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.
© 2003 Kawasaki Heavy Industries, Ltd. Second Edition (1) : Jan. 16 2004 (K)
LIST OF ABBREVIATIONS
A
ABDC after bottom dead center m meter(s)
AC
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
DC
F farad(s) TDC top dead center
°F degree(s) Fahrenheit
ft foot, feet V volt(s)
g
h hour(s) Ω ohm(s)
kg
kgf (force)
L
ampere(s)
alternating current min
direct current
gram(s) (mass)
(mass)
liter(s)
lb
Pa
psi
r/min, rpm revolution(s) per minute
TIR total indicator reading
W
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
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
2
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
E
Cylinder head, cylinder – inspect
N
Piston pin – replace
G
I
Valve clearance – inspect †
N
Hot start – adjust
E
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
C
Brake master cylinder cup and dust seal – replace Every 2 years 2-38
H
Brake caliper piston seal and dust seal – replace Every 2 years 2-39
A
Brake hoses and pipe – replace Every 4 years 2-42
S
S
Brake hoses, connections - inspect †
I
Spoke tightness and rim runout – inspect †
S
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
2-20
2-20
2-17
2-12
2-24
2-21
2-21
—
2-32
2-15
2-16
2-26
2-26
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
2-44
2-46
2-55
2-11
2-52
2-54
2-51
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
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)
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
S
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].
•
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