Kawasaki KX450F (2006) User Manual [ru]
KX450F
Motorcycle
Service Manual
Quick Reference 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
KX450F
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 Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2005 Kawasaki Heavy Industries, Ltd. First Edition (1) : Aug. 4, 2005 (M)
LIST OF ABBREVIATIONS
A
ABDC after bottom dead center
AC
ATDC after top dead center
BBDC before bottom dead center
BDC
BTDC before top dead center
°C degree(s) Celsius
DC
F
°F degree(s) Fahrenheit
ft foot, feet
g
h
kg
kgf (force)
L
ampere(s)
alternating current min
bottom dead center
direct current
farad(s) TDC
gram(s) (mass)
hour(s) Ω ohm(s)
(mass)
liter(s)
lb
m
N
Pa
PS
psi
r revolution
r/min, rpm revolution(s) per minute
TIR total indicator reading
V
W
pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
top dead center
volt(s)
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 Maintenance 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
Service 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 this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil 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 symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age 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.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
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 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.
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 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
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and them remove them. 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, O-ring
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, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking agent, clean the surfaces so
that no oil residue remains before applying liquid gasket
or Non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.
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 i nner 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
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing to prevent deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.
1-6 GENERAL INFORMATION
Before Servicing
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wire s
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.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.
Model Identification
KX450D6F Left Side View
GENERAL INFORMATION 1-7
KX450D6F Right Side View
1-8 GENERAL INFORMATION
General Specifications
Items KX450D6F
Dimensions
Overall Length 2 185 mm (86.02 in.)
Overall Width 820 mm (32.3 in.)
Overall Height 1 280 mm (50.39 in.)
Wheelbase 1 485 mm (58.46 in.)
Road Clearance 345 mm (13.6 in.)
Seat Height 965 mm (38.0 in.)
Dry Mass 99.8 kg (220 lb)
Fuel Tank Capacity 7.2 L (1.9 US gal)
Performance
Minimum Turning Radius –
Engine
Type 4-stroke, single cylinder, DOHC 4 valve
Cooling System Liquid-cooled
Bore and Stroke 96.0 × 62.1 mm (3.78 × 2.44 in.)
Displacement 449 cm³ (27.4 cu in.)
Compression Ratio 12.0 : 1
Carburetion System Carburetor, KEIHIN FCR40
Starting System Primary kick
Ignition System Digital AC-CDI
Timing Advance
Ignition Timing BTDC 10° @1 800 r/min (rpm)
Spark Plug NGK CPR8EB-9
Valve Timing:
Inlet:
Open BTDC 32°
Close ABDC 72°
Duration
Exhaust:
Open BBDC 62°
Close ATDC 42°
Duration 284°
Lubrication System Forced lubrication (semi-dry sump)
Engine Oil:
Type
Viscosity SAE 10W-40
Capacity 1.2L(1.3USqt)
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type Wet, multi disc
Transmission:
Type 4-speed, constant mesh, return shift
284°
API SG, SH, SJ o
Gear
2.727 (60/22
)
rSLwithJASOMA
GENERAL INFORMATION 1-9
General Specifications
Items KX450D6F
Gear ratios:
1st 1.800 (27/15)
2nd 1.411 (24/17)
3rd 1.187 (19/16)
4th 1.000 (19/19)
Final Drive System:
Type Chain drive
Reduction Ratio
Overall Drive Ratio 10.489 @Top gear
Frame
Type Tubular, semi-double cradle
Steering Angle 42° to either side
Caster (rake angle) 27.1°
Trail 117 mm (4.60 in.)
Front tire:
Size 90/100-21 57M
Make/Type DUNLOP D742F, Tube type
Rear tire:
Size 120/80-19 63M
Make/Type DUNLOP D756, Tube type
Rim size:
Front 1.60-21
Rear 2.15-19
Front suspension:
Type Telescopic fork (up side down)
Wheel travel 315 mm (12.4 in.)
Rear suspension:
Type
Wheel travel 315 mm (12.4 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.)
3.4846 (50/13)
Swingarm (New Uni-trak)
Specifications subject to change without notice, and may not apply to every country.
1-10 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix Symbol
mega M × 1 000 000
kilo k × 1 000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Power
Units of Mass:
kg × 2.205 = lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 = gal (imp)
L×1.057=
L × 0.8799 =
L×2.113=
L × 1.816 = pint (imp)
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
qt (US)
qt (imp)
pint (US)
Units of Length:
km × 0.6214 = mile
m × 3.281 = ft
mm × 0.03937 = in
Units of Torque:
N·m × 0.1020 =
N·m × 0.7376 =
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m
× 86.80 = in·lb
kgf·m
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
cm Hg × 1.333 = kPa
kgf/cm²
Units of Speed:
km/h
× 0.6214 = mph
Units of Force:
N × 0.1020 =
N × 0.2248 = lb
kgf × 9.807 = N
kgf × 2.205 = lb
Units of Temperature:
kgf
Units of Power:
kW × 1.360 =
kW × 1.341 = HP
PS × 0.7355 = kW
PS × 0.9863 = HP
PS
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart .............. 2-3
Torque and Locking Agent................. 2-5
Specifications .................................... 2-9
Special Tools ..................................... 2-11
Periodic Maintenance Procedures..... 2-12
Fuel System.................................... 2-12
Fuel Hose and Connection
Inspection.................................. 2-12
Throttle Grip Free Play Inspection 2-12
Throttle Grip Free Play
Adjustment ................................ 2-12
Hot Starter Lever Free Play
Inspection.................................. 2-13
Idle Speed Inspection .................. 2-13
Idle Speed Adjustment................. 2-14
Air Cleaner E lement Cleaning and
Inspection.................................. 2-14
Fuel Inspection ............................. 2-16
Fuel Tank, Filter and Tap
Cleaning .................................... 2-17
Fuel Tap and Filter Inspection...... 2-17
Cooling System............................... 2-17
Coolant Level Inspection.............. 2-18
Coolant Deterioration Inspection.. 2-18
Radiator Hoses and Connections
Inspection.................................. 2-19
Engine Top End .............................. 2-19
Valve Clearance Inspection ......... 2-19
Valve Clearance Adjustment........ 2-20
Cylinder Head Warp Inspection ... 2-22
Cylinder Wear Inspection............. 2-22
Piston/Cylinder Clearance ........... 2-23
Piston, Piston Ring and Piston
Pin Replacement....................... 2-23
Exhaust System Inspection.......... 2-23
Muffler Baffle Change .................. 2-23
Engine Right Side ........................... 2-24
Clutch Lever Free Play Check ..... 2-25
Clutch Lever Free Play
Adjustment ................................ 2-25
Friction and Steel Plates
Inspection.................................. 2-25
Engine Lubrication System ............. 2-26
Engine Oil Change....................... 2-26
Oil Filter Change .......................... 2-27
Breather Hose Inspection ............ 2-27
2
Crankshaft/Transmission................ 2-28
Crankshaft Inspection .................. 2-28
Wheel/Tires..................................... 2-28
Air Pressure Inspection/Adjust-
ment .......................................... 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 Slack Inspection ....... 2-31
Drive Chain Slack Adjustment ..... 2-31
Drive Chain Wear Inspection ....... 2-32
Drive Chain Lubrication................ 2-33
Sprocket Wear Inspection............ 2-33
Rear Sprocket Warp Inspection ... 2-34
Brakes............................................. 2-34
Brake Lever and Pedal Position
Adjustment ................................ 2-34
Brake Fluid Level Inspection........ 2-35
Brake Fluid Change ..................... 2-36
Brake Pad Wear Inspection ......... 2-38
Brake Master Cylinder Cup and
Dust Seal Replacement ............ 2-38
Caliper Piston Seal and Dust Seal
Replacement............................. 2-40
Brake Hose and Connection
Check ........................................ 2-43
Brake Hose Replacement ............ 2-43
Suspension..................................... 2-44
Front Fork Inspection ................... 2-44
Front Fork Oil Change (each fork
leg) ............................................ 2-44
Rear Shock Absorber Inspection . 2-53
Rear Shock Absorber Oil Change 2-53
Swingarm and Uni-Trak Linkage
Inspection .................................. 2-58
Swingarm and Uni-Track Linkage
Pivot Lubricate .......................... 2-58
Steering .......................................... 2-58
Steering Inspection ...................... 2-58
Steering Adjustment .................... 2-58
Stem Bearing Lubrication............. 2-60
Frame ............................................. 2-60
Frame Inspection ......................... 2-60
Electrical System ............................ 2-61
2-2 PERIODIC MAINTENANCE
Spark Plug Cleaning and
Inspection .................................. 2-61
Cable Inspection............................. 2-61
Lubrication ................................... 2-61
Nut, Bolt, and Fastener Tightness
Inspection..................................... 2-62
Tightness Inspection .................... 2-62
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The maintenance must be done in accordance with this chart to keep the motorcycle in good running
condition.
FREQUENCY
OPERATION
Spark plug-clean, gap †
Spark plug-replace
Clutch cable-adjust
Clutch and friction plates-inspect †
Throttle cable-adjust
Air cleaner element-clean †
Air cleaner element-replace If damaged 2-14
Carburetor-inspect and adjust
Engine Oil-change
Piston and piston ring-replace Every 6 races 2-23
E
Cylinder head, cylinder-inspect
N
G
Piston pin-replace
I
Valve clearance-inspect †
N
E
Hot starter cable-adjust
Oil filter-replace
Muffler-clean and inspect†
Muffler Baffle-change
Kick pedal and shift pedal-clean
Engine sprocket-inspect †
Coolant-check †
Radiator hoses and connections-inspect †
Crankshaft-inspect
Breather hose-inspect
Brake adjustment-inspect †
Brake pad wear-inspect †
Brake fluid level-inspect †
Brake fluid-change Every 2 years 2-36
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 2-40
A
Brake hoses and pipe-replace Every 4 years 2-43
S
S
Brake hoses, connections-inspect †
I
Spoke tightness and rim runout-inspect †
S
Wheel bearing-inspect †
Frame-inspect and clean
Drive chain wear-inspect †
Drive chain-inspect and adjust
Each
race or
2.5 hr
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Every
3 races
or 7.5
hr
•
Every
6 races
or 15 hr
•
•
•
•
•
•
Every
12
races or
30 hr
•
See
Page
2-61
2-61
2-25
2-25
2-12
2-14
2-13
2-26
2-22
2-23
2-19
2-13
2-27
2-23
2-23
–
2-33
2-18
2-19
2-28
2-27
2-34
2-38
2-35
2-43
2-29
2-30
2-60
2-32
2-31
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY
OPERATION
Drive chain-lubricate
Wheels/tires-inspect
Rear sprocket-inspect †
Front fork-inspect and clean
Front fork oil-change
Rear shock oil-replace
Cable-inspect
Fuel hose-replace Every 4 years 2-12
Fuel hose, connections-inspect †
Fuel system-clean
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 †
Chassis parts-lubricate
†: Replace, add, adjust, clean or torque if necessary.
Each
race or
2.5 hr
•
•
•
•
•
•
•
•
•
Every
3 races
or 7.5
hr
•
•
•
Every
6 races
or 15 hr
•
•
•
Every
12
races or
30 hr
See
Page
2-33
2-28
2-33
2-44
2-44
2-53
2-61
2-12
2-16
2-58
2-60
2-58
2-58
2-62
–
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may 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.
2T: Apply 2-stroke oil.
Fastener
Fuel System
Throttle Pulley Cover Bolt 3.4 0.35 30 in·lb
Throttle Cable Locknut 6.9 0.70 61 in·lb
Air Cleaner Duct Clamp Screw 2.0 0.20 18 in·lb
Air Cleaner Duct Mounting Nuts 3.0 0.31 27 in·lb
Air Cleaner Duct Mounting Screw 3.0 0.31 27 in·lb
Air Cleaner Housing Bolts 9.8 1.0 87 in·lb
Cooling System
Water Pump Cover Bolts 9.8 1.0 87 in·lb
Water Pump Impeller Bolt 9.8 1.0 87 in·lb
Radiator Hose Clamp Screws 1.5 0.15 13 in·lb
Coolant Drain Plug 6.9 0.70 61 in·lb
Radiator Mounting Bolts 9.8 1.0 87 in·lb
Radiator Screen Bolts 9.8 1.0 87 in·lb
Radiator Shroud Bolts 9.8 1.0 87 in·lb
Engine Top End
Cylinder Head Cover Bolts
Cylinder Head Bolts (M10)
Cylinder Head Bolts (M6)
Camshaft Cap Bolts 9.8 1.0 87 in·lb S, MO
Camsfaft Sprocket Bolts 12 1.2 106 in·lb L
Decompressor Plug Plate Bolt 9.8 1.0 87 in·lb
Radiator Hose Fitting Bolts 9.8 1.0 87 in·lb
Oil Line Plug 3.0 0.31 27 in·lb L
Carburetor Holder Clamp Screws 2.0 0.20 18 in·lb
Plug 20 2.0 15 L
Lower Camshaft Chain Guide Bolt 9.8 1.0 87 in·lb
Rear Camshaft Chain Guide Bolt 15 1.5 11
Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb
Chain Tensioner Cap 5.0 0.51 44 in·lb
Cylinder Bolt 12 1.2 106 in·lb S
Exhaust Pipe Cover Screws 12 1.2 106 in·lb
N·m
9.8 1.0 87 in·lb
59 6.0 44
12 1.2 106 in·lb
Torque
Remarks
kgf·m ft·lb
S, MO
S
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Exhaust Pipe Holder Nuts 21 2.1 15
Muffler Mounting Bolts 21 2.1 15
Engine Right Side
Primary Gear Nut 98 10 72 Lh
Shift Drum Cam Bolt 24 2.4 18 L
Clutch Spring Bolts 8.8 0.90 78 in·lb
Clutch Hub Nut 98 10 72
Gear Set Lever Nut
Ratchet Plate Mounting Bolt 9.8 1.0 87 in·lb
Ratchet Plate M ount
Ratchet Guide Bolt 8.8 0.90 78 in·lb
Kick Pedal Bolt 25 2.5 18 L
Shift Pedal Bolt 9.8 1.0 87 in·lb
Clutch Cover Bolts
Right Engine Cover Bolts
Engine Lubricati
Engine Oil Drain Bolt (M10)
(for crank room oil sump) 15 1.5 11
Engine Oil Drain Bolt (M6)
(for transmission room oil sump) 7.0 0.71 62 in·lb
Oil Pump (Scavenge) Cover Bolts 9.8 1.0 87 in·lb S
Oil Pump (Feed) Cover Bolts 9.8 1.0 87 in·lb S
Oil Filter Cover Bolt 9.8 1.0 87 in·lb
Oil Screen (Feed) Mounting Bolts 9.8 1.0 87 in·lb
Oil Pressure Relief Valve 15 1.5 11 L
Piston Oil Nozzle
Breather Fitting 15 1.5 11 L
Engine Removal/Installation
Engine Mounting Bolt, Nuts 49 5.0 36
Engine Bracket Bolt, Nuts 29 3.0 21
Swingarm Pivot Shaft Nut 98 10 72
Crankshaft/Transmission
Piston Oil Nozzle
Crankcase Bo
Crankcase Bolts (M7) 15 1.5 1.1 S
Engine Oil Drain Bolt (M10)
(for crank room oil sump) 15 1.5 11
Engine Oil Drain Bolt (M6)
(for transmission room oil sump) 7.0 0.71 62
Bearing Retaining Screw 15 1.5 11 L
Gear Set Lever Nut 8.8 0.90 78 in·lb
Shift Drum Cam Bolt 24 2.4 17 L
Balancer Weight Mounting Nut 52 5.3 38
lts (M6)
ing Screw
on System
N·m kgf·m ft·lb
8.8 0.90 78 in·lb
6.4 0.65 57 in·lb
9.8 1.0 87 in·lb
9.8 1.0 87 in·lb
2.9 0.30 26 in·lb
2.9 0.30 26 in·lb
12 1.2 106 in·lb
Torque
Remarks
S
S, L
S
Torque and Locking Agent
PERIODIC MAINTENANCE 2-7
Fastener
Gear Position Switch Screws 2.9 0.30 26 in·lb L
Wheels/Tires
Front Axle 79 8.1 58
Front Axle Clamp Bolts 20 2.0 15 AL
Rear Axle Nut 110 11.2 81.1
Spoke Nipples
Final Drive
Rear Sprocket Nuts 34 3.5 25
Engine Sprocket Nut 127 13.0 93.7
Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb
Brakes
Brake Lever Pivot Locknut 5.9 0.60 52 in·lb
Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
Brake Lever Pivot Bolt 5.9 0.60 52 in·lb
Caliper Mounting Bolts (Front) 25 2.5 18
Brake Hose Banjo Bolts 34 3.5 25
Front Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Bolts 10 1.0 89 in·lb
Rear Master Cylinder Push Rod Locknut 17 1.7 13
Brake Reservoir Cap Bolts 1.5 0.15 13 in·lb
Brake Disc Mounting Bolts:
(Front)
(Rear)
Caliper Bleed Valves (Front, Rear) 7.8 0.80 69 in·lb
Caliper Holder Bolt (Rear) 27 2.8 20
Brake Pad Bolt 17 1.7 13
Rear Brake Pad Bolt Plug 2.5 0.25 22 in·lb
Brake Pedal Mounting Bolt 25 2.5 18 L, G
Suspension
Front Fork Clamp Bolts (Upper) 23 2.3 17 AL
Front Fork Clamp Bolts (Lower) 20 2.0 15 AL
Front Fork Top Plug 30 3.1 22
Adjuster Assembly 58 5.9 43 L
Base Valve Assembly 28 2.9 21
Locknut/Adjuster Assembly 29 3.1 21
Swingarm Pivot Shaft Nut 98 10 72
Rear Shock Absorber Mounting Nuts:
(Upper) 39 4.0 29
(Lower)
Air Bleed Bolt 6.4 0.65 57 in·lb
Tie-Rod Mounting Nut (Front, Rear) 83 8.5 61
Rocker Arm Pivot Nut 83 8.5 61
N·m kgf·m ft·lb
Not less
than 2.2
8.8 0.90 78 in·lb
10 1.0 89 in·lb L
23 2.3 17 L
34 3.5 25
Torque
Not less
than 0.22
Remarks
Not less
than 19 in·lb
S
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Steering
Steering Stem Head Nut
Steering Stem Nut
Handlebar Clamp Bolts
Frame
Rear Frame Mounting Bolts 34 3.5 25
Upper Footpeg Bracket Bolts 54 5.5 40 L
Electrical System
Gear Position Switch Screws
Flywheel Nut 78 8.0 58
Stator Bolts 4.0 0.41 35 in·lb L
Crankshaft Sensor Bolts 7.0 0.71 62 in·lb
Spark Plug 13 1.3 115 i n ·lb
C.D.I. Unit Bolts
Magneto Cover Bolts
Breather Fitting 15 1.5 11 L
Ignition Coil Bolts 7.0 0.71 62 in·lb
N·m kgf·m ft·lb
98 10 72
4.9 0.50 43 in·lb
25 2.5 18 2T
2.9 0.30 26 in·lb L
9.8 1.0 87 in·lb
9.8 1.0 87 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
PERIODIC MAINTENANCE 2-9
Specifications
Item Standard Service Limit
Fuel System
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––
Hot Starter Lever Free Play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) –––
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
Total Amount
Engine Top End
Valve Clearance:
Exhaust
Inlet 0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.) –––
Cylinder Head Warp ––– 0.05 mm (0.002 in.)
Cylinder Inside Diameter (see
text)
Piston/cylinder Clearance 0.020 ∼ 0.042 mm (0.00079 ∼ 0.0016 in.) –––
Engine Right Side
Clutch Lever Free Play 8 ∼ 13 mm (0.3 ∼ 0.5 in.) –––
Friction Plate Thickness
Friction Plate Warp
Steel Plate Warp Not more than 0.2 mm (0.008 in.) 0.3 mm (0.01 in.)
Engine Lubrication System
Engine oil:
Type
Viscosity
Capacity 1.2 L (1.3 US qt)
Crankshaft/Transmission
Connecting Rod Big End Side
Clearance
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
Standard Tire:
Front:
Size 90/100-21 57M –––
Make
Type D742F
–35 °C (–31 °F)
1.05 L (1.11 US qt)
0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)
96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) 96.10 mm (3.783 in.)
2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 2.6 mm (0.10 in.)
Not more than 0.15 mm (0.0059 in.) 0.3 mm (0.01 in.)
Castrol “R4 superbike” 5W-40 or
API SG, SH, SJ or SL with JASO MA
SAE 10W-30, 10W-40, or 10W-50
0.25 ∼ 0.35 mm (0.0098 ∼ 0.014 in.) 0.6 mm (0.02 in.)
100 kPa (1.0 kgf/cm², 14 psi)
DUNLOP
–––
–––
–––
2-10 PERIODIC MAINTENANCE
Specifications
Item Standard Service Limit
Rear:
Size 120/80-19 63M –––
Make DUNLOP
Type D756, Tube
Final Drive
Drive Chain Slack 52 ∼ 58 mm (2.0 ∼ 2.3 in.) –––
Drive Chain 20 Link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.)
Rear Sprocket Warp 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
Rear DOT4 –––
Brake pad lining thickness:
Front
Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)
Suspension
Fork Oil:
Oil Viscosity KHL15-10 (KAYABA 01) or equivalent –––
Oil Quantity: (Adjustable range)
Outer (Outer/Inner Tubes) 345 mL (11.7 US oz.)
Inner (Subtank) 170 mL (5.75 US oz.) –––
Electrical System
Spark Plug Gap 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) –––
DOT3 or DOT4
3.8 mm (0.15 in.) 1 mm (0.04 in.)
(11.0 ∼ 12.3 US oz.)
(EUR) 350 mL (11.8 US oz.) (EUR) 330 ∼ 370 mL
(11.2 ∼ 12.5 US oz.)
–––
325 ∼ 365 mL
TIR: Total Indicator Readings
EUR: Europe Model
Special Tools
PERIODIC MAINTENANCE 2-11
Steering Stem Nut Wrench:
57001-1100
Jack:
57001-1238
Spark Plug Wrench, Hex 16:
57001-1262
Pilot Screw Adjuster Adapter, 4:
57001-1371
Filler Cap Driver:
57001-1454
Pilot Screw Adjust, D:
57001-1588
Pilot Screw Adjuster, C:
57001-1292
TopPlugWrench,49mm:
57001-1653
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Fuel Hose and Conn ection 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], bulges [C]
or ozonic cranks [D] 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.
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 G rip Free Play
Standard: 2 ∼ 3 mm (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].
•
WARNING
Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
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