Kawasaki KLV1000 (2004) User Manual [ru]

KLV1000

Motorcycle

Service Manual

KLV1000

Motorcycle

Service Manual

Supplement

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 Motorcycle dealer for the latest information on product improvements incorporated after this publication.

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

 2004 Kawasaki Heavy Industries, Ltd. First Edition (1) Feb. 12, 2004 (K)

Foreword

This Kawasaki Service manual supplement information provides unique to the Kawasaki KLV1000-A1, which is based on the Suzuki DL1000K4. It must be used in conjunction with the other chapters of this manual. Read both this supplement and the base manual for complete information on proper service procedures for the model covered by this manual.

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.

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 motorcycle: zFollow the Periodic Maintenance Chart in the

Service Manual.

zBe alert for problems and non-scheduled

maintenance.

zUse proper tools and genuine Kawasaki

Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are listed in this manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

zFollow the procedures in this manual carefully.

Don’t take shortcuts.

zRemember to keep complete records of

maintenance and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, the product was divided into its major systems, and these systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

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

For example, if you want crankshaft information, use the Group Index to locate the Engine chapter. Then, use the Table of Contents on the first page of the chapter to find the Crankshaft section.

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

WARNING

This warning symbol identified 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 the other 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.

zIndicates a procedural step or work to be done.

Symbol

Throughout this manual are symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is included in the table below. Where applicable, comparable Kawasaki products and their part numbers have been included.

SYMBOL SUZUKI DEFINITION KAWASAKI DEFINITION

Torque control required. Data beside it indicates specified torque.

Indicates service data.

Apply oil. Use engine oil unless otherwise specified.

Apply molybdenum oil solution. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1)

Apply SUZUKI SUPER GREASE “A”. 99000-25030 (For USA) 99000-25010 (For the other countries)

Apply SUZUKI SILICONE GRESE. 99000-25100

Apply SUZUKI MOLY PASTE. 99000-25140

Apply SUZUKI BOND “1207B”. 99104-31140 (For USA) 99000-31140 (For the other countries)

Apply SUZUKI BOND “1215”. 99000-31110 (Except USA)

Apply THREAD LOCK SUPER “1303”. 99000-32030

Apply molybdenum disulfide oil. (a mixture of engine oil and molybdenum disulfide grease with a weight ratio of 1:1)

Apply grease.

Apply Silicone grease.

Apply molybdenum disulfide grease.

Apply THREE BOND “TB1207B”.

Apply THREE BOND “TB1215”.

Apply a non-permanent locking agent.

Apply THREAD LOCK SUPER “1322”. 99000-32110 (Except USA)

Apply THREAD LOCK “1342”. 99000-32050

Apply a non-permanent locking agent.

SYMBOL SUZUKI DEFINITION KAWASAKI DEFINITION

Apply or use brake fluid,

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Measure in diode test range. Use a suitable commercially

available digital multi meter for a diode tester and measure in diode test range.

Measure in continuity test range.

Use special tool. Refer to the special tools in

Servicing Information chapter.

Use engine coolant. 99000-99032-11X (Except USA)

Use fork oil. 99000-99001-SS8

Use rear shock absorber oil. 99000-99001-S25

Front Fork Oil Viscosity SAE 10W-20

GENERAL INFORMATION 1-1

General Information

Contents

WARNING/CAUTION/NOTE......................................................................................... Base Manual

GENERAL PRECAUTIONS .......................................................................................... 1-2

KAWASAKI LV1000-A1................................................................................................. 1-3

SERIAL NUMBER LOCATION ...................................................................................... Base Manual

FUEL, OIL, AND ENGINE COOLANT RECOMMENDATION ....................................... Base Manual

FUEL.......................................................................................................................... Base Manual

ENGINE OIL .............................................................................................................. Base Manual

BRAKE FLUID ........................................................................................................... Base Manual

FRONT FORK OIL..................................................................................................... Base Manual

ENGINE COOLANT................................................................................................... Base Manual

WATER FOR MIXING................................................................................................ Base Manual

ANTI-FREEZE/ENGINE COOLANT .......................................................................... Base Manual

LIQUID AMOUNT OF WATER/ENGINE COOLANT.................................................. Base Manual

BREAK-IN PROCEDURES........................................................................................... Base Manual

CYLINDER IDENTIFICATION....................................................................................... Base Manual

INFORMATION LABELS............................................................................................... Base Manual

SPECIFICATIONS......................................................................................................... 1-5

DIMENSIONS ............................................................................................................ 1-5

PERFORMANCE....................................................................................................... 1-5

ENGINE ..................................................................................................................... 1-5

DRIVE TRAIN ............................................................................................................ 1-6

FRAME ...................................................................................................................... 1-6

ELECTRICAL............................................................................................................. 1-6

COUNTRY AND AREA CODES.................................................................................... 1-7

GENERAL INFORMATION 1-2

GENERAL PRECAUTIONS

CAUTION

If parts replacement is necessary, replace the parts with KAWASAKI Genuine Parts or their

equivalent.

When removing parts that are to be reused, keep them arranged in an orderly manner so that they

may be reinstalled in the proper order and orientation.

Be sure to use special tools when instructed. Make sure that all parts used in reassembly are clean. Lubricate them when specified. Use the specified lubricants, bands, or sealant. When removing the battery, disconnect the negative cable first and then the positive cable.

When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal.

When performing service to electrical parts, if the service procedures not require use of battery

power, disconnect the negative cable the battery.

When tightening the cylinder head and case bolts and nuts tighten the larger sizes first.

Always tighten the bolts and nuts from the inside working out, in a crisscross manner.

Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter

pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than

required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is

smeared with them.

After reassembling, check parts for tightness and proper operation. To protect the environment, do not unlawfully dispose of used motor oil and all other fluids: batteries

and tires.

To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.

Kawasaki LV1000-A1

GENERAL INFORMATION 1-3

GENERAL INFORMATION 1-4

SPECIFICATIONS

Items LV1000-A1

Dimensions:

Overall length 2 295 mm (90.4 in.)

Overall width 910 mm (35.8 in.)

Overall height 1 395 mm (54.9 in.)

Wheelbase 1 535 mm (60.4 in.)

Road clearance 165 mm (6.5 in.)

Seat height 840 mm (33.1 in.)

Dry mass 208 kg (458 lbs)

Fuel tank capacity 22 L (5.81 US gal)

Performance:

Minimum turning radius 2.7 m (106.3 ft.)

Engine:

Type 4-stroke, DOHC, V2-cylinder

Cooling system Liquid-cooled

Bore and stroke

Displacement 996 mL (60.8 cu in.)

Compression ratio 11.3

Carburetion system FI (Fuel Injection)

Starting system Electric starter

Ignition system Electronic ignition (transistorized)

Ignition timing

Spark plugs NGK CR8EK or ND U24ETR

Lubrication system Forced lubrication (wet sump with cooler)

Engine oil:

Type API SF or SG

Viscosity SAE10W-40

Capacity 3.3 L (3.5 US qt)

Drive Train:

Primary reduction system:

Type Gear

Reduction ratio 1.838 (57/31)

Clutch type Wet multi disc

Transmission:

Type 6-speed, constant mesh, return shift

Gear ratios: 1st 3.000 (36/12)

2nd 1.933 (29/15)

3rd 1.500 (27/18)

4th 1.227 (27/22)

5th 1.086 (25/23)

6th 0.913 (21/23)

98.0 u 66.0 mm (3.858 u 2.598 in.)

4q BTDC @ 1 200 r/min (rpm)

GENERAL INFORMATION 1-5

Items LV1000-A1

Final drive system:

Type Chain drive

Reduction ratio 2.411 (41/17)

Overall drive ratio 4.045 @Top gear

Frame:

Type Tubular, diamond

Caster (rake angel)

Trail 111 mm (4.4 in.)

Front tire:

Type Tubeless

Size 110/80 R19 M/C 59H

Rear tire:

Type Tubeless

Size 150/70 R17 M/C 69H

Front suspension:

Type Telescopic fork

Wheel travel 160 mm (6.3 in.)

Rear suspension:

Type Swingarm

Wheel travel 159 mm (6.3 in.)

Brake type:

Front Dual discs

Rear Single disc

Electrical Equipment:

Battery 12 V 10 Ah

Headlight

Tail/brake light

Alternator:

Type Three-phase AC

26q 30c

12 V 60/55W u 2 (H4 u 2)

12 V 21/5W u 2

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

GENERAL INFORMATION 1-6

COUNTRY AND AREA CODES

The following codes stand for the applicable countries and area.

CODE COUNTRY OR AREA

E-02 U.K. E-03 U.S.A. (Except for California) E-19 EU E-24 Australia E-28 Canada E-33 California (U.S.A.)

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Contents

PERIODIC MAINTENANCE SCHEDULE .................................................................... 2-2

PERIODIC MAINTENANCE CHART........................................................................ 2-2

VALVE CLEARANCE ADJUSTMENT CHART ......................................................... 2-3

MAINTENANCE AND TUNE-UP PROCEDURES ....................................................... Base Manual

AIR CLEANER.......................................................................................................... Base Manual

SPARK PLUG ........................................................................................................... Base Manual

TAPPET CLEARANCE ............................................................................................. Base Manual

FUEL HOSE.............................................................................................................. Base Manual

ENGINE OIL AND OIL FILTER ................................................................................. Base Manual

ENGINE IDLE SPEED.............................................................................................. Base Manual

THROTTLE CABLE PLAY ........................................................................................ Base Manual

THROTTLE VALVE SYNCHRONIZATION ............................................................... Base Manual

CLUTCH ................................................................................................................... Base Manual

COOLING SYSTEM ................................................................................................. Base Manual

DRIVE CHAIN........................................................................................................... Base Manual

BRAKES ................................................................................................................... Base Manual

TIRE.......................................................................................................................... Base Manual

STEERING ............................................................................................................... Base Manual

FRONT FORK .......................................................................................................... Base Manual

REAR SUSPENSION ............................................................................................... Base Manual

EXHAUST PIPE BOLT.............................................................................................. Base Manual

CHASSIS BOLT AND NUT ....................................................................................... Base Manual

COMPRESSION PRESSURE CHECK ........................................................................ Base Manual

COMPRESSION TEST PROCEDURE..................................................................... Base Manual

OIL PRESSURE CHECK ............................................................................................. Base Manual

OIL PRESSURE TEST PROCEDURE ..................................................................... Base Manual

PERIODIC MAINTENANCE 2-2

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of hours.

NOTE

{More frequent servicing may be performed on motorcycles that are use under severe conditions.

Periodic Maintenance chart

Interval

km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 15 000

Item Air cleaner element — I I R I Exhaust pipe bolts and muffler bolts T — T — T Valve clearance — — — — I Spark plugs — I R I R

Engine oil R R R R R

Engine oil filter R — — R — Idle speed I I I I I Throttle cable play I I I I I

Evaporative emission control system (E-33 only)

PAIR(air supply)system — — I — I Engine coolant Replace every 2 years. Radiator hose — I I I I

Brakes I I I I I

Tires — I I I I Steering I — I — I Front fork — — I — I Rear suspension — — I — I Chassis bolts and nuts T T T T T

months 1 6 12 18 24

— I I I I Fuel hose

Replace every 4 years

— I — I Throttle valve synchronization I (E-33 only)

— — I — I

Replace vapor hose every 4 years

— I I I I Clutch hose

Replace every 4 years

— I I I I Clutch fluid

Replace every 2 years

I I I I I Drive chain

Clean and lublicate every 1 000 km (600 miles)

— I I I I Brake hose

Replace every 4 years

— I I I I Brake fluid

Replace every 2 years

I=Inspect and clean, adjust, replace or lubricate as necessary R=Replace T=Tighten C=Clean

PERIODIC MAINTENANCE 2-3

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

INLET

㪜㫏㪸㫄㫇㫃㪼㩷

PRESENT SHIM

Part No. (92180)

MARK and

THICKNESS (mm)

0.00 ~ 0.04 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40

0.05 ~ 0.09 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45

0.10 ~ 0.20 SPECIFIED CLEARANCE/NO CHANGE REQUIRED

0.21 ~ 0.25 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

㸣Example㩷

0.26 ~ 0.30 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.31 ~ 0.35 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.36 ~ 0.40 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.41 ~ 0.45 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.46 ~ 0.50 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.51 ~ 0.55 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.56 ~ 0.60 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.61 ~ 0.65 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.66 ~ 0.70 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.71 ~ 0.75 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.76 ~ 0.80 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.81 ~ 0.85 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.86 ~ 0.90 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.91 ~ 0.95 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.96 ~ 1.00 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.01 ~ 1.05 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.06 ~ 1.10 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.11 ~ 1.15 3.30 3.35 3.40 3.45 3.50 3.50 INSTALL THE SHIM OF THIS THICKNESS (mm)

VALVE CLEARANCE MEASUREMENT (mm)

1.16 ~ 1.20 3.35 3.40 3.45 3.50 3.50

1.21 ~ 1.25 3.40 3.45 3.50 3.50

1.26 ~ 1.30 3.45 3.50 3.50

1.31 ~ 1.35 3.50 3.50

1.36 ~ 1.40 3.50

S018 S019 S020 S021 S022 S023 S024 S025 S026 S027 S028 S029 S030 S031 S032 S033 S034 S035 S036 S037 S038 S039 S040 S041 S042

2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50

㩷㸣㩷

1. Measure the clearance (when engine is cold.)

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example : Present shim is 2.70 mm. Measured clearance is 0.23 mm. Replace 2.70 mm shim with 2.80 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

PERIODIC MAINTENANCE 2-4

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

EXHAUST

㩷㸣㩷

PRESENT SHIM

Part No. (92180)

MARK and

THICKNESS (mm)

0.00 ~ 0.04 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30

0.05 ~ 0.09 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35

0.10 ~ 0.14 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40

0.15 ~ 0.19 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45

0.20 ~ 0.30 SPECIFIED CLEARANCE/NO CHANGE REQUIRED

0.31 ~ 0.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.36 ~ 0.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

㸣Example㩷

0.41 ~ 0.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.46 ~ 0.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.51 ~ 0.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.56 ~ 0.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.61 ~ 0.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.66 ~ 0.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.71 ~ 0.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.76 ~ 0.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.81 ~ 0.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.86 ~ 0.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.91 ~ 0.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

0.96 ~ 1.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.01 ~ 1.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.06 ~ 1.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.11 ~ 1.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50

1.16 ~ 1.20 3.25 3.30 3.35 3.40 3.45 3.50 3.50 INSTALL THE SHIM OF THIS THICKNESS (mm)

1.21 ~ 1.25 3.30 3.35 3.40 3.45 3.50 3.50

VALVE CLEARANCE MEASUREMENT (mm)

1.26 ~ 1.30 3.35 3.40 3.45 3.50 3.50

1.31 ~ 1.35 3.40 3.45 3.50 3.50

1.36 ~ 1.40 3.45 3.50 3.50

1.41 ~ 1.45 3.50 3.50

1.46 ~ 1.50 3.50

S018 S019 S020 S021 S022 S023 S024 S025 S026 S027 S028 S029 S030 S031 S032 S033 S034 S035 S036 S037 S038 S039 S040 S041 S042

2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50

㩷

㪜㫏㪸㫄㫇㫃㪼㩷

1. Measure the clearance (when engine is cold.)

2. Check present shim size.

3. Match clearance in vertical column with present shim size in horizontal column.

4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example : Present shim is 2.90 mm. Measured clearance is 0.38 mm. Replace 2.90 mm shim with 3.05 mm shim.

5. Remeasure the valve clearance and readjust if necessary.

ENGINE 3-1

Engine

Contents

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...........................Base Manual

ENGINE LEFT SIDE.................................................................................................Base Manual

ENGINE RIGHT SIDE...............................................................................................Base Manual

ENGINE CENTER ....................................................................................................Base Manual

ENGINE REMOVAL AND REMOUNTING ...................................................................Base Manual

ENGINE REMOVAL..................................................................................................Base Manual

ENGINE REMOUNTING ..........................................................................................Base Manual

ENGINE DISASSEMBLY .............................................................................................Base Manual

ENGINE COMPONENTS INSPECTION AND SERVICE.............................................Base Manual

CYLINDER HEAD.....................................................................................................Base Manual

CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY ...................................Base Manual

CYLINDER................................................................................................................Base Manual

PISTON AND PISTON RING....................................................................................Base Manual

CONROD..................................................................................................................Base Manual

CRANKSHAFT .........................................................................................................Base Manual

STARTER CLUTCH..................................................................................................Base Manual

STARTER TORQUE LIMITER ..................................................................................Base Manual

OIL PUMP.................................................................................................................Base Manual

CLUTCH ...................................................................................................................Base Manual

GEARSHIFT FORK AND GEAR...............................................................................Base Manual

TRANSMISSION ......................................................................................................Base Manual

BEARINGS ...............................................................................................................Base Manual

OIL SEALS ...............................................................................................................Base Manual

ENGINE REASSEMBLY ..............................................................................................Base Manual

CRANKSHAFT .........................................................................................................Base Manual

GEARSHIFT CAM AND FORK.................................................................................Base Manual

CRANKCASE ...........................................................................................................Base Manual

STARTER CLUTCH AND GENERATOR ROTOR....................................................Base Manual

BALANCER SHAFT..................................................................................................Base Manual

PRIMARY DRIVE GEAR ..........................................................................................Base Manual

GEARSHIFT CAM DRIVEN GEAR...........................................................................Base Manual

GEARSHIFT SHAFT.................................................................................................Base Manual

OIL PUMP.................................................................................................................Base Manual

CAM CHAIN..............................................................................................................Base Manual

CLUTCH ...................................................................................................................Base Manual

RIGHT CRANKCASE COVER..................................................................................Base Manual

CLUTCH COVER .....................................................................................................Base Manual

GENERATOR ROTOR COVER................................................................................Base Manual

STARTER DRIVE GEAR COVER ............................................................................Base Manual

PISTON RING...........................................................................................................Base Manual

PISTON AND CYLINDER.........................................................................................Base Manual

CYLINDER HEAD.....................................................................................................Base Manual

CAMSHAFT/AUTOMATIC DECOMPRESSION ASSEMBLY ...................................Base Manual

CYLINDER HEAD COVER.......................................................................................Base Manual

CAM CHAIN TENSION ADJUSTER.........................................................................Base Manual

ENGINE 3-2

FI SYSTEM 4-1

FI System

Contents

PRECAUTIONS IN SERVICING ................................................................................... Base Manual

CONNECTOR/COUPLER ......................................................................................... Base Manual

FUSE ......................................................................................................................... Base Manual

ECM/VARIOUS SENSORS ....................................................................................... Base Manual

ELECTRICAL CIRCUIT INSPECTION PROCEDURE .............................................. Base Manual

FI SYSTEM TECHNICAL FEATURES .......................................................................... Base Manual

INJECTION TIME (INJECTION VOLUME)................................................................ Base Manual

COMPENSATION OF INJECTION TIME (VOLUME)................................................ Base Manual

INJECTION STOP CONTROL................................................................................... Base Manual

FUEL DELIVERY SYSTEM ....................................................................................... Base Manual

FUEL PUMP .............................................................................................................. Base Manual

FUEL PRESSURE REGULATOR.............................................................................. Base Manual

FUEL INJECTOR....................................................................................................... Base Manual

FUEL PUMP CONTROL SYSTEM ............................................................................ Base Manual

ECM (FI CONTROL UNIT) ........................................................................................ Base Manual

INJECTION TIMING .................................................................................................. Base Manual

SENSORS ................................................................................................................. Base Manual

FI SYSTEM PARTS LOCATION ................................................................................... Base Manual

FI SYSTEM WIRING DIAGRAM ................................................................................... Base Manual

SELF-DIAGNOSIS FUNCTION..................................................................................... Base Manual

USER MODE ........................................................................................................... Base Manual

DEALER MODE......................................................................................................... Base Manual

TPS ADJUSTMENT................................................................................................... Base Manual

FAIL-SAFE FUNCTION................................................................................................. Base Manual

FI SYSTEM TROUBLESHOOTING .............................................................................. Base Manual

CUSTOMER COMPLAINT ANALYSIS ...................................................................... Base Manual

SELF-DIAGNOSTIC PROCEDURES........................................................................ Base Manual

SELF-DIAGNOSIS RESET PROCEDURE................................................................ Base Manual

MALFUNCTION CODE AND DEFECTIVE CONDITION........................................... Base Manual

“C11” CMP SENSOR CIRCUIT MALFUNCTION....................................................... Base Manual

“C12” CKP SENSOR CIRCUIT MALFUNCTION ....................................................... Base Manual

“C13” IAP SENSOR CIRCUIT MALFUNCTION......................................................... Base Manual

“C14” TP SENSOR CIRCUIT MALFUNCTION.......................................................... Base Manual

“C15” ECT SENSOR CIRCUIT MALFUNCTION....................................................... Base Manual

“C21” IAT SENSOR CIRCUIT MALFUNCTION......................................................... Base Manual

“C22” AP SENSOR CIRCUIT MALFUNCTION.......................................................... Base Manual

“C23” TO SENSOR CIRCUIT MALFUNCTION ......................................................... Base Manual

“C24” or “25” IGNITION SYSTEM MALFUNCTION................................................... Base Manual

“C28” STV ACTUATOR CIRCUIT MALFUNCTION ................................................... Base Manual

“C29” STP SENSOR CIRCUIT MALFUNCTION ....................................................... Base Manual

“C31” GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION .......................... Base Manual

“C32” or “C33” FUEL INJECTION MALFUNCTION................................................... Base Manual

“C41” FP RELAY CIRCUIT MALFUNCTION ............................................................. Base Manual

FI SYSTEM 4-2

“C42” IG SWITCH CIRCUIT MALFUNCTION ........................................................... Base Manual

“C44” HO

FUEL SYSTEM ............................................................................................................. Base Manual

FUEL TANK LIFT-UP ................................................................................................. Base Manual

FUEL TANK REMOVAL ............................................................................................. Base Manual

FUEL TANK INSTALLATION ..................................................................................... Base Manual

FUEL PRESSURE INSPECTION.............................................................................. Base Manual

FUEL PUMP INSPECTION ....................................................................................... Base Manual

FUEL PUMP RELAY INSPECTION ........................................................................... Base Manual

FUEL PUMP AND FUEL FILTER REMOVAL ............................................................ Base Manual

FUEL MESH FILTER INSPECTION AND CLEANING .............................................. Base Manual

FUEL PUMP AND FUEL MESH FILTER INSTALLATION ......................................... Base Manual

THROTTLE BODY AND STV ACTUATOR ................................................................... Base Manual

CONSTRUCTION...................................................................................................... Base Manual

THROTTLE BODY REMOVAL .................................................................................. Base Manual

THROTTLE BODY DISASSEMBLY........................................................................... Base Manual

THROTTLE BODY CLEANING ................................................................................. Base Manual

INSPECTION............................................................................................................. Base Manual

THROTTLE BODY REASSEMBLY............................................................................ Base Manual

STP SENSOR ADJUSTMENT................................................................................... Base Manual

THROTTLE BODY INSTALLATION........................................................................... Base Manual

TP SENSOR ADJUSTMENT ..................................................................................... Base Manual

FUEL INJECTOR INSPECTION................................................................................ Base Manual

FUEL INJECTOR INSTALLATION............................................................................. Base Manual

FAST IDLE INSPECTION.......................................................................................... Base Manual

FAST IDLE ADJUSTMENT ........................................................................................ Base Manual

THROTTLE VALVE SYNCHRONIZATION ................................................................ Base Manual

THROTTLE CABLE ADJUSTMENT .......................................................................... Base Manual

SENSOR ....................................................................................................................... Base Manual

IAP SENSOR INSPECTION...................................................................................... Base Manual

IAP SENSOR REMOVAL/INSTALLATION................................................................. Base Manual

TP SENSOR INSPECTION ....................................................................................... Base Manual

TP SENSOR REMOVAL/INSTALLATION.................................................................. Base Manual

STP SENSOR INSPECTION..................................................................................... Base Manual

STP SENSOR REMOVAL/INSTALLATION ............................................................... Base Manual

CKP SENSOR INSPECTION .................................................................................... Base Manual

CKP SENSOR REMOVAL/INSTALLATION ............................................................... Base Manual

CMP SENSOR INSPECTION.................................................................................... Base Manual

CMP SENSOR REMOVAL/INSTALLATION .............................................................. Base Manual

IAT SENSOR INSPECTION ...................................................................................... Base Manual

IAT SENSOR REMOVAL/INSTALLATION................................................................. Base Manual

ECT SENSOR INSPECTION..................................................................................... Base Manual

ECT SENSOR REMOVAL/INSTALLATION ............................................................... Base Manual

AP SENSOR INSPECTION....................................................................................... Base Manual

AP SENSOR REMOVAL/INSTALLATION.................................................................. Base Manual

TO SENSOR INSPECTION....................................................................................... Base Manual

TO SENSOR REMOVAL/INSTALLATION ................................................................. Base Manual

SENSOR INSPECTION ..................................................................................... Base Manual

SENSOR REMOVAL/INSTALLATION................................................................ Base Manual

SENSOR (HO2S) CIRCUIT MALFUNCTION ........................................... Base Manual

COOLING SYSTEM 5-1

Cooling System

Contents

ENGINE COOLANT ...................................................................................................... Base Manual

COOLING CIRCUIT ...................................................................................................... Base Manual

COOLING CIRCUIT INSPECTION............................................................................ Base Manual

RADIATOR.................................................................................................................... Base Manual

REMOVAL ................................................................................................................. Base Manual

INSPECTION AND CLEANING................................................................................. Base Manual

INSTALLATION.......................................................................................................... Base Manual

RADIATOR RESERVOIR TANK.................................................................................... Base Manual

REMOVAL./INSTALLATION ...................................................................................... Base Manual

RADIATOR CAP............................................................................................................ Base Manual

INSPECTION............................................................................................................. Base Manual

WATER HOSE .............................................................................................................. Base Manual

INSPECTION............................................................................................................. Base Manual

COOLING FAN.............................................................................................................. Base Manual

REMOVAL ................................................................................................................. Base Manual

INSPECTION............................................................................................................. Base Manual

INSTALLATION.......................................................................................................... Base Manual

COOLING FAN THERMO-SWITCH.............................................................................. Base Manual

REMOVAL ................................................................................................................. Base Manual

INSPECTION............................................................................................................. Base Manual

INSTALLATION.......................................................................................................... Base Manual

ENGINE COOLANT TEMPERATURE SENSOR .......................................................... Base Manual

REMOVAL ................................................................................................................. Base Manual

INSPECTION............................................................................................................. Base Manual

INSTALLATION.......................................................................................................... Base Manual

COOLING SYSTEM 5-2

THERMOSTAT.............................................................................................................. Base Manual

REMOVAL ................................................................................................................. Base Manual

INSPECTION............................................................................................................. Base Manual

INSTALLATION.......................................................................................................... Base Manual

WATER PUMP .............................................................................................................. Base Manual

REMOVAL AND DISASSEMBLY ............................................................................... Base Manual

INSPECTION............................................................................................................. Base Manual

REASSEMBLY AND INSTALLATION ........................................................................ Base Manual

LUBRICATION SYSTEM............................................................................................... Base Manual

OIL PRESSURE ........................................................................................................ Base Manual

OIL FILTER ................................................................................................................ Base Manual

OIL PRESSURE REGULATOR ................................................................................. Base Manual

OIL STRAINER.......................................................................................................... Base Manual

OIL JET...................................................................................................................... Base Manual

OIL PUMP.................................................................................................................. Base Manual

OIL PRESSURE SWITCH ......................................................................................... Base Manual

OIL COOLER ................................................................................................................ Base Manual

REMOVAL ................................................................................................................. Base Manual

INSPECTION AND CLEANING................................................................................. Base Manual

INSTALLATION.......................................................................................................... Base Manual

ENGINE LUBRICATION FLOW CHART....................................................................... Base Manual

ENGINE LUBRICATION CIRCUIT ................................................................................ Base Manual

CHASSIS 6-1

Chassis

Contents

EXTERIOR PARTS.........................................................................................Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL ...................................................................................................Base Manual

FRONT WHEEL .............................................................................................Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL ...................................................................................................Base Manual

INSPECTION AND DISASSEMBLY ............................................................ Base Manual

REASSEMBLY AND REMOUNTING........................................................... Base Manual

FRONT FORK ................................................................................................ Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL AND DISASSEMBLY................................................................. Base Manual

INSPECTION ..............................................................................................Base Manual

REASSEMBLY AND REMOUNTING........................................................... Base Manual

STEERING AND HANDLEBAR ...................................................................... Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL ...................................................................................................Base Manual

INSPECTION AND DISASSEMBLY ............................................................ Base Manual

REASSEMBLY AND REMOUNTING........................................................... Base Manual

STEERING TENSION ADJUSTMENT ........................................................Base Manual

REAR WHEEL................................................................................................ Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL ...................................................................................................Base Manual

INSPECTION AND DISASSEMBLY ............................................................ Base Manual

REASSEMBLY AND REMOUNTING........................................................... Base Manual

REAR SHOCK ABSORBER ...........................................................................Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL ...................................................................................................Base Manual

INSPECTION ..............................................................................................Base Manual

REAR SHOCK ABSORBER DISPOSAL .....................................................Base Manual

REMOUNTING............................................................................................ Base Manual

SUSPENSION SETTING ............................................................................Base Manual

REAR SWINGARM ........................................................................................Base Manual

CONSTRUCTION........................................................................................ Base Manual

REMOVAL ...................................................................................................Base Manual

INSPECTION AND DISASSEMBLY ............................................................ Base Manual

REASSEMBLY ............................................................................................Base Manual

REMOUNTING............................................................................................ Base Manual

FINAL INSPECTION AND ADJUSTMENT ..................................................Base Manual

CHASSIS 6-2

FRONT BRAKE ..............................................................................................Base Manual

CONSTRUCTION........................................................................................ Base Manual

BRAKE PAD REPLACEMENT .................................................................... Base Manual

BRAKE FLUID REPLACEMENT ................................................................. Base Manual

CALIPER REMOVAL AND DISASSEMBLY................................................. Base Manual

CALIPER INSPECTION .............................................................................. Base Manual

CALIPER REASSEMBLY AND REMOUNTING ..........................................Base Manual

BRAKE DISC INSPECTION........................................................................ Base Manual

MASTER CYLINDER REMOVAL AND DISASSEMBLY .............................. Base Manual

MASTER CYLINDER INSPECTION............................................................ Base Manual

MASTER CYLINDER REASSEMBLY AND REMOUNTING........................ Base Manual

REAR BRAKE ................................................................................................Base Manual