Kawasaki KX250F (2004) User Manual [ru]

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KX250F

Motorcycle

Service Manual

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Quick Reference Guide

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

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

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

General Information	1	j
Periodic Maintenance	2	j
Fuel System	3	j
Cooling System	4	j
Engine Top End	5	j
Engine Right Side	6	j
Engine Lubrication System	7	j
Engine Removal/Installation	8	j
Crankshaft/Transmission	9	j
Wheels/Tires	10	j
Final Drive	11	j
Brakes	12	j
Suspension	13	j
Steering	14	j
Frame	15	j
Electrical System	16	j
Appendix	17	j

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KX250F

Motorcycle

Service Manual

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

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

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

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

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© 2003 Kawasaki Heavy Industries, Ltd.

Second Edition (1) : Jan. 16 2004 (K)

LIST OF ABBREVIATIONS

A	ampere(s)	lb	pound(s)
ABDC	after bottom dead center	m	meter(s)
AC	alternating current	min	minute(s)
ATDC	after top dead center	N	newton(s)
BBDC	before bottom dead center	Pa	pascal(s)
BDC	bottom dead center	PS	horsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	r/min, rpm	revolution(s) per minute
F	farad(s)	TDC	top dead center
°F	degree(s) Fahrenheit	TIR	total indicator reading
ft	foot, feet	V	volt(s)
g	gram(s) (mass)	W	watt(s)
h	hour(s)	Ω	ohm(s)
kg	(mass)
kgf	(force)
L	liter(s)

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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 Maintenance Chart in the

•Service Manual.

Be alert for problems and non-scheduled

•maintenance.

Use proper tools and genuine Kawasaki Motorcycle 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 maintenance 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 personal injury, or loss of life.

CAUTION

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

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

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NOTE

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

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

also precedes the text of a NOTE.

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

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

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GENERAL INFORMATION 1-1

General Information	1
Table of Contents
Before Servicing .....................................................................................................................	1-2
Model Identification.................................................................................................................	1-7
General Specifications............................................................................................................	1-8
Unit Conversion Table ............................................................................................................	1-10

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1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Edges of Parts

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

Solvent

Use a high flush point solvent when 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.

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GENERAL INFORMATION 1-3

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.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. 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 to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

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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, Oring

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.

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GENERAL INFORMATION 1-5

Before Servicing

Ball Bearing and Needle Bearing

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

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

Oil Seal, Grease Seal

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.

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).

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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.

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GENERAL INFORMATION 1-7

Model Identification

KX250–N1 Left Side View

KX250–N1 Right Side View

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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, DOHC 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 PS) @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			BTDC 8° @ 2 000 r/min (rpm)
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			API SH or SJ with JASO MA
Viscosity			SAE 10W-40
Capacity			1.5 L (1.6 USqt)
Drive Train:
Primary reduction system:			Gear
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Reduction ratio			3.350 (67/20)
Clutch type			Wet, multi disc

GENERAL INFORMATION 1-9

General Specifications

Items		KX250–N1
Transmission:
Type		5-speed, constant mesh, return shift
Gear ratios:	1st	2.142 (30/14)
	2nd	1.785 (25/14)
	3rd	1.444 (26/18)
	4th	1.200 (24/20)
Final drive system:	5th	1.052 (20/19)
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
	Make/Type	BRIDGESTONE M601 (EU, M201) Tube type
Rear tire:	Size	100/90-19 57M
	Make/Type	BRIDGESTONE M602 (EU, M202) Tube type
Front suspension:	Type	Telescopic fork (up side down)
	Wheel travel	300 mm (11.8 in.)
Rear suspension:	Type	Swingarm (New Uni-trak)
	Wheel travel	310 mm (12.2 in.)
Brake type:	Front and Rear	Single disc
Effective disc diameter:
	Front (effect. dia.)	225 mm (8.86 in.)
	Rear (effect. dia.)	215 mm (8.46 in.)
EU: European Model
Specifications are subject to change without notice, and may not apply to every country.

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1-10 GENERAL INFORMATION

Unit Conversion Table

Prefixes for Units:

Units of Length:

km

×

0.6214

=

mile

Prefix

Symbol

Power

m

×

3.281

=

ft

mega

M

× 1 000 000

mm

×

0.03937

=

in

kilo

k

×

1 000

centi

c

×

0.01

milli

m

×

0.001

Units of Torque:

micro

µ

× 0.000001

N·m

×

0.1020

=

kgf·m

N·m

×

0.7376

=

ft·lb

Units of Mass:

N·m

×

8.851

=

in·lb

kgf·m

×

9.807

=

N·m

kg

×

2.205

=

lb

kgf·m

×

7.233

=

ft·lb

g

×

0.03527

=

oz

kgf·m

×

86.80

=

in·lb

Units of Volume:

Units of Pressure:

L

×

0.2642

=

gal (US)

kPa

×

0.01020

=

kgf/cm²

L

×

0.2200

=

gal (imp)

kPa

×

0.1450

=

psi

L

×

1.057

=

qt (US)

kPa

×

0.7501

=

cm Hg

L

×

0.8799

=

qt (imp)

kgf/cm²

×

98.07

=

kPa

L

×

2.113

=

pint (US)

kgf/cm²

×

14.22

=

psi

L

×

1.816

=

pint (imp)

cm Hg

×

1.333

=

kPa

mL

×

0.03381

=

oz (US)

mL

×

0.02816

=

oz (imp)

mL

×

0.06102

=

cu in

Units of Speed:

km/h

×

0.6214

=

mph

Units of Force:

N

×

0.1020

=

kgf

Units of Power:

N

×

0.2248

=

lb

kgf

×

9.807

=

N

kW

×

1.360

=

PS

kgf

×

2.205

=

lb

kW

×

1.341

=

HP

PS

×

0.7355

=

kW

PS

×

0.9863

=

HP

Units of Temperature:

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PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents	2

Periodic Maintenance Chart ..............		2-2	Tires Inspection............................		2-29
Torque and Locking Agent.................		2-4	Spoke Tightness Inspection.........		2-29
Specifications ....................................		2-8	Rim Runout Inspection.................		2-30
Special Tools .....................................		2-10	Wheel Bearing Inspection ............		2-30
Periodic Maintenance Procedures.....		2-11	Final Drive.......................................		2-31
Fuel System....................................		2-11	Drive Chain Wear Inspection .......		2-31
Fuel Hose and Connection			Drive Chain Lubrication................		2-31
Inspection..................................		2-11	Sprocket Wear Inspection............		2-32
Throttle Grip Free Play Inspection		2-11	Rear Sprocket Warp Inspection ...		2-32
Throttle Grip Free Play			Brakes.............................................		2-33
Adjustment ................................		2-11	Brake Lever and Pedal
Hot Start Lever Free Play			Adjustment ................................		2-33
Inspection..................................		2-12	Brake Fluid Level Inspection........		2-34
Idle Speed Inspection ..................		2-12	Brake Fluid Change .....................		2-35
Idle Speed Adjustment.................		2-13	Brake Pad Wear Inspection .........		2-37
Air Cleaner Element Cleaning and			Brake Master Cylinder Cup and
Inspection..................................		2-13	Dust Seal Replacement ............		2-38
Cooling System...............................		2-15	Caliper Piston Seal and Dust Seal
Coolant Level Inspection..............		2-15	Replacement.............................		2-39
Coolant Deterioration Inspection..		2-16	Brake Hose and Connection
Radiator Hoses and Connections			Check ........................................		2-42
Inspection..................................		2-16	Brake Hose Replacement............		2-42
Engine Top End ..............................		2-17	Suspension.....................................		2-44
Valve Clearance Inspection .........		2-17	Front Fork Inspection ...................		2-44
Valve Clearance Adjustment........		2-17	Front Fork Oil Change (each fork
Cylinder Head Warp Inspection ...		2-19	leg) ............................................		2-44
Cylinder Wear Inspection.............		2-20	Rear Shock Absorber Oil Change		2-46
Piston/Cylinder Clearance ...........		2-20	Swingarm and Uni-Trak Linkage
Piston, Piston Ring and Piston			Inspection..................................		2-51
Pin Replacement.......................		2-20	Swingarm and Uni-Track Linkage
Exhaust System ...........................		2-21	Pivot Lubricate ..........................		2-51
Silencer Packing Change.............		2-21	Steering ..........................................		2-52
Engine Right Side...........................		2-22	Steering Inspection ......................		2-52
Clutch Adjustment........................		2-22	Steering Adjustment ....................		2-52
Friction and Steel Plates			Stem Bearing Lubrication.............		2-54
Inspection..................................		2-23	Frame .............................................		2-54
Engine Lubrication System .............		2-23	Frame Inspection .........................		2-54
Engine Oil Change.......................		2-23	Electrical System ............................		2-54
Oil Filter Change ..........................		2-24	Spark Plug Cleaning and
Oil Screen Cleaning .....................		2-26	Inspection..................................		2-54
Breather Hose Inspection ............		2-26	Cable Inspection.............................		2-55
Crankshaft/Transmission ................		2-26	Lubrication ...................................		2-55
Crankshaft Inspection ..................		2-26	Nut, Bolt, and Fastener Tightness
Wheel/Tires	http://manuals.magnamaniac.com				2-57
		2-28	Inspection	.....................................
Air Pressure			Tightness Inspection ....................		2-57
Inspection/Adjustment...............		2-28

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart to 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 †		•					2-54
	Clutch – adjust			•				2-22
	Clutch and friction plates - inspect †		•			R		2-23
	Throttle cable – adjust		•					2-11
	Air cleaner element – clean							2-13
	Air cleaner element – replace		•	If damaged				2-13
	Carburetor – inspect and adjust					•		2-12
	Engine Oil – change					•		2-23
E	Piston and piston ring – replace							2-20
	Cylinder head, cylinder – inspect					•		2-20
N
G	Piston pin – replace						•	2-20
I	Valve clearance – inspect †					•		2-17
N
E	Hot start – adjust		•			•		2-12
	Oil filter – replace		•					2-24
	Silencer – clean and inspect†					•		2-21
	Silencer packing – change		•					2-21
	Kick pedal and shift pedal – clean		•					—
	Engine sprocket – inspect †		•					2-32
	Coolant – check †		•					2-15
	Radiator hoses and connections – inspect †					•		2-16
	Crankshaft – inspect					•		2-26
	Oil screen – clean		•					2-26
	Breather hose – inspect		•					2-26
	Brake adjustment – inspect †		•					2-33
	Brake pad wear – inspect †		•					2-37
	Brake fluid level – inspect †							2-34
C	Brake fluid – change			Every 2 years				2-35
	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
S	Brake hoses and pipe – replace		•	Every 4 years				2-42
S	Brake hoses, connections - inspect †							2-42
I
	Spoke tightness and rim runout – inspect †		•					2-29
S
			•
	Wheel bearing – inspect †		•					2-30
	Frame – inspect							2-54
	Drive chain wear – inspect †		•					2-31
			•	.com
	Wheels/tires – inspect	http://manuals.magnamaniac						2-28
			•
	Rear sprocket – inspect †							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				•		2-44
	Front fork oil – change				•		2-44
	Rear shock oil – replace		•				2-46
	Cable – inspect						2-55
	Fuel hose – replace		•	Every 4 years			2-11
	Fuel hose, connections - inspect †		•				2-11
	Steering play – inspect †				•		2-52
	Steering stem bearing – grease			•			2-54
	Swingarm and Uni-Trak linkage pivots – grease			•			2-51
	Swingarm and Uni-Trak linkage pivots – inspect †						2-51
	Nuts, bolts, fasteners – inspect †		•				2-57
†: Replace, add, adjust, clean or torque if necessary.
R: Replace

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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 the 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 two 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			Torque			Remarks
		N·m	kgf·m	ft·lb
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	7 in·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		9.8	1.0	87	in·lb
Rear Camshaft Chain Guide Bolt		15	1.5		11
Exhaust Pipe Stud		–	–		–	L
http://manuals.		magnamaniac	.com			(Planted
						side)
Chain Tensioner Mounting Bolts		9.8	1.0	87	in·lb
Chain Tensioner Cap		20	2.0	14.5

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

	Fastener				Torque			Remarks
			N·m	kgf·m		ft·lb
	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		98		10		72	Lh
	Shift Drum Cam Bolt		24		2.4		17	L
	Clutch Spring Bolts		9.8		1.0	87	in·lb
	Clutch Hub Nut		98		10		72
	Gear Set Lever Nut		8.8		0.9	78	in·lb
	Gear Set Lever Pivot Stud		–		–		–	L
								(Planted
								Side)
	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		9.8		1.0	87	in·lb	L (1)
	Water Pump Cover Bolt (with washer)		7.0		0.7	61	in·lb	L (1)
	Right Engine Cover Bolts		9.8		1.0	87	in·lb
	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:
		http://manuals.magnamaniac.com
	Breather Fitting		15		1.5		11	L
	Reed Valve Screws		7.0		0.7	61	in·lb

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener				Torque				Remarks
			N·m	kgf·m		ft·lb
Piston Oil Nozzle			2.5	0.25		22	in·lb	L
Crankcase Bolts			9.8	1.0		87	in·lb	S
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 Bearing 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
			than 2.2	than 0.22		than 19 in·lb
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 Cylinder 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:			20	2.0		14.5		AL
Front Fork Clamp Bolts (Upper, Lower)
	http://manuals		.magnamaniac	.com
Front Fork Cylinder Valve Assembly			54	5.5			40	L
Front Fork Top Plug			29	3.0			22

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Fastener			Torque			Remarks
		N·m	kgf·m	ft·lb
Push Rod Nut		28	2.85	20.6
Swingarm Pivot Shaft Nut		98	10		72
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)		20	2.0	14.5		AL
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		4.0	0.4	43	in·lb
Stator Bolts		7.0	0.7	61	in·lb
Crankshaft Sensor Bolts		7.0	0.7	61	in·lb
Spark Plug		13	1.3	115 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

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

http://manuals.magnamaniac.com

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
		Soft water 50% and coolant 50%
Freezing point		–35°C (–31°F)
Total amount		1.20 L (1.27 US qt)
Engine Top End:
Valve clearance:
Exhaust		0.17	0.22 mm (0.0067		0.0087 in.)		- - -
Inlet		0.10	0.15 mm (0.0039
					0.0059 in.)		- - -
Cylinder head warp		- - -					0.05 mm
							(0.0020 in.)
Cylinder inside diameter (see text)		77.000		77.012 mm			77.06 mm
		(3.0315		3.0320 in.)			(3.0339 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 thickness		2.72	2.88 mm (0.107		0.113 in.)		2.6 mm (0.102 in.)
		1.46	1.74 mm (0.057
Steel plate thickness					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 JASO 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		0.002	0.014 mm				0.06 mm
clearance		(0.00008 0.0006 in.)					(0.0024 in.)
Connecting rod big end side		0.25
			0.35 mm				0.55 mm
clearance		(0.0098		0.0138 in.)			(0.0217 in.)
Crankshaft runout		TIR 0.03 mm (0.012 in.) or less					TIR 0.08 mm
	http://manuals.magnamaniac.com						(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.)		- - -
		317.5
Drive chain 20 link length			318.2 mm	323 mm
		(12.50	12.53 in.)	(12.72 in.)
		55.48
Engine sprocket diameter			55.68 mm	54.8 mm
		(2.184	2.192 in.)/13T	(2.157 in.)
		232.62
Rear sprocket diameter			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				(Adjustable range)
removed)		95 mm (3.7 in.)		70	120 mm
Electrical System:				(2.8
					4.7 in.)
Spark plug gap		0.7 0.8 mm (0.028 0.031 in.)		- - -
TIR: Total Indicator Readings

http://manuals.magnamaniac.com

2-10 PERIODIC MAINTENANCE

Special Tools

Valve Spring Compressor Assembly :	Fork Oil Level Gauge :
57001–241	57001–1290

Steering Stem Nut Wrench : 57001–1100

Pilot Screw Adjuster, C : 57001–1292

Valve Spring Compressor Adapter, 20 : 57001–1154

Pilot Screw Adjuster Adapter, 4 : 57001–1371

Jack : 57001–1238

Pilot Screw Adjust, D: 57001–1588

Spark Plug Wrench, M16 : 57001–1262

http://manuals.magnamaniac.com

PERIODIC MAINTENANCE 2-11

Periodic Maintenance Procedures

Fuel System

Fuel Hose and Connection Inspection

○The fuel 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, kinking, 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.

Throttle• Grip Free Play Inspection

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

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

Throttle Grip Free Play	2 3 mm (0.08 0.12 in.)
Standard:

•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-

•tle grip plenty of play.

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 3 mm

•(0.08 0.12 in.) of throttle grip play is obtained. Tighten the locknut [B].

http://manuals.magnamaniac.com