Kawasaki KLF 250 (2003) User Manual [ru]

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Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System 3 j

Engine Top End 4 j

Engine Right Side 5 j

Recoil Starter 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

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

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

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

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

KLF 250

BAYOU 250

Workhorse 250

All Terrain Vehicle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted i n any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to m ake it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication a re intended for reference use only and may not depict actual model component parts.

LIST OF ABBREVIATIONS

ABDC after bottom dead center

ATDC after top dead center

BBDC before bottom dead center

BDC

BTDC before top dead center

°C degree(s) Celcius

°F degree(s) Fahrenheit

ft foot, feet

ampere(s)

alternating current min

bottom dead center

direct current rpm

farad(s) TDC

gram(s)

hour(s) Ω ohm(s)

liter(s)

psi

r revolution

TIR total indicator reading

pounds(s)

meter(s)

minute(s)

newton(s)

pascal(s)

horsepower

pound(s) per square inch

revolution(s) per minute

top dead center

volt(s)

watt(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board.

1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow

-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from

the crankcase, and then returned back to the bottom of crankcase.

2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that

consist of a modified carburetor and an ignition system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum

fuel economy with a suitable air cleaner and exhaust system.

A m aintenance free ignition system provides the most favorable ignition timing and helps main-

tain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is

commonly referred to as the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed

on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading

motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."

NOTE

The phrase "re move or render inoperative any device or e lement of design" has been generally

○

interpreted as follows:

1. Tampering does not include the temporary removal or rendering inoperative of de vices or elements o f design in order to perform maintenance.

2. Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are ex-

ceeded.

b.Use of replacement parts or accessories which adversely affect the performance

or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the stan-

dards.

d.Permanently removing, disconnecting, or rendering inoperative any component or

element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE TH ESE PROVISIONS OF FEDERAL LAW,

THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

PLEASE DO NOT TAMPER W ITH NOISE CONTROL SYSTEM

(US MODEL only)

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

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

For the duration of the warranty period,

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

To get the longest life out of your vehicle:

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Vehi-

•

cle parts. Special tools, gauges, and testers

that are necessary when servicing Kawasaki

vehicles are introduced by the Special Tool

Catalog or M anual. Genuine parts provided

as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

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

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

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

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution symbol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-5

General Specifications............................................................................................................ 1-6

Unit Conversion Table ............................................................................................................ 1-9

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings.

(2) Battery Ground

Disconnect the ground (−) wire from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible.

(4) Tightening Sequence

When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a pat, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them.

(5) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.

(6) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.

(8) High-Flash Point Solvent

A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(9) Gasket, O-ring

Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.

GENERAL INFORMATION 1-3

Before Servicing

(10)Liquid Gasket, Locking Agent

Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage.

(11) Press

When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit.

(12)Ball Bearing and Needle Bearing

Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component.

(13)Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks, press it in with the marks facing out.

(14)Circlip, Retaining Ring, and Cotter Pin

When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well.

Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem.

(15)Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular s hould be used only in certain applications and may be harmful if used in an application for which they are not intended.

(16)Direction of Engine Rotation

To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well.

(17)Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed.

Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts.

(18)Electrical Wires

All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stripe color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed. Unless instructed otherwise, electrical wires must be connected to wires of the same color.

1-4 GENERAL INFORMATION

Before Servicing

Two-Color Electrical Wire

(19)Inspection

When parts have been disassembled, visually inspect these parts for the following conditions

or other damage. If there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp

Bent Dent Scratch Wear

Color change Deterioration Seizure

(20)Specifications

Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. "Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete-

riorated performance, replace the damaged parts.

Model Identification

KLF250-A1 Left Side View

GENERAL INFORMATION 1-5

KLF250-A1 Right Side View

1-6 GENERAL INFORMATION

General Specifications

Item KLF250-A1 ∼ A3

Dimensions

Overall Length 1 780 mm (70.08 in..)

Overall Width 1 120 mm (44.09 in.),

(US) (CA) 1 020 mm (40.16 in.)

Overall Height 1 040 mm (40.94 in.)

Wheelbase 1 115 mm (43.90 in.)

Ground Clearance 155 mm (6.10 in.)

Seat Height 730 mm (28.74 in.)

Dry Mass 185 kg (408 lb), (US) 183 kg (404 lb),

(CA) 183.5 kg (405 lb)

Curb Mass:

Fuel Tank Capacity 10 L (2.6 US gal)

Performance

Minimum Turning Radius 2.7 m (8.86 ft)

Engine

Type 4-stroke, SOHC, 1-cylinder

Cooling System Air-cooled

Bore and Stroke 69.0 × 61.0 mm (2.72 × 2.40 in.)

Displacement 228 mL (13.9 cu in.)

Compression Ratio 8.9

Maximum Horsepower 12.5 kW (17 PS) @7 000 r/min (rpm), (US) –

Maximum Torque 17.9 N·m (1.83 kgf·m, 13.24 ft·lb)

Carburetion System Carburetor, MIKUNI VM24SS

Starting System Electric starter & Recoil starter

Ignition System CDI

Timing Advance Electronically advanced

Ignition Timing From 10° BTDC @1 800 r/min (rpm)

Spark Plug NGK DR8ES

Valve Timing:

Inlet: Open 35° BTDC

Exhaust: Open 54° BBDC

Lubrication System Forced lubrication (wet sump)

Engine Oil: Type API SF or SG

Front

Rear 106 kg (234 lb), (US) 104.5 kg (230 lb),

Close 57° ABDC

Duration 272°

Close 26° ATDC

Duration 260°

Viscosity SAE 10W-40

Capacity 2.0L(2.11USqt)

89 kg (196 lb), (US) (CA) 88.5 (195 lb)

(CA) 105 kg (232 lb)

@5 500 r/min (rpm)

to 35° BTDC @4 600 r/min (rpm)

API SH or SJ with JASO MA

GENERAL INFORMATION 1-7

General Specifications

Item KLF250-A1 ∼ A3

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 3.450 (69/20)

Clutch Type Wet multi disc and centrifugal

Transmission:

Type 5-speed plus reverse, constant mesh, return shift

Gear Ratio: 1st 2.923 (38/13)

2nd 1.684 (32/19)

3rd 1.173 (27/23)

4th

5th 0.785 (22/28)

Reverse 3.115 (27/13 × 33/22)

Final Drive System:

Type Shaft

Reduction Ratio 4.680 (18/15 × 39/10)

Overall Drive Ratio (@Top Gear)

Final Gear Case Oil:

Type Hypoid gear oil

Capacity 0.2L(0.21USqt)

Frame

Type Double tubular

Caster (Rake Angle) 4.0°

Camber 3.0°

King Pin Angle 10°

Trail 17 mm (0.67 in.)

Tread:

Front 764 mm (30.08 in.)

Rear 776 mm (30.55 in.)

Front Tire:

Type Tubeless

Size AT21 × 8 - 9

Rear Tire:

Type Tubeless

Size AT22 × 10 - 10

Suspension:

Front:

Type Independent swing axle

Wheel Travel

Rear:

Type Torque tube-link

Wheel Travel 125 mm (4.92 in.)

0.923 (24/26)

12.686

SAE90 (above 5°C, 41°F) or

SAE80 (below 5°C, 41°F)

115 mm (4.53 in.)

1-8 GENERAL INFORMATION

General Specifications

Item KLF250-A1 ∼ A3

Brake type:

Front Drum (Mechanical)

Rear Drum (Mechanical)

Electrical Equipment

Battery 12 V 14 Ah, (US) 12 V 11 Ah

Headlight:

Type Semi-sealed beam

Bulb 12 V 25/25 W × 2

Tail/brake light 12 V 8/27 W × 2

Alternator:

Type Three - phase AC

Rated Output 13 A, 14 V @8 000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country. (CA): Canada Model (US): U.S.A. Model

Unit Conversion Table

GENERAL INFORMATION 1-9

Prefixes fo r Units:

Prefix Symbol Power

mega M ×1000000

kilo k × 1 000

centi c ×0.01

milli m × 0.001

micro µ × 0.000001

Units o f Mass:

kg ×2.205=lb g × 0.03527 = oz

Units of Volume:

L × 0.2642 = L × 0.2200 = L × 1.057 = qt (US) L × 0.8799 = qt (imp) L × 2.113 = pint (US) L × 1.816 = mL × 0.03381 = mL × 0.02816 = mL × 0.06102 = cu in.

gal (US) gal (imp)

pint (imp) oz (US) oz (imp)

Units of Force:

N × 0.1020 = kg N × 0.2248 = lb

kg ×9.807=N kg ×2.205=lb

Units of Length:

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

Units of Torque:

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

kgf·m × 9.807 = N·m kgf·m kgf·m

×7.233= × 86.80 = in·lb

ft·lb

Units of Pressure:

kPa × 0.01020 = kPa × 0.1450 = psi kPa × 0.7501 = cmHg

kg/cm² kg/cm² × 14.22 = psi cm Hg × 1.333 = kPa

× 98.07 = kPa

kg/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Power:

kW × 1.360 = kW × 1.341 = HP

PS × 0.7355 = kW PS × 0.9863 = HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent................. 2-3

Specifications .................................... 2-6

Periodic Maintenance Procedures..... 2-7

Fuel System.................................... 2-7

Throttle Lever Free Play

Inspection.................................. 2-7

Throttle Lever Free Play

Adjustment ................................ 2-7

Fuel System Cleanliness

Inspection.................................. 2-8

Air Cleaner Element Cleaning and

Inspection.................................. 2-8

Air Cleaner Draining..................... 2-9

Fuel Hose and Connection

Check........................................ 2-9

Fuel Hose Replacement .............. 2-9

Engine Top End .............................. 2-10

Valve Clearance Inspection ......... 2-10

Spark A rrester Cleaning............... 2-10

Clutches.......................................... 2-11

Clutch Adjustment........................ 2-11

Engine Lubrication System ............. 2-12

Engine Oil Change....................... 2-12

Oil Filter Change .......................... 2-12

Wheels/Tires................................... 2-13

Tire Inspection ............................. 2-13

Final Drive....................................... 2-14

Final Gear Case Oil Change ........ 2-14

Propeller Shaft Joint Boot

Inspection.................................. 2-14

Brakes............................................. 2-15

Front Brake Adjustment ............... 2-15

Rear (Parking) Brake Lever Free

Play Inspection.......................... 2-16

Brake Pedal Free Play Inspection 2-16 Rear (Parking) Brake Lever and

Pedal Free Play Adjustment...... 2-17

Steering .......................................... 2-18

Steering Inspection ...................... 2-18

Electrical System ............................ 2-18

Battery Inspection ........................ 2-18

Spark Plug Cleaning / Inspection . 2-18

Spark Plug Gap Inspection .......... 2-18

Brake Light Switch Adjustment .... 2-19

General Lubrication ........................ 2-19

Lubrication ................................... 2-19

Bolts and Nuts Tightening............... 2-21

Tightness Inspection .................... 2-21

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

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

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

FREQUENCY

OPERATION

ENGINE

Air cleaner - service*

Throttle lever play - inspect

Valve clearance - inspect

Fuel system cleanliness - inspect*

Engine oil - change*

Oil filter - replace*

Clutch adjustment*

Spark plug - clean and gap

Spark arrester - clean

Fuel hoses and connections - inspect

Fuel hose - replace 4 years

CHASSIS

First

Service

After 10

hrs. or 100 km (60 mi)

of use

Every 10

days or 200 km

(120 mi)

of use

Every 30

(360 mi)

• •

Regular Service

Every 90 days or 600 km

of use

days or

1 700 km

(1 100 mi)

of use

Every

year of

use

•

Joint boots - inspect*

Rear brake pedal and lever adjustment - inspect*

Cables adjustment*

Bolts and nuts - tighten

Brake wear - inspect*

Brake light switch - inspect*

Battery - inspect

Steering - inspect

Tire wear - inspect*

Final gear case oil - change

General lubrication*

*: Service more frequently when operated in mud, dust, or other harsh riding conditions.

: Clean, adjust, lubricate, torque, or replace parts as necessary.

•

• •

•

• •

•

PERIODIC MAINTENANCE 2-3

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners, and the parts requiring use of

a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

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

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

grease in a weight ratio 10 : 1).

S: Tighten the fasteners following the specified sequence.

St: Stake the fasteners to prevent loosening.

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

Basic Torque for General Fasteners

Threads Torque

dia. (mm) N·m kgf·m ft·lb

5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb

8 14 ∼19 1.4 ∼1.9 10.0 ∼ 13.5 10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25 12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45 14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72 16 115 ∼ 155 11. 5 ∼ 16.0 83 ∼ 11 5 18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165 20 225 ∼ 325 23 ∼ 33 165 ∼ 240

Fastener

Fuel Sytem

Carburetor Holder Bolts 11 1.1 95 in·lb L

Throttle Lever Bolt 5.9 0.6 52 in·lb

Engine Top End

Cylinder Head Bolts (M10), first torque

Cylinder Head Bolts (M10), final torque

Cylinder Head Bolts (M6), first torque 5.9 0.6 52 in·lb MO, S

Cylinder Head Bolts (M6), final torque 9.8 1.0 87 in·lb S

Valve Adjusting Cap Bolts 8.8 0.9 78 in·lb

Retaining Bolt 4.4 0.45 39 in·lb

Compression Releasing Lever Bolt 8.8 0.9 78 in·lb

Camshaft Sprocket Bolt 34 3.5 25 MO

Rear Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb

Camshaft Chain Tensioner Mounting Bolts

Valve Adjusting Screw Locknuts

Rocker Shaft Retainer Screws 4.4 0.45 39 in·lb

Camshaft Chain Guard Screws 4.4 0.45 39 in·lb

Engine Right Side

Right Engine Cover Bolts 8.8 0.9 78 in·lb

N·m

13 1.3 113 in·lb

34 3.5 25

8.8 0.9 78 in·lb

12 1.2 104 in·lb

Torque

Remarks

kgf·m ft·lb

L(1), MO, S

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Clutch Spring Bolts

Primary Clutch Hub Nut 127 13 94 MO

Secondary Clutch Hub Nut 78 8.0 58 MO

Balancer Drive Gear Nut 83 8.5 61 MO

Balancer Gear Nut 118 12 87 MO

Clutch Adjusting Screw Locknut 11 1.1 95 in·lb

Recoil Starter

Recoil Starter Mounting Bolts 8.8 0.9 78 in·lb

Recoil Starter Flange Nut 12 1.2 104 in·lb

Engine Lubrication System

Oil Pipe Banjo Bolts 15 1.5 11

Oil Pump Screws 4.4 0.45 39 in·lb

Engine Drain Plug 29 3.0 22

Oil Filter Cover Bolts 8.8 0.9 78 in·lb

Relief Valve 15 1.5 11 L

Engine Removal/Installation

Engine Bracket Bolts and Nuts 26 2.7 20

Engine Mounting Nuts (M10) 39 4.0 29

Engine Mounting Nut (M8)

Crankshaft/Transmission

Engine Drain Plug 29 3.0 22

Crankcase Bolts

Clutch Release Cam Pin 25 2.5 18 L

Return Spring Pin 25 2.5 18 L

Output Shaft Bearing Position Plate Screws 8.8 0.9 78 in·lb L

Relief Valve 15 1.5 11 L

Bearing Stopper Screws 9.8 1.0 87 in·lb

Positioning Lever Bolt 8.8 0.9 78 in·lb

Neutral and Reverse Switch Screws – – – L

Shift Drum Pin Plate Bolt 12 1.2 104 in·lb

Wheels/Tires

Wheel Nuts 34 3.5 25 S

Rear Axle Nut 147 15 108

Final Drive

Output Bevel Gear Case Bolts (M8) 25 2.5 18 L(1)

Output Bevel Gear Case Bolts (M6) 8.8 0.9 78 in·lb

Oil Seal Housing Nuts

Drive Gear Nut 118 12 87 MO

Cam Damper Mounting Nut 78 8.0 58 MO

Driven Gear Shaft Nut 147 15 108 L

Bearing Retainer 108 11 80 L

Pinion Gear Nut 69 7.0 51 St

Propeller Shaft Housing Nuts 25 2.5 18

N·m kgf·m ft·lb

12 1.2 104 in·lb

29 3.0 22

8.8 0.9 78 in·lb

25 2.5 18

Torque

Remarks

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Fastener

Final Gear Case Drain Bolt 20 2.0 14

Speedometer Plug 20 2.0 14

Final Gear Case Filler Cap 15 1.5 11

Ring Gear Cover Bolts

Axle Shaft Pipe Bolts 20 2.0 14

Oil Level Inspection Bolt 7.8 0.8 69 in·lb

Brakes

Front Axle Nut 34 3.5 25

Rear Axle Nut 147 15 108

Front Brake Panel Bolts 25 2.5 18 L

Rear Brake Panel Bolts 29 3.0 22 L

Rear Brake Drum Drain Bolts 29 3.0 22

Suspension

Front Suspension Arm Pivot Bolts 88 9.0 65

Rear Suspension Arm Pivot Bolts and Nuts 34 3.5 25

Shock Absorber Mounting Bolts and Nuts

Steering Knuckle Pivot Nuts 39 4.0 29

Steering

Steering Stem Clamp Allen Bolts 26 2.7 20

Stem Bottom End Nut 29 3.0 22

Tie-rod End Nuts 41 4.2 30

Tie-rod Adjusting Sleeve Locknuts 26 2.7 20

Steering Knuckle Arm Pivot Nuts 39 4.0 29

Handlebar Holder Bolts 20 2.0 14 S

Frame

Rear Carrier Bolts 20 2.0 14

Electrical System

Alternator Cover Bolts

Spark Plug 14 1.4 10

Starter Motor Clutch Bolts 34 3.5 25 L

Ignition Switch Nut 2.9 0.3 26 in·lb

Alternator Rotor Bolt 59 6.0 43

Starter Motor Mounting Bolts 8.8 0.9 78 in·lb

Starter Motor Terminal Nut 4.9 0.5 43 in·lb

Starter Motor Terminal Locknut 6.9 0.7 61 in·lb

Starter Motor Bolts 3.4 0.3 30 in·lb

N·m kgf·m ft·lb

25 2.5 18 L

34 3.5 25

8.8 0.9 78 in·lb

Torque

Remarks

2-6 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System

Throttle Lever Free Play 2 ∼ 3mm(0.08∼ 0.12 in.) ––– Idle Speed 1 300 ∼ 1 400 r/min (rpm) –––

Air Cleaner Element Oil High-quality foam air filter oil –––

Engine Top End

Valve Clearance:

Exhaust 0.18 ∼ 0.23 mm (0.0071 ∼ 0.0091 in.) –––

Inlet

Engine Lubrication System

Engine Oil:

Type API SF or S G –––

Viscosity SAE10W40 –––

Capacity 2.0L(2.11USqt)

Wheels/Tires

Tire Tread Depth:

Front ––– 4 mm (0.16 in.)

Rear –––

Standard Tire:

Front AT 21 X 8-9 –––

Rear AT 22 x 10-10 –––

Final Drive

Final Gear Case:

Gear Case Oil:

Type

Viscosity SAE90 (above 5°C, 41°F) –––

Capacity 0.2 L (0.21 US qt) –––

Brakes

Front Brake Lever Free Play 1 ∼ 2mm(0.04∼ 0.08 in.) –––

Rear (Parking) Brake Lever Free Play

Brake Pedal Free Play 25 ∼ 35 mm (1.0 ∼ 1.4 in.) ––– Cam Lever angle 80 ∼ 90° –––

Electrical System

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

Rear Brake Light Switch Timing On after 10 mm (0.4 in.) of pedal travel

0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.)

API SH or SJ with JASO MA –––

(When filter is not removed)

2.1 L (2.22 US qt) –––

(When filter is removed)

2.75 L (2.91 US qt) –––

(When engine is completely dry)

4 mm (0.16 in.)

Dunlop, KT856, Tubeless –––

Dunlop, KT857, Tubeless –––

API GL-5 Hypoid gear oil

SAE80 (below 5°C, 41°F) –––

2 ∼ 3mm(0.08∼ 0.12 in.) –––

–––

Periodic Maintenance Procedures

Fuel System

Throttle Lever Free Play Inspection

Check that the throttle lever moves smoothly from full

•

open to close, and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle lever does not return properly, check the throttle cable routing, lever free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed, and turn the handlebar

•

all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle lever free play and the cable routing. Stop the engine and check the throttle lever free play [A].

•

If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0. 12 in.)

PERIODIC MAINTENANCE 2-7

Throttle Lever Free Play Adjustment

Slide the rubber cover off the adjuster at the throttle case.

•

Loosen the locknut [A] and turn the throttle cable upper

•

adjuster [B] until the cable has proper amount of play. Tighten the locknut and reinstall the rubber cover.

•

If the free play cannot be adjusted by using the upper cable adjuster, pull up the rubber cover [A] at the carburetor. Loosen the locknut [B] and turn the throttle cable lower adjuster [C] to obtain the specified free play. Tighten the locknut and reinstall the rubber cover.

2-8 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System Cleanliness Inspection

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

Turn the fuel tap to the OFF position.

•

Run the lower end of the carburetor drain hose to a suit-

•

able container. Turn out the carburetor drain plug a few turns and drain

•

the fuel system. Check to see if water or dirt comes out.

•

Tighten the drain plug.

•

If any water or dirt appears during the above inspection, clean the fuel system (carburetor, tank, fuel hose).

Air Cleaner Element Cleaning and Inspection

NOTE

In dusty areas, the element should be cleaned more

○

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

○

should be cleaned immediately. Since repeated cleaning opens the pores of the ele-

○

ment, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, if there is a break in the element material or any

○

other damage to the element, replace the element with a new one.

WARNING

Clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the foam element.

Remove the air cleaner element (see Air Cleaner Element

•

Removal). Clean the element in a bath of high-flash point solvent

•

using a soft bristle brush.

Periodic Maintenance Procedures

Squeeze it dry in a clean towel [A]. Do not wring the ele-

•

ment or blow it dry; the element can be damaged. Inspect the element for damage.

•

If it is torn, punctured, or hardened, replace it.

NOTE

Replace the element after cleaning it five times or if it is

○

damaged.

After cleaning, saturate the element with a high-quality

•

foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element.

Air Cleaner Draining

Two drain tubes [A] are connected to the bottom of the air cleaner housing to drain water or oil accumulated in the housing.

Squeeze open the two drain tubes to expel dust and/or

•

water accumulated inside.

PERIODIC MAINTENANCE 2-9

Fuel Hose and Connection Check

Turn the fuel tap to the OFF position.

•

Check the fuel hose [A].

•

If the fuel hose is frayed, cranked, or bulged, replace the

fuel hose.

Check that the hose is securely c onnected and clamps

•

are tightened.

If the fuel hose has been sharply bent or kinked, replace

the fuel hose.

If the clamps are loosened or damaged, replace the

clamps.

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

•

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

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

structed.

Fuel Hose Replacement

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Turn the ignition

switch OFF. Do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Turn the fuel tap to the OFF position.

•

Remove:

•

Clamps Fuel Hose

2-10 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fit the fuel hose [A] onto the pipe fully and install the

•

clamps [B] beyond the raised rib [C].

Engine Top End

Valve Clearance Inspection

NOTE

Check the valve clearance only when the engine is cold

○

(at room temperature).

Remove:

•

Front Fender (see Frame chapter) Bolts [A] and Valve Adjusting Caps [B]

Remove:

•

Recoil Starter (see Recoil Starter chapter) Timing Inspection Plug

Turn the crankshaft counterclockwise with a wrench on

•

the alternator rotor bolt until the “T” mark [A] on the alternator rotor aligns with the slot [B], as shown.

Measure the clearance of each valve between the end of

•

the valve stem and the adjusting screw on the rocker arm with a thickness gauge [A]. If the valve clearance is not correct, adjust it.

Valve Clearance (when cold)

Exhaust: 0.18 ∼ 0.23 mm (0.0071 ∼ 0.0091 in.) Inlet: 0.15 ∼ 0.20 mm (0.0059 ∼ 0.0079 in.)

Spark Arrester Cleaning

WARNING

To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.

Periodic Maintenance Procedures

Remove the drain plug [A] on the muffler.

•

In an open area away from combustible materials, start

•

the engine with the transmission in neutral.

Raise and lower engine speed while tapping on the muf-

•

fler with a rubber mallet until carbon particles are purged

from the muffler.

WARNING

Do not run the engine in a closed area. Exhaust

gases contain carbon monoxide; a colorless, odor-

less, poisonous gas. Breathing exhaust gas leads

to carbon monoxide poisoning, asphyxiation, and

death.

Stop the engine.

•

Remove:

•

Bolt [A] Spark Arrester [B] Muffler [C]

Scrape carbon deposits off the spark arrester and slide it

•

back into the muffler.

WARNING

PERIODIC MAINTENANCE 2-11

Never run the engine with the spark arrester re-

moved near combustible materials. Hot carbon

particles may start a fire.

Install the drain plug.

•

Clutches

Clutch Adjustment

Remove:

•

Screws [A] Adjusting Screw Cover [B]

Loosen the locknut [A].

•

Turn the adjusting screw [B] clockwise until it becomes

•

hard to turn.

Turn the adjusting screw counterclockwise until it be-

•

comes hard to turn.

Tighten the locknut without changing the adjusting screw

•

position.

Torque - Clutch Adjustment Locknut: 11 N·m (1.1 kgf·m, 95

in·lb)

Install the adjusting screw cover.

•

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Engine Lubrication System

Engine Oil Change

Support the vehicle so that it is level side to side and front

•

to back after warming up the engine. Remove the engine drain plug [A] to drain the oil.

•

The oil in the filter can be drained by removing the filter

○

(see Oil Filter Change). Replace the drain plug gasket with a new one if it is damaged. Tighten:

•

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

Pour in the specified type and amount of oil.

•

Engine Oil

Type:

Viscosity:

Amount:

API SF or SG

API SH or SJ with JASO MA

SAE 10W-40

2.0 L (2.11 US qt)

(When filter is not removed)

2.1 L (2.22 US qt)

(When filter is removed)

2.75 L (2.91 US qt)

(When engine is completely dry)

NOTE

Depending on the atmospheric temperature of your rid-

○

ing area, the engine oil viscosity should be changed according to the chart.

Oil Filter Change

Drain the engine oil.

•

Remove:

•

Oil Filter Cover Bolts [A] Oil Filter Cover [B]

Replace the filter [A] with a new one.

•

When installing the oil filter, be careful of the following.

•

The large end of mounting pin [B] goes in first.

○

Periodic Maintenance Procedures

Apply grease to the O-ring [A] in the cover.

○

Tighten:

•

Torque - Oil Filter Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)

Pour in the specified type and amount of oil.

○

Wheels/Tires

Tire Inspection

Examine the tire for damage and wear.

•

If the tire is cut or cracked, replace it.

Lumps or high spots on the tread or sidewalls indicate

○

internal damage requiring tire replacement.

Remove any foreign objects from the tread. After re-

○

moval, check for leaks with a soap and water solution.

Measure the tread depth at the center of the tread with

•

a depth gauge. Since the tire may wear unevenly, take

measurements at several places.

If any measurements are less than the service limit, re-

place the tire.

PERIODIC MAINTENANCE 2-13

Tire Tread Depth

Service L imit:

Front:

Rear: 4 mm (0.16 in.)

Standard Tire

Front:

Rear: AT 22 x 10 - 10 DUNLOP KT857 Tubeless

AT 21 x 8 - 9 DUNLOP KT856 Tubeless

4 mm (0.16 in.)

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Final Drive

Final Gear Case Oil Change

Warm up the oil by running the vehicle so that the oil will

•

pick up any sediment and drain easily. Then stop the vehicle. Park the v ehicle so that it is level, both side-to-side and

•

front-to-rear. Place an oil pan beneath the final gear case and remove

•

the drain plug [A].

CAUTION

When draining or filling the final g ear case, be careful that no oil gets on the tire or rim because oil will deteriorate the tire. Clean off any oil that inadvertently gets on them with a high-flash point solvent.

After the oil has completely drained out, install the drain

•

plug with a new aluminum gasket.

Torque - Final Gear Case Drain Plug : 20 N·m (2.0 kgf·m , 14

ft·lb)

Unscrew the oil level inspection bolt.

•

Pour the oil into the case until the oil comes out of the bolt

•

hole.

Final Gear Case Oil

Type:

Viscosity:

Capacity 0.2 L (0.21 US qt)

"GL-5" indicates a quality and additive rating. "GL-6"

○

rated hypoid gear oils can also be used.

Be sure the O-ring [A] is in place and tighten the filler cap

•

[B].

Torque - Final Gear Case Filler Cap : 15 N·m (1.5 kgf·m, 11

ft·lb)

Propeller Shaft Joint Boot Inspection

Visually inspect the rear propeller shaft joint boot [A] in

•

accordance with the Periodic Maintenance Chart or if the shaft is noisy during operation. If the j oint boot is torn, worn, or deteriorated, replace the joint boot and check the propeller shaft (see Propeller Shaft Inspection in Final Drive chapter).

API "GL-5" Hypoid gear oil

SAE90 (above 5°, 41°F)

SAE80 (below 5°, 41°F)

NOTE

Periodic Maintenance Procedures

Brakes

Front Brake Adjustment

Loosen the locknut [A] at the brake lever [B] and turn in

•

the adjuster [C] as far as it will go to make the brake lever

loose.

Turn each adjuster [A] at both lower ends of the cable so

•

that each brake cam lever [B] will have 2 ∼ 3 mm (0.08 ∼

0.12 in.) [C] of free play.

PERIODIC MAINTENANCE 2-15

Turn the adjuster [A] at the brake lever until the brake lever

•

has the specified amount of free play [B].

Front Brake Lever Free Play

Standard: 1 ∼ 2 mm (0.04 ∼ 0.08 in.)

Tighten the locknut [C].

•

NOTE

Once the adjustment has been made following the

○

above procedures, ordinarily adjust the free play by using the adjusters at both lower ends of the cable. Make sure that the equalizer [A] is lifted parallel to the

○

bottom of the case [B] when brake lever is pulled in to prevent the brakes from pulling to either side.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check that the brake lining wear indicator [A] points within

•

the USABLE RANGE [B] when the brake is fully applied. If does not, replace the brake shoes.

Check the cam lever angle [A] when the brake is fully

•

applied.

Cam Lever Angle

Standard: 80 ∼ 90°

If the cam lever angle is not within the specified range, adjust it (see Cam Lever Angle Adjustment).

WARNING

Since a cam lever angle greater than 90° reduces braking effectiveness, cam lever angle adjustment should not be neglected. Reduced braking effectiveness could lead to a crash.

Rear (Parking) Brake L

Check the rear (parking) brakelever free play [A].

•

Pull the rear brake lever lightly until the brake is applied.

○

If the play is incorrect,

Rear (Parking) Brake Lever Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

Brake Pedal Free Play Inspection

Check the brake pedal free play [A].

•

Depress the brake pedal [B] lightly by hand until the brake

○

is applied. If the free play is incorrect, adjust it.

Brake Pedal Free Play

Standard: 25 ∼ 35 mm (1.0 ∼ 1.4 in.)

ever Free Play Inspection

adjust it.

Periodic Maintenance Procedures

Rear (Parking) Brake Lever and Pedal Free Play Adjustment

Loosen the locknut [A] and turn in the adjuster [B] at the

•

rear brake (parking) lever as far as it will go.

Turn in or out the adjuster [A] at the rear end of the brake

•

cable so that the brake pedal will have 25 ∼ 35 mm (1.0 ∼

1.4 in.) of free play before the brake starts to take hold.

PERIODIC MAINTENANCE 2-17

Turn out the adjuster at the rear brake lever until brake

•

lever has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of free play. Tighten

the locknut.

Check the cam lever angle [A] when the brake is fully

•

applied.

Cam Lever Angle

Standard: 80 ∼ 90°

If the cam lever angle is not within the range specified,

adjust it (see Cam Lever Angle Adjustment).

WARNING

Since a cam lever angle greater than 90° reduces

braking effectiveness, cam lever angle ad

should not be neglected. Reduced braking effec-

tiveness could lead to a crash.

justment

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering

Steering Inspection

Turn the handlebar left and right, and check the steering

•

action. If the steering action is not smooth, or if the steering binds or catches before the stop, lubricate the steering stem bearing.

NOTE

The cables and wires will have some effect on the steer-

○

ing action which must be taken into account.

Check the steering action again.

•

If steering stem bearing lubrication does not remedy the problem, inspect the steering stem for straightness, steering stem clamps, and tie-rod bearings. If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts. Tighten loose bolts and nuts to the specified torque (see

•

Exploded View), and check the steering action again. If the steering action does not change by tightening the bolts and nuts, inspect the steering stem clamps, steering stem bearings, tie-rod bearings, and steering knuckle joints.

Electrical System

Battery Inspection

Refer to the Electlyte Level Inspection in the Electrical

•

System chapter. Refer to the Electlyte Specific Gravity Inspection in the

•

Electrical System chapter. Refer to the Ordinary Charging in the Electrical System

•

chapter.

Spark Plug Cleaning / Inspection

Clean the spark plug, preferably in a sandblasting device,

•

and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

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.)

Periodic Maintenance Procedures

Brake Light Switch Adjustment

Check the operation of the brake light switch by depress-

•

ing the brake pedal [A]. The brake light should go on after

about 10 mm (0.4 in..) of pedal travel [B].

If it does not, adjust the brake light switch [A] up or down.

To change the switch position, turn the adjusting nut [B].

Brake Light Switch Timing

Standard: ON after 10 mm (0.4 in.) of pedal travel

CAUTION

To avoid damaging the electrical connections in-

side the switch, be sure that the switch body does

not turn during adjustment.

PERIODIC MAINTENANCE 2-19

General Lubrication

Lubrication

Before lubricating each part, clean off any rusty spots with

•

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 spray water, perform the general lubrication.

Cables: Lubricate with Cable Lubricant

Brake Cables

Throttle Cable

Choke Cable

Lubricate the cables by seeping the oil between the ca-

•

ble and housing. The cable may be lubricated by using a pressure cable

○

luber with an aerosol cable lubricant.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

With the cable disconnected at the 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, or if the cable housing is kinked, replace the cable.

Points:

Throttle Inner Cable ENds [A] Choke Cable Lower End Brake Cable Ends

Slide Points: Lubricate with Grease.

Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft

Lubricate with Grease.

Periodic Maintenance Procedures

Bolts and Nuts Tightening

Tightness Inspection

Check the tightness of the bolts and nuts listed here in

•

accordance with the Periodic Maintenance Chart. Also,

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

condition.

If there are loose fasteners, retorque them to the speci-

fied torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not listed in the appropriate

chapter, see the Basic Torque Table (see Torque and

Locking Agent). For each fastener, first loosen it by 1/2

turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Bolts, Nuts, and Fasteners to be checked Wheels:

Front Axle Nuts and Cotter Pins

Rear Axle Nuts and Cotter Pins

Wheel Nuts

Brakes:

Brake Lever Pivot Bolt

Brake Lever Pivot Nut

Brake Pedal Cotter Pin

Steering/Suspension:

Handlebar Clamp Bolts

Stem Clamp Allen Bolts

Stem Bearing Housing Bolts

Tie-Rod End Nuts and Cotter Pins

Tie-Rod Adjusting Sleeve Locknuts

Shock Absorber Mounting Bolts and Nuts

Suspension Arm Pivot Bolts

Steering Knuckle Pivots Nuts and Cotter Pins

Engine:

Engine Mounting Bolts

Engine Mounting Bracket Bolts

Exhaust Pipe Holder Nuts

Muffler Mounting Bolts

Muffler Clamp Bolt

PERIODIC MAINTENANCE 2-21

Others:

Footrest Mounting Bolts

Throttle Mounting Bolts

Carrier Mounting Bolts

Fuel System

Table of Contents

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

Specifications .................................... 3-4

Special Tools and Sealant ................. 3-5

Throttle Lever and Cable................... 3-6

Throttle Lever Free Play

Inspection.................................. 3-6

Throttle Lever Free Play

Adjustment ................................ 3-6

Throttle Case Removal/Disas-

sembly....................................... 3-6

Throttle Case Assembly/Installa-

tion ............................................ 3-7

Throttle Cable Installation ............ 3-7

Throttle Case Inspection and

Lubrication................................. 3-7

Throttle Cable Lubrication and

Inspection.................................. 3-8

Choke Lever and Cable..................... 3-9

Choke Lever Removal ................. 3-9

Choke Lever and Cable

Installation ................................. 3-9

Choke Lever Lubrication .............. 3-9

Choke Cable Lubrication and

Inspection.................................. 3-9

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

Idle Speed Adjustment................. 3-10

Carburetor Pilot Screw

Adjustment ................................ 3-10

FUEL SYSTEM 3-1

Fuel Level Inspection ................... 3-10

Fuel Level Adjustment ................. 3-11

Fuel System Cleanliness

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

Carburetor Removal..................... 3-12

Carburetor Installation.................. 3-13

Carburetor Disassembly .............. 3-13

Carburetor Assembly ................... 3-14

Carburetor Cleaning..................... 3-15

Carburetor Inspection .................. 3-15

Air Cleaner......................................... 3-17

Air Cleaner Element Removal...... 3-17

Air Cleaner Element Installation... 3-17 Air Cleaner Element Cleaning and

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

Air Cleaner Draining..................... 3-18

Air Cleaner Housing Removal...... 3-18

Fuel Tank ........................................... 3-19

Fuel Tank Removal ...................... 3-19

Fuel Tank Installation ................... 3-19

Fuel Tap Removal ........................ 3-20

Fuel Tap Installation ..................... 3-20

Fuel Tank and Fuel Tap Cleaning 3-20

Fuel Tap Inspection...................... 3-21

Fuel Level Gauge Removal ......... 3-21

Fuel Level Gauge Installation ...... 3-22

Fuel Level Gauge Check ............. 3-22

3-2 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1 Carburetor Holder Bolts 11 1.1 95 in·lb L

2 Throttle Lever Bolt 5.9 0.6 52 in·lb

3: Choke Lever 4: Choke Cable 5: Throttle Cable 6: Throttle Lever 7: Jet Needle 8: Pilot Jet 9: Main Jet

10: Needle Jet

11: Pilot Screw 12: Tighten the clamp screws from rear, then front. Gr: Apply grease.

L: Apply a non-permanent locking agent.

3-4 FUEL SYSTEM

Specifications

Item

KLF250-A1 KLF250-A2 ∼

Throttle Case and Cable

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

Carburetor

Make/Type MIKUNI VM24SS –––

Main Jet #115 #120 –––

Main Air Jet 1.0 1.8 –––

Needle Jet O-6M O-2M –––

Jet Needle 5GN64-1 5GN74-1 –––

Pilot Jet #30 #22.5 –––

Pilot Air Jet 1.3 1.0 –––

Pilot Screw 1 1/2 turns out 2 1/2 turns out –––

Starter Jet #45 –––

Idle Speed 1 300 ∼ 1 400 r/min (rpm)

Service Fuel Level 5 ± 1 mm (0.20 ± 0.04 i n.) –––

below bottom edge of

carburetor body

Float Height 22.6 ± 2 mm (0.89 ± 0.04 in.) –––

Optional Parts:

Main Jet:

Altitude:

0 ∼ 500 m (0 ∼ 1 600 ft) #115 #120 –––

(92063-1109) (92063-1106)

500 ∼ 1 500 m (1 600 ∼ 4 900 ft) #112.5 #117.5 –––

(92063-1110) (92063-1107)

1 500 ∼ 2 500 m (4 900 ∼ 8 200 ft) #110 #115 –––

(92063-1038) (92063-1109)

2500∼ 3 500 m (8 200 ∼ 11 500 ft) #107.5 #112.5 –––

(92063-073) (92063-1110)

3 500 ∼ 4 500 m (11 500 ∼ 14 800 ft) #102.5 #110 –––

(92063-1028) (92063-1038)

Air Cleaner

Air cleaner element oil High-quality foam air filter oil –––

Standard

Service Limit

–––

Special Tools and Sealant

FUEL SYSTEM 3-5

Fuel Level Gauge: 57001-1017

Pilot Screw Adjuster, A: 57001-1239

3-6 FUEL SYSTEM

Throttle Lever and Cable

Throttle Lever Free Play Inspection

Refer to the Throttle Lever Free Play Inspection in the

•

Periodic Maintenance chapter.

Throttle Lever Free Play Adjustment

Refer to the Throttle Lever Free Play Adjustment in the

•

Periodic Maintenance chapter.

Throttle Case Removal/Disassembly

Remove the throttle case screws [A] and separate the

•

case halves.

Pull the cable tip [A] out of the throttle lever catch with the

•

throttle lever opened. Loosen the locknut [B] and unscrew the adjuster [C].

•

Remove:

•

Throttle Lever Bolt [A], Spring Washer [B], and Washer [C] Arm [D] and Spring [E] Collars [F] Throttle Lever [G]

Loosen the locknut [H] and unscrew the therottle limiter

•

screw [I].

Throttle Lever and Cable

Throttle Case Assembly/Installation

Lubricate the throttle case and cable before assembly/in-

•

stallation. Be certain that the return spring [A] is correctly installed

•

on the throttle lever. Tighten:

•

Torque - Throttle Lever Bolt : 5.9 N·m (0.6 kgf·m, 52 in·lb)

Swing the throttle lever so that the carburetor throttle

•

valve is fully open. Turn the throttle limiter screw [A] until it is spaced about 1 mm (0.04 in.) [B] away from the throttle lever stop [C]. Tighten the locknut [D].

NOTE

Refer to the Owner’s Manual for the function of the throt-

○

tle limiter and adjustment procedure of it.

FUEL SYSTEM 3-7

WARNING

Operation with an improperly assembled throttle case could result in an unsafe riding condition.

Check the throttle lever free play (see Throttle Lever Free

•

Play Inspection).

Throttle Cable Installation

Lubricate the throttle cable before installation.

•

Route the cable correctly according to Appendix chapter.

•

WARNING

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

Check the throttle cable (see Throttle Lever Free Play In-

•

spection).

Throttle Case Inspection and Lubrication

With the throttle cable disconnected from the throttle

•

lever, the lever should move freely and return smoothly by spring. If the lever is heavy, disassemble the throttle case, clean and lubricate the throttle case. Examine the lever and case for cracks. Replace the case

•

assembly if it is cracked.

3-8 FUEL SYSTEM

Throttle Lever and Cable

Apply a thin coating of multi-purpose grease to the throttle

•

lever pivot area [A] and throttle cable end [B].

Throttle Cable Lubrication and Inspection

Whenever the throttle cable is removed or in accordance

•

with the Periodic Maintenance Chart in the Periodic Maintenance chapter, lubricate the cable. Refer to the General Lubrication in the Periodic Mainte-

•

nance chapter for the cable lubrication and inspection.

Choke Lever and C able

Choke Lever Removal

Unscrew the choke lever mounting screw [A] and take off

•

the plane washer and the wave washer. Remove the choke lever [B] and free the choke cable up-

•

per end from the lever.

Pull off the retaining ring [A] and free the choke cable [B]

•

from the switch case. Pull the cable out of the vehicle.

•

FUEL SYSTEM 3-9

Choke Lever and Cable Installation

Lubricate the choke cable before installation.

•

Install the wave washer, plane washer and screw in that

•

order. Route the choke cable according to the General Informa-

•

tion chapter.

WARNING

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

Choke Lever Lubrication

Whenever the choke cable is removed, lubricate the

choke lever as follows:

Apply a thin coating of multi-purpose grease to the wave

•

washer [A].

Choke Cable Lubrication and Inspection

Whenever the choke cable is removed or in accordance

•

with the Periodic Maintenance Chart in the Periodic Maintenance chapter, lubricate the cable. Refer to the General Lubrication in the Periodic Mainte-

•

nance chapter for the cable lubrication and inspection.

3-10 FUEL SYSTEM

Carburetor

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

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

•

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

WARNING

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

Check idle speed with a suitable tachometer.

•

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

Idle Speed

Standard: 1 300 ∼ 1400r/min(rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.

•

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

•

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

○

the idle speed is within the specified range.

Carburetor Pilot Screw Adjustment

Adjust the pilot screw if necessary.

•

Turn the carburetor pilot screw [A] all the way in until it

•

seats lightly.

Special Tool - Pilot Screw Adjuster, A: 57001-1239 [B]

CAUTION

Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement.

Back the pilot screw out the specified number of turns.

•

Carburetor Pilot Screw Setting

Standard: 1 1/2 turns out

Fuel Level Inspection

WARNING

Park the vehicle on a level surface.

•

Carburetor

Connect the fuel level gauge to the open end of the car-

•

buretor drain hose.

Special Tool - Fuel Level Gauge: 57001-1017

Fuel Level Gauge [A] ZeroLine[B] DrainPlug[C] Carburetor Body Bottom Edge [D] Fuel Level [E]

Hold the gauge vertically against the side of the carburetor

•

body so that the "zero" line is several millimeters higher than the bottom edge of the carburetor body. Turn the fuel tap to the ON position to feed fuel to the

•

carburetor and gauge, then turn out the carburetor drain plug a few turns. Wait until the fuel level in the gauge settles.

•

Keeping the gauge vertical, slowly lower the gauge until

•

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

FUEL SYSTEM 3-11

NOTE

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

○

the carburetor body. If the gauge is lowered and then raised it 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. Tighten the drain plug and remove the fuel level gauge.

•

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

Fuel Level

Standard:

Fuel Level Adjustment

Remove the carburetor.

•

Drain the carburetor.

•

Remove the float bowl by taking out the screws.

•

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.

5 ± 1 mm (0.20 ± 0.04 in.) below the bottom edge of the carburetor body

Float Height

Standard: 22.6 ± 2 mm (0.89 ± 0.04 in.)

3-12 FUEL SYSTEM

Carburetor

Float Bowl Mating Surface [A] Float Valve Needle Rod (contacted but unloaded) [B] Float [C]

Float Height [D] If the fuel level cannot be adjusted by this method, the float or the float valve is damaged. Assemble the carburetor, install it on the vehicle, and

•

recheck the fuel level.

Fuel System Cleanliness Inspection

Refer to the Fuel System Cleanliness Inspection in the

•

Periodic Maintenance chapter.

Carburetor Removal

WARNING

Turn the fuel tap to the OFF position.

•

Remove:

•

Fuel Hose

Starter Plunger

Clamps [A]

Pull out the carburetor.

•

Remove the carburetor cap [A].

•

Carburetor

Carburetor Installation

Align the slit [A] on the side of the throttle valve with the

•

guide pin [B] in the carburetor body. Route the carburetor hoses according to Appendix chap-

•

ter. Check fuel leakage from the carburetor.

•

WARNING

Fuel spilled from the carburetor is hazardous.

If the carburetor has been disassembled, or if there is some other reason that the fuel level may be incorrect, inspect the fuel level (see Carburetor Fuel Level Inspection). Adjust the idle speed (see Idle Speed Adjustment).

•

Check the throttle cable (see Throttle Lever Free Play In-

•

spection in Periodic Maintenance chapter).

FUEL SYSTEM 3-13

Carburetor Disassembly

Remove:

•

Carburetor (see Carburetor Removal) Float Bowl Screws [A] Float Bowl [B]

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

•

drop out the float valve needle with its hanger.

Remove:

•

Main Jet Fence [A] Plate Screw [B] Plate [C]

3-14 FUEL SYSTEM

Carburetor

Remove:

•

Float Valve Seat [A]

Main Jet [B]

Needle Jet Holder [C]

Pilot Jet [D]

Remove:

•

Needle Jet [A]

Carburetor Assembly

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

•

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

CAUTION

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

Drop the float valve needle into the valve seat and hold

•

the float in place with the tang [A] hooked into the needle hanger. Slip the float pivot pin [B] through the pivot posts and the

•

float [C] as shown.

WARNING

If the float is improperly installed, the specified fuel level cannot be maintained. Fuel spilled from the carburetor is hazardous.

Set the float height as specified.

•

Carburetor

Carburetor Cleaning

WARNING

Clean the carburetor 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 carburetor. A fire or explosion could result.

CAUTION

Do not use compressed air on an assembled carburetor, the float may be crushed by the pressure, and the vacuum piston diaphragm 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 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.

FUEL SYSTEM 3-15

Disassemble the carburetor (see Carburetor Disassem-

•

bly). 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 the air and fuel passages with compressed air.

•

Assemble the carburetor (see Carburetor Assembly).

•

Carburetor Inspection

WARNING

Before removing the carburetor, check the fuel level (see

•

Fuel Level Inspection). If the fuel level is incorrect, inspect the rest of the carburetor before correcting it.

3-16 FUEL SYSTEM

Carburetor

Disassemble the carburetor (see Carburetor Disassem-

•

bly). Clean the carburetor (see Carburetor Cleaning).

•

Check the carburetor holder, starter plunger, plunger cap,

•

idle adjusting screw, pilot screw, needle jet holder [A], and float valve seat [B] and the gaskets on the carburetor cap and float bowl [C] are in good condition. If any of the O-rings or gaskets 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 the rod [D] in the other end of the float valve needle

•

and then release it [E]. If it does not spring out, replace the float valve needle.

Check the tapered portion [A] of the pilot screw [B] for

•

wear or damage. If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine f rom idling smoothly. Replace it.

Air Cleaner

Air Cleaner Element Removal

Remove:

•

Seat (see Frame chapter) Clips [A] Air Cleaner Housing Cap [B]

Remove:

•

Element Mounting Screw [A] Element Clamp Screw [B] Element [C]

After removing the element, stuff pieces of lint-free, clean

•

cloth into the air cleaner duct to keep dirt out of the carburetor and engine.

WARNING

FUEL SYSTEM 3-17

If dirt or dust is allowed to pass through into the carburetor, 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.

Remove:

•

Screw [A] and Washer Stopper [B] Element [C]

Air Cleaner Element Installation

Install the following parts on the holder [A].

•

Metal Net [B ] Element [C] Stopper [D] Screw [E] and Washer

After cleaning the element, grease to the both sides [F]

○

on the element 2.8 ± 0.4 g (0.01 ± 0.014 oz) on one side.

Grease the element inlet [A] as shown.

•

3-18 FUEL SYSTEM

Air Cleaner

Air Cleaner Element Cleaning and Inspection

Refer to the Air Cleaner Element Cleaning and Inspection

•

in the Periodic Maintenance chapter.

Air Cleaner Draining

Refer to the Air Cleaner Draining in the Periodic Mainte-

•

nance chapter.

Air Cleaner Housing Removal

Remove:

•

Seat (see Frame chapter)

Housing Mounting Bolts [A] Loosen the clamp screw [B].

•

Remove:

•

Engine Breather Hose [A]

Remove:

•

Regulator Mounting Bracket Bolt [A]

Air Cleaner Housing [B]

Fuel Tank

Fuel Tank Removal

WARNING

Remove:

•

Front Fender (see Frame chapter)

Turn the fuel tap to the OFF position.

•

Remove:

•

Fuel Hose [A]

FUEL SYSTEM 3-19

Remove:

•

Bolts [A] Fuel Tank [B]

Fuel Tank Installation

WARNING

Check the rubber dampers [A] on the frame top-tubes as

•

shown. If the dampers are damaged or deteriorated, replace them. Be sure the fuel hose is clamped to the fuel tap to prevent

•

leakage.

WARNING

Fuel spilled from the fuel tap is hazardou s.

3-20 FUEL SYSTEM

Fuel Tank

Fuel Tap Removal

Remove the fuel tank and drain it (see Fuel Tank Re-

•

moval). Remove:

•

Bolts [A]

Fuel Tap [B]

Fuel Tap Installation

Be sure the O-rings [A] are in good condition to prevent

•

leakage.

Fuel Tank and Fuel Tap Cleaning

Remove the fuel tank and drain it (see Fuel Tank Re-

•

moval). 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 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 tank. A fire or explosion could result.

Pour the solvent out the tank.

•

Remove the fuel filter from the tank by taking out the bolts.

•

Clean the fuel filter screens in a high-flash point solvent.

•

Pour high-flash point solvent through the tap in both ON

•

and RES positions. Dry the tank fuel filter with compressed air.

•

Install the fuel filter in the tank (see Fuel Tap, Fuel Filter

•

Installation). Install the fuel tank (see Fuel Tank Installation).

•

Fuel Tank

Fuel Tap Inspection

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

•

oration. If the fuel filter screens have any breaks or are deteriorated, it 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 OFF, replace the damaged gasket [A] or O-rings [B].

FUEL SYSTEM 3-21

Fuel Level Gauge Removal

Remove the fuel tank cap.

•

WARNING

Remove the fuel tank cover (see Fuel Tank Removal).

•

Install the fuel tank cap immediately.

•

Pry off the gauge cap [A] and discard the cap.

•

Check the grooves [B] in the fuel tank boss. If the grooves

•

are damaged by removing the cap or can not hold the cap nails, the fuel tank must be replaced. Pull out the fuel level gauge [C].

•

3-22 FUEL SYSTEM

Fuel Tank

Fuel Level Gauge Installation

WARNING

Install the fuel level gauge so that the 1/2 scale [A] faces

•

the front [B]. Push the new gauge cap over the gauge so that the notch

•

[C] aligns with the 1/2 scale. Check that the gauge cap nails fit securely in the grooves

•

in the fuel tank boss.

Fuel Level Gauge Check

Remove the fuel level gauge from the fuel tank (see Fuel

•

Level Gauge Removal). Check that the float [A] moves up and down [B] smoothly

•

without binding. It should go down under its own weight. If the float does not move smoothly or has visual damage, replace the gauge.

ENGINE TOP E ND 4-1

Engine Top E nd

Table of Contents

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

Specifications .................................... 4-6

Special Tools and Sealant ................. 4-9

Camshaft Chain Tensioner ................ 4-11

Camshaft Chain Tensioner

Removal .................................... 4-11

Camshaft Chain Tensioner

Installation ................................. 4-11

Camshaft Chain Tensioner Wear. 4-11

Camshaft Sprocket ............................ 4-12

Camshaft Sprocket Removal ....... 4-12

Camshaft Sprocket Installation .... 4-12

Rocker Arms and Shafts.................... 4-14

Compression Releasing Lever

Removal .................................... 4-14

Compression Releasing Lever

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

Rocker Arm and Shaft Removal .. 4-15 Rocker Arm and Shaft Installation 4-15 Rocker Arm and Shaft Inspection 4-16

Camshaft ........................................... 4-17

Camshaft Removal ...................... 4-17

Camshaft Installation ................... 4-17

Cam Wear Inspection .................. 4-17

Camshaft Bearing Inspection....... 4-17

Camshaft Chain and Guides ............. 4-18

Camshaft Chain Removal ............ 4-18

Camshaft Chain Installation ......... 4-18

Camshaft Chain Guide Removal . 4-18 Camshaft Chain Guide Installation

.................................................. 4-18

Camshaft Chain Guide Wear ....... 4-18

Cylinder Head.................................... 4-19

Cylinder Compression

Measurement ............................ 4-19

Cylinder Head Removal ............... 4-20

Cylinder Head Installation ............ 4-21

Cylinder Head Assembly.............. 4-21

Cylinder Head Cleaning ............... 4-22

Cylinder Head Warp..................... 4-22

Valves, Guides, Seats, Springs, Oil

Seals............................................... 4-23

Valve Clearance Inspection ......... 4-23

Valve Clearance Adjustment ........ 4-23

Valve Removal............................. 4-23

Valve Installation .......................... 4-24

Valve Visual Inspection ................ 4-24

Valve Guide Removal .................. 4-24

Valve Guide Installation ............... 4-25

Valve-to-Guide Clearance

Measurement ............................ 4-25

Valve Seat Inspection .................. 4-26

Valve Seat Repair (Valve

Lapping) .................................... 4-26

Cylinder and Piston ........................... 4-31

Cylinder Removal......................... 4-31

Cylinder Installation...................... 4-31

Piston Removal............................ 4-32

Piston Installation......................... 4-32

Cylinder/Piston Wear ................... 4-33

Piston/Cylinder Clearance ........... 4-34

Piston Ring and Ring Groove

Wear.......................................... 4-34

Piston Ring Groove Width............ 4-34

Piston Ring Thickness ................. 4-35

Piston Ring End Gap

Measurement ............................ 4-35

Exhaust System................................. 4-36

Spark Arrester Cleaning............... 4-36

Muffler Removal........................... 4-36

Exhaust Pipe Removal................. 4-36

Exhaust Pipe Installation.............. 4-37

Exhaust System Inspection.......... 4-37

4-2 ENGINE TOP END

Exploded View

ENGINE TOP END 4-3

Exploded View

Torque

No. Fastener N·m kgf·m ft·lb Remarks

1 Cylinder Head Bolts (M10), first torque 13 1.3 113 in·lb L(1), MO, S

1 Cylinder Head Bolts (M10), final toque 34 3.5 25 S

2 Cylinder Head Bolts (M6), first torque 5.9 0.6 52 in·lb MO, S

Cylinder Head Bolts (M6), final torque

3 Valve Adjusting Cap Bolts 8.8 0.9 78 in·lb

4 Retaining Bolt 4.4 0.45 39 in·lb

Compression Releasing Lever Bolt

G: Apply grease for oil seal and O-ring.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil.

R: Replacement Parts S: Follow the specific tightening sequence.

9.8 1.0 87 in·lb

8.8 0.9 78 in·lb

4-4 ENGINE TOP END

Exploded View

No. Fastener N·m

Camshaft Sprocket Bolt

Rear Camshaft Chain Guide Bolt

Camshaft Chain Tensioner Mounting Bolts

Valve Adjusting Screw Locknuts

Rocker Shaft Retainer Screws

Camshaft Chain Guard Screws

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

R: Replacement Parts

ENGINE TOP END 4-5

Torque

kgf·m ft·lb

34 3.5 25

9.8 1.0 87 in·lb

8.8 0.9 78 in·lb

12 1.2 104 in·lb

4.4 0.45 39 in·lb

Remarks

4-6 ENGINE TOP END

Specifications

Item Standard Service Limit

Rocker Case

Rocker Arm Inside Diameter 13.000 ∼ 13.018 mm 13.05 mm

(0.5118 ∼ 0.5125 in.) (0.514 in.)

Rocker Shaft Diameter 12.976 ∼ 12.994 mm 12.95 mm

(0.5109 ∼ 0.5116 in.) (0.510 in.)

Camshafts

Cam Height:

Exhaust 39.720 ∼ 39.828 mm 39.62 mm

(1.5638 ∼ 1.5680 in.) (1.560 in.)

Inlet 40.395 ∼ 40.503 mm 40.30 mm

(1.5904 ∼ 1.5946 in.) (1.587 in.)

Cylinder Head

Cylinder Compression: (usable range)

with Recoil Starter (5 times)

with Electric Starter 930 ∼ 1 435 kPa –––

Cylinder Head Warp

Valve

Valve Clearance:

Exhaust 0.18 ∼ 0.23 mm –––

Inlet 0.15 ∼ 0.20 mm –––

Valve Head Thickness:

Exhaust 1.0 mm (0.039 in.) 0.5 mm (0.020 in.)

Inlet 0.8 mm (0.031 in.) 0.4 mm (0.016 in.)

Valve Stem Bend ––– TIR 0.05 mm

Valve Stem Diameter:

Exhaust 5.480 ∼ 5.495 mm 5.47 mm

Inlet 5.495 ∼ 5.510 mm 5.48 mm

Valve Guide Inside Diameter:

Exhaust 5.520 ∼ 5.532 mm 5.60 mm

Inlet 5.520 ∼ 5.532 mm 5.60 mm

750 ∼ 1 180 kPa –––

(7.7 ∼ 12 kgf/cm², 110 ∼ 171 psi)

@450 r/min (rpm)

(9.5 ∼ 14.6 kgf/cm², 135 ∼ 208 psi)

@600 r/min (rpm)

–––

(0.0071 ∼ 0.0091 in.)

(0.0059 ∼ 0.0079 in.)

(0.2157 ∼ 0.2163 in.) (0.2154 in.)

(0.2163 ∼ 0.2169 in.) (0.2157 in.)

(0.2173 ∼ 0.2178 in.) (0.220 in.)

0.05 mm (0.002 in.)

(0.002 in.)

ENGINE TOP END 4-7

Specifications

Item Standard Service Limit

Valve Guide Clearance (wobble method):

Exhaust 0.05 ∼ 0.11 mm 0.27 mm

(0.0020 ∼ 0.0043 in.) (0.0106 in.)

Inlet 0.02 ∼ 0.08 mm 0.23 mm

(0.0008 ∼ 0.0032 in.) (0.0091 in.)

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

Valve Stem Bend ––– TIR 0.05 mm

Valve Seat Surface:

Width:

Exhaust 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) –––

Inlet

Outside Diameter:

Exhaust 26.9 ∼ 27.1 mm (1.059 ∼ 1.067 in.) ––– Inlet 30.9 ∼ 31.1 mm (1.217 ∼ 1.224 in.) –––

Valve spring free length:

Inner 37.8 mm (1.488 in.) 36.2 mm (1.425 in.)

Outer 40.4 mm (1.591 in.) 38.7 mm (1.524 in.)

Cylinder, Piston

Cylinder Inside Diameter 68.995 ∼ 69.007 mm 69.10 mm

Piston Diameter 68.960 ∼ 68.975 mm 68.81 mm

Piston/Cylinder Clearance

Piston Ring/Groove Clearance:

Top 0.02 ∼ 0.06 mm 0.16 mm

Second 0.02 ∼ 0.06 mm 0.16 mm

Piston Ring Groove Width:

Top 0.81 ∼ 0.83 mm 0.91 mm

Second 1.21 ∼ 1.23 mm 1.31 mm

Oil

Piston Ring Thickness:

Top 0.77 ∼ 0.79 mm 0.70 mm

Second 1.17 ∼ 1.19 mm 1.10 mm

0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

(2.7163 ∼ 2.7168 in.) (2.720 in.)

(2.7150 ∼ 2.7155 in.) (2.709 in.)

0.020 ∼ 0.047 mm (0.0008 ∼ 0.0019

in.)

(0.0008 ∼ 0.0024 in.) (0.0063 in.)

(0.0319 ∼ 0.0327 in.) (0.0358 in.)

(0.0476 ∼ 0.0484 in.) (0.0516 in.)

2.51 ∼ 2.53 mm 2.61 mm (0.0988 ∼ 0.0996 in.) (0.1028 in.)

(0.0303 ∼ 0.0311 in.) (0.028 in.)

(0.0461 ∼ 0.0469 in.) (0.043 in.)

–––

4-8 ENGINE TOP END

Specifications

Item Standard Service Limit

Piston Ring End Gap:

Top 0.15 ∼ 0.30 mm 0.6 mm

(0.0059 ∼ 0.0118 in.) (0.0236 in.)

Second 0.30 ∼ 0.45 mm 0.8 mm

(0.0118 ∼ 0.0177 in.) (0.0315 in.)

Oil 0.20 ∼ 0.70 mm 1.0 mm

(0.0079 ∼ 0.0276 in.) (0.0394 in.)

Special Tools and Sealant

ENGINE TOP E ND 4-9

Piston Ring Pliers: 57001-115

Compression Gauge, 20 kgf/cm²: 57001-221

Valve Spring Compressor Assembly: 57001-241

Valve Guide Reamer, 5.5: 57001-1020

Valve Guide Arbor, 5.5: 57001-1021

Valve Seat Cutter, 45° - 35: 57001-1116

Piston Pin Puller A ssembly: 57001-910

Valve Spring Compressor Adapter, 25: 57001-1019

Valve Seat Cutter, 32° - 35: 57001-1121

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

4-10 ENGINE TOP END

Special Tools and Sealant

Valve Seat Cutter, 60° - 41: 57001-1124

Valve Seat Cutter Holder, 5.5: 57001-1125

Valve Seat Cutter Holder B ar: 57001-1128

Compression Gauge Adapter, M12 × 1.25: 57001-1183

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

Filler Cap Driver: 57001-1454

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

Loosen the lock bolt [A] in the top of the camshaft chain

•

tensioner. Do not remove it yet. Remove:

•

Tensioner Mounting Bolts [B] and Clamp [C] Camshaft Chain Tensioner [D]

CAUTION

Do not turn the engine while the camshaft chain tensioner is removed. Engine damage could result.

Remove the lock bolt.

•

Carefully pull the push rod out of the tensioner body. Do

•

not drop the ball and retainer assembly or the spring. Slide the retainer and the spring off the push rod.

•

Camshaft Chain Tensioner Installation

Slip the spring [A] over the push rod [B] and compress it

•

down past the hole. Insert a piece of wire [C] in the hole to hold the spring in

•

place. Drop the retainer [D] onto the push rod.

•

ENGINE TOP END 4-11

Insert the push rod [A] into the tensioner body.

•

The flat side of the push rod must face up as shown.

○

When the push rod is in as far as it will go, screw in the

•

lock bolt [B] with its washer to lock the push rod. Pull out the wire to release the spring [C].

•

Be sure the O-ring [D] is in place in the tensioner body.

•

Install:

•

Tensioner Body and Clamp

Tighten:

•

Torque - Camshaft Chain Tensioner Mounting Bolts:

8.8 N·m (0.9 kgf·m, 78 in·lb)

Loosen the lock bolt and then tighten it. With the bolt loos-

•

ened, the spring inside takes up any slack automatically.

Camshaft Chain Tensioner Wear

Visually inspect the push rod [A], spring [B], ball and re-

•

tainer assembly [C], tensioner body [D], and O-ring [E]. Slide the push rod in and out of the tensioner body without

•

the spring or ball and retainer assembly. If the parts show any damage, or if the push rod does not slide smoothly in the tensioner body, replace the camshaft chain tensioner.

4-12 ENGINE TOP END

Camshaft Sprocket

Camshaft Sprocket Removal

Remove:

•

Fuel Tank (see Fuel System chapter) Front Fender (see Frame chapter) Recoil Starter (see Recoil Starter chapter) Bolts [A] and Camshaft Cover [B]

Turn the crankshaft with a wrench on the alternator rotor

•

bolt until the punch mark [A] on the camshaft sprocket aligns with the pointer [B] on the cylinder head. Remove the c amshaft chain tensioner (see Camshaft

•

Chain Tensioner Removal). Remove the camshaft sprocket bolt [C].

•

Hold the crankshaft from turning with a wrench on the

○

alternator rotor bolt. Slide the sprocket off the shoulder on the camshaft and

•

out from under the chain.

Camshaft Sprocket Installation

Remove:

•

Timing Inspection Plug [A]

Special Tool - Filler Cap Driver [B]: 57001-1454

Check to see that the “T” mark [A] on the alternator rotor

•

aligns with the slot [B]. If the “T” mark is not aligned, hold the camshaft chain taut and turn the crankshaft with a wrench on the alternator rotor bolt.

Camshaft Sprocket

Fit the sprocket under the chain and slip it over the shoul-

•

der on the camshaft so that the tab on the sprocket fits the hole in the end of the camshaft and the punch mark [A] on the sprocket aligns with the pointer [B] on the cylinder head. Apply molybdenum disulfide oil to the threads of the

•

camshaft sprocket bolt. Tighten the camshaft sprocket bolt, while holding the

•

crankshaft from turning with a wrench on the alternator rotor bolt.

Torque - Camshaft Sprocket Bolt: 34 N·m (3.5 kgf·m, 25

ft·lb)

Install the camshaft chain tensioner (see Camshaft Chain

•

Tensioner Installation). Before going any further, check the cam timing.

•

Turn the crankshaft counterclockwise with a wrench on

○

the alternator rotor bolt, until the punch mark on the sprocket realigns with the pointer on the head.

ENGINE TOP END 4-13

CAUTION

If any resistance is felt when turning the crankshaft, stop immediately, or you may bend the valves.

The “T” mark on the alternator rotor should align with the

○

slot. If the camshaft timing is not correct, remove the sprocket from the camshaft, and install it again as detailed above.

Smear a little engine oil on the camshaft cover O-ring [A],

•

and push the cover into place. Put in the camshaft cover bolts and tighten them securely.

•

Install the timing inspection plug.

•

4-14 ENGINE TOP END

Rocker Arms and Shafts

Compression Releasing Lever Removal

Remove:

•

Retaining Bolt [A] and Washer Compression Releasing Lever Bolt [B] Compression Releasing Lever [C], Return Spring, and Washer Compression Releasing Shaft

Compression Releasing Lever Installation

Replace the oil s eal [A], if it is damaged.

•

Apply grease to the oil seal lip.

•

Install:

•

Compression Releasing Shaft [A] Retaining Bolt [B] and Washer

Tighten:

•

Torque - Retaining Bolt: 4.4 N·m (0.45 kgf·m, 39 in·lb)

Install:

•

Washer [C] Return Spring [D] Compression Releasing Lever [E] Compression Releasing Lever Bolt [F]

Tighten:

•

Torque - Compression Releasing Lever Bolt: 8.8 N·m (0.9

kgf·m, 78 in·lb)

Hook the return spring ends [A] as shown.

○

Rocker Arms and Shafts

Rocker Arm and Shaft Removal

Remove:

•

Camshaft Sprocket (see Camshaft Sprocket Removal) Screws [A] and Rocker Shaft Retainer [B]

Remove:

•

Compression Releasing Lever (see Compression Releasing Lever Removal) Valve Adjusting Caps

Screw the camshaft sprocket bolt [A] into the rocker shaft

•

and pull out the shaft with it. Pull out the rocker shafts [B] and remove the rocker arms.

•

ENGINE TOP END 4-15

Rocker Arm and Shaft Installation

Before installation of the rocker arms and shafts, turn the

•

camshaft so that the cam lobes [A] point to the “down”.

Apply molybdenum disulfide oil to the rocker shaft.

•

Install each rocker shaft with the shaft notch [A] to the

•

inside. Install the rocker shaft retainer [B] with the chamfered side

•

[C] to the front side. Tighten:

•

Torque - Rocker Shaft Retainer Screws: 4.4 N·m (0.45

kgf·m, 39 in·lb)

After installation, be sure to check and adjust the valve

•

clearance.

4-16 ENGINE TOP END

Rocker Arms and Shafts

Rocker Arm and Shaft Inspection

Inspect the area [A] on the rocker arm where the cam

•

rubs. If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes. Inspect the end of the valve clearance adjusting screw [B]

•

where it contacts the valve stem. If the end of the adjusting screw is mushroomed or damaged in any way, or if the screw will not turn smoothly, replace it. Also inspect the end of the valve stem. Measure the inside diameter [C] of the rocker arm with a

•

dial bore gauge. If the rocker arm inside diameter is larger than the service limit, replace it. Also check the rocker shaft diameter [D].

Rocker Arm Inside Diameter

Standard:

Service Limit: 13.05 mm (0.514 in.)

13.000 ∼ 13.018 mm (0.5118 ∼ 0.5125 in.)

Measure the diameter of the rocker shaft where the rocker

•

armpivotsonitwithamicrometer. If the rocker shaft diameter is smaller than the service limit, replace it.

Rocker Shaft Diameter

Standard:

Service Limit: 12.95 mm (0.510 in.)

12.976 ∼ 12.994 mm (0.5109 ∼ 0.5116 in.)

Camshaft

Camshaft Removal

Remove:

•

Camshaft Sprocket (see Camshaft Sprocket Removal) Rocker Shaft Retainer (see Rocker Arm and Shaft Removal)

Pull the camshaft [A] straight out of the head.

•

Camshaft Installation

Blow the oil passage with compressed air [A].

•

ENGINE TOP END 4-17

Apply molybdenum disulfide oil to the cam lobes [A].

•

Carefully push the camshaft into the cylinder head with

•

the cam lobes “down”.

Cam Wear Inspection

Measure the height [A] of each cam lobe with a microm-

•

eter. If the cam height is less than the service limit for either lobe, replace the camshaft.

Cam Height

Standard Service Limit

Exhaust 39.720 ∼ 39.828 mm 39.62 mm

(1.5638 ∼ 1.5680 in .) (1.560 in.)

Inlet 40.395 ∼ 40.503 mm 40.30 mm

(1.5904 ∼ 1.5946 in .) (1.587 in.)

Camshaft Bearing Inspection

Check the ball bearing which is press-fitted on the

•

camshaft. Since the ball bearing is made to extremely close toler-

○

ances, the wear must be judged by feel rather than measurement. Clean the bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. Spin the bearing by hand to check its condition.

○

If the bearing is noisy, does not spin smoothly, or has any rough stops, replace it.

4-18 ENGINE TOP END

Camshaft Chain and Guides

Camshaft Chain Removal

Remove:

•

Camshaft Sprocket (see Camshaft Sprocket Removal) Alternator Rotor (see Electrical System chapter) Screws [A] and Camshaft Chain Guard [B] Camshaft Chain [C]

Camshaft Chain Installation

CAUTION

Always pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.

Tighten:

•

Torque - Camshaft Chain Guard Screws: 4.4 N·m (0.45

kgf·m, 39 in·lb)

Install the camshaft sprocket (see Camshaft Sprocket In-

•

stallation).

Camshaft Chain Guide Removal

Remove:

•

Cylinder Head (see Cylinder Head Removal) Camshaft Chain (see Camshaft Chain Removal) Front Camshaft Chain Guide [A] Bolt [B], Rear Camshaft Chain Guide [C], and Collar

Camshaft Chain G uide Installation

Slip the front camshaft chain guide [A] into position [B]. Be

•

sure the hook [C] of the chain guide hangs on the cylinder catch. Tighten:

•

Torque - Rear Camshaft Chain Guide Bolt: 9.8 N·m (1.0

kgf·m, 87 in·lb)

Camshaft Chain Guide Wear

Visually inspect the rubber on the guides.

•

If the rubber is damaged, cut, or is missing pieces, replace the guide.

Cylinder Head

Cylinder Compression Measurement

Before measuring compression, do the following:

•

Be sure the battery is fully charged.

○

Warm up the engine (if the engine will run).

○

During warm-up, check for leaks around the cylinder head

○

gasket. Remove the spark plug.

•

Set the compression gauge [A] and adapter [B] into the

•

spark plug hole.

Special Tools - Compression Gauge: 57001-221

Compression Ga ug e Adapter, M12 × 1.25:

57001-1183

Hold the throttle wide open and crank the engine with the

•

recoil starter or the electric starter. When the gauge stops rising, stop cranking and read the

•

gauge.

Cylinder Compression (Usable Range)

Recoil Starter 750 ∼ 1 180 kPa (7.7 ∼ 12 kgf/cm², (5 times): 110 ∼ 171 psi) @450 r/min (rpm) Electric Starter: 930 ∼ 1 435 kPa (9.5 ∼ 14.6 kgf/cm²,

135 ∼ 208 psi) @600 r/min (rpm)

ENGINE TOP END 4-19

If the compression is within the specified range, the piston rings, cylinder and valves are probably in good condition. If the compression is higher than the specified range, see the Compression Too High table. If the compression is below the specified range, squirt a little oil into the spark plug hole and repeat the compression measurement. If the compression does not change very much, the piston rings are probably OK. See the Wet Compression - No Change table. If the compression increases, the piston rings are not sealing properly. See the Wet Compression - Increase table.

4-20 ENGINE TOP END

Cylinder Head

Compression Too High

Possible Problems

Remove carbon

Carbon build up on piston head and cylinder head

Cylinder head or base gasket too thin

Wet Compression - No Change

Possible Problems

Improper valve clearance Check clearance

Worn valve seats

Burned valve

Cylinder head leak

Check possible oil leaks to combustion chamber

Replace gaskets

Check seats Valve Seat Inspection, and Valve Seat Repair

Check valves

Check head gasket

Check head flatness Cylinder Head Warp

Solutions References

Piston Cleaning and Cylinder Head Cleaning

Valve Stem Oil Seal Inspection,

Valve Stem Diameter, Valve Guide Inside Diameter,

and ch eck piston oil ring for visible damage.

Cylinder Head Removal, Cylinder Head Installation,

Cylinder Removal, and Cylinder Installation

Valve C learance Check, and Valve Clearance

Adjustment

Valve Visual Inspection, and Valve Head Thickness

Cylinder Head Removal, and Cylinder Head

Installation

Wet Compression - Increas

Possible Problems

Toomuchpiston-tocylinder clearance

Worn piston rings, and ring grooves

Solutions References

Check clearance Cylinder/Piston Wear, Piston/Cylinder Clearance

Check piston and rings

Piston Ring and Ring Groove Wear,

and Piston Ring End Gap (top and second only).

Cylinder Head Removal

Remove:

•

Front Fender (see Frame chapter) Fuel Tank, Carburetor (see Fuel System chapter) Exhaust Pipe and Muffler (see Exhaust Pipe and Muffler Removal) Camshaft Sprocket (see Camshaft Sprocket Removal) Oil Pipes [A]

Pull the spark plug cap [B] off the spark plug.

•

Remove:

•

Engine Mounting Bolt [A] Bolts [B] and Engine Bracket [C]

Cylinder Head

Loosen the cylinder head M6 bolts [A] and M10 bolts [B]

•

completely and remove all the bolts. Remove the cylinder head.

•

Cylinder Head Installation

Blow out the oil passage with compressed air.

•

Install a new cylinder head gasket [A].

•

Be sure the dowel pins [B] are in place.

•

Be sure the front camshaft chain guide [C] is in place (see

•

Camshaft Chain Guide Installation).

ENGINE TOP END 4-21

Apply molybdenum disulfide oil [M] to the flange and

•

threads of all cylinder head bolts. Apply a non-permanent locking agent [L] to the right front

•

cylinder head bolt [4]. Tighten the cylinder head bolts in a criss-cross pattern as

•

shown, in two steps.

Cylinder Head Bolt Torque

First Torquing

M10 Bolts [1 ∼ 4] : 13 N·m (1.3 kgf·m, 113 in·lb) M6 Bolts [5 ∼ 6] : 5.9 N·m (0.6 kgf·m, 52 in·lb)

Final Torquing

M10 Bolts [1 ∼ 4]: 34 N·m (3.5 kgf·m, 25 ft·lb) M6 Bolts [5 ∼ 6]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Tighten:

•

Torque - Engine Bracket Bolts : 26 N·m (2.7 kgf·m, 20 ft·lb)

Engine Mounting Nut (M8) : 29 N·m (3.0 kgf·m, 22

ft·lb)

Cylinder Head Assembly

Apply grease to the O-rings [A].

•

Install:

•

Insulator [B] Carburetor Holder [C]

Be careful not to pinch the O-rings when installing the

○

insulator. Apply a non-permanent locking agent to the carburetor

•

holder bolts [D] and tighten them.

Torque - Carburetor Holder Bolts: 11 N·m (1.1 kgf·m, 95

in·lb)

4-22 ENGINE TOP END

Cylinder Head

Cylinder Head Cleaning

Remove the cylinder head (see Cylinder Head Removal).

•

Remove the valves (see Valve Removal).

•

Wash the head with a high-flash point solvent.

•

Scrape the carbon out of the combustion chamber and

•

exhaust port with a suitable tool. Install the valves (see Valve Installation).

•

Cylinder Head Warp

Clean the cylinder head (see Cylinder Head Cleaning).

•

Lay a straightedge across the lower surface of the cylinder

•

head at the positions shown.

Use a thickness gauge [A] to m easure the space between

•

the straightedge [B] and the head.

Cylinder Head Warp

Service L imit: 0.05 mm (0.002 in.)

If the cylinder head is warped more than the service limit, replace it. If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate (first No. 200, then No.

400).

Valves, Guides, Seats, Springs, Oil Seals

Valve Clearance Inspection

Refer to the Valve Clearance Inspection in the Periodic

•

Maintenance chapter.

Valve Clearance Adjustment

Loosen the locknut [A] and turn the adjusting screw [B]

•

until the clearance is correct. Hold the adjusting screw from turning and tighten the lock-

•

nut to the specified torque.

Torque - Valve Adjusting Screw Locknuts: 12 N·m (1.2

kgf·m, 104 in·lb)

Recheck the clearance.

•

If the clearance is incorrect, repeat the adjustment procedure. If the clearance is correct, perform the adjustment procedure on the other valve.

Be sure that the valve adjusting cap O-ring [A] are in

•

place. The valve adjusting caps are marked “UP” [B] on the top

•

end. Tighten:

•

Torque - Valve Adjusting Cap Bolts: 8.8 N·m (0.9 kgf·m, 78

in·lb)

ENGINE TOP END 4-23

Valve Removal

Remove:

•

Cylinder Head (see Cylinder Head Removal) Camshaft (see Camshaft Removal) Rocker Arms and Shafts (see Rocker Arm and Shaft Removal)

Use the valve spring compressor assembly [A] and

•

adapter to press down the valve spring retainer.

Special Tools - Valve Spring Compressor Assembly: 57001

-241

Valve Spring Compressor Adapter,

57001-1019

Remove the split keepers.

•

Loosen the valve spring compressor and take out the fol-

•

lowing parts:

Valve Spring Retainer Outer Spring Inner Spring Outer Spring Seat

Push out the valve.

•

Repeat the procedure for the other valve.

•

25:

4-24 ENGINE TOP END

Valves, Guides, Seats, Springs, Oil Seals

Valve Installation

If a new valve is to be used, check the valve-to-guide

•

clearance. If there is too little clearance, ream the valve guide. If there is too much clearance, install a new valve guide. Check the valve seating.

•

After proper valve seating has been confirmed, replace

•

the valve stem oil seal [A]. Smear the valve stem end with a thin coat of molybdenum

•

disulfide engine assembly grease, and push the valve [B] into the guide. Put the spring seat [C] and the inner and outer springs [D]

•

in place. Place the springs so that the closed coil end [E] of each

○

spring faces down. Set the spring retainer [F] on the springs.

•

Use the valve spring compressor to press down the valve

•

spring retainer. Install the split keepers [G], and slowly remove the spring

•

compressor. Be sure the keepers stay in place, holding the retainer down. Repeat the procedure for the other valve.

•

Install the removed parts to the cylinder head.

•

Install the cylinder head (see Cylinder Head Installation).

•

Adjust the valve clearance (see Valve Clearance Inspec-

•

tion).

Valve Visual Inspection

Inspect the valve head seating area [A] for erosion, nicks,

•

and warpage. If the valve head seating area is warped, replace the valve. If the valve head seating area is eroded or nicked, it may be possible to repair the valve on a valve refacing machine. Inspect the stem [B] for obvious wear, discoloration, and

•

stem end [C] damage. If the stem is obviously worn or discolored, replace the valve. If the stem end is damaged, it may be possible to repair it on a valve refacing machine.

Valve Guide Removal

Remove:

•

Valve(seeValveRemoval) Valve Stem Oil Seal

Hammer lightly on the valve guide arbor [A] to remove the

•

guide from the top of the head.

Special Tool - Valve Guide Arbor, φ5.5 : 57001-1021

Valves, Guides, Seats, Springs, Oil Seals

Valve Guide Installatio n

Clean the valve guide hole in the cylinder head.

•

Lightly oil the valve guide.

•

Set the O-ring under the valve guide flange.

•

Use the valve guide arbor and a hammer to drive the

•

guide into the head from the outside until the flange on the guide seats against the head. Ream the valve guide with the valve guide reamer [A]

•

even if the old guide is reused.

Special Tool - Valve Guide Reamer, 5.5 : 57001-1020

Valve-to-Guide Clearance Measurement

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

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

•

gauge against the stem perpendicular to it a s close as

possible to the cylinder head mating surface.

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

•

guide clearance.

Repeat the measurement in a direction at a right angle to

•

the first.

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

ENGINE TOP END 4-25

NOTE

The reading is not actual valve/valve guide clearance

○

because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

Standard Service Limit

Exhaust 0.05 ∼ 0.11 mm 0.27 mm

(0.0020 ∼ 0.0043 in.) (0.0106 in.)

Inlet 0.02 ∼ 0.08 mm 0.23 mm

(0.0008 ∼ 0.0032 in.) (0.0091 in.)

4-26 ENGINE TOP END

Valves, Guides, Seats, Springs, Oil Seals

Valve Seat Inspection

Remove the valve (see Valve Removal).

•

Check the valve seat width [A].

•

Measure the seat width of the portion where there is no

○

build-up carbon (white portion) of the valve seat with vernier calipers.

Valve Seat Surface Width

Exhaust:

Inlet:

If the valve seat width is not within the specified range, repair the valve seat. Measure the outside diameter [B] of the seating pattern

•

on the valve seat.

Good [C] Too W i d e [ D ] Too Narrow [E]

Uneven [F] If the outside diameter of the valve seating pattern is too large or too small, repair the valve seat.

0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

Valve Seat Surface Outside Diameter

Exhaust:

Inlet:

26.9 ∼ 27.1 mm (1.059 ∼ 1.067 in.)

30.9 ∼ 31.1 mm (1.217 ∼ 1.224 in.)

Valve Seat Repair (Valve Lapping)

Using the valve seat cutters, repair the valve seat.

•

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

Valve Seat Cutter, 45° Valve Seat Cutter, 32° Valve Seat Cutter, 60° Valve Seat Cutter, 60° Valve Seat Cutter Holder, Valve Seat Cutter Holder Bar: 57001-1128

If the manufacturer’s instructions are not available, use the following procedure.

35: 57001-1116 35: 57001-1121 30: 57001-1123 41: 57001-1124

5.5: 57001-1125

Valves, Guides, Seats, Springs, Oil Seals

Seat Cutter Operating Care:

1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair.

2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.

3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.

CAUTION

Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.

4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.

NOTE

Prior to grinding, apply engine oil to the cutter and dur-

○

ing the operation, wash off any ground particles sticking to the cutter with washing oil.

ENGINE TOP END 4-27

5. After use, wash it with washing oil and apply thin layer of engine oil before storing.

Marks Stamped on the Cutter:

The marks stamped on the back of the cutter [A] represent the following.

60° ........................... Cutter angle [B]

37.5

Operating Procedures:

•

....................... Outer diameter of cutter [C]

Clean the seat area carefully.

Coat the seat with machinist’s dye.

Fit a 45° cutter into the holder and slide it into the valve

guide.

Press down lightly on the handle and turn it right or left.

Grind the seating surface only until it is smooth.

CAUTION

Do not grind the seat too much. Overgrinding will

reduce valve clearance by sinking the valve into the

head. If the valve sinks too far into the head, it will

be impossible to adjust the clearance, and the cylin-

der head must be replaced.

4-28 ENGINE TOP END

Valves, Guides, Seats, Springs, Oil Seals

Widened Width [A] of engagement by machining with 45° cutter Ground Volume [B] by 32° cutter 32° [C] Correct Width [D] Ground Volume [E] by 60° cutter 60° [F]

Measure the outside diameter of the seating surface with

•

a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.

Original Seating Surface [B]

NOTE

Remove all pittings of flaws from 45° ground surface.

○

After grinding with 45° cutter, apply thin coat of machin-

○

ist’s dye to seating surface. This makes seating surface distinct and 32° and 60° grinding operation easier. When the valve guide is replaced, be sure to grind with

○

45° cutter for centering and good contact.

If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. Grind the seat at a 32° angle [B] until the seat outside

•

diameter is within the specified range. To make the 32° grind, fit a 32° cutter into the holder, and

○

slide it into the valve guide. Turn the holder one turn at a time while pressing down

○

very lightly. Check the seat after each turn.

CAUTION

The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding.

After making the 32° grind, return to the seat outside di-

○

ameter measurement step above. To measure the seat width, use a vernier caliper to mea-

•

sure the width of the 45° angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above.

Valves, Guides, Seats, Springs, Oil Seals

If the seat width is too wide, make the 60° [A] grind de-

scribed below.

If the seat width is within the specified range, lap the valve

to the seat as described below.

Grind the seat at a 60° angle until the seat width is within

•

the specified range.

To make the 60° grind, fit 60° cutter into the holder, and

○

slide it into the valve guide.

Turn the holder, while pressing down lightly.

○

After making the 60° grind, return to the seat width mea-

○

surement step above.

Correct Width [B]

Lap the valve to the seat, once the seat width and outside

•

diameter are within the ranges specified above.

Put a little coarse grinding compound on the face of the

○

valve in a number of places around the valve head.

Spin the valve against the seat until the grinding com-

○

pound produces a smooth, matched surface on both the

seat and the valve.

Repeat the process with a fine grinding compound.

○

[A] Lapper

[B] Valve Seat

[C] Valve

The seating area should be marked about in the middle

•

of the valve face.

If the seat area is not in the right place on the valve, check

to be sure the valve is the correct part. If it is, it may have

been refaced too much; replace it.

Be sure to remove all grinding compound before assem-

•

bly.

When the engine is assembled, be sure to adjust the valve

•

clearance (see Valve Clearance Adjustment).

ENGINE TOP END 4-29

4-30 ENGINE TOP END

Valves, Guides, Seats, Springs, Oil Seals

Valve Seat Repair

Cylinder and Piston

Cylinder Removal

Remove:

•

Cylinder Head (see Cylinder Head Removal) Front Chain Guide [A]

Lift off the cylinder [B], and remove the cylinder base gas-

•

ket. If necessary, tap lightly around the base of the cylin-

der with a plastic mallet, taking care not to damage the

cylinder.

Immediately stuff a clean cloth around the piston to pre-

○

vent parts or dirt from falling into the crankcase.

Cylinder Installation

NOTE

If a new cylinder is installed, be sure to check pis-

○

ton/cylinder clearance (see Piston/Cylinder Clearance).

Clean any remains of the old cylinder base gasket from

•

the bottom of the cylinder and the top of the crankcase.

Install:

•

Dowel Pins [A] New Cylinder Base Gasket [B]

ENGINE TOP END 4-31

The arrow on the piston head must point toward the front

•

of the engine.

The piston ring openings must be positioned as shown.

•

The openings of the oil ring steel rails must be about 30°

∼ 150° of angle from the opening of the top ring.

TopRing[A] Second Ring [B] Oil Ring Expander [C] Top Oil Ring Steel Rail [D] Bottom Oil Ring Steel Rail [E] Arrow Mark [F] Front [G]

Apply molybdenum disulfide oil to the piston rings and

•

smear some oil inside the cylinder bore.

The rear camshaft chain guide also fit inside the tunnel.

•

Fit the cylinder down over the piston and rings.

•

Hold the rings into their groove with your fingers so that

○

the cylinder does not catch on them.

Be sure the O-ring [A] is in place at the bottom of the

•

cylinder.

Push the cylinder down solidly against the crankcase.

•

4-32 ENGINE TOP END

Cylinder and Piston

Piston Removal

Remove the cylinder (see Cylinder Removal).

•

Place a clean cloth under the piston, remove the one of

•

the piston pin snap rings.

CAUTION

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

Push out the piston pin, and remove the piston.

•

If necessary, use the piston pin puller assembly [A].

○

Special Tool - Piston Pin Puller Assembly: 57001-910

Remove the top and second piston rings [A].

•

Spread the ring open with your thumbs.

○

Push up on the opposite side with your fingers.

○

If necessary, use the piston ring pliers.

○

Special Tool - Piston Ring Pliers: 57001-115

Remove the oil ring upper and lower steel rails.

•

Spread the rail open with your thumbs.

•

Push up on the opposite side with your fingers.

○

Remove the oil ring expander.

•

Piston Installation

NOTE

If a new piston is used, check piston to cylinder clear-

○

ance (see Piston/Cylinder Clearance), and use new piston rings. The oil ring rails have no “top” or “bottom”.

○

Install the oil ring expander [A] i n the bottom piston ring

•

groove so the ends [B] butt together. Install the oil ring steel rails, one above the expander and

•

one below it. Spread the rail with your thumbs, but only enough to fit

○

the rail over the piston. Release the rail into the bottom piston ring groove.

○

Cylinder and Piston

Install the second ring [A] so that the “RN” mark [B] faces

•

up.

Install the top ring [C] so that the “R” mark [D] f aces up.

•

Install the piston pin.

•

Oil the piston pin lightly and slide it through the side of the

○

piston without a snap ring.

Hold the piston in position over the connecting rod, with

○

the arrow [A] pointing forward, and slide the piston pin the

rest of the way through the connecting rod and piston.

Fit a new piston pin snap ring into the side of the piston

•

so that the ring opening does not coincide with the slit of

the piston pin hole.

ENGINE TOP END 4-33

Cylinder/Piston Wear

Since there is a difference in cylinder wear in different di-

•

rection, take a side-to-side and a front-to-back measure-

ment at each of the 3 locations (total of 6 measurements)

showninthefigure.

If any of the cylinder inside diameter measurements ex-

ceeds the service limit, replace the cylinder.

20 mm (0.79 in.) [A] 40 mm (1.57 in.) [B] 10 mm (0.39 in.) [C]

Cylinder Inside Diameter

Standard: 68.995 ∼ 69.007 mm (2.7163 ∼ 2.7168 in.),

and less than 0.01 mm (0.0004 in.)

difference between any two measurements

Service Limit: 69.10 mm (2.720 in.), or more than

0.05 mm (0.0020 in.) difference betwee n any two measurements

easure the piston diameter [A] of each piston 5 mm

•

(0.20 in.) [B] up from the bottom of the piston at a right

angle to the direction of the piston pin.

Piston Diameter

Standard:

Service Limit: 68.81 mm (2.709 in.)

If the piston diameter is less than the service limit, replace

it.

.960 ∼ 68.975 mm

(2.7150 ∼ 2.7155 in.)

4-34 ENGINE TOP END

Cylinder and Piston

Piston/Cylinder Clearance

Subtract the piston diameter from the cylinder inside di-

•

ameter to get the piston/cylinder clearance.

Piston/Cylinder Clearance

Standard: 0.020 ∼ 0.047 mm (0.0008 ∼ 0.0019 in.)

Piston Ring and Ring Groove Wear

Check for uneven groove wear by inspecting the ring seat-

•

ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several mea-

•

surements with a thickness gauge [A] to determine piston ring/groove clearance.

Piston Ring/Groove Clearance

Standard Service Limit

Top: 0.02 ∼ 0.06 mm 0 .16 mm

(0.0008 ∼ 0.0024 in.) (0.0063 in.)

Second:

0.02 ∼ 0.06 mm 0.16 mm (0.0008 ∼ 0.0024 in.) (0.0063 in.)

If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both.

Piston Ring Groove Width

Measure the piston ring groove width.

•

Use a vernier caliper at several points around the piston.

○

Piston Ring Groove Width

Standard Service Limit

Top: 0.81 ∼ 0.83 mm 0.91 mm

(0.0319 ∼ 0.0327 in.) (0.0358 in.)

Second: 1.21 ∼ 1.23 mm 1.31 mm

(0.0476 ∼ 0.0484 in.) (0.0516 in.)

Oil: 2.51 ∼ 2.53 mm 2.61 mm

(0.0988 ∼ 0.0996 in.) (0.1028 in.)

If the width of any of the two grooves is wider than the service limit at any point, replace the piston.

Cylinder and Piston

Piston Ring Thickness

Measure the piston ring thickness.

•

Use a micrometer to measure at several points around

○

the ring.

Piston Ring Thickness

Standard Service Limit

Top: 0.77 ∼ 0.79 mm 0.70 mm

(0.0303 ∼ 0.0311 in.) (0.028 in.)

Second:

If any of the measurements is less than the service limit

on either of the rings, replace all the rings.

When using new rings in a used piston, check for un-

○

even groove wear. The rings should fit perfect parallel to the groove sides. If not, replace the piston.

1.17 ∼ 1.19 mm 1.10 mm

(0.0461 ∼ 0.0469 in.) (0.043 in.)

NOTE

ENGINE TOP END 4-35

Piston Ring End G ap Measurement

Place the piston ring inside the cylinder, using the piston

•

to locate the ring squarely in place. Set it close to the

bottom of the cylinder, where cylinder wear is low.

Measure the gap [A] between the ends of the ring with a

•

thickness gauge, where cylinder wear is low.

Piston Ring End Gap

Standard Service Limit

Top: 0.15 ∼ 0.30 mm 0.6 mm

(0.0059 ∼ 0.0118 in.) (0.0236 in.)

Second:

Oil:

If the end gap of either ring is greater than the service

limit, replace all the rings.

0.30 ∼ 0.45 mm 0.8 mm

(0.0118 ∼ 0.0177 in.) (0.0315 in.)

0.20 ∼ 0.70 mm 1.0 mm

(0.0079 ∼ 0.0276 in.) (0.0394 in.)

4-36 ENGINE TOP END

Exhaust System

This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.

CAUTION

The spark arrester must be installed correctly and

functioning properly to provide adequate fire pro-

tection.

Spark Arrester Cleaning

Refer to the Spark Arrester Cleaning in the Periodic M ain-

•

tenance chapter.

Muffler Removal

Loosen the muffler clamp bolt [A] until the clamp turns

•

freely on the muffler.

Take out the muffler mounting bolts [B].

•

Remove the muffler [C] from the rear of the frame.

•

Exhaust Pipe Removal

Remove:

•

Muffler (see Muffler Removal) Exhaust Pipe Holder Nuts [A] (both sides)

Take off the exhaust pipe [B], work them out of the frame,

•

and remove the exhaust pipe assembly.

Remove the exhaust pipe gaskets from the cylinder head.

•

Kawasaki KLF 250 (2003) User Manual [ru]

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

EMISSION CONTROL INFORMATION

Foreword

General Information

Especially note the following:

Two-Color Electrical Wire

KLF250-A1 Left Side View

KLF250-A1 Right Side View

Prefixes fo r Units:

Units o f Mass:

Units of Volume:

Units of Force:

Units of Length:

Units of Torque:

Units of Pressure:

Units of Speed:

Units of Power:

Units of Temperature:

Periodic Maintenance

Basic Torque for General Fasteners

Fuel System

Throttle Lever Free Play Inspection

Throttle Lever Free Play

Throttle Lever Free Play Adjustment

Fuel System Cleanliness Inspection

Air Cleaner Element Cleaning and Inspection

Air Cleaner Draining

Fuel Hose and Connection Check

Fuel Hose Replacement

Engine Top End

Valve Clearance Inspection

Valve Clearance (when cold)

Spark Arrester Cleaning

Clutches

Clutch Adjustment

Engine Lubrication System

Engine Oil Change

Engine Oil

Oil Filter Change

Wheels/Tires

Tire Inspection

Tire Tread Depth

Standard Tire

Final Drive

Final Gear Case Oil Change

Final Gear Case Oil

Propeller Shaft Joint Boot Inspection

Brakes

Front Brake Adjustment

Front Brake Lever Free Play

Cam Lever Angle

Rear (Parking) Brake Lever Free Play

Brake Pedal Free Play Inspection

Brake Pedal Free Play

Rear (Parking) Brake Lever and Pedal Free Play Adjustment

Cam Lever Angle

Steering

Steering Inspection

Electrical System

Battery Inspection

Spark Plug Cleaning / Inspection

Spark Plug Gap Inspection

Spark Plug Gap

Brake Light Switch Adjustment

Brake Light Switch Timing

General Lubrication

Lubrication

Cables: Lubricate with Cable Lubricant

Bolts and Nuts Tightening

Tightness Inspection

Fuel System

Throttle Lever Free Play Inspection

Throttle Lever Free Play Adjustment

Throttle Case Removal/Disassembly

Throttle Case Assembly/Installation

Throttle Cable Installation