Kawasaki KLF 250 (2003) User Manual [ru]

4.7 (6)
Kawasaki KLF 250 (2003) User Manual

Quick Reference Guide

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

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

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

General Information

1

j

 

 

 

Periodic Maintenance

2

j

 

 

 

Fuel System

3

j

 

 

 

Engine Top End

4

j

 

 

 

Engine Right Side

5

j

 

 

 

Recoil Starter

6

j

 

 

 

Engine Lubrication System

7

j

 

 

 

Engine Removal/Installation

8

j

 

 

 

Crankshaft/Transmission

9

j

 

 

 

Wheels/Tires

10

j

 

 

 

Final Drive

11

j

 

 

 

Brakes

12

j

 

 

 

Suspension

13

j

 

 

 

Steering

14

j

 

 

 

Frame

15

j

 

 

 

Electrical System

16

j

 

 

 

Appendix

17

j

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 in 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 make it as complete and accurate as possible.

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

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

© 2002 Kawasaki Heavy Industries, Ltd.

Third Edition (1) :Apr. 27, 2004 (K)

LIST OF ABBREVIATIONS

A

ampere(s)

lb

pounds(s)

ABDC

after bottom dead center

m

meter(s)

AC

alternating current

min

minute(s)

ATDC

after top dead center

N

newton(s)

BBDC

before bottom dead center

Pa

pascal(s)

BDC

bottom dead center

PS

horsepower

BTDC

before top dead center

psi

pound(s) per square inch

°C

degree(s) Celcius

r

revolution

DC

direct current

rpm

revolution(s) per minute

F

farad(s)

TDC

top dead center

°F

degree(s) Fahrenheit

TIR

total indicator reading

ft

foot, feet

V

volt(s)

g

gram(s)

W

watt(s)

h

hour(s)

ohm(s)

L

liter(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 maintenance free ignition system provides the most favorable ignition timing and helps maintain 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 "remove or render inoperative any device or element of design" has been generally interpreted as follows:

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

2.Tampering could include:

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

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 standards.

d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

PLEASE DO NOT TAMPER WITH 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 Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual carefully. Don’t take shortcuts.

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

How to Use This Manual

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

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

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

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

WARNING

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

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

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

NOTE

This note symbol indicates points of particular interest for more efficient and convenient operation.

Indicatesdone. a procedural step or work to be Indicates a procedural sub-step or how to do the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

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

GENERAL INFORMATION 1-1

General Information

1

Table of Contents

 

Before Servicing .....................................................................................................................

1-2

Model Identification.................................................................................................................

1-5

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 should 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.

GENERAL INFORMATION 1-5

Model Identification

KLF250-A1 Left Side View

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:

Front

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

 

Rear

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

 

 

(CA) 105 kg (232 lb)

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)

 

 

@5 500 r/min (rpm)

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)

 

 

to 35° BTDC @4 600 r/min (rpm)

Spark Plug

 

NGK DR8ES

Valve Timing:

 

 

Inlet:

Open

35° BTDC

 

Close

57° ABDC

 

Duration

272°

Exhaust:

Open

54° BBDC

 

Close

26° ATDC

 

Duration

260°

Lubrication System

 

Forced lubrication (wet sump)

Engine Oil:

Type

API SF or SG

 

 

API SH or SJ with JASO MA

 

Viscosity

SAE 10W-40

 

Capacity

2.0 L (2.11 US qt)

 

 

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

0.923 (24/26)

 

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)

12.686

Final Gear Case Oil:

 

 

 

Type

Hypoid gear oil

 

 

SAE90 (above 5°C, 41°F) or

 

 

SAE80 (below 5°C, 41°F)

 

Capacity

0.2 L (0.21 US qt)

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

115 mm (4.53 in.)

Rear:

 

 

 

Type

Torque tube-link

 

Wheel Travel

125 mm (4.92 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

GENERAL INFORMATION 1-9

Unit Conversion Table

Prefixes for Units:

Units of Length:

Prefix

Symbol

 

Power

mega

M

× 1 000

000

kilo

k

×

1 000

 

centi

c

×

0.01

 

milli

m

×

0.001

 

micro

 

 

µ

× 0.000001

Units of Mass:

kg

×

2.205

=

lb

g

×

0.03527

=

oz

km

×

0.6214

=

mile

m

×

3.281

=

ft

mm

×

0.03937

=

in

Units of Torque:

N·m

×

0.1020

=

kgf·m

N·m

×

0.7376

=

ft·lb

N·m

×

8.851

=

in·lb

kgf·m

×

9.807

=

N·m

kgf·m

×

7.233

=

ft·lb

kgf·m

×

86.80

=

in·lb

Units of Pressure:

Units of Volume:

 

 

 

kPa

×

0.01020

=

kg/cm²

 

 

 

kPa

×

0.1450

=

psi

L

×

0.2642

=

gal (US)

 

kPa

×

0.7501

=

cmHg

L

×

0.2200

=

gal (imp)

 

kg/cm²

×

98.07

=

kPa

L

×

1.057

=

qt (US)

 

kg/cm²

×

14.22

=

psi

L

×

0.8799

=

qt (imp)

 

cm Hg

×

1.333

=

kPa

L

×

2.113

=

pint (US)

 

 

 

 

 

 

L

×

1.816

=

pint (imp)

 

Units of Speed:

 

 

mL

×

0.03381

=

oz (US)

 

 

 

 

km/h

×

0.6214

=

mph

mL

×

0.02816

=

oz (imp)

 

 

 

 

 

 

 

mL

×

0.06102

=

cu in.

 

Units of Power:

 

 

 

 

 

 

 

 

 

 

Units of Force:

 

 

 

kW

×

1.360

=

PS

N

×

0.1020

=

kg

 

kW

×

1.341

=

HP

 

PS

×

0.7355

=

kW

N

×

0.2248

=

lb

 

 

 

 

 

 

 

PS

×

0.9863

=

HP

kg

×

9.807

=

N

 

 

 

 

 

 

kg

×

2.205

=

lb

 

 

 

 

 

 

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

2

 

 

 

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 Arrester 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

First

 

Regular Service

 

 

Service

 

 

 

 

 

 

 

 

 

 

After 10

Every 10

Every 30

Every 90

 

 

 

hrs. or

days or

days or

days or

Every

OPERATION

100 km

200 km

600 km

1 700 km

year of

 

 

(60 mi)

(120 mi)

(360 mi)

(1 100 mi)

use

 

 

of use

of use

of use

of use

 

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

 

 

 

 

 

 

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

anon-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

 

 

14

19

 

1.4 1.9

 

10.0

13.5

8

 

 

 

10

 

25

 

34

 

2.6

3.5

 

19.0

25

12

 

44

 

61

 

4.5

6.2

 

33

45

14

 

73

 

98

 

7.4

10.0

 

54

72

16

 

115

155

 

11.5

16.0

83

 

115

18

 

165

 

225

 

17.0

23.0

 

125

165

20

 

225

 

325

 

23

33

 

165

240

 

 

 

 

 

 

 

 

 

 

 

 

 

Fastener

 

 

 

 

 

Torque

 

 

 

 

Remarks

 

 

 

 

N·m

kgf·m

 

ft·lb

 

 

 

 

 

 

 

 

 

 

 

 

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

 

13

1.3

 

113 in·lb

 

 

L(1), MO, S

Cylinder Head Bolts (M10), final torque

 

34

3.5

 

25

 

 

S

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

 

8.8

0.9

 

78 in·lb

 

 

 

Valve Adjusting Screw Locknuts

 

 

12

1.2

 

104 in·lb

 

 

 

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

 

 

 

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

Clutch Spring Bolts

12

1.2

104 in·lb

 

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)

29

3.0

22

 

Crankshaft/Transmission

 

 

 

 

Engine Drain Plug

29

3.0

22

 

Crankcase Bolts

8.8

0.9

78 in·lb

 

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

25

2.5

18

 

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

 

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

Fastener

 

Torque

 

Remarks

N·m

kgf·m

ft·lb

 

 

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

25

2.5

18

L

Axle Shaft Pipe Bolts

20

2.0

14

 

Oil Level Inspection Bolt

 

 

69 in·lb

 

7.8

0.8

 

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

34

3.5

25

 

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

8.8

0.9

78 in·lb

 

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

 

2-6 PERIODIC MAINTENANCE

Specifications

Item

 

 

Standard

 

Service Limit

Fuel System

 

 

 

 

 

 

Throttle Lever Free Play

2

3 mm (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

0.15

0.20 mm (0.0059

0.0079 in.)

– – –

Engine Lubrication System

 

 

 

 

 

 

Engine Oil:

 

 

 

 

 

 

Type

API SF or SG

 

 

– – –

 

API SH or SJ with JASO MA

– – –

Viscosity

SAE10W40

 

 

– – –

Capacity

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)

 

Wheels/Tires

 

 

 

 

 

 

Tire Tread Depth:

 

 

 

 

 

 

Front

– – –

 

 

 

4 mm (0.16 in.)

Rear

– – –

 

 

 

4 mm (0.16 in.)

Standard Tire:

 

 

 

 

 

 

Front

AT 21 X 8-9

 

 

– – –

 

Dunlop, KT856, Tubeless

 

– – –

Rear

AT 22 x 10-10

 

 

– – –

 

Dunlop, KT857, Tubeless

 

– – –

Final Drive

 

 

 

 

 

 

Final Gear Case:

 

 

 

 

 

 

Gear Case Oil:

 

 

 

 

 

 

Type

API GL-5 Hypoid gear oil

 

– – –

Viscosity

SAE90 (above 5°C, 41°F)

 

– – –

 

SAE80 (below 5°C, 41°F)

 

– – –

Capacity

0.2 L (0.21 US qt)

 

– – –

Brakes

 

 

 

 

 

 

 

1

2 mm (0.04

 

 

 

Front Brake Lever Free Play

0.08 in.)

 

– – –

Rear (Parking) Brake Lever Free

2

3 mm (0.08

0.12 in.)

 

– – –

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

– – –

PERIODIC MAINTENANCE 2-7

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 com-

pletely 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.)

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 suitable 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 element, 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 2-9

Periodic Maintenance Procedures

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

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 connected 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, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed.

Fuel Hose Replacement

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.

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.

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