

•

•

•

•

•

•

2-22

Tire tread wear-inspect

•

•

•

2-22

Wheel/tire damage-inspect

•

•

•

2-23

Wheel bearing damage-inspect

year

•

•

•

2-24

Spoke tightness and rim runout-inspect

•

•

•

•

•

•

•

2-24

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

year

•

•

•

•

•

•

•

2-27

pipe)-inspect

Brake hose damage-inspect

year

•

•

•

•

•

•

•

2-28

Brake hose installation condition-inspect

year

•

•

•

•

•

•

•

2-28

Brake operation (effectiveness, play, no

year

•

•

•

•

•

•

•

2-28

drag)-inspect

Brake fluid level-inspect

6 months

•

•

•

•

•

•

•

2-28

Brake pad wear-inspect #

•

•

•

•

•

•

2-29

Brake light switch operation-inspect

•

•

•

•

•

•

•

2-30

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

Whichever

* ODOMETER READING

× 1000 km

comes first

See

(× 1000 mile)

Page

1

6

12

18

24

30

36

OPERATION

Every

(0.6)

(4)

(7.5)

(12)

(15)

(20)

(24)

Suspensions

Front forks/rear shock absorber operation

•

•

•

2-30

(damping and smooth stroke)-inspect

Front forks/rear shock absorber oil

year

•

•

•

2-31

leak-inspect

Rocker arm operation-inspect

•

•

•

2-31

Rocker arm bearings and sleeves

•

2-31

-lubricate

Tie-rods operation-inspect

•

•

•

2-32

Swingarm pivot-lubricate

•

2-32

Steering System

Steering play-inspect

year

•

•

•

•

2-32

Steering stem bearings-lubricate

2 years

•

2-33

Electrical System

Spark plug condition-inspect

•

•

•

2-34

Lights and switches operation-inspect

year

•

•

•

2-34

Headlight aiming-inspect

year

•

•

•

2-36

Side stand switch operation-inspect

year

•

•

•

2-37

Engine stop switch operation-inspect

year

•

•

•

2-38

Others

Chassis parts-lubricate

year

•

•

•

2-38

Bolts, nuts and fasteners tightness-inspect

•

•

•

•

2-39

#: 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.

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY

Whichever

* ODOMETER READING

come

× 1000 km

See

first

(× 1000 mile)

Page

1

12

18

24

36

48

CHANGE/REPLACEMENT

Every

(0.6)

(7.5)

(12)

(15)

(24)

(30)

Fuel hose

4 years

•

2-40

Air cleaner element

2 years

2-40

Coolant

3 years

•

2-40

Radiator hose and O-ring

3 years

•

2-43

Engine oil #

year

•

•

•

•

•

2-43

Oil filter

year

•

•

•

•

•

2-44

Brake hose

4 years

•

2-44

Brake fluid

2 years

•

•

2-45

Master Cylinder/Caliper Rubber Parts

4 years

•

2-47

#: 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.

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 liquid 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		Torque			Remarks
		N·m	kgf·m	ft·lb
	Fuel System
	Fuel Tap Cover Screws	0.8	0.08	7 in·lb
	Fuel Tap Mounting Bolts	5.0	0.51	44	in·lb
	Air Cut Valve Cover Screws	1.0	0.10	9 in·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 Cover Bolts	11	1.1	95 in·lb
	Water Pump Shaft	25	2.5	18		Lh
	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	12	1.2	104 in·lb		S
	Rocker Shafts	39	4.0	29		EO
	Valve Adjuster Locknuts	25	2.5	18
	Camshaft Sprocket Bolts	15	1.5		11	L
	Cylinder Head Bolts (10 mm)	51	5.2	38		S
	Cylinder Head Bolts (6 mm)	9.8	1.0	87	in·lb	S
	Camshaft Chain Tensioner Mounting Bolts	11	1.1	95	in·lb
	Camshaft Chain Tensioner Cap Bolt	13	1.3	9.5

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

	Fastener		Torque			Remarks
		N·m	kgf·m	ft·lb
	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	1.5	0.15	13	in·lb
	Clutch Hub Nut	132	13.5	98
	Clutch Spring Bolts	9.3	0.95	82	in·lb
	Clutch Cable Holder Bolt	11	1.1	95	in·lb
	Clutch Cover Bolts	11	1.1	95	in·lb
	Engine Lubrication System
	Oil Filler Plug	1.5	0.15	13	in·lb
	Oil Passage Plug	18	1.8	13
	Oil Filter Mounting Stud	25	2.5	18		L
						(Planted
						side)
	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 M8	12	1.2	104 in·lb
	Oil Pipe for Output Shaft Upper Banjo Bolt M6	7.8	0.8	69	in·lb
	Oil Pipe for Output Shaft Lower Banjo Bolt M8	12	1.2	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	15	1.5		11	SS
	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	11	1.1	95	in·lb
	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

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

	Fastener			Torque			Remarks
			N·m	kgf·m	ft·lb
	Upper Primary Chain Guide Mounting Bolt		11	1.1	95 in·lb		L
	Lower Primary Chain Guide Mounting Bolt		11	1.1	95 in·lb		L
	Connecting Rod Big End Nuts
			36	3.7	27
	Return Spring Pin		20	2.0	14.5		L
	Gear Positioning Lever Pivot Stud		–	–		–	L
							(planted
							side)
	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		11	1.1	95	in·lb	L
	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		2.0 3.9	0.2 0.4	17	35 in·lb
	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
							(planted
							side)
	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	9 in·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		7.8	0.8	69	in·lb
	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

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

	Fastener		Torque			Remarks
		N·m	kgf·m	ft·lb
	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	98	10	72
	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	39	4.0	29
	Steering Stem Locknut	Hand	Hand	Hand
		-Tighten	-Tighten	-Tighten
		(about 4.9)	(about 0.5)	(about 43
				in·lb)
	Frame
	Tail Grip Bolts	25	2.5	18
	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	8.3	0.85	74 in·lb		L
	Timing Inspection Plug	2.5	0.25	22	in·lb
	Alternator Rotor Bolt Plug	1.5	0.15	13	in·lb
	Alternator Cover Bolts	11	1.1	95	in·lb
	Alternator Lead Clamp Screws	2.9	0.30	26	in·lb
	Spark Plug	14	1.4	10
	Alternator Stator Allen Bolts	12	1.2	104 in·lb
	Alternator Rotor Bolt	69	7.0	51		Lh
	Starter Motor Mounting Bolts	11	1.1	95	in·lb
	Starter Chain Guide Bolts	4.9	0.5	43	in·lb	L
	Starter Motor Through Bolts	6.9	0.7	65	in·lb
	Starter Motor Terminal Nut				in·lb
		4.9	0.5	43
	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	44	4.5	33
	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

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

	Fastener		Torque		Remarks
		N·m	kgf·m	ft·lb
	Oil Pressure Switch	15	1.5	11	SS
	Neutral Switch	15	1.5	11
	Tail Light Mounting Nut	5.9	0.6	52 in·lb

The table relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads				Torque
dia. (mm)	N·m			kgf·m			ft·lb
5	3.4		4.9	0.35		0.50	30	43 in·lb
6	5.9		7.8	0.60		0.80	52	69 in·lb
8	14 19			1.4 1.9			10.0		13.5
			34	2.6		3.5	19.0		25
10	25
12	44		61	4.5		6.2	33		45
14	73		98	7.4		10.0	54		72
16	115		155	11.5		16.0	83		115
18	165		225	17.0		23.0	125		165
20	225		325	23		33	165		240