Kawasaki KX250F Service Manual

KX250F

Motorcycle

Service Manual

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.

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

Quick Reference Guide

General Information 1

j

Periodic Maintenance 2

j

Fuel System 3

j

Cooling System 4

j

Engine Top End 5

j

Clutch 6

j

Engine Lubrication System 7

j

Engine Removal/Installation 8

j

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

KX250F

Motorcycle

Service Manual

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

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

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

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

© 2009 Kawasaki Heavy Industries, Ltd. First Edition (1) : Jul. 28, 2009 (S)

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)
ABDC after bottom dead center

m

meter(s)

AC

alternating current min

minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current r/min, rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator r eading
ft foot, feet V volt(s)
g gram(s) (mass) W watt(s)
h

hour(s) Ω ohm(s)

kg

(mass)
kgf (force)
L liter(s)

COUNTRY AND AREA CODES

AU Australia EUR Europe
BR Brazil US United States
CA Canada

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However,itcontainsenoughdetailandbasicin­formationtomakeitusefultotheownerwho de­siresto perform his own basic maintenanceand
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
beforestarting work, and then do the work ca

re­fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurem

ents
can only be made if the proper instruments are
used, and the use of substitute tools may ad­versely affect safe operation.

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 genu

ine Kawasaki Mo­torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycle

s are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.

•

Follow the procedu

res in this manual care-

fully. Don’t take shortcuts.

•

Rememberto keep completerecords ofmain­tenance and r

epair 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.

Forexample, if youwant stickcoil 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 Stick Coil section.

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

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situa-

tion which, if not avoided, could result

in minor or moderate injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more symbols
which will help you distinguish different types
of information.

NOTE

○

This note symbol indicates points of par-

ticular interest for more efficient and con-

venient operation.

•

Indicates a procedural step or work to be

done.

○

Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

takebased on the resultsofthe test or inspec-

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

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

GENERAL INFORMATION 1-1

1

General Information

Table of Contents

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

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-8

Unit Conversion T able............................................................................................................ 1-10

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:

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent

Use a high-flash point solvent when cleaning parts. High

-flash point solvent should be used according to directions
of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thorou

ghly before disassembly. Dirt or
otherforeign materials enteringinto sealed areas duringve­hicle disassembly can cause excessive wear and decrease
performance of t

he vehicle.

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy t o confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

GENERAL INFORMATION 1-3

Before Servicing

Storage of Removed Parts

After all the parts including subassemblyparts havebeen
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious ac­cident. Visually inspect removed parts for corrosion,discol­oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be­yond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-locking nuts must
be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverseof disassem­bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

Tightening Sequence

Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and t ighten them to
a snug fit. Then tighten them according to the specified se­quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar­ter turn and then remove them. If the specified tightening
sequence i s not indicated, tighten the fasteners alternating
diagonally.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.

Force

Use common sense during disassembly and assembly,
excessiveforce can cause expensive or hard to repair dam­age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or dam

age of both gaskets
and O-rings after disassembly can reduce sealing per­formance. Remove old gaskets and clean the sealing
surfaces thoroughly so th

at no gasket material or other
material remains. Install new gaskets and replace used
O-rings when re-assembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces­sively. Excessive application can clog oil passages and
cause serious damage.

Press

For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con­tact area. Be sure to maintain proper alignment and use
smooth movements when installing.

GENERAL INFORMATION 1-5

Before Servicing

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Donot remove pressedoil or greaseseals unlessremoval
is necessary. Replace with new ones whenever removed.
Pressnew oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins

Replacecirclips orcotter pinst hat were removedw ith new
ones. Take care not to open the clip excessively when in­stalling to prevent deformation.

Lubrication

It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri­cation points are called out throughout this manual, apply
the specific oil or grease as specified.

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro­tate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Leads

A two-color lead is identified first by theprimary color and
then the stripe color. Unless instructedotherwise, electrical
leads must be connected to those of the same color.

Instrument

Use a meter that has enough acc

uracy for an accurate
measurement. Read the manufacture’s instructions thor­oughly before using the meter. Incorrect values may lead
to improper adjustments.

GENERAL INFORMATION 1-7

Model Identification

KX250XAF Left Side View

KX250XAF Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

General Specifications

Items KX250XAF

Dimensions

Overall Length 2 170 mm (85.43 in.)
Overall Width 820 mm (32.3 in.)
Overall Height 1 270 mm (50.00 in.)
Wheelbase 1 470 mm (57.87 in.)
Road Clearance 340 mm (13.4 in.)
Seat Height 955 mm (37.6 in.)
Curb Mass: 105.1 kg (231.7 lb)

(US, CA) 105.0 kg (231.5 lb)
Front 50.8 kg (112 lb)
Rear 54.3 kg (119.7 lb)

(US, CA) 54.2 kg (119.5 lb)

Fuel Tank Capacity 8.0 L (2.1 US gal)

Engine

Type 4-stroke, single cylinder, DOHC 4 valve
Cooling System Liquid-cooled
Bore and Stroke 77.0 × 53.6 mm (3.03 × 2.11 in.)
Displacement

249 cm³ (15.2 cu in.)

Compression Ratio

13.2 : 1
Carburetion System Carburetor, KEIHIN FCR-MX37
Starting System Primary kick
Ignition System Digital AC-CDI
Timing Advance Electronically advanced
Ignition Timing BTDC 8° @2 000 r/min (rpm)
Spark Plug:

Standard NGK CR8E
Option NGK CR9E

Valve Timing:

Inlet:

Open BTDC 41°
Close ABDC 71°
Duration 292°

Exhaust:

Open BBDC 69°
Close ATDC 49°

Duration 298°
Lubrication System Forced lubrication (semi-dry sump)
Engine Oil:

Grade API SG, SH, SJ or SL with JASO MA, MA1 or MA2
Viscosity SAE 10W-40
Capacity 1.0 L (1.1 USqt)

GENERAL INFORMATION 1-9

General Specifications

Items KX250XAF

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 3.350 (67/20)
Clutch Type Wet multi disc, Manual
Transmission:

Type 5-speed, constant mesh, return shift

Gear Ratios:

1st 2.142 (30/14)
2nd 1.769 (23/13)
3rd 1.444 (26/18)
4th 1.200 (24/20)
5th 1.045 (23/22)

Final Drive System:

Type Chain drive

Reduction Ratio

3.692 (48/13)

Overall Drive Ratio 12.931 @Top gear

Frame

Type

Semi-double cradle
Steering Angle 42° to either side
Caster (Rake Angle) 27.4°
Trail 118.6 mm (4.669 in.)
Front Wheel:

Tire Size 80/100-21 51M
Tire Make/Type BRIDGESTONE M403, Tube type
Rim Size 21 × 1.60

Rear Wheel:

Tire Size 100/90-19 57M
Tire Make/Type BRIDGESTONE M404, Tube type
Rim Size 19 × 1.85

Front Suspension:

Type Telescopic fork (upside down)
Wheel Travel 315 mm (12.4 in.)

Rear Suspension:

Type Swingarm (New Uni-trak)
Wheel Travel 310 mm (12.2 in.)

Brake Type:

Front and Rear Single disc

Effective Disc Diameter:

Front

225 mm (8.86 in.)

Rear

215 mm (8.46 in.)

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

1-10 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

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

Units of Volume:

L × 0.2642 = gal (US)
L × 0.2200 = gal (imp)
L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
L×2.113=

pint (US)
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in

Units of Force:

N × 0.1020 = kgf
N × 0.2248 = lb
kgf × 9.807 = N
kgf × 2.205 = lb

Units of Length:

km × 0.6214 = mile
m × 3.281 =

ft

mm × 0.03937 = in

Units of Torque:

N·m × 0.1020 = kgf·m
N·m × 0.7376 =

ft·lb
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m

× 7.233 =

ft·lb
kgf·m

× 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm²
kPa × 0.1450 = psi
kPa × 0.7501 = cm Hg
kgf/cm² × 98.07 = kPa
kgf/cm² × 14.22 = psi
cmHg×1.333=kPa

Units of Speed:

km/h × 0.6214 = mph

Units of Power:

kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS × 0.9863 = HP

Units of Temperature:

PERIODIC MAINTENANCE 2-1

2

Periodic Maintenance

Table of Contents

Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-5

Specifications ......................................................................................................................... 2-9

Special Tools .......................................................................................................................... 2-11

Periodic Maintenance Procedures.......................................................................................... 2-12

Fuel System......................................................................................................................... 2-12

Fuel Hose and Connection Inspection.............................................................................. 2-12

Throttle Grip (Throttle Cable) Free Play Inspection .......................................................... 2-12

Throttle Grip (Throttle Cable) Free Play Adjustment......................................................... 2-12

Hot Starter Lever (Hot Starter Cable) Free Play Inspection.............................................. 2-13

Idle Speed (Carburetor) Inspection .................................................................................. 2-13

Idle Speed (Carburetor) Adjustment ................................................................................ 2-14

Air Cleaner Element Cleaning and Inspection.................................................................. 2-15

Fuel System Clean............................................................................................................ 2-17

Cooling System.................................................................................................................... 2-18

Coolant Level Inspection................................................................................................... 2-18

Coolant Deterioration Inspection....................................................................................... 2-19

Water Hoses and Connections Inspection........................................................................ 2-19

Engine Top End ................................................................................................................... 2-19

Valve Clearance Inspection .............................................................................................. 2-19

Valve Clearance Adjustment............................................................................................. 2-20

Cylinder Head Warp Inspection ........................................................................................ 2-22

Cylinder Wear Inspection.................................................................................................. 2-22

Piston/Cylinder Clearance Inspection............................................................................... 2-23

Piston, Piston Ring and Piston Pin Replacement ............................................................. 2-23

Exhaust System Inspection............................................................................................... 2-23

Muffler Baffle Replacement............................................................................................... 2-24

Clutch................................................................................................................................... 2-25

Clutch Operation Inspection.............................................................................................. 2-25

Clutch Plates Inspection ................................................................................................... 2-26

Engine Lubrication System.................................................................................................. 2-26

Engine Oil Change............................................................................................................ 2-27

Oil Filter Change............................................................................................................... 2-28

Breather Hose Inspection ................................................................................................. 2-28

Crankshaft/Transmission..................................................................................................... 2-29

Crankshaft Inspection ....................................................................................................... 2-29

Wheel/Tires.......................................................................................................................... 2-29

Air Pressure Inspection/Adjustment.................................................................................. 2-29

Tires Inspection.................................................................................................................2-30

Spoke Tightness Inspection.............................................................................................. 2-30

Rim R unout Inspection...................................................................................................... 2-30

Wheel Bearing Inspection................................................................................................. 2-31

Final Drive............................................................................................................................ 2-31

Drive Chain Wear Inspection ............................................................................................ 2-31

Drive Chain Slack Inspection............................................................................................ 2-32

Drive Chain Slack Adjustment .......................................................................................... 2-33

Drive Chain Lubrication..................................................................................................... 2-34

Sprocket Wear Inspection................................................................................................. 2-34

Rear Sprocket Warp (Runout) Inspection......................................................................... 2-34

Brakes.................................................................................................................................. 2-35

2-2 PERIODIC MAINTENANCE

Brake Lever and Pedal Adjustment .................................................................................. 2-35

Brake Fluid Level Inspection............................................................................................. 2-36

Brake Fluid Change.......................................................................................................... 2-37

Brake Pad Wear Inspection .............................................................................................. 2-39

Brake Master Cylinder Rubber Parts Replacement.......................................................... 2-39

Caliper Rubber Parts Replacement.................................................................................. 2-41

Brake Hoses and Connections Inspection........................................................................ 2-44

Brake Hose Replacement................................................................................................. 2-44

Suspension.......................................................................................................................... 2-46

Front Fork Inspection........................................................................................................ 2-46

Front Fork Oil Change (each fork leg) .............................................................................. 2-46

Rear Shock Absorber Oil Change..................................................................................... 2-56

Swingarm and Uni-Trak Linkage Inspection ..................................................................... 2-65

Swingarm and Uni-Trak Linkage Pivot Lubrication........................................................... 2-65

Steering ............................................................................................................................... 2-66

Steering Inspection........................................................................................................... 2-66

Steering Adjustment ......................................................................................................... 2-66

Steering Stem Bearing Lubrication................................................................................... 2-68

Frame .................................................................................................................................. 2-68

Frame Inspection.............................................................................................................. 2-68

Electrical System................................................................................................................. 2-69

Spark Plug Cleaning and Inspection................................................................................. 2-69

Spark Plug Replacement.................................................................................................. 2-69

General Lubrication and Cable Inspection........................................................................... 2-70

Lubrication........................................................................................................................ 2-70

Nut, Bolt, and Fastener Tightness Inspection...................................................................... 2-71

Tightness Inspection ......................................................................................................... 2-71

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The maintenancemust be done in accordance with this chart to keepthemotorcyclein good running

condition.

FREQUENCY

OPERATION

Each

race or

2.5 hr

Every 3

races or

7.5 hr

Every 6

races or

15 hr

Every12

races or

30 hr

See

Page

Spark plug - clean, inspect †

•

2-69

Spark plug - replace

•

2-69

Clutch - inspect

•

2-25

Clutch plates - inspect †

•

2-26

Throttle cable - inspect and adjust

•

2-12

Air cleaner element - clean

•

2-15
Air cleaner element - replace If damaged 2-15
Carburetor - inspect and adjust

•

2-13
Engine Oil - change

•

2-27
Piston and piston ring - replace

•

2-23
Cylinder head, cylinder - inspect

•

2-22
Piston pin - replace

•

2-23
Valve clearance - inspect †

•

2-19
Hot starter cable - inspect

•

2-13
Oil filter - replace

•

2-28
Exhaust system - inspect†

•

2-23
Muffler baffle- change

•

2-24
Kick pedal and shift pedal - clean

•

–

Engine sprocket - inspect †

•

2-34
Coolant level - inspect

•

2-18
Water hoses and connections - inspect †

•

2-19
Crankshaft - inspect

•

2-29

E
N
G

I

N

E

Breather hose - inspect

•

2-28

Brake - adjust †

•

2-35

Brake pad wear - inspect †

•

2-39

Brake fluid level - inspect †

•

2-36
Brake fluid - change Every 2 years 2-37
Brake master cylinder cup and dust cover - replace Every 2 years 2-39
Brake caliper fluid seal and dust seal - r eplace Every 2 years 2-41
Brake hoses - replace Every 4 years 2-44
Brake hoses, connections - inspect †

•

2-44
Spoke tightness and rim runout - inspect †

•

2-30
Wheel bearing - inspect †

•

2-31
Frame - inspect

•

2-68
Drive chain wear - inspect †

•

2-31
Drive chain - inspect and adjust

•

2-32

C
H

A
S
S

I

S

Drive chain - lubricate

•

2-34

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

FREQUENCY

OPERATION

Each

race or

2.5 hr

Every 3

races or

7.5 hr

Every 6

racesor

15 hr

Every12

races or

30 hr

See

Page

Wheels/tires - inspect

•

2-30

Rear sprocket - inspect †

•

2-34

Front fork - inspect and clean

•

2-46

Front fork oil - change

•

2-46

Rear shock absorber oil - change

•

2-56

Cable - inspect

•

2-70
Fuel hose - replace Every 4 years 2-12
Fuel hose, connections - inspect †

•

2-12
Fuel system - clean

•

2-17
Steering play - inspect †

•

2-66
Steering stem bearing - lubricate

•

2-68
Swingarm and Uni-Trak linkage pivots - l ubricate

•

2-65
Swingarm and Uni-Trak linkage pivots - inspect †

•

2-65
Nuts, bolts, fasteners - inspect †

•

2-71
General lubrication - perform

•

2-70

†: Replace, add, adjust, clean or torque if necessary.

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may becomedamaged, strip an internalthread, or break and then fall out. The
following table lists the tighteningtorque for the major bolts and nuts, and the parts requiring use of a
non-permanent locking agent or silicone grease etc.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten to specified torque.
Letters used in the "Remarks" column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent.

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil.

(mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 : 1)

R: Replacement Parts

S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

Torque

Fastener

N·m kgf·m ft·lb

Remarks

Fuel System

Throttle Pulley Cover Bolt 3.4 0.35 30 in·lb
Throttle Cable Bolts

3.5 0.36 31 in·lb

Hot Starter Plunger Cap Bolt

1.0 0.10 9in·lb

Air Cleaner Element Wing Bolt – – –

Hand

Tighten
Air Cleaner Duct Nuts 3.0 0.30 27 in·lb
Air Cleaner Duct Bolt 7.1 0.72 63 in·lb
Air Cleaner Housing Bolts 9.8 1.0 87 in·lb

Cooling System

Water Pump Cover Bolts (L = 30, 65
mm)

9.8 1.0 87 in·lb

Water Pump Cover Bolts (L = 55 mm)

9.8 1.0 87 in·lb L
Coolant Drain Bolt 7.0 0.71 62 in·lb
Water Pump Impeller Bolt 7.0 0.71 62 in·lb
Water Hose Clamp Screws

3.0 0.31 27 in·lb
Water Pipe Bolt 9.8 1.0 87 in·lb
Radiator Mounting Bolts 9.8 1.0 87 in·lb
Radiator Screen Bolts 9.8 1.0 87 in·lb
Radiator Shroud Bolts 9.8 1.0 87 in·lb

Engine Top End

Auto-Decompressor Bolt 12 1.2 106 in·lb
Cylinder Head Cover Bolts 9.8 1.0 87 in·lb
Camshaft Cap Bolts 9.8 1.0 87 in·lb S, MO
Cylinder Head Bolts (M10) 49 5.0 36 S, MO
Cylinder Head Bolts (M6) 12 1.2 106 in·lb S
Plug 20 2.0 15 L
Decompressor Plug Plate Bolt 9.8 1.0 87 in·lb
Carburetor Holder Clamp Screw 2.0 0.20 18 in·lb

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m ft·lb

Remarks

Carburetor Clamp Screw 2.0 0.20 18 in·lb
Cylinder Bolt 12 1.2 106 in·lb S
Camshaft Chain Tensioner Cap Bolt 20 2.0 15
Camshaft Chain Tensioner Mounting

Bolts

9.8 1.0 87 in·lb

Lower Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb
Rear Camshaft Chain Guide Bolt 15 1.5 11
Exhaust Pipe Cover Screws

12 1.2 106 in·lb

Exhaust Pipe Holder Nuts 15 1.5 11

S
Muffler M ounting Bolts 21 2.1 15 S
Muffler Clamp Bolt 11 1.1 97 in·lb S

Clutch

Clutch Cover Bolts 9.8 1.0 87 in·lb
Right Engine Cover Bolts 9.8 1.0 87 in·lb
Clutch Spring Bolts 9.8 1.0 87 in·lb
Clutch Hub Nut 98 10 72 R
Oil Filler Plug 5.0 0.51 44 in·lb
Primary Gear Nut 98 10 72 Lh, R

Engine Lubrication System

Breather Fitting 15 1.5 11 L
Oil Pump Mounting Bolts 7.0 0.71 62 in·lb L
Oil Pump Idle Gear Shaft Screws 5.9 0.60 52 in·lb L
Oil Filter Cap Bolts

9.8 1.0 87 in·lb

Piston Oil Nozzle

2.9 0.30 26 in·lb

Engine Oil Drain Bolt 20 2.0 15

Engine Removal/Installation

Upper Engine Mounting Bolts (M10) 49 5.0 36 S
Upper Engine Bracket Bolts (M8) 29 3.0 21 S
Middle Engine Mounting Nut (M10) 49 5.0 36 R, S
Middle Engine Bracket Nuts (M8) 29 3.0 21 R, S
Lower Engine Mounting Nut (M10) 49 5.0 36 R, S
Swingarm Pivot Shaft N ut 98 10 72 R, S

Crankshaft/Transmission

Crankcase Bolts 50 mm (2.0 in.) 9.8 1.0 87 in·lb S
Crankcase Bolts 60

mm (2.4 in.)

9.8 1.0 87 in·lb

S
Crankcase Bolts 65 mm (2.6 in.)

9.8 1.0 87 in·lb

S
Crankcase Bolts 70 mm (2.8 in.) 9.8 1.0 87 in·lb S
Crankcase Bearing Retainer Bolts 15 1.5 11 L
Piston Oil Nozzle 2.9 0.30 26 in·lb
Reed Valve Screws 7.0 0.71 62 in·lb
Primary Gear Nut 98 10 72 Lh, R
Kick Pedal Bolt 25 2.5 18 L
Kick Ratchet Guide Bolt 8.8 0.90 78 in·lb L

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Torque

Fastener

N·m kgf·m ft·lb

Remarks

Ratchet Plate Bolt (Front) 9.8 1.0 87 in·lb L, S
Ratchet Plate Bolt (Rear) 15 1.5 11 L, S
Shift Drum Cam Bolt 24 2.4 18 L
Gear Positioning Lever Nut 8.8 0.90 78 in·lb
Shift Pedal Bolt 9.8 1.0 87 in·lb

Wheels/Tires

Spoke Nipples

Not Less
Than 2.2

Not Less

Than 0.22

Not Less

Than 19 in·lb
Front Axle Nut 79 8.1 58
Front Axle Clamp Bolts 20 2.0 15 AL
Rear Axle Nut 108 11.0 80

Final Drive

Rear Sprocket Nuts 34 3.5 25 R
Engine Sprocket C over Bolts 4.9 0.50 43 in·lb

Brakes

Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S
Brake Lever Pivot Bolt 5.9 0.60 52 in·lb Si
Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb
Brake Hose Banjo Bolts 25 2.5 18
Brake Hose Clamp Mounting Bolt 3.0 0.31 27 in·lb
Front Brake Disc Mounting Bolts 9.8 1.0 87 in·lb L
Caliper Bleed Valve 7.8 0.80 69 in·lb
Front Brake Pad Pin 17 1.7 13
Front Caliper Mounting Bolts 25 2.5 18
Rear Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
Rear Master Cylinder Mounting Bolts 9.8 1.0 87 in·lb
Rear Master Cylinder Push Rod Locknut 17 1.7 13
Brake Pedal Bolt 25 2.5 18 L, G
Rear Brake Disc Mounting Bolts 23 2.3 17 L
Rear Brake Pad Pin Plug 2.5 0.25 22 in·lb
Rear Brake Pad Pin 17 1.7 13
Rear Caliper Holder Shaft 27 2.8 20 Si

Suspension

Front Fork Cylinder Unit 34 3.5 25
Front Fork Clamp Bolts (Lower) 20 2.0 15 AL
Front Fork Clamp Bolts (Upper) 20 2.0 15 AL, L
Front Fork Adjuster Assembly Locknut 22 2.2 16
Front Fork Base Valve Assembly 30 3.1 22
Front Fork A djuster Assembly 69 7.0 51 L
Pressure Relief Screws 1.3 0.13 12 in·lb
Swingarm Pivot Shaft Nut 98 10 72 R
Rocker Arm Pivot Nut 59 6.0 44 R

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Torque

Fastener

N·m

kgf·m ft·lb

Remarks

Tie-Rod Mounting Nuts 59 6.0 44 R
Rear Shock Absorber Mounting Nut

(Upper)

39 4.0 29 R

Rear Shock Absorber Mounting Nut
(Lower)

34 3.5 25 R

Rear Shock Absorber Spring Locknut 45 4.6 33
Piston Rod Locknut 37 3.8 27 R
Gas R eservoir Damping Adjuster

Assembly

29 3.0 21

Steering

Handlebar Clamp Bolts 25 2.5 18 AL
Steering Stem Head Nut 98 10 72
Steering Stem Nut 4.9 0.50 43 in·lb
Front Fork Clamp Bolts (Upper ) 20 2.0 15 AL, L
Front Fork Clamp Bolts (Lower) 20 2.0 15 AL

Frame

Rear Frame Mounting Bolts 34 3.5 25
Footpeg Bracket Bolts (Upper) 54 5.5 40 L

Electrical System

C.D.I. Unit Mounting B olts 9.8 1.0 87 in·lb
Spark Plug 13 1.3 115 in·lb
Timing Inspection Cap 3.9 0.40 35 in·lb
Flywheel Cap 4.9 0.50 43 in·lb
Magneto Cover Bolts 9.8 1.0 87 in·lb
Flywheel Nut 49 5.0 36
Stator Bolts 7.0 0.71 62 in·lb L
Crankshaft Sensor Bolts 7.0 0.71 62 in·lb L
Neutral Switch 12 1.2 106 in·lb
Neutral Switch Terminal Screw

1.5 0.15 13 in·lb

Basic Torque for General Fasteners

Threads

diameter

Torque

(mm) N·m kgf·m ft·lb

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

8 14 ∼ 19 1.4 ∼ 1.9 10.0 ∼ 13.5
10 25 ∼ 34 2.6 ∼ 3.5 19.0 ∼ 25
12 44 ∼ 61 4.5 ∼ 6.2 33 ∼ 45
14 73 ∼ 98 7.4 ∼ 10.0 54 ∼ 72
16 115 ∼ 155 11.5 ∼ 16.0 83 ∼ 115
18 165 ∼ 225 17.0 ∼ 23.0 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240

PERIODIC MAINTENANCE 2-9

Specifications

Item Standard Service Limit

Fuel System

Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––
Hot Starter Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) –––
Idle Speed 1 950 ±50 r/min (rpm) –––
Air Cleaner Element O il High quality foam air filter oil –––

Cooling System

Coolant:

Type (recommended) Permanent type antifreeze

–––
Color Green –––
Mixed Ratio Soft water 50%, antifreeze 50% –––
Freezing Point –35°C (–31°F) –––
Total Amount 1.2 L (1.3 US qt.) –––

Engine Top End

Valve Clearance:

Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.) –––
Inlet 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) –––

Cylinder Head Warp ––– 0.05 mm

(0.0020 in.)

Cylinder Inside Diameter (see text) 77.000 ∼ 77.012 mm 77.10 mm

(3.0315 ∼ 3.0320 in.) (3.035 in.)

Piston/Cylinder Clearance 0.041 ∼ 0.068 mm –––

(0.0016 ∼ 0.0027 in.)

Clutch

Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) –––
Friction Plate Thickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.5 mm (0.10 in.)
Friction Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)

Engine Lubrication System

Engine Oil:

Grade Castrol “POWER1 R4 Racing” 5W-40

or API SG, SH, SJ or SL with JASO
MA, MA1 or MA2

–––

Viscosity SAE 10W-30, 10W-40, or 10W-50 –––
Capacity

0.75 L (0.79 U S qt.) (when filter is not
removed)

–––

0.80 L (0.85 US qt.) (when filter is
remove)

1.00 L (1.06 US qt.) (when engine is
completely dry)

Crankshaft/Transmission

0.25 ∼ 0.35 mm 0.6 mm

Connecting Rod Big End Side
Clearance

(0.0098 ∼ 0.0138 in.) (0.02 in.)

2-10 PERIODIC MAINTENA NCE

Specifications

Item Standard Service Limit

Wheels/Tires

Rim Runout (with tire installed):

Axial TIR 1.0 mm (0.039 in.) or less TIR 2.0 mm

(0.079 in.)

Radial TIR 1.0 mm (0.039 in.) or less TIR 2.0 mm

(0.079 in.)
Tires Air Pressure (Front/Rear) 100 kPa (1.00 kgf/cm², 14 psi) –––
Standard Tire:

Front:

Size 80/100-21 51M –––
Make BRIDGESTONE –––
Type M403, Tube –––

Rear:

Size 100/90-19 57M –––
Make BRIDGESTONE –––
Type M404, Tube –––

Final Drive

DriveChainSlack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) –––
Drive Chain 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Rear Sprocket Warp (Runout) TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm

(0.020 in.)

Brakes

Brake Lever Free Play Adjustable (to suit rider) –––
Brake Fluid Type:

Front DOT3 or DOT4 –––
Rear DOT3 or DOT4 –––

Brake Pad Lining Thickness:

Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)

Suspension

Fork Oil:

Viscosity SHOWA SS-19 or equivalanet S AE 5W –––
Capacity (per unit):

Cylinder Unit 180 mL (6.09 US oz.)

–––
Cylinder Unit Oil Level 42 ∼ 49 mm (1.7 ∼ 1.9 in.) –––
Outer Tube 369 ±2.5 mL (12.5 ±0.085 US oz.) 307 ∼ 408 mL

(10.4 ∼ 13.8 US oz.)

Rear Shock Absorber Oil:

Viscosity SHOWA SS-25 or equivalent SAE 2.5W –––
Capacity Approximately 395 mL (13.4 US oz.) –––

Electrical System

Spark Plug Gap 0.7 ∼ 0.8 mm (0.026 ∼ 0.031 in.) –––

PERIODIC MAINTENANCE 2-11

Special Tools

Inside Circlip Pliers:
57001-143

Steering Stem Nut Wrench:
57001-1100

Jack:
57001-1238

Attachment Jack:
57001-1252

Spark Plug Wrench, Hex 16:
57001-1262

Carburetor Drain Plug Wrench, Hex 3:
57001-1269

Filler Cap Driver:
57001-1454

Pilot Screw Adjuster, D:
57001-1588

Jack Attachment:
57001-1608

Top Plug Wrench, 50 mm:
57001-1645

2-12 PERIODIC MAINTENA NCE

Periodic Maintenance Procedures
Fuel System

Fuel Hose and Connection Inspection

○

If the motorcycle is not properly handled, the inside the
fuel line can cause fuel to leak [A].

•

Check the fuel hose.
Replace thefuelhose ifany fraying, cracks [B], bulges [C]
or ozone cracks [D] are noticed.

•

Check that the hose [A] are securely connected and
clamps [B] are tightened correctly.

•

Routethehoseaccording to Cable, Wire, and HoseRout­ing section in the Appendix chapter.

○

Avoid sharp bending, kinking, flattening or twisting, and
route the fuel hosewith a minimum of bending so that the
fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.

ThrottleGrip(ThrottleCable)FreePlayInspection

•

Check throttle grip free play by lightly turning the throttle
grip [A] back and forth [B].

Throttle Grip Free Play

Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

If the free play is improper, adjust the throttle cable.

•

Checkthatthethrottlegrip moves smoothly from full open
to close, and the throttle closes quickly and completely in
all steering positions by the return spring.
Ifthe throttlegrip does not returnproperly,check the throt­tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.

•

Run t he engine at the idle speed, and turn the handlebar
allthe wayto the rightand leftto ensurethatthe idlespeed
does not change.
If the idle speed increase, check the throttle cable free
play and the cable routing.

Throttle G rip (Throttle Cable) Free Play
Adjustment

•

Loosen the locknuts [A] [B] at theupper end ofthe throttle
cable.

•

Screw both throttle cable adjuster [C][D] togive the throt­tle grip plenty of play.

•

Turn out the decelerator adjuster [C] until there is no play
when the t hrottle grip is completely closed.

•

Tighten the locknut [A].

•

Turn the accelerator cable adjuster [D] until 2 ∼ 3mm
(0.08 ∼ 0.12 in.) of throttle grip play is obtained.

•

Tighten the locknut [B].