Kawasaki KX250F (2004) User Manual [ru]

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KX250F

Motorcycle

Service Manual

Quick R eference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System 3 j

Cooling System 4 j

Engine Top End 5 j

Engine Right Side 6 j

Engine Lubrication System 7 j

Engine Removal/Installation 8 j

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

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

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

Crankshaft/Transmission 9 j

Wheels/Tires 10 j

Final Drive 11 j

Brakes 12 j

Suspension 13 j

Steering 14 j

Frame 15 j

Electrical System 16 j

Appendix 17 j

KX250F

Motorcycle

Service Manual

All r ights 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 l atest 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 com ponent parts.

LIST OF ABBREVIATIONS

ABDC after bottom dead center m meter(s)

ATDC after top dead center N newton(s)

BBDC before bottom dead center

BDC bottom dead center PS horsepower

BTDC before top dead center

°C degree(s) Celsius r revolution

F farad(s) TDC top dead center

°F degree(s) Fahrenheit

ft foot, feet V volt(s)

h hour(s) Ω ohm(s)

kgf (force)

ampere(s)

alternating current min

direct current

gram(s) (mass)

(mass)

liter(s)

psi

r/min, rpm revolution(s) per minute

TIR total indicator reading

pound(s)

minute(s)

pascal(s)

pound(s) per square inch

watt(s)

Foreword

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

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

To get the longest life out of your vehicle:

Follow the Periodic M aintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki Mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Special Tool Catalog or Manual. Genuine

parts provided as spare parts are listed in the

Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use This Manual

In preparing this manual, we divided the product into its major systems. 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 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.

The Periodic Maintenance Chart is located in the Periodic Maintenance chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Periodic Maintenance chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

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

WARNING

This warning symbol identifies special

instructions or procedures which, if not

correctly followed, could result in per-

sonal injury, or loss of life.

CAUTION

This caution sym bol identifies special

instructions or procedures which, if not

strictly observed, could result in dam-

age to or destruction of equipment.

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

NOTE

This note symbol indicates points of par-

○

ticular interest for more efficient and convenient operation.

Indicates a procedural step or work to be

•

done. Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it fol-

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

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

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

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

Unit Conversion Table ............................................................................................................ 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 t he 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 flush point solvent w hen cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Arrangement and Cleaning of Removed Parts

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

Before Servicing

Storage of Removed Parts

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

Inspection

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

GENERAL INFORMATION 1-3

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by K AWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

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

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the specified sequence t o prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is 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, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non

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

Gasket, Or ing

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Locking Agent

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

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.

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

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

GENERAL INFORMATION 1-5

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded. 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.

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).

1-6 GENERAL INFORMATION

Before Servicing

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

Model Identification

KX250–N1 Left Side View

GENERAL INFORMATION 1-7

KX250–N1 Right Side View

1-8 GENERAL INFORMATION

General Specifications

Items KX250–N1

Dimensions:

Overall length 2 170 mm (85.43 in.)

Overall width 840 mm (33.1 in.)

Overall height 1 270 mm (50 in.)

Wheelbase 1 475 mm (8.07 in.)

Road clearance 340 mm (13.4 in.)

Seat height 960 mm (37.8 in.)

Dry mass 92.5 kg (204 lb)

Curb mass: Front 49.9 kg (110 lb)

Rear 52.6 kg (116 lb)

Fuel tank capacity 7.5 L (2.0 US gal)

Performance

Minimum turning radius —

Engine:

Type 4-stroke, single cylinder, DOH C 4 valve

Cooling system Liquid-cooled

Bore and stroke 77.0 × 53.6 mm (3.03 × 2.11 in.)

Displacement 249 mL (15.2 cu in.)

Compression ratio 12.6 : 1

Maximum horsepower 31.6 kW (43.0 P S) @11 000 r/min (rpm)

Maximum torque 28.7 N·m (2.93 kgf·m, 6.45 in·lb) @ 8 500 r/min (rpm)

Carburetion system Carburetor, KEIHIN FCR37

Starting system Primary kick

Ignition system Digital AC-CDI

Timing advance

Ignition timing

Spark plug NGK CR8EB or NGK CR9EB

Valve timing

Inlet Open BTDC 49°

Close ABDC 63°

Duration 292°

Exhaust Open BBDC 69°

Close ATDC 49°

Duration 298°

Lubrication system Forced lubrication (semi-dry sump)

Engine oil:

Type

Viscosity

Capacity 1.5 L (1.6 USqt)

Drive Train:

Primary reduction system:

Type Gear

Reduction ratio 3.350 (67/20)

Clutch type Wet, multi disc

BTDC 8° @ 2 000 r/min (rpm)

API SH or SJ with JASO M A

SAE 10W-40

GENERAL INFORMATION 1-9

General Specifications

Items KX250–N1

Transmission:

Type

Gear ratios:

Final drive system:

Type Chain drive Reduction ratio 3.692 (48/13) Overall drive ratio 13.020 @ Top gear

Frame:

Type Tubular, semi-double cradle Steering angle 42° to either side Caster (rake angle) 26.5° Trail 110 mm (4.33 in.) Front tire: Size 80/100-21 51M

Rear tire: Size 100/90-19 57M

Front suspension: Type Telescopic fork (up side down)

Rear suspension: Type Swingarm (New Uni-trak)

Brake type: Front and Rear Effective disc diameter:

EU: European Model

1st 2nd 1.785 (25/14) 3rd 1.444 (26/18) 4th 1.200 (24/20) 5th 1.052 (20/19)

Make/Type BRIDGESTONE M601 (EU, M201) Tube type

Make/Type BRIDGESTONE M602 (EU, M202) Tube type

Wheel travel 300 mm (11.8 in.)

Wheel travel 310 mm (12.2 in.)

Front (effect. dia.) 225 mm (8.86 in.) Rear (effect. dia.) 215 mm (8.46 in.)

5-speed, constant mesh, return s hift

2.142 (30/14)

Single disc

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 = L × 1.057 = qt (US) L × 0.8799 = 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

gal (imp)

qt (imp)

Units of Length:

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

Units of Torque:

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

× 7.233 =

ft·lb

Units of Pressure:

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

kgf/cm²

Units of Speed:

km/h × 0.6214 = mph

Units of Force:

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

Units of Temperature:

Units of Power:

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

× 0.9863 = HP

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent................. 2-4

Specifications .................................... 2-8

Special Tools ..................................... 2-10

Periodic Maintenance Procedures..... 2-11

Fuel System.................................... 2-11

Fuel Hose and Connection

Inspection .................................. 2-11

Throttle Grip Free Play Inspection 2-11 Throttle Grip Free Play

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

Hot Start Lever Free Play

Inspection .................................. 2-12

Idle Speed Inspection .................. 2-12

Idle Speed Adjustment................. 2-13

Air Cleaner Element Cleaning and

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

Cooling System............................... 2-15

Coolant Level Inspection.............. 2-15

Coolant Deterioration Inspection.. 2-16 Radiator Hoses and Connections

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

Engine Top End .............................. 2-17

Valve Clearance Inspection ......... 2-17

Valve Clearance Adjustment ........ 2-17

Cylinder Head Warp Inspection ... 2-19

Cylinder Wear Inspection............. 2-20

Piston/Cylinder Clearance ........... 2-20

Piston, Piston Ring and Piston

Pin R eplacement....................... 2-20

Exhaust System........................... 2-21

Silencer Packing Change............. 2-21

Engine Right Side ........................... 2-22

Clutch Adjustment........................ 2-22

Friction and Steel Plates

Inspection .................................. 2-23

Engine Lubrication System ............. 2-23

Engine Oil Change....................... 2-23

Oil Filter Change .......................... 2-24

Oil Screen Cleaning ..................... 2-26

Breather Hose Inspection ............ 2-26

Crankshaft/Transmission ................ 2-26

Crankshaft Inspection .................. 2-26

Wheel/Tires..................................... 2-28

Air Pressure

Inspection/Adjustment............... 2-28

Tires Inspection............................ 2-29

Spoke Tightness Inspection......... 2-29

Rim Runout Inspection................. 2-30

Wheel Bearing Inspection ............ 2-30

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

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

Drive Chain Lubrication................ 2-31

Sprocket Wear Inspection ............ 2-32

Rear Sprocket Warp Inspection ... 2-32

Brakes............................................. 2-33

Brake Lever and Pedal

Adjustment ................................ 2-33

Brake Fluid Level Inspection........ 2-34

Brake Fluid Change ..................... 2-35

Brake Pad Wear Inspection ......... 2-37

Brake Master Cylinder Cup and

Dust Seal Replacement . ........... 2-38

Caliper Piston Seal and Dust Seal

Replacement ............................. 2-39

Brake Hose and Connection

Check ........................................ 2-42

Brake Hose Replacement ............ 2-42

Suspension..................................... 2-44

Front Fork Inspection ................... 2-44

Front Fork Oil Change (each fork

leg) ............................................ 2-44

Rear Shock Absorber Oil Change 2-46 Swingarm and Uni-Trak Linkage

Inspection .................................. 2-51

Swingarm and Uni-Track Linkage

Pivot Lubricate .......................... 2-51

Steering .......................................... 2-52

Steering Inspection ...................... 2-52

Steering Adjustment .................... 2-52

Stem B earing Lubrication............. 2-54

Frame ............................................. 2-54

Frame Inspection ......................... 2-54

Electrical System ............................ 2-54

Spark Plug Cleaning and

Inspection .................................. 2-54

Cable Inspection ............................. 2-55

Lubrication ................................... 2-55

Nut, Bolt, and Fastener Tightness

Inspection..................................... 2-57

Tightness Inspection .................... 2-57

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart t o keep the motorcycle in good running

condition.

FREQUENCY Each Every 3 Every 6 Every 12 See

OPERATION race races races races Page

Spark plug – clean, gap †

Clutch – adjust

Clutch and friction plates - inspect †

Throttle cable – adjust

Air cleaner element – clean

Air cleaner element – replace If damaged 2-13

Carburetor – inspect and adjust

Engine Oil – change

Piston and piston ring – replace

Cylinder head, cylinder – inspect

Piston pin – replace

Valve clearance – inspect †

Hot start – adjust

Oil filter – replace

Silencer – clean and inspect†

Silencer packing – change

Kick pedal and shift pedal – clean

Engine sprocket – inspect †

Coolant – check †

Radiator hoses and connections – inspect †

Crankshaft – inspect

Oil screen – clean

Breather hose – inspect

Brake adjustment – inspect †

Brake pad wear – inspect †

Brake fluid level – inspect †

Brake fluid – change Every 2 years 2-35

Brake master cylinder cup and dust seal – replace Every 2 years 2-38

Brake caliper piston seal and dust seal – replace Every 2 years 2-39

Brake hoses and pipe – replace Every 4 years 2-42

S S

Brake hoses, connections - inspect †

Spoke tightness and rim runout – inspect †

Wheel bearing – inspect †

Frame – inspect

Drive chain wear – inspect †

Wheels/tires – inspect

Rear sprocket – inspect †

•

R 2-23

•

2-54

2-22

2-11

2-13

2-12

2-23

2-20

2-17

2-12

2-24

2-21

—

2-32

2-15

2-16

2-26

2-33

2-37

2-34

2-42

2-29

2-30

2-54

2-31

2-28

2-32

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

FREQUENCY Each Every 3 Every 6 Every 12 See

OPERATION race races races races Page

Front fork – inspect and clean

Front fork oil – change

Rear shock oil – replace

Cable – inspect

Fuel hose – replace Every 4 years 2-11

Fuel hose, connections - inspect †

Steering play – inspect †

Steering stem bearing – grease

Swingarm and Uni-Trak linkage pivots – grease

Swingarm and Uni-Trak linkage pivots – inspect †

Nuts, bolts, fasteners – inspect †

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

R: Replace

•

2-44

2-46

2-55

2-11

2-52

2-54

2-51

2-57

2-4 PERIODIC MAINTENANCE

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 become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for t he major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

When checking the tightening toque 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 t wo clamp bolts alternately two times to ensure even tightening torque.

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

Lh: Left-hand Threads

S: Tighten the fasteners following the specified sequence.

Fastener

Fuel System:

Throttle Pulley Cover Bolt 3.4 0.3 30 in·lb

Throttle Cable Locknut 7.0 0.7 61 in·lb

Plunger Cap Bolt 1.0 0.1 10 in·lb

Rear Frame Mounting Bolts 34 3.5 25

Air Cleaner Duct Clamp Screw 2.0 0.2 17 in·lb

Fuel Tap Plate Mounting Screws 0.8 0.08 7in·lb

Cooling System:

Right Engine Cover Bolt 9.8 1.0 87 in·lb

Water Pipe Bolt 9.8 1.0 87 in·lb

Water Pump Cover Bolts 9.8 1.0 87 in·lb L(1)

Water Pump Cover Bolts (with washer) 7.0 0.7 61 in·lb L(1)

Water Pump Impeller Bolt 7.0 0.7 61 in·lb

Radiator Hose Clamp Screws 1.5 0.15 13 in·lb

Radiator Screen Bolts 9.8 1.0 87 in·lb

Coolant Drain Plug 7.0 0.7 61 in·lb

Radiator Mounting 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 1.2 104 in·lb

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb

Cylinder Head Bolts: M10 50 5.0 36 S

M6 12 1.2 104 in·lb S

Camshaft Cap Bolts 12 1.2 104 in·lb S

Carburetor Holder Clamp Screws 2.0 0.2 17 in·lb

Plug 20 2.0 14 L

Lower Camshaft Chain Guide Bolt

Rear Camshaft Chain Guide Bolt

Exhaust Pipe Stud – – – L

Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb

Chain Tensioner Cap 20 2.0 14.5

N·m kgf·m ft·lb

9.8 1.0 87 in·lb

15 1.5 11

Torque

Remarks

(Planted

side)

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Fastener

Cylinder Bolt M6 12 1.2 104 in·lb S

Exhaust Pipe Cover Screws 12 1.2 104 in·lb

Exhaust Pipe Holder Nuts 21 2.1 15 S

Muffler Mounting Bolts 21 2.1 15 S

Engine Right Side:

Primary Gear Nut

Shift Drum Cam Bolt

Clutch Spring Bolts

Clutch Hub Nut 98 10 72

Gear Set Lever Nut 8.8 0.9 78 in·lb

Gear Set Lever Pivot Stud – – – L

Ratchet Plate Mounting Bolt 9.8 1.0 87 in·lb

Ratchet Plate Mounting Screw 6.4 0.65 56 in·lb L

Kick Ratchet Guide Bolt 8.8 0.9 78 in·lb L

Kick Pedal Bolt 25 2.5 18 L

Shift Pedal Bolt 9.8 1.0 87 in·lb

Clutch Cover Bolts 9.8 1.0 87 in·lb L(1)

Clutch Cover Bolt (with washer) 7.0 0.7 61 in·lb L

Right Engine Cover Bolts 9.8 1.0 87 in·lb

Engine Lubrication System:

Engine Oil Drain Plug M10

(for crank room oil sump) 15 1.5 11

Engine Oil Drain Plug M6

(for transmission room oil sump) 7.0 0.7 61 in·lb

Engine Oil Drain Plug M6

(for oil filter oil chamber) 7.0 0.7 61 in·lb

Oil Pump Mounting Bolts 7.0 0.7 61 in·lb L

Water Pump Cover Bolts

Water Pump Cover Bolt (with washer)

Right Engine Cover Bolts

Piston Oil Nozzle 2.5 0.25 22 in·lb L

Breather Fitting 15 1.5 11 L

Clutch Cover Bolts 9.8 1.0 87 in·lb

Oil Pump Idle Gear Shaft Screws 6.4 0.65 56 in·lb L

Engine Removal/Installation:

Engine Mounting Bolt, Nuts 49 5.0 33

Engine Bracket Bolt, Nuts 29 3.0 22

Swingarm Pivot Shaft Nut 98 10 72

Crankshaft/Transmission:

Breather Fitting 15 1.5 11 L

Reed Valve Screws 7.0 0.7 61 in·lb

N·m kgf·m ft·lb

98 10 72 Lh

24 2.4 17 L

9.8 1.0 87 in·lb

7.0 0.7 61 in·lb

9.8 1.0 87 in·lb

Torque

Remarks

(Planted

Side)

L(1)

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Piston Oil Nozzle

Crankcase Bolts

Engine Oil Drain Plug

(for crank room oil sump) 7.0 0.7 61 in·lb

(for transmission room oil sump) 15 1.5 11

Output Shaft Bearing Retaining Screw 6.4 0.65 56 in·lb L

Drive Shaft B earing Retaining Screw 6.4 0.65 56 in·lb L

Shift Drum Bearing Retaining Bolts 9.8 1.0 87 in·lb L

Gear Set Lever Nut 8.8 0.9 78 in·lb

Shift Drum Cam Bolt 24 2.4 17 L

Neutral Switch 12 1.2 104 in·lb

Wheels/Tires:

Front Axle 79 8.0 58

Front Axle Clamp Bolts 20 2.0 14.5 AL

Rear Axle Nut 110 11. 0 80

Spoke Nipple Not less Not less Not less

Final Drive:

Rear Sprocket Nuts 34 3.5 25

Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb

Brakes:

Brake Lever Pivot Locknut 5.9 0.6 52 in·lb

Brake Reservoir Cap Screws 1.5 0.15 13 in·lb

Brake Lever Pivot Bolt 5.9 0.6 52 in·lb

Caliper Mounting Bolts (Front) 25 2.5 18

Brake Hose Banjo Bolts 25 2.5 18

Front Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S

Rear Master Cylinder Mounting Bolts 9.8 1.0 87 in·lb

Rear Master C ylinder Push Rod Locknut 17 1.7 12.5

Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb

Brake Disc Mounting Bolts (Front) 9.8 1.0 87 in·lb L

(Rear) 23 2.3 16.6 L

Caliper Bleed Valves (Front, Rear) 7.8 0.8 69 in·lb

Front Caliper Holder Bolt 27 2.8 20 L

Rear Caliper Holder Bolt 27 2.8 20

Caliper Pin Bolts 12 1.2 104 in·lb L

Brake Pad Bolt 17 1.7 12.5

Rear Brake Pad Bolt Plug 2.5 0.25 22 in·lb

Brake Pedal Mounting Bolt 25 2.5 18

Suspension:

Front Fork Clamp Bolts (Upper, Lower) 20 2.0 14.5 AL

Front Fork Cylinder Valve Assembly 54 5.5 40 L

Front Fork Top Plug 29 3.0 22

N·m

2.5 0.25 22 in·lb L

9.8 1.0 87 in·lb

than 2.2 than 0.22 than 19 in·lb

Torque

Remarks

kgf·m ft·lb

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Push Rod Nut 28 2.85 20.6

Swingarm Pivot Shaft Nut

Rear Shock Absorber Mounting Nuts: (Upper) 39 4.0 29

(Lower) 34 3.5 25

Air Bleed Bolt 6.4 0.65 56 in·lb

Tie-Rod Mounting Nut (Front, Rear) 83 8.5 61

Rocker Arm Pivot Nut 83 8.5 61

Steering:

Steering Stem Head Nut 79 8.0 58

Steering Stem Locknut 4.9 0.5 43 in·lb

Handlebar Clamp Bolts 25 2.5 18 S

Front Fork Clamp Bolts (Upper, Lower)

Frame:

Rear Frame Mounting Botls 34 3.5 25

Electrical System:

Neutral Switch 12 1.2 104 in·lb

Neutral Switch Lead Terminal Screw 1.3 0.13 12 in·lb

Flywheel Nut 49 5.0 36

Timing Inspection Cap

Stator Bolts

Crankshaft Sensor Bolts 7.0 0.7 61 in·lb

Spark Plug 13 1.3 11 5 in · lb

C.D.I. Unit Bolts 9.8 1.0 87 in·lb

Magneto Cover Bolts L:30 9.8 1.0 87 in·lb

L:35 9.8 1.0 87 in·lb L

Ignition Coil Bolts 7.0 0.7 61 in·lb

N·m kgf·m ft·lb

98 10 72

20 2.0 14.5 AL

4.0 0.4 43 in·lb

7.0 0.7 61 in·lb

Torque

Remarks

Basic Torque for General Fasteners

Threads dia. 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

2-8 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System:

Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) --Hot start lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

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

Cooling System:

Coolant:

Type (recommended) Permanent type antifreeze

Color Green

Mixed ratio

Freezing point –35°C (–31°F)

Total amount

Engine Top End:

Valve clearance:

Exhaust 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.) ---

Inlet

Cylinder head warp --- 0.05 mm

Cylinder inside diameter (see text) 77.000 ∼ 77.012 mm 77.06 mm

Soft water 50% and coolant 50%

1.20 L (1.27 US qt)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

(3.0315 ∼ 3.0320 in.) (3.0339 in.)

---

(0.0020 in.)

Piston/cylinder clearance 0.030 ∼ 0.057 mm ---

(0.0012 ∼ 0.0022 in.)

Engine Right Side:

Clutch Lever free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Friction plate t hickness 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) 2.6 mm (0.102 in.) Steel plate thickness 1.46 ∼ 1.74 mm (0.057 ∼ 0.069 in.) 1.36 mm (0.054 in.)

Friction plate warp Not more than 0.15 mm (0.006 in.) 0.3 mm (0.012 in.)

Steel plate warp Not more than 0.2 mm (0.008 in.) 0.3 mm (0.012 in.)

Engine Lubrication System:

Engine oil:

Type Castrol “R4 superbike” 5W-40 or

API SH or SJ with JA SO MA

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

Capacity: 1.5 L (0.74 US qt)

Crankshaft/Transmission:

Connecting rod big end radial clearance

Connecting rod big end side clearance

0.002 ∼ 0.014 mm 0.06 mm (0.00008 ∼ 0.0006 in.) (0.0024 in.)

0.25 ∼ 0.35 mm 0.55 mm (0.0098 ∼ 0.0138 in.) (0.0217 in.)

---

Crankshaft runout TIR 0.03 mm (0.012 in.) or less

TIR 0.08 mm

(0.0031 in.)

PERIODIC MAINTENANCE 2-9

Specifications

Item Standard Service Limit

Wheels/Tires:

Rim Runout:

Axial Under 1.0 mm (0.039 in.) 2 mm (0.08 in.)

Radial Under 1.0 mm (0.039 in.) 2 mm (0.08 in.)

Front and rear tires air pressure 100 kPa (1.0 kgf/cm², 14 psi)

Standard tire:

Front: Size 80/100-21 51M ---

Make BRIDESTONE

Type M601, Tube (EU) M201, Tube

Rear: Size 100/90-19 57M ---

Make BRIDESTONE

Type M602, Tube (EU) M202, Tube

Final Drive:

Drive chain slack 52 ∼ 62 mm (2.05 ∼ 2.44 in.) --Drive chain 20 link length 317.5 ∼ 318.2 mm 323 mm

(12.50 ∼ 12.53 in.) (12.72 in.)

Engine sprocket diameter 55.48 ∼ 55.68 mm 54.8 mm

(2.184 ∼ 2.192 in.)/13T (2.157 in.)

Rear sprocket diameter 232.62 ∼ 233.12 mm 232.1 mm

(9.158 ∼ 9.178 in.)/48T (9.138 in.)

Rear sprocket warp Under 0.4 mm (0.016 in.) 0.5 mm (0.020 in.)

Brakes:

Brake lever free play (to suit rider) ---

Brake fluid:

Type: Front DOT3 or DOT4 ---

Rear DOT4 ---

Brake pad lining thickness: Front 3.8 mm (0.150 in.) 1 mm (0.04 in.)

Rear 6.4 mm (0.252 in.) 1 mm (0.04 in.)

Suspension:

Fork Oil:

Oil viscosity KAYABA 01 or SAE 5W

Oil capacity (per unit) 564 ± 4 mL (19.07 ± 0.14 US oz.) ---

Oil level (fully compressed, spring removed)

Electrical System: (2.8 ∼ 4.7 in.)

Spark plug gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) ---

TIR: Total Indicator Readings

95 mm (3.7 in.) 70 ∼ 120 mm

(Adjustable range)

2-10 PERIODIC MAINTENANCE

Special Tools

Valve Spring Compressor Assembly : 57001–241

Steering Stem Nut Wrench : 57001–1100

Valve Spring Compressor Adapter, 20 : 57001–1154

Fork Oil Level Gauge : 57001–1290

Pilot Screw Adjuster, C : 57001–1292

Pilot Screw Adjuster Adapter, 4: 57001–1371

Jack : 57001–1238

Spark Plug Wrench, M16 : 57001–1262

Pilot Screw Adjust, D: 57001–1588

Periodic Maintenance Procedures

Fuel System

Fuel Hose and Connection Inspection

The f uel hoses are designed to be used throughout the

○

motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. Check the fuel hose.

•

Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.

Check that the hose [A] are securely connected and

•

clamps [B] are tightened correctly. When installing, route the hose according to Cable, Wire,

•

and Hose Routing section in the Appendix chapter. When installing the fuel hose, avoid sharp bending, kink-

•

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

PERIODIC MAINTENANCE 2-11

Throttle Grip Free Play Inspection

Check throttle grip free play [B] by lightly turning the throt-

•

tle grip [A] back and forth. If the free play is improper, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 ∼ 3mm(0.08∼ 0.12 in.)

Check that the throttle grip moves smoothly from full open

•

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

•

all the way to the right and left to ensure that the idle speed does not change. If the idle speed increase, check the throttle cable free play and the cable routing.

Throttle Grip Free Play Adjustment

Loosen the locknuts [A] [B] at the upper end of the throttle

•

cable. Screw both throttle cable adjuster [C] [D] to give the throt-

•

tlegripplentyofplay. Turn out the decelerator adjuster [C] until there is no play

•

when the throttle 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].

•

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If the throttle grip free play cannot be adjusted with the adjusters at the upper end of the throttle cables, use the cable adjusters [A] at the carburetor. Make the necessary free play adjustment at the lower ca-

•

ble adjusters, tighten the locknuts [B]. If the throttle grip free play cannot be adjusted with the lower adjuster, replace the throttle cables. Turn the handlebar from side to side while idling the en-

•

gine. If idle speed varies, the throttle cable m ay be poorly routed or it may be damaged.

WARNING

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

Hot Start Lever Free Play Inspection

Slide the clutch lever dust cover [A] back.

•

Check the hot start lever play [B] when pulling the start

•

lever [C] lightly.

Hot Start Le ver Free Play

Standard: 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

If the free play is improper, adjust the hot start cable.

Slide the adjuster cover [A] back.

•

Loosen the locknut [B] and turn the adjuster [C] to obtain

•

the proper lever free play. Tighten the locknut securely.

•

Check that the hot start lever moves smoothly from full

•

open to close, and the lever closes quickly and completely in all steering positions by the return spring. If the hot start lever does not return properly, check the hot start cable routing, free play and cable damage. Then lubricate the hot start cable.

Idle Speed Inspection

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides

•

[A]. If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these conditions before riding (see Cable, Harness, Hose Routing in the Appendix chapter).

WARNING

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

Periodic Maintenance Procedures

Check the idle speed, using the engine revolution tester

•

[A] for high accuracy. If the idle speed is out of specified range, adjust it.

Idle Speed:

Standard: 2 000 ± 50 r/min (rpm)

Idle Speed Adjustment

First, turn in the air screw [A] using the pilot screw ad-

•

juster [A], until it seats lightly, and back it out the specified number of turns. (see specifications in the Fuel System chapter)

Special Tool - Pilot Screw Adjuster, C : 57001–1292

(or Pilot Screw Adjuster, D : 57001–1588) Pilot Screw Adjuster Adapter,

57001–1371

Start the engine and warm it up thoroughly.

•

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

•

correct.

To increase idle speed [C] To decrease idle speed [D]

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

•

the idle speed is with in the specified range. Readjust if necessary.

PERIODIC MAINTENANCE 2-13

Air Cleaner Element Cleaning and Inspection

NOTE

In dusty areas, the element should be cleaned more

○

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

○

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

○

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

WARNING

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

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove:

•

Seat (see Frame chapter) Wing Bolt [A] Air Cleaner Element [B]

Stuff a clean, lint-free towel into the carburetor so no dirt

•

is allowed to enter the carburetor. Wipe out the inside of the air cleaner housing with a clean

•

damp towel.

CAUTION

Check inside of the inlet tract and carburetor for dirt. If dirt is present, clean the intake tract and carburetor thoroughly. You may also need to replace the element and seal the housing and inlet tract.

Separate the element [A] from the frame [B].

•

Clean the element [A] in a bath of a high-flash-point sol-

•

vent using a soft bristle brush.

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

•

ment or blow it dry; the element can be damaged. Check all the parts of the element for visible damage.

•

If any of the parts of the element are damaged, replace them.

After cleaning, saturate the element with a high-quality

•

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

○

Assemble the element.

•

Remove the towel from the carburetor.

•

Periodic Maintenance Procedures

Apply grease to all connections and screw holes in the air

•

cleaner housing and intake tract. Install the element onto its frame, and coat the element

•

lip and lip seat with a thick layer of all-purpose grease to assure a compete seal.

Install the air cleaner element so that its tab faces [A]

•

upward and its projections [B] align with the holes [C] in the housing. Tighten the wing bolt [D]

•

Install the seat.

•

PERIODIC MAINTENANCE 2-15

Cooling System

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on t ires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the wheels. Since coolant is harmful to the human body, do not use for drinking.

Coolant Level Inspection

NOTE

Check the level when the engine is cold (room or ambi-

○

ent temperature).

Lean the motorcycle slightly to the right until the radiator

•

cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator. Remove the radiator cap [A].

•

NOTE

Remove the radiator cap in two steps. First turn the

○

cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Check the coolant level. The coolant level [A] should be

•

at the bottom of the filler neck [B]. If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap.

Recommended coolant:

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Water and coolant mixture ratio:

1:1 (water 50 %, Coolant 50 %)

Total amount:

1.2L(1.27USqt.)

Coolant Deterioration Inspection

Visually inspect the coolant.

•

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Radiator Hoses and Connections Inspection

The high pressure inside the radiator hose [A] can cause

○

coolant to leak [B] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [C] or bulges [D] are noticed. Check that the hoses are securely connected and clamps

•

are tightened correctly.

Torque - Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m,

13 in·lb)

Periodic Maintenance Procedures

Engine Top End

Valve Clearance Inspection

NOTE

Valve clearance must be checked and adjusted when

○

the engine is cold (at room temperature).

Remove:

•

Cylinder Head Cover (see Engine Top End chapter) Timing Inspection Cap [A] Flywheel Cap [B]

Fist, bring the piston to the top-dead-center of its com-

•

pression stroke to inspect the valve clearance (the position at the end of the compression stroke), when the cam lobe faces outside of the camshaft. Place a wrench over the flywheel nut and turn it counter-

○

clockwise to align the TDC mark [A] with the center of the grove [B] of the inspection hole.

PERIODIC MAINTENANCE 2-17

Using a thickness gauge [A], m easure the clearance be-

•

tween each cam lob and valve lifter, for all four valves. For the purpose of adjusting the valve clearances, record

○

the measured values.

Valve clearance: between cam and valve lifter

Standard:

Exhaust Inlet

If the valve clearance is not within the specified range, adjust it.

Valve Clearance Adjustment

Remove the camshaft caps [A] (see Engine Top End

•

chapter). Remove the camshafts [B] (see Engine Top End chapter).

•

Remove the valve lifters [C] of the applicable valve.

•

Remove the shim [D] from the top of the spring retainer.

•

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

Mark and record the locations of the valve lifters and

○

shims so that they can be reinstalled in their original positions.

Clean the shim to remove any dust or oil.

•

Measure the thickness of the removed shim [A].

•

Select a new shim thickness calculation as follows.

•

A=(B–C)+D [A] Replace Shim Thickness [B] Measured Valve Clearance [C] Specified Valve Clearance [D] Present Shim Thickness

Example:

(0.31 mm – 0.10 ∼ 0.15 mm) + 2.60 mm =

2.81 ∼ 2.76 mm

Exchange the shims for the 2.775 or 2.800 size shim.

○

CAUTION

Don’t use the shims for another models. This could cause wear of the valve stem end, and valve stem damage.

Adjustment shims

Thick-

ness

2.500 92180-0023 50 3.025 92180-0044 03

2.525 92180-0024 53 3.050 92180-0045 05

2.550 92180-0025 55 3.075 92180-0046 08

2.575 92180-0026 58 3.100 92180-0047 10

2.600 92180-0027 60 3.125 92180-0048 13

2.625 92180-0028 63 3.150 92180-0049 15

2.650 92180-0029 65 3.175 92180-0050 18

2.675 92180-0030 68 3.200 92180-0051 20

2.700 92180-0031 70 3.225 92180-0052 23

2.725 92180-0032 73 3.250 92180-0053 25

2.750 92180-0033

2.775 92180-0034 78 3.300 92180-0055 30

2.800 92180-0035 80 3.325 92180-0056 33

2.825 92180-0036 83 3.350 92180-0057 35

2.850 92180-0037 85 3.375 92180-0058 38

2.875 92180-0038 88 3.400 92180-0059 40

2.900 92180-0039 90 3.425 92180-0060 43

2.925 92180-0040 93 3.450 92180-0061 45

2.950 92180-0041 95 3.475 92180-0062 48

2.975 92180-0042 98 3.500 92180-0063 50

3.000 92180-0043 00

P/No.

Mark

Thick-

ness

3.275 92180-0054 28

P/No.

Mark

Periodic Maintenance Procedures

CAUTION

Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance.

If there is no valve clearance, use a shim that is a few

○

sizes smaller, and remeasure the valve clearance.

When installing the shim, face t he marked side [A] t oward

•

the valve lifter [B]. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation.

CAUTION

Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage.

PERIODIC MAINTENANCE 2-19

Apply engine oil to the valve lifter surface and install the

•

lifter. Install the camshaft (see Engine Top End chapter).

•

Recheck the valve clearance and readjust if necessary.

•

Install the cylinder head cover (see Engine Top End chap-

•

ter), timing inspection cap, and the flywheel cap.

Torque - Timing Inspection Cap: 4 N·m (0.4 kgf·m, 35 in·lb)

Flywheel Cap: 5 N·m (0.5 kgf·m, 43 in·lb)

Cylinder Head Warp Inspection

Remove the cylinder head (see Engine Top E nd chapter).

•

Lay a straightedge [A] across the lower surface of the

•

head at several different points, and measure warp by inserting a thickness gauge between the straightedge and the head. If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.

Cylinder Head Warp

Service Limit: 0.05 mm (0.0020 in.)

Remove the valves (see Engine Top End chapter).

•

Space the carbon out of the combustion chamber and

•

exhaust port with a scraper [A] or a suitable tool. Clean the cylinder head, using high-flash point solvent.

•

Blow out any particles which may obstruct the oil passage

•

in the cylinder head using compressed air. Install the valves (see Valve Installation).

•

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cylinder Wear Inspection

NOTE

Measure the cylinder inside diameter when the cylinder

○

is cold (room or ambient temperature).

Visually Inspect the inside of the cylinder for scratches

•

and abnormal wear. If the cylinder is damaged or badly worn, replace it with a new one. Since there is a difference in cylinder wear in different di-

•

rections, take a side-to-side and a front-to back measurement shown in the figure. If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed.

(A): 10 mm (0.39 in.) (B): 25 mm (0.98 in.) (C): 60 mm (2.36 in.)

Cylinder Inside Diameter

Standard 77.000 ∼ 77.012 mm (3.0315 ∼ 3.0320

in.), and less than 0.01 mm (0.0004 in.) difference between any two measurements.

Service Limit 77.06 mm (3.0339 in.), or more than 0.05

mm (0.020 in.) difference between any two measurements.

Piston/Cylinder Clearance

The piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced.

If only a piston is replaced, the clearance may exceed the standard slightly. But it must not be less than the minimum, in order to avoid piston seizure.

The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measurements and then computing the difference between the two values. Measure the piston diameter as just described, and measure the cylinder diameter at the very bottom of the cylinder.

Piston/Cylinder Clearance

Standard:

0.030 ∼ 0.057 mm (0.0012 ∼ 0.0022 in.)

Piston, Piston R ing and Piston Pin Replacement

Refer to the Cylinder Section in Engine Top End chapter.

•

Periodic Maintenance Procedures

Exhaust System

The exhaust system, in particular the silencer, is designed

•

to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the silencer, exhaust efficiency is reduced, causing engine performance to drop. If the silencer is badly damaged, dented, cracked or

•

rusted, replace it. Replace the silencer packing if the exhaust noise becomes too loud or engine performance drops.

Silencer Packing Change

Remove the silencer (see Engine Top End chapter).

•

Remove the inner pipe mounting bolts [A].

•

PERIODIC MAINTENANCE 2-21

Tap the bracket [A] of the silencer body with a plastic mal-

•

let [B] to separate from the inner pipe.

Pull off the old silencer packing, and install the new si-

•

lencer packing [A] into the silencer.

Install the end [A] of the inner pipe [B] to the baffle [C].

•

Apply a non-permanent locking agent to the pipe mount-

•

ing bolts. Install the silencer body.

•

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Apply silicone sealant to the circumference [A] of the si-

•

lencer pipe.

Install the muffler (see Engine Top End chapter).

•

Engine Right Side

WARNING

To avoid a serious burn, never touch the hot engine

or exhaust chamber during clutch adjustment.

Clutch Adjustment

Clutch Lever Free Play Inspection

Slide the clutch lever dust cover [A] out of place.

•

Check that the clutch cable upper end is fully seated in

•

the adjuster [B].

Pull the clutch lever [C] just enough to take up the free

•

play [D].

Measure the gap between the lever and the lever holder.

•

If the gap is too wide, the clutch may not release fully. If

the gap is too narrow, the clutch may not engage fully. In

either case, adjust it.

Clutch Lever Free Play

Standard: 2 ∼ 3mm(0.08∼ 0.12 in.)

Clutch Lever Free Play Adjustment

Slide the clutch lever dust cover out of place.

•

Loosen the knurled locknut [A].

•

Turn the adjuster [B] so that the clutch lever will have 2 ∼

•

3 mm (0.08 ∼ 0.12 in.) of play [C].

NOTE

Be sure that the outer cable end at the clutch lever is

○

fully seated in the adjuster at the clutch lever, or it could slip into the place later, creating enough cable play to prevent clutch disengagement.

If it cannot be done. Turn the adjuster [A] so that 5 ∼ 6

•

mm (0.20 ∼ 0.24 in.) [B] of threads are visible.

Tighten the locknut.

•

Periodic Maintenance Procedures

Slide the adjuster cover [A] back.

•

If it cannot be done, loosen the locknut [B] at the middle

•

of the clutch cable, and turn the adjusting nut [C] so t hat

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

After t he adjustment is made, tighten the locknut, and

•

start the engine and check that the clutch does not slip and that it release properly.

Friction and Steel Plates Inspection

Remove the clutch plates (see Engine Right Side chapter)

•

Visually inspect the friction and steel plates to see if they

•

show any signs of seizure, or uneven wear. If any plates show signs of damage, replace the friction plates and steel plates as a set. Measure the thickness [A] of the friction and steel plates

•

with vernier calipers. If they have worn past t he service limit, replace them with new ones.

PERIODIC MAINTENANCE 2-23

Friction Plate Thickness

Standard: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.)

Service Limit: 2.6 mm (0.102 in.)

Steel Plate Thickness

Standard: 1.46 ∼ 1.74 mm (0.057 ∼ 0.069 in.)

Service Limit: 1.36 mm (0.054 in.)

Place each friction plate or steel plate on a surface plate,

•

and measure the gap between the s urface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one.

Friction and Steel Plates Warp

Friction Plate

Standard:

Service Limit: 0.3 mm (0.012 in.) 0.3 mm (0.012 in.)

Not more than 0.15 mm (0.006 in.)

Steel Plate Not more than 0.2 mm (0.008 in.)

Engine Lubrication System

Engine Oil Change

Warm up the engine thoroughly so that the oil will pick up

•

any sediment and drain easily. Then stop the engine. Place an oil pan beneath the engine.

•

Remove the oil filler cap [A].

•

Remove the drain plug [B] and drain the engine oil in the

•

oil filter oil chamber.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Remove the engine oil drain plugs on the bottom of the

•

engine, and let the oil drain completely.

Drain Plug (for crank room oil sump) [A] Drain Plug (for transmission oil sump) [B]

NOTE

Hold the motorcycle upright so that the oil may drain

○

completely.

Replace the gaskets at the drain plugs with a new one.

•

After the oil has completely drained out, install the drain

•

plugs with the gaskets, and tighten them.

Torque - Engine Oil Drain Plugs:

Oil Filter Oil Chamber : 7.0 N·m (0.7 kgf·m, 61 in·lb) Crank Room O il Sump : 7.0 N·m (0.7 kgf·m, 61

in·lb)

Transmission Oil Sump : 15 N·m (1.5 k gf·m, 11

ft·lb)

Fill the engine with a good quality motor oil specified be-

•

low.

Recommended Engine

Type

Viscosity

Capacity 1.3 L (1.4 US qt.) (when filter is not

The oil viscosity may need to be changed to accommo-

○

date atmospheric conditions in your riding area.

Check the oil level (see Engine Lubrication System chap-

•

ter).

Oil Filter Change

Drain:

•

Engine oil (see Engine Oil change) Coolant (see Coolant change)

Unscrew the water pipe bolt [A] and pull out the water pipe

•

end [B].

Unscrew the water pump cover bolts [C].

•

Castrol “R4 Superbike” 5W-40 or

API SH or SJ with JASO MA

SAE 10W-30, 10W-40, 10W-50

removed)

1.35 L (1.43 US qt.) (when filter is remove)

1.5 L (1.6 US qt.) (when engine is completely dry)

NOTE

Periodic Maintenance Procedures

Using the pry point [A], remove the water pump cover [B].

•

Remove the oil filter [A].

•

PERIODIC MAINTENANCE 2-25

Replace the oil filter with a new one.

•

Apply grease to the grommet.

•

Be sure to install the filter with the grommet [A] facing

•

inside as shown.

CAUTION

Inside–out installation stop oil flow, causing engine seizure.

Install the spring [A] and dowel pins [B].

•

Replace the pump cover gasket [C] with a new one. Apply grease to the pump cover gasket.

•

Install the water pump cover and water pipe (see Cooling

•

System chapter). Tighten:

•

Apply a non-permanent locking agent to two cover bolts

○

(see Cooling System chapter). Tighten two cover bolt with the washer (see Cooling Sys-

○

tem chapter).

Torque - Water Pump Cover Bolts : 9.8 N·m (1.0 kgf·m, 87

in·lb)

Water Pump Cover Bolts (with washer) : 7.0 N·m

(0.7 kgf·m, 61 in·lb) Coolant Drain Plug : 7.0 N·m (0.7 kgf·m, 61 in·lb) Water Pipe Bolt : 9.8 N·m (1.0 kgf·m, 87 in·lb)

Pour in the specified type and amount of oil (see Engine

•

Oil Change) and coolant (see Cooling System chapter).

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Oil Screen Cleaning

Split the crankcase (see Crankshaft/Transmission chap-

•

ter). Remove the oil screen [A].

•

Clean the oil screens with a high-flash point solvent and

•

remove any particles stuck to them.

WARNING

Clean t he screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent.

Check the screens [A] carefully for any damage, holes,

•

broke wires gasket pulling off. If the screen is damaged, replace it. Install:

•

Oil Screen (see Crankshaft/Transmission chapter) Crankcase (see Crankshaft/Transmission chapter)

Breather Hose Inspection

Be certain that the breather hose are routed without being

•

flattened or kinked and is connected correctly. If it is not, correct it. Inspect the breather hose [A] for damage or sings of de-

•

terioration. This hose should not be hard and brittle, nor should be

○

soft swollen. Replace it i f any cracks or swelling is noticed.

Crankshaft/Transmission

Crankshaft Inspection

Connecting Rod Big End Radial Clearance

Set the crankshaft on V blocks, and place a dial gauge [A]

•

against the connecting rod big end. Push [B] the connecting rod first towards the gauge and

•

then in the opposite direction. The difference between two gauge readings is the radial clearance.

Connecting Rod Big End Radial Clearance

Standard:

Service Limit: 0.06 mm (0.0024 in.)

If the radial clearance exceeds the service limit, crankshaft should be either replaced or disassembled and crankpin, needle bearing, and connecting rod big end examined for wear.

0.002 mm ∼ 0.014 mm (0.00008 ∼ 0.0006 in.)

Periodic Maintenance Procedures

Connecting Rod Big End Side Clearance

Measure the connecting rod big end side clearance [A].

•

Connecting Rod Big End Side Clearance

Standard: 0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.)

Service Limit: 0.55 mm (0.0217 in.)

If the clearance exceeds the service limit, replace the crankshaft assembly.

Crankshaft Runout

Set the crankshaft in a flywheel alignment jig or on V

•

blocks, and place a dial gauge as shown and turn the crankshaft slowly. The maximum difference in gauge reading is the crankshaft runout.

Standard: TIR 0.03 mm (0.0012 in.) or less Service Limit: TIR 0.08 mm (0.0031 in.)

If the runout at either point exceeds the service limit, replace the crankshaft assembly w ith a new one or align the crankshaft so that the runout falls within the service limit.

8 mm (0.354 in.) [A]

PERIODIC MAINTENANCE 2-27

First correct the horizontal m isalignment by striking the

•

projecting crank half [A] with a plastic, soft lead, or brass hammer as shown. Recheck the runout with a dial gauge and repeat the

•

process until the runout falls within the service limit.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Next, correct the vertical misalignment by either driving a

•

wedge [A] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalignment.

CAUTION

Do not hammer the crank half at the point [B].

If flywheel misalignment cannot be corrected by the above method, replace the crankpin or the crankshaft itself.

Connecting Rod Big End Seizure

In case of serious seizure with damaged flywheels, the crankshaft must be replaced. In case of less serious damage, disassemble the crankshaft and replace the crankpin, needle bearing, and connecting rod.

Wheel/Tires

Air Pressure Inspection/Adjustment

Using tire air pressure gauge [A], measure the tire pres-

•

sure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recommended pressure.

Track Condition Tire Pressure

When the track is wet, muddy, sandy or slippery, reduce the tire pressure to increase the tire tread surface on the ground.

When the track is pebbly or hard, increasethetirepressuretoprevent damage or punctures, through the tires will skid more easily.

80 kPa (0.8 kgf/cm²,

11 psi)

↑

↓

100 kPa (1.0 kgf/cm²,

14 psi)

Periodic Maintenance Procedures

Tires Inspection

As the tire tread wears down, the tire becomes more sus-

ceptible the puncture and failure.

Remove any imbedded stones or other foreign particles

•

from the tread. Visually inspect the tire for cracks and cuts, replacing the

•

tire in case of bad damage. Swelling or high spots indicate internal damage, requiring tire replacement.

WARNING

To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.

NOTE

Check and balance the wheel when a tire is replaced

○

with a new one.

Standard Tire

Front:

Size: 80/100-21 51M Make: BRIDESTONE Type :

Rear:

Size: 100/90-19 57M Make: Type :

M601, Tube (EU) M201, Tube

BRIDESTONE M602, Tube (EU) M202, Tube

PERIODIC MAINTENANCE 2-29

Spoke Tightness Inspection

Check that all the spokes are tightened evenly.

•

If spoke tightness is uneven or loose, tighten the spoke nipples evenly.

Torque - Spoke Nipples: 2.2 N·m (0.22 kgf·m, 19 in·lb)

Check the rim runout.

•

WARNING

If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load on the other spokes, which will eventually cause other spokes to break.

2-30 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rim Runout Inspection

Place the jack under the frame so that the front/rear wheel

•

off the ground.

Special Tool - Jack: 57001–1238

Inspect the rim for small cracks, dents, bending, or warp-

•

ing. If there is any damage to the rim, it must be replaced. Set a dial gauge against the side of the rim, and rotate

•

the rim to measure the axial runout [A]. The difference between the highest and lowest dial readings is the amount of runout. Set a dial gauge against the outer circumference of the

•

rim, and rotate the rim to measure radial runout [B]. The difference between the highest and lowest dial readings is the amount of runout. If rim runout exceeds the service limit, check the wheel bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp (runout). A certain amount of rim warp can be corrected by recentering the rim. Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim. If the rim i s badly bent, however, it must be replaced.

Rim Runout (with tire installed)

Standard Service Limit

Axial under 1.0 mm (0.039 in.) 2 mm (0.08 in.)

Radial

Wheel Bearing Inspection

Raise the front/rear wheel off the ground.

•

Special Tool - Jack: 57001–1238

Spin the wheel lightly, and check for roughness, binding

•

or noise. If roughness, binding, abnormal noize is found, replace the hub bearing.

Turn the handlebar until the handlebar doesn’t move to

•

either side. The wheel edge is moved to one direction gripping the

•

edge of the wheel by both hands and the play of the wheel bearing is checked. If the play is found, replace the bearing.

under 1.0 mm (0.039 in.) 2 mm (0.08 in.)

Periodic Maintenance Procedures

Final Drive

Drive Chain Wear Inspection

Rotate the rear wheel to inspect the drive chain for dam-

•

aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.

[A] Bushing [D] Pin Link [B] Roller [E] Roller Link

[C]

Stretch the chain taut by hanging a 98 N (10 kgf, 20 lb)

•

weight [A] on the chain. Measure the length of 20 links [B] on the straight part [C] of

•

the chain from t he pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places.

Chain 20-link Length

Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

Service Limit: 3 23 mm (12.72 in.)

If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced.

PERIODIC MAINTENANCE 2-31

WARNING

If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.

Standard Chain

Make: Type: D.I.D 520DMA2 Link: 114 Links

Drive Chain Lubrication

The chain should be lubricated with a lubricant which will

○

both prevent the exterior from rusting and also absorb shock and reduce friction in t he interior of the chain. If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward s oaked in a heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller. An effective, good quality lubricant specially formulated

•

for chains is best for regular chain lubrication.

DAIDO

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

If a special lubricant is not available, a heavy oil such as

•

SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Apply oil to the sides of the rollers so that oil will penetrate

•

to the rollers and bushings. Wipe off any excess oil.

•

Oilappliedarea[A]

Sprocket Wear Inspection

Visually inspect the front and rear sprocket teeth for wear

•

and damage. If they are worn as illustrated or damaged, replace t he sprocket.

[A] Worn Tooth ( Engine Sprocket) [B] Worn Tooth (Rear Sprocket) [C] Direction of Rotation

Measure the diameter of the sprocket at the base of the

•

teeth. If the sprocket is worn down to less than the service limit, replace the sprocket.

Engine Sprocket Diameter

Standard: 55.48 ∼ 55.68 mm (2.184 ∼ 2.192 in.)/13T

Service Limit: 54.8 mm (2.16 in.)

Rear Sprocket Diameter

Standard:

Service Limit: 232.1 mm (9.138 in.)

If a sprocket requires replacement, the chain is proba-

○

bly worn also. When replacing a sprocket, inspect the chain.

Rear Sprocket Warp Inspection

Using the jack, raise the rear wheel off the ground.

•

Special Tool - Jack: 57001–1238

Set a dial gauge [A] against the rear sprocket [B] near the

•

teeth as shown and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp). If the runout exceeds the service limit, replace the rear sprocket.

232.62 ∼ 233.12 mm (9.158 ∼ 9.178

in.)/48T

NOTE

Rear Sprocket Warp

Standard: Under 0.4 mm (0.016 in.) Service Limit: 0.5 mm (0.020 in.)

Periodic Maintenance Procedures

Brakes

Brake Lever and Pedal Adjustment

WARNING

Always maintain proper brake adjustment. If adjustment is improper, the brake could drag and overheat. This could damage the brake assembly and possibly lock the wheel resulting in loss of control.

Adjust the front brake lever [A] to suit you.

•

Slide the brake lever dust cover [B] out of place.

•

Loosen the adjuster locknut [C] and turn the adjuster [D]

•

to either side. After adjustment, tighten the locknut.

•

PERIODIC MAINTENANCE 2-33

NOTE

Usually it is not necessary to adjust the pedal position,

○

but always adjust it when the master cylinder is disassembled or pedal position is incorrect.

Measure the length indicated in the figure.

•

Length [A]

Standard: 68.5 ± 1 mm (3.09 ± 0.04 in.)

If it is not specified length, the brake pedal may be deformed or incorrectly installed. If it is not within the specified length, adjust the push rod in the master cylinder as following.

Loosen the push rod locknut [A].

○

Replace the cotter pin with a new one.

○

Remove:

○

Cotter Pin [B] Washer Joint Pin [C]

Turn the bracket [D] to obtain the specified length.

○

Tighten the locknut.

○

Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m

(1.7 kgf·m, 12.5 ft·lb)

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake F luid Level Inspection

Check the brake fluid level in the front or rear brake reser-

•

voir [A].

NOTE

Hold the reservoir horizontal when checking brake fluid

○

level.

The front or rear reservoir must be kept above the lower

•

level line [B]. If the fluid level in front or rear reservoir is lower than the

○

lower level line, fill the reservoir to the upper level line. Inside the reservoir is stopped end showing the upper level line [C].

Torque - Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,

13 in·lb)

WARNING

Do not mix two brands of fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter.

Periodic Maintenance Procedures

Brake Fluid C hange

In accordance with the Periodic Maintenance Chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the air quickly and com pletely whenever the brake line parts are removed.

WARNING

When working with the disc brake, observe the pre-

cautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong wind is blowing.

6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and w ill eventually deteriorate t he rubber used in the disc brake.

7. When handing the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.

8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.

9. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM

THE BRAKE LINE.

PERIODIC MAINTENANCE 2-35

Recommended Disc Brake Fluid

Type: Front

Rear

DOT3 or DOT4 DOT4

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

The procedure to change the front brake fluid. Chang-

○

ing the rear brake fluid is the same as for the front brake.

Level the brake fluid reservoir.

•

Remove the screw [A], reservoir cap [B] and diaphragm

•

[C].

Remove the rubber cap [A] on the bleed valve [B].

•

Attach a clear plastic hose [A] to the bleed valve on the

•

caliper, and run the other end of the hose into a container [B].

Change the brake fluid as follows:

•

Repeat this operation until fresh brake fluid comes out

○

from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A]

2. Apply the brake and hold it [B]

3. Close the bleed valve [C]

4. Release the brake [D] Fill the reservoir with fresh specified brake fluid.

○

NOTE

The fluid level must be checked often during the chang-

○

ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line.

Periodic Maintenance Procedures

Remove the clear plastic hose.

•

Tighten the bleed valves, and install the rubber caps.

•

Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)

Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,

13 in·lb)

After changing the fluid, check the brake for good braking

•

power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines (see Brakes chapter).

WARNING

Brake Pad Wear Inspection

Remove the brake pad (see Brake Pad Removal in

•

Brakes chapter). Check the lining thickness and condition of the pads in

•

each caliper. If either pad is damaged, replace both pads in the caliper as a set. If the lining thickness [A] of either pad is less than the service limit [B], replace both pads in the caliper as a set.

PERIODIC MAINTENANCE 2-37

Lining Thickness

Front Rear Standard: 3.8 mm (0.150 in.) 6.4 mm (0.252 in.) Service Limit: 1 mm (0.04 in.) 1 mm (0.04 in.)

Install the brake pad (see Brake Pad Installation in Brakes

•

chapter). Tighten:

•

Torque - Brake Pad Bolt: 18 N·m (1.8 kgf·m, 13 ft·lb)

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Mast er Cylinder Cup and Dust Seal Replacement

Remove the front master cylinder (see Brake chapter).

•

Remove the r eservoir cap and diaphragm, and pour the

•

brake fluid into a container. Unscrew the locknut and pivot bolt, and remove the brake

•

lever. Pull the dust cover [A] out of place, and remove the circlip

•

[B].

Special Tool - Inside Circlip Pliers: 57001–143

Remove the washer [C].

•

Pull out the piston [D], secondary cup [E], primary cup [F],

•

and return spring [G].

CAUTION

Do not remove the secondary cup from the piston since removal will damage it.

Remove the rear master cylinder (see Brake chapter).

•

NOTE

Do not remove the push rod clevis for master cylinder

○

disassembly since removal requires brake pedal position adjustment.

Remove the r eservoir cap and diaphragm, and pour the

•

brake fluid into a container. Slide the dust cover [A] on the push rod [B] out of place,

•

and remove the circlip [C].

Special Tool - Inside Circlip Pliers: 57001–143

Pull out the push rod with the piston stop [D].

•

Take off the piston [E], secondary cup [F], primary cup [G],

•

and return spring [H].

CAUTION

Do not remove the secondary cup from the piston since removal will damage it.

Before assembly, clean all parts including the master

•

cylinder with brake fluid or alcohol.

CAUTION

Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid f or cleaning of these parts, Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.

Periodic Maintenance Procedures

Apply brake fluid to the removed parts and to the inner

•

wall of the cylinder. Take care not to scratch the piston or the inner wall of the

•

cylinder. Apply silicone grease (ex. PBC grease).

•

Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact (Rear) Dust Covers

Tighten:

•

Torque - Brake Lever Pivot Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Caliper Piston Seal and Dust Seal Replacement

Loosen the brake pad pin [A] and banjo bolt [B], and

•

tighten them loosely. Remove:

•

Front Caliper Mounting Bolts [C] Banjo Bolt BrakeHose[E] Front Caliper [D] (see Brakes chapter) Brake Pads (see Brakes chapter)

PERIODIC MAINTENANCE 2-39

Separate the caliper holder [A] from the caliper [B] and

•

remove the anti-rattle spring.

Using compressed air, remove the pistons. One way to

•

remove the pistons is as follows. Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the pistons by lightly applying compressed air [B]

○

to the hose joint opening.

WARNING

To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

2-40 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pull out the piston [A] by hand.

○

Remove the dust seals [B] and fluid seals [C].

•

NOTE

If compressed air is not available, do as follows for both

○

calipers coincidentally, with the brake hose connected to the caliper. Prepare a container for brake fluid, and perform the

○

work above it. Remove the spring and pads (see Brakes chapter)

○

Pump the brake lever until the pistons come out of the

○

cylinders, and then disassembly the caliper.

Remove the rear caliper (see Brakes chapter).

•

Remove the pads (see Brakes chapter).

•

Separate the caliper holder [B] from the caliper [A].

•

Using compressed air, remove the piston.

•

Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the piston by lightly applying compressed air [B]

○

to where the brake line fits into the caliper.

WARNING

To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or finger.

Pull out the piston [A] by hand.

•

Remove the dust seal [B] and fluid seal [C].

•

Clean the caliper parts except for the pads.

•

CAUTION

For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

The bleed valve was removed, install t he bleed valve and

•

rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Periodic Maintenance Procedures

Replace the fluid seal(s) [A] with new ones.

•

Apply brake fluid to the fluid seal(s), and install them into

○

the cylinders by hand. Replace the dust seal(s) [B] with new ones.

•

Apply brake fluid to the dust seal(s), and install them into

○

the cylinder by hand. Apply brake fluid to the outside of the pistons [C], and

•

push them into each cylinder by hand.

PERIODIC MAINTENANCE 2-41

Install the anti-rattle spring [A] in the caliper as shown.

•

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Replace the shaft rubber friction boot [A] and dust boot

•

[B] if they are damaged. Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to

•

the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistance grease).

Install the pads (see Brakes chapter).

•

Install the caliper (see Brakes chapter).

•

Wipe up any spilled brake fluid on the caliper with wet

•

cloth.

Brake Hose and Connection Check

Inspect the brake hose and fittings for deterioration,

•

cracks and signs of leakage. Thehighpressureinsidethebrakelinecancausefluidto

○

leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose i f any cracks [B] or bulges [C] are noticed. Tighten any loose fittings.

BrakeHoseReplacement

CAUTION

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.

When removing the brake hose, take care not to spill the

•

brake fluid on the painted or plastic parts. When removing the brake hose temporarily secure the

•

end of the brake hose to some high place to keep fluid loss to a minimum. Immediately wash away any brake fluid that spills.

•

Periodic Maintenance Procedures

Remove each banjo bolts [A] and washers [B].

•

Replace the washers with new ones.

•

For Front Brake

Remove

•

Bolts [A] BrakeHoseClamps[B]

PERIODIC MAINTENANCE 2-43

For Rear Brake

Remove:

•

Master Cylinder [A] Hose Clamps [B] Caliper Cover [C]

When installing the hoses, avoid sharp bending, kinking,

•

flattening or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. Tighten the banjo bolts on the hose fittings.

•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18.0

ft·lb)

Fill the brake line after installing the brake hose (see

•

Brake Fluid Changing).

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Suspension

Front Fork Inspection

Holding the brake lever, pump the front fork back and forth

•

manually to check f or smooth operation. Visually inspect the front fork for oil leakage, scoring or

•

scratches on the outer surface of the inner tube [A]. If necessary, repair any damage. Nick or rust damage can sometimes be repaired by using

•

a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced. If the fork is not smooth, confirm the cause.

•

CAUTION

If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.

Front Fork Oil Change (each fork leg)

Loosen the front fork upper clamp bolts [A].

•

Loosen the fork top plug [B].

•

Remove:

•

Front Wheel (see Wheels/Tires chapter) Front Brake Cliper (see Brakes chapter) Brake Hose Clamps (see Brake Hose and Connection Check)

Loosen the front fork lower clamp bolts [A].

•

Remove the front fork.

•

With a twisting motion, work the fork leg [B] down and out.

○

Hold the inner tube lower end in a vise.

•

Disassemble the top plug [A] from the outer tube [B].

•

Push the outer tube all the way down away from the top

•

plug and hold it there throughout the following procedure.

Periodic Maintenance Procedures

Use wrenches [A] on the rod nut [B] and the top plug [C]

•

to loosen the top plug. Remove the top plug from the push rod.

•

Lift the fork spring [ D] and its top spring seat [E] out of the

•

outer tube.

Take the rebound damping adjuster rod [A] out of the push

•

rod.

PERIODIC MAINTENANCE 2-45

Hold the fork tube [A] upside down over a clean container

•

[B] and pump it to drain the oil.

NOTE

Pump the push rod up [C] and down to discharge the

○

fork oil.

Hold the fork tube upright, press the outer tube and the

•

push rod all the way down. Insert the rebound damping adjuster rod into the push rod.

•

Fill the specified oil to the outer tube [A].

•

Recommended Oil

KAYABA 01 or SAE 5W Front Fork Oil Capacity

564 ± 4 mL (19.07 ± 0.14 US oz.)

NOTE

While doing this, take care to keep the oil level topped

○

off so that it stays above the two large holes [A] near the top of the inner tube [B].

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Purge the air from the fork cylinder by gently moving the

•

piston rod [A] up and down ten times.

Purge the air from between the inner and outer tubes by

•

pumping the outer tube [A] up and down. After purging the air from the assembly, let it sit for about

•

five minutes so that any suspended air bubbles can surface.

Adjust the oil level.

•

With the fork fully compressed, put the oil level gauge [A]

○

and the stopper [B], and inspect the distance from the top of the inner tube to the oil.

Special Tools - Fork Oil Lev el Gauge: 57001–1290

Oil Level (fully compressed, without spring)

Standard 95 mm (3.7 in.)

Adjustable Range

If no oil is drawn out, there is insufficient oil in the outer tube. Pour in enough oil, then drawn out the excess oil. Install the parts removed (see Front Fork Assembly in

•

Suspension chapter).

Rear Shock Absorber Oil Change

The oil should be changed in the rear shock absorber at least once per racing season. The f requency for best performance must be based upon riding conditions and rider ability.

Remove the rear shock absorber from the frame (see

•

Suspension chapter).

Remove the shock absorber spring (see Suspension

•

chapter).

Point the valve [A] away from you. slowly release nitrogen

•

gas pressure by pushing down the valve core with a screw

driver.

70 ∼ 120 mm (2.8 ∼ 4.7 in.)

Periodic Maintenance Procedures

WARNING

Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure. An oil mist is often released with the nitrogen. Always release nitrogen gas pressure before disassembling the rear shock absorber to prevent explosive separation of parts.

Adjust the gas reservoir damping adjusters [A] to the soft-

•

est position. Remove the air bleeder bolt [B] and pump t he rear shock

•

to drain the oil out the rear shock body. Install the air bleeder bolt.

•

PERIODIC MAINTENANCE 2-47

Using the suitable tool [A] and press, push the reservoir

•

cap[B]in10mm(0.39in.). Remove the circlip [C] from the gas reservoir.

•

Pull the gas reservoir cap [B] out of the gas reservoir using

•

the pliers [A].

Pry or tap [A] at the gaps [B] in the stop [C] with suitable

•

tools to free the stop from the rear shock body [D].

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Slide the stop up the top of the piston rod then lightly tap

•

around the seal with a suitable rod and mallet, and push

the seal assembly 10 mm (0.39 in.) down.

Remove the circlip [A].

•

Lightly move the piston rod back and forth, and pull out

•

thepistonrodassembly.

Pour the oil out of the rear shock body.

•

Visually inspect the piston [A], O-ring [B], and oil seal assy

•

[C].

If the piston, O-ring and oil seal assy are badly scored,

•

rusty or damaged, replace them.

Using the grinder, shave off the stopper portion [A] of the

•

rod.

Remove:

•

Nut [B] Washer [C] Piston [D]

Install the new piston and tighten the locknut.

•

Discard a washer or two.

○

Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the

•

gas reservoir to 60 ∼ 70 mm (2.63 ∼ 2.76 in.) [A] from the

gas reservoir upper end.

Check that the bladder [A] on the gas reservoir cap is not

•

partially collapsed.

If it is, push down the valve core with a screwdriver.

Check the bladder for sign of damage or crack.

•

If necessary, replace it with a new one.

CAUTION

Do not use a damaged or partially collapsed blad-

der, because it may burst, gently reducing rear

shock performance. .

Apply grease to the lip [B] of the bladder and install the

•

reservoir cap [C].

Periodic Maintenance Procedures

Push the bladder into the gas reservoir slowly until it just

•

clears the circlip groove. Wipe out any spilled oil.

CAUTION

Ensure that no air remains in the system.

Check the circlip for weakening, deformity and flaws.

•

If necessary, replace it with a new one.

CAUTION

If weakened, deformed or flawed circlip is used, the gas reservoir cap may not hold when injecting the nitrogen gas. This w ould allow oil and internal parts to explode out of the reservoir.

Mount the circlip [A] in t he groove in the gas reservoir.

•

PERIODIC MAINTENANCE 2-49

Pull up the gas reservoir cap [A] against the circlip. The

•

end of the gas reservoir cap must align [B] with the end of the gas reservoir [C].

WARNING

If the end of the gas reservoir cap and the end of the gas reservoir are not aligned, the circlip is not correctly fitting in the groove in the gas reservoir or is deformed. In this case, the oil and internal parts could explode out of the reservoir when injecting the nitrogen gas or while riding the motorcycle.

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the

•

rear shock body to 55 mm (1.77 in.) [A] from the lower end

of the rear shock body [B].

Insert the piston end [A] of the piston rod assembly into

•

the rear shock body [C] slowly. Do not insert the seal

assembly [B] yet. Pump the piston rod until all the air is

forced out of the rear shock body.

Push the seal assembly into the r ear shock body until it

•

just clears the circlip groove.

Check the circlip.

•

If it is deformed or damaged, replace it with a new one.

Fit the circlip [A] into the groove in the rear shock body

•

[B].

CAUTION

If the circlip is not a certain fit in the groove in the

rear shock body, the piston rod assembly may come

out of the shock absorber when injecting the nitro-

gen gas or riding the motorcycle.

Pull up the piston rod assembly [C] against the circlip.

•

Force the stop [D] into the rear shock body by lightly tap-

•

ping around the edge of the stop with a mallet.

Fully extend the piston rod assembly.

•

Periodic Maintenance Procedures

Install the suitable oil cup [A] to the air bleeder bolt hole,

•

and fill the specified oil into the cup. Purge the air from between the gas reservoir [B] and rear

•

shock body [C] by slowly pumping the push rod [D] i n and out. Install the air bleeder bolt securely.

•

Torque - Air Bleeder Bolt: 6.4 N·m (0.65 kgf·m, 56 in·lb)

Fully extend the push rod assembly.

•

Inject nitrogen gas to a pressure of 50 kPa (0.5 kgf/cm²,

•

7 psi) through the valve on the gas reservoir. Check the rear shock body and gas reservoir for oil and

•

gas leaks. If there are no leaks, inject the nitrogen gas up to the 980 kPa (10 kgf/cm², 142 psi) pressure.

WARNING

Pressurize the gas reservoir with nitrogen gas only. Do not use air or other gases, since they may cause premature wear, rust, fire hazard or substandard performance. High pressure gas is dangerous. Have a qualified mechanic perform this procedure.

PERIODIC MAINTENANCE 2-51

Install the spring and spring guide.

•

Adjust spring preload. Reinstall the rear shock absorber.

•

Install the parts removed.

•

Swingarm and Uni-Trak Linkage Inspection

Check the uni-trak component parts for wear periodically,

•

or whenever excessive play is suspected. Using the jack under the f rame, raise the rear wheel off

•

the ground.

Special Tool - Jack: 57001–1238

Push and pull on the swingarm [A], up and down, to check

•

for wear. A small amount of play on the swingarm is normal and no corrective action is needed. However, if excessive play is felt, remove the uni-trak parts from the frame and check for wear.

Swingarm and Uni-Track Linkage Pivot Lubricate

Refer to t he Swingarm Bearing Installation and Rocker

•

Arm Bearing Installation in Suspension chapter.

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Steering

Steering Inspection

Using the jack, raise the front wheel off the ground.

•

Special Tool - Jack : 57001–1238

With the front wheel pointing straight ahead, alternately

•

nudge each end of the handlebar. The front wheel should

swing fully left and right from the force of gravity until the

fork hits the stop.

If the steering binds or catches before the stop, check the

routing of the cables, hoses, and harnesses.

If the steering feels tight, adjust or lubricate the steering.

Feel for steering looseness by pushing and pulling the

•

forks.

If you feel looseness, adjust the steering.

Steering Adjustment

Using the jack, raise the front wheel off the ground.

•

Special Tool - Jack : 57001–1238

Slide the holder belt [A] out off.

•

Remove Number Plate Bolt [B] and number plate [C]

•

Remove:

•

Handlebar Clamp Bolts [A] Handlebar Clamp [B] Handle Bar [C]

Periodic Maintenance Procedures

Loosen the front fork upper clamp bolts [A], and remove

•

the steering stem head nut [B] and steering stem head [C].

Turn the steering stem locknut [A] with the steering stem

•

nut wrench [B] to obtain the proper adjustment. If the steering is too tight, loosen the stem locknut a fraction of a turn; if the steering is too loose, tighten the locknutafractionofaturn.

Special Tool - Steering Stem Nut Wrench: 57001–1100

NOTE

Turn the locknut 1/8 turn at a time maximum.

○

PERIODIC MAINTENANCE 2-53

Install the steering stem head.

•

Tighten the following:

•

Torque - Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58

ft·lb)

Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,

14.5 ft·lb)

NOTE

Tighten the two clamp bolts alternately two times to en-

○

sure even tightening torque.

Check the steering again.

•

If the steering is too tight or too loose, repeat the adjustment as mentioned above.

Install the handlebar [A] on the handlebar holder as

•

shown.

Same Length [B] Bridge Bar [C]

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Install the handlebar clamp [A] so that the cut side [B] on

•

the clamp points at the front.

Tighten the handlebar clamp bolts [C].

•

Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

Tighten the clamp bolts, rear first and then the front. If

○

the handlebar clamp is correctly installed, there w ill be no

gap at the rear and a gap at the front after tightening.

Install the number plate.

•

Stem Bearing Lubrication

Remove the steering stem (see Steering chapter).

•

Using a high-flash-point solvent, wash the upper and

•

lower tapered rollers in the cages, and wipe the upper

and lower outer races, which are press-fitted into the

frame head pipe, clean off grease and dirt.

Visually check the outer races and the r ollers.

•

Replace the bearing assemblies if they show wear or

damage.

Pack the upper and lower tapered roller bearings [A] in

•

the cages with grease, and apply a light coat of grease to

the upper and lower outer races.

Install the steering stem, and adjust the steering (see

•

Steering chapter).

Frame

Frame Inspection

Clean the frame with steam cleaner.

•

Visually inspect the frame and rear frame for cracks,

•

dents, bending, or warp.

If there is any damage to the frame, replace it.

WARNING

A repaired frame m ay fail in use, possibly causing

an accident. If the frame is bent, dented, cracked,

or warped, replace it.

Electrical System

Spark Plug Cleaning and Inspection

Remove:

•

Seat (see Frame chapter) Fuel Tank (see Fuel System chapter) Spark Plug Cap

Clean the plug hole [A], using the compressed air [B].

•

Periodic Maintenance Procedures

Remove the spark plug [A], using the spark plug wrench

•

[B].

Special Tool - Spark Plug Wrench: 57001–1262

Owner’s Tool - Spark Plug Wrench, 16 mm: 92110–0002

Clean the spark plug, preferably in a sandblasting device,

•

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

Measure the gap [A] with a wire-type thickness gauge.

•

If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

Standard 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)

Install the spark plug.

•

Torque - Spark Plug: 13 N·m (1.3 kgf·m, 9.4 ft·lb)

PERIODIC MAINTENANCE 2-55

Fit the plug cap securely.

•

Pull the spark plug cap [A] to make sure the installation of

○

the spark plug cap.

Cable Inspection

Lubrication

Before lubricating each part, clean off any rusty spots with

•

rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant.

•

NOTE

Whenever the vehicle has been operated under

○

wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication.

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A]

Hot Start Inner Cable Upper End

Throttle Inner Cable Upper End

Cables: Lubricate with Rust Inhibitor.

Throttle Cables

Clutch Cable

Hot Start Cable

With the cable disconnected at the both ends, the cable

•

should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable

is frayed [B], or if the cable housing is kinked [C], replace

the cable.

Periodic Maintenance Procedures

Nut, Bolt, and Fastener Tightness Inspection

Tightness Inspection

Check the tightness of the bolts and nuts listed here in

•

accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition.

NOTE

For the engine fasteners, check the tightness of them

○

when the engine is cold (at room temperature).

If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications. For each fastener, first loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones.

Nut, Bolt and Fastener to be checked

Wheels:

Spoke Nipples Front Axle N ut Front Axle Clamp Bolt Rear Axle Nut Cotter Pin Rear Axle Nut

Final Drive:

Chain Adjuster Locknut Rear Sprocket Nuts

Brakes:

Front Master Cylinder Clamp Bolts Brake Lever Pivot Nut Front Caliper Mounting Bolts Brake Pedal Bolt Rear Brake Joint Cotter Pin Rear Master Cylinder Mounting Bolts Rear Caliper Mounting Bolts

Suspension:

Front Fork Clamp Bolts Front Fender Bolts Rear Shock Absorber Mounting Bolts, Nuts Swingarm Pivot Nut

Steering:

Steering Stem Head Bolt Handlebar Clamp Bolts

Engine:

Throttle Cable Adjuster Lock Nuts Engine Mounting Bolts, Nuts Shift Pedal Bolt Muffler Mounting Bolts Exhaust Pipe Holder Nuts Muffler Clamp Bolt Clutch Cable Adjuster Locknut Clutch Lever Pivot Nut

Others:

Footpeg Cotter Pins Rear Frame Bolts

PERIODIC MAINTENANCE 2-57

FUEL SYSTEM 3-1

Fuel System

Table of Contents

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

Specifications ......................................................................................................................... 3-6

Special Tools .......................................................................................................................... 3-7

Throttle Grip and Cable .......................................................................................................... 3-8

Free Play Inspection ......................................................................................................... 3-8

Free Play Adjustment........................................................................................................ 3-8

Throttle Cable Replacement ............................................................................................. 3-8

Throttle Cable Lubrication ................................................................................................. 3-9

Throttle Cable Inspection .................................................................................................. 3-9

Hot Start Cable Removal .................................................................................................. 3-10

Hot Start Cable Installation ............................................................................................... 3-10

Hot Start Lever Free Play Inspection ................................................................................ 3-11

Hot Start Lever Free Play Adjustment .............................................................................. 3-11

Hot Start Cable Lubrication............................................................................................... 3-11

Hot Start Cable Inspection ................................................................................................ 3-11

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

Idle Speed Inspection ....................................................................................................... 3-12

Idle Speed Adjustment...................................................................................................... 3-12

Service Fuel Level Inspection ........................................................................................... 3-12

Service Fuel Level Adjustment ......................................................................................... 3-13

Carburetor Removal.......................................................................................................... 3-14

Carburetor Installation....................................................................................................... 3-16

Fuel Inspection..................................................................................................................3-17

Carburetor Disassembly ................................................................................................... 3-17

Carburetor Cleaning.......................................................................................................... 3-21

Carburetor Inspection ....................................................................................................... 3-22

Carburetor Assembly ........................................................................................................ 3-23

Air Cleaner.............................................................................................................................. 3-29

Air Cleaner Housing Removal........................................................................................... 3-29

Air Cleaner Housing Installation........................................................................................ 3-29

Element Removal.............................................................................................................. 3-29

Element Installation........................................................................................................... 3-29

Element Cleaning and Inspection ..................................................................................... 3-30

Fuel Tank ................................................................................................................................ 3-31

Fuel Tank Removal ........................................................................................................... 3-31

Fuel Tank Installation ........................................................................................................ 3-31

Fuel Tap Removal ............................................................................................................. 3-32

Fuel Tap Installation .......................................................................................................... 3-32

Fuel Tank and Tap Cleaning ............................................................................................. 3-32

Fuel Tap Inspection........................................................................................................... 3-32

3-2 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-3

No. Fastener

N·m

1 Throttle pulley cover bolt 3.4 0.3 30 in·lb 2 Throttle cable l ocknut 7.0 0.7 61 in·lb

3 Hot start plunger cap bolt 1.0 0.1 10 in·lb

4. Throttle Cables

5. Throttle Grip

6. Carburetor Cap

7. Throttle Valve Plate

8. Throttle Valve

9. Jet Needle

10. Throttle Pulley Shaft

11. Choke Knob

12. Idle Adjusting Screw

13. Pilot Air Screw

14. Slow Jet

15. Main Jet

16. Needle Jet

17. Starter Jet

18. Float

19. Leak Jet

20. Throttle Sensor

21. Hot Start Plunger

22. Acceleration Pump Diaphragm

23. Slow Air Jet O: Apply 2 stroke oil. G: Apply grease.

L: Apply a non-permanent locking agent.

Torque

kgf·m ft·lb

Remarks

3-4 FUEL SYSTEM

Exploded View

FUEL SYSTEM 3-5

No. Fastener

N·m

1 Rear frame mounting bolts 34 3.5 25 2 Air cleaner duct clamp screw 2.0 0.2 17 in·lb

3 Fuel tap plate mounting screws 0.8 0.08 7in·lb

4. Fuel Tank Cap

5. Fuel Tank

6. Fuel Tap

7. Element

8. Frame

9. Holder

10. Air Cleaner Duct

11. Air Cleaner Housing

12. Rear Frame G: Apply grease. O: High-quality foam-air-filter oil.

Torque

kgf·m ft·lb

Remarks

3-6 FUEL SYSTEM

Specifications

Item

Carburetor:

Make/Type KEIHIN FCR37

Starter Jet #68 ---

Leak Jet #60 ---

Main jet #178 ---

Throttle valve cutaway #1.5 ---

Jet needle OBEKS ---

Jet needle clip position 3rd groove from the top ---

Slow jet #40 ---

Slow Air Jet #100 ---

Pilot Air Screw (turns out) 21/4 ---

Service fuel level 6.5 ± 1 mm (0.256 ± 0.039 in.) ---

(above the bottom edge of the carb. body)

Float height 8 ± 1 mm (0.315 ± 0.039 in.) ---

Standard

Service Limit

KX250-N1

---

Special Tools

Fuel Level Gauge, M18 × 1.0 : 57001-122

FUEL SYSTEM 3-7

3-8 FUEL SYSTEM

Throttle Grip and Cable

If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle response. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed w ill be erratic. Check the throttle grip play periodically in accordance w ith the Periodic Maintenance Chart, and adjust the play if necessary.

The throttle cable routing is shown in Cable, Wire, and Hose Routing in the Appendix chapter.

Free Play Inspection

Refer to the Throttle Grip Free Play Inspection in Periodic

•

Maintenance chapter.

Free Play Adjustment

Refer to the Throttle Grip Free Play Adjustment in Periodic

•

Maintenance chapter.

Throttle Cable Replacement

Remove the front master cylinder [A] (see Brakes chap-

•

ter).

Slide out the dust cover [B].

•

Pull out the cable housing dust cover [C].

•

Unscrew the screws [A].

•

Separate the throttle cable housing [B].

•

Freethetips[A]fromthegrip[B].

•

Throttle Grip and Cable

Remove the r ear frame assy (see Frame c hapter).

•

Remove the carburetor and move it to the right side of the

•

frame. Unscrew the bolt [A].

•

Remove the throttle pulley cover [B].

•

Loosen the locknuts [A].

•

Remove the cables [B] from the carburetor.

•

Free the tips [C] from the pulley.

•

Pull out the cables from the frame.

•

FUEL SYSTEM 3-9

Lubricate the cable.

•

Apply grease to the tips of the cables.

•

Install the throttle cable lower end as shown.

•

Turn out the locknut [A] fully.

○

Install the cable tips [B].

○

Set the outer cable ends [C] to the holder.

○

Turn the adjuster [D] until the cable is extend.

○

Install the throttle pulley cover.

•

Torque - Throttle Cable Locknut: 7.0 N·m (0.7 kgf·m, 61

ft·lb)

Throttle Pulley Cover Bolt: 3.4 N ·m (0.3 kgf·m, 30

in·lb)

Install the throttle cable in accordance with the Cable,

•

Wire, and Hose Routing section in the Appendix chapter. After the installation, adjust each cable properly.

•

WARNING

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

Throttle Cable Lubrication

Whenever the throttle cable is removed or in accordance

•

with the Periodic Maintenance Chart, lubricate the these cables, Refer to General Lubrication in the Periodic Maintenance Chapter. Apply a thin coating of grease to the cable upper or lower

○

ends. Use a comm ercially available pressure cable lubricator to

○

lubricate these cables.

Throttle Cable Inspection

Refer to the Cable Inspection in the Periodic Maintenance

•

chapter.

3-10 FUEL SYSTEM

Throttle Grip and Cable

Hot Start C able Removal

Remove:

•

Dust Cover [A] (Slide out) Locknut [B] (Loosen)

Turn in the adjuster [C] fully.

•

Remove the cable end [D] from the hot start lever [E].

•

Remove:

•

Carburetor (Inlet side out )

Unscrew the plunger cap bolt [A] and remove the cable

•

end.

Cut the band [B].

•

Disassemble the cable end from the plunger [A].

•

Spring [B] Plunger Cap Assy [C]

Remove:

•

Left Radiator Shround (see Fuel Tank R emoval) Clamps [A] (Open) Hot Start Cable [B]

Hot Start Cable Installation

Torque - Hot Start Plunger Cap Bolt: 1.0 N ·m (0.1 kgf·m, 10

in·lb)

Install the hot start cable in accordance with the Cable,

•

Wire and Hose Routing section in the appendix chapter.

After the installation, adjust the cable properly.

•

WARNING

Operation with an incorrectly routed or improperly

adjusted cable could result in an unsafe riding con-

dition.

Throttle Grip and Cable

Hot Start Lever Free Play Inspection

Refer to the Hot Start Lever Free Play Inspection in Peri-

•

odic Maintenance

Hot Start Lever Free Play Adjustment

Refer to the Hot Start Lever Free Play Inspection in Peri-

•

odic Maintenance

Hot Start Cable Lubrication

Whenever the hot start cable is removed or in accordance

•

with the Periodic Maintenance Chart, lubricate the these cable. Refer t o General Lubrication in the Periodic Maintenance Chapter.

Hot Start Cable Inspection

Refer to the Cable Inspection in Periodic Maintenance

•

FUEL SYSTEM 3-11

3-12 FUEL SYSTEM

Carburetor

Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carburetor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber. A dirty or damaged air cleaner can also alter the fuel to air ratio.

Idle Speed Inspection

Refer to the Idle Speed Inspection in Periodic Mainte-

•

nance chapter.

Idle Speed Adjustment

Refer to the Idle Speed Adjustment in Periodic Mainte-

•

nance chapter.

Service Fuel Level Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Always stop the

engine and do not smoke. Make sure the area is

well ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Turn the fuel tap to the OFF position.

•

Remove the fuel tank.

•

Remove the carburetor, and hold it in true vertical position

•

on a stand. The fuel hose and carburetor cable do not

have to be removed to inspect the fuel level [A].

Put the fuel tank on a bench, and connect the fuel tap to

•

the carburetor using a suitable hose.

Remove the drain plug from the bottom of the float bowl,

•

and screw a fuel level gauge [B] into the plug hole.

Special Tools - Fuel Level Gauge: 57001–122

Carburetor

Hold the gauge vertically against the side of the carbure-

•

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

•

carburetor. Wait until the fuel level in the gauge settles.

•

Keeping the gauge vertical, slowly lower the gauge until

•

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

NOTE

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

○

the carburetor body. If the gauge is lowered and then raised again, the fuel level measure shows somewhat higher than the actual fuel level. If the gauge is lowered too far, dump the fuel out of it into a suitable container and start the procedure over again.

Read the fuel level in the gauge and compare it to the

•

specification.

FUEL SYSTEM 3-13

Service Fuel Level (above the bottom edge of the carb. body)

Standard: 6.5 ± 1 mm (0.256 ± 0.039 in.)

If the fuel level is incorrect, adjust it. Turn the fuel tap to the OFF position and remove the fuel

•

level gauge. Install the drain plug on the bottom of the float bowl.

•

Service Fuel Level Adjustment

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

Remove the carburetor, and drain the fuel into a suitable

•

container. Remove the float bowl (see Carburetor Disassembly).

•

Drive out the pivot pin [A] and remove the float [B] with

•

valve needle [C].

3-14 FUEL SYSTEM

Carburetor

Bend the tang [A] on the float arm very slightly to change

•

the float height. Increasing the float height lowers the fuel

level and decreasing the float height raises the fuel level.

Float Height

Standard: 8 ± 1 mm (0.315 ± 0.039 in.)

NOTE

Float height [A] is the distance from the float bowl mat-

○

ing surface [B] of the carburetor body (with the gasket removed) to the top of the float [C]. Measure the height with the carburetor upside down. Do not push the needle rod [D] in during the float height

○

measurement.

Assemble the carburetor, and recheck the fuel level.

•

If the fuel level cannot be adjusted by this method, the

float or the float valve is damaged.

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Always stop the

engine and do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Turn the fuel tap lever [A] to the OFF position.

•

Slid off the clam p [C] and pull the fuel hose [B] off the tap.

○

Carburetor

Disconnect the throttle sensor connector [A].

•

Loosen the clamp screws [A], and remove the carburetor

•

from the carburetor holder [B] and then pull it out of the end of the air cleaner duct [C].

FUEL SYSTEM 3-15

If necessary, do the following procedure. Remove:

•

Seat Side Covers Silencer Rear Frame Bolt [A]

Pull out the rear frame [B] with the air cleaner housing and

•

remove the carburetor.

Unscrew the hot start plunger cap bolt [A].

•

Remove the hot start plunger.

•

Unscrew the throttle pulley cover bolt [A].

•

Remove the throttle pulley cover [B].

•

3-16 FUEL SYSTEM

Carburetor

Loosen the locknut [A].

•

Pull out the end of the throttle cables [B].

•

Free the tips [C].

•

Remove the carburetor right side of the frame.

•

Drain the fuel from the float bowl by removing the drain

•

plug. After draining, install the drain plug securely.

After removing the carburetor, push a clean, lint-free towel

•

into the carburetor holder and the air cleaner duct to keep

dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the

carburetor, the throttle may become stuck, possibly

causing an accident.

CAUTION

If dirt gets through into the engine, excessive en-

gine wear and possibly engine damage will occur.

Carburetor Installation

Install:

•

Throttle Cables (see this chapter) Hot Start Plunger (see this chapter)

Tighten:

•

Torque - Carburetor Throttle Pulley Cover Bolt: 3.4 N·m

(0.3 kgf·m, 30 in·lb)

Throttle Cable Locknuts: 7.0 N·m (0.7 kgf·m, 61

in·lb)

When installing the carburetor into the carburetor holder,

•

fit the projection [A] of the carburetor with the groove [B]

on the holder.

Fit the claw [C] of the clamp onto the groove [D] of the

○

inlet duct.

Tighten the clamps securely.

•

Torque - Carburetor Holdi ng Clamp Screw : 2.0 N·m (0.2

kgf·m, 17 in·lb)

Carburetor

Route the air vent and overflow hoses properly (see Ap-

•

pendix chapter).

CAUTION

Always keep the hoses free of obstruction, and make sure they do not get pinched by the chain or shock absorber.

Connect the throttle sensor connector.

•

After installing the carburetor, do the following.

•

Turn the fuel tap to the ON position, and check for fuel

○

leakage from the carburetor.

WARNING

Fuel spilled from the carburetor is hazardous.

Adjust the following items if necessary:

○

Throttle Cable Idle Speed (see Periodic Maintenance chapter)

Fuel Inspection

FUEL SYSTEM 3-17

WARNING

Turn the fuel tap to the OFF position.

•

Remove the carburetor (see Carburetor Removal).

•

Place a suitable container beneath the carburetor.

•

Remove the drain plug [A] from the bottom of the float

•

bowl and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor, fuel tap and fuel tank (see this chapter). Install the drain plug on the float bowl, and tighten it se-

•

curely. Install the carburetor.

•

Carburetor Disassembly

Remove the carburetor.

•

Remove all vent hoses [A].

•

3-18 FUEL SYSTEM

Carburetor

Unscrew the screw [A].

•

Pull out the fuel hose fitting [B].

•

Unscrew the carburetor cap bolts [A].

•

Remove the carburetor cap [B].

•

Unscrew the throttle valve link screw [A].

•

Pull out the throttle valve assembly [B].

•

Disassemble the throttle valve assembly; jet needle

•

holder [A] (unscrew), spring [B], retainer [C], jet needle

with circlip [D], O-ring with throttle valve plate [E] and

throttle valve [F].

Remove the choke knob/starter plunger assembly [A]

•

from the carburetor.

Carburetor

Remove the throttle pulley shaft [A] with the spring [B],

•

steel washer [C], plastic washer [D] and throttle valve link [E].

Turn the throttle pulley shaft [A] clockwise while holding

○

down the acceleration pump lever [B] and clear the idle stop screw [C] to the stopper [D] of the pulley.

FUEL SYSTEM 3-19

Turn in the pilot air screw [A] fully but not tightly and count

•

the number of turns. Record this number as the manufacture-set number of

○

turns out. Unscrew the pilot air screw.

•

Unscrew the screws [A].

•

Remove the acceleration pump cover [B] from the carbu-

•

retor.

Remove the spring [A], diaphragm [B], and the O-ring [C].

•

3-20 FUEL SYSTEM

Carburetor

Remove the following parts from the carburetor body.

•

[A] Idle Adjusting Screw [B] Screws [C] Clamps [D] Float Bowl [E] Leak Jet [F] O-ring [G] Pin [H] Float [I] Main Jet [J] Needle Jet [K] Starter Jet [L] Pilot Jet [M]PilotAirJet [N] Stopper Screw [O] Fuel Hose Fitting [P] O-rings

Pull out the push rod [A] of the acceleration pump.

•

Unscrew the leak jet [A].

•

Remove:

•

E-clip [A] Washer [B]

Pull out the acceleration pump lever assembly [C] as a

•

set.

Carburetor

Remove the throttle sensor mounting bolt [A].

•

Before removing the throttle sensor [B], mark [C] the car-

•

buretor body and sensor so that it can be installed later in the same position.

Carburetor Cleaning

WARNING

Clean the carburetor in a well-ventilated area, and take care that there is no spark or f lame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash

-point solvent to clean the carburetor.

FUEL SYSTEM 3-21

Make sure the fuel tap is in the OFF position.

•

Remove the carburetor (see Carburetor Removal).

•

Drain the fuel in the carburetor.

•

Disassemble the carburetor (see this chapter).

•

CAUTION

Do not use compressed air on an assembled carburetor, the float may be deformed by the pressure. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. Do not use a strong carburetor cleaning solution which could attack the plastic parts; instead, use a mild high flash-point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

Immerse all the metal parts in a carburetor cleaning solu-

•

tion. Rinse the parts in water.

•

After the parts are cleaned, dry them with compressed air.

•

Blow through the air and fuel passages with compressed

•

air [A]. Assemble the carburetor, and install it on the motorcycle.

•

3-22 FUEL SYSTEM

Carburetor

Carburetor Inspection

WARNING

Gasoline is extremely flammable and can be ex-

plosive under certain conditions. Always stop the

engine and do not smoke. Make sure the area is

well-ventilated and free from any source of flame

or sparks; this includes any appliance with a pilot

light.

Remove the carburetor.

•

Before disassembling the carburetor, check the fuel level

•

(see Fuel Level Inspection).

If the fuel level is incorrect, inspect the rest of the carbu-

retor before correcting it.

Turn the throttle pulley to check that the throttle valve [A]

•

moves smoothly and returns by spring pressure.

If the throttle valve does not move smoothly. Replace the

throttle valve or pulley spring.

Disassemble the carburetor.

•

Clean the carburetor.

•

Check the O-rings on the float bowl, pilot screw, and throt-

•

tle sensor are in good condition.

If any of the O-rings are not in good condition, replace

them.

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

•

wear or damage.

If the pilot screw is worn or damaged on the tapered por-

tion , it will prevent the engine from idling smoothly. Re-

place it.

Remove the float valve needle.

•

Check the plastic tip [A] of the float valve needle [B] for

•

wear.

If the needle is worn as shown right [C], replace the valve

needle.

Push the rod [D] in the valve needle, then release it.

•

If the rod does not come out fully by spring tension, re-

place the valve needle.

Push and release [E]

Carburetor

Remove the starter jet.

•

Check the slow jet for any damage.

•

If the slow jet is damaged, replace it with a new one. Remove the throttle valve and jet needle.

•

Inspect the outside of the throttle valve and plate for

•

scratches and abnormal wear. If it is badly scratched or worn, replace the throttle valve or plate. Inspect the inside of the carburetor body for these same

•

faults. If it is badly scratched or worn, replace the entire carburetor. Check the jet needle for wear.

•

For the throttle sensor inspection, see the Electrical Sys-

•

tem chapter. A worn jet needle should be replaced. Clean the fuel and air passages with a high flash-point

•

solvent and compressed air.

Carburetor Assembly

Clean the disassembly parts before assembling.

•

Clean the fuel and air passages with a high flash-point

○

solvent and compressed air [A].

FUEL SYSTEM 3-23

Set up the acceleration pump lever assembly as shown.

•

Acceleration pump lever [A] Spring [B] Push Rod Holder [C] Adjusting Screw with Spring [D]

Fit the spring end on the stopper [E] of the push rod

○

holder.

Install the return spring [A] to the acceleration pump lever

•

[B].

Kawasaki KX250F (2004) User Manual [ru]

Specifications and Main Features

Frequently Asked Questions

User Manual

LIST OF ABBREVIATIONS

Foreword

General Information

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

Tightening Sequence

Tightening Torque

Force

Liquid Gasket, Locking Agent

Press

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

Lubrication

Direction of Engine Rotation

Electrical Wires

KX250–N1 Left Side View

KX250–N1 Right Side View

Prefixes for Units:

Units of Mass:

Units of Volume:

Units of Length:

Units of Torque:

Units of Pressure:

Units of Speed:

Units of Force:

Units of Temperature:

Units of Power:

Periodic Maintenance

Basic Torque for General Fasteners

Fuel System

Fuel Hose and Connection Inspection

Throttle Grip Free Play Inspection

Throttle Grip Free Play

Throttle Grip Free Play Adjustment

Hot Start Lever Free Play Inspection

Hot Start Le ver Free Play

Idle Speed Inspection

Idle Speed:

Idle Speed Adjustment

Air Cleaner Element Cleaning and Inspection

Cooling System

Coolant Level Inspection

Coolant Deterioration Inspection

Radiator Hoses and Connections Inspection

Engine Top End

Valve Clearance Inspection

Valve clearance: between cam and valve lifter

Valve Clearance Adjustment

Example:

Adjustment shims

Cylinder Head Warp Inspection

Cylinder Head Warp

Cylinder Wear Inspection

Cylinder Inside Diameter

Piston/Cylinder Clearance

Piston/Cylinder Clearance

Piston, Piston R ing and Piston Pin Replacement

Exhaust System

Silencer Packing Change

Engine Right Side

Clutch Adjustment

Clutch Lever Free Play

Friction and Steel Plates Inspection

Friction Plate Thickness

Steel Plate Thickness

Friction and Steel Plates Warp

Engine Lubrication System

Engine Oil Change

Recommended Engine