NINJA 250R
Ninja 250R
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
Clutch 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
Ninja 250R
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2007 Kawasaki Heavy Industries, Ltd. First Edition (1): Nov. 15, 2007 (M)
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
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
bottom dead center
PS
V
horsepower
volt(s)
COUNTRY AND AREA CODES
AT Austria
AU Australia MY Malaysia
CA Canada US United States
CAL California
CH Switzerland PH Phi
DE Germany WVTA Whole Vehicle Type Approval
FR France
GB
ID Indonesia
United Kingdom
lippines
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California in-
cludes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In-
stead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”
NOTE
The phrase “remo ve or render inoperative any device or element of design” has been generally
○
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement p arts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10
000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliance
•
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
•
Removal of the air box or air box cover.
•
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
•
modifications result in increased noise levels.
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.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
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 ............................................................................................................ 1-11
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.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
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.
Before Servicing
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.
Storage of Remov ed 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.
GENERAL INFORMATION 1-3
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.
1-4 GENERAL INFORMATION
Before Servicing
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 then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
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.
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 the old gaskets and clean the sealing surfaces
thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the 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.
Before Servicing
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.
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.
GENERAL INFORMATION 1-5
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.
Apply specified grease to the lip of seal before installing
the seal.
Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
1-6 GENERAL INFORMATION
Before Servicing
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).
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.
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
EX250J8F Left Side View (United States and Canada)
GENERAL INFORMATION 1-7
EX250J8F Right Side View (United States and Canada)
Frame Number Engine Number
1-8 GENERAL INFORMATION
General Specifications
Items EX250J8F
Dimensions
Overall Length 2 085 mm (82.1 in.)
Overall Width 715 mm (28.1 in.)
Overall Height 1 110 mm (43.7 in.)
Wheelbase 1 400 mm (55.1 in.)
Road Clearance 130 mm (5.1 in.)
Seat Height 775 mm (30.5 in.)
Dry Mass 152 kg, (335 lb)
Curb Mass:
Front
Rear
Fuel Tank Capacity 18.0 L (4.8 US gal)
Performance
Minimum Turning Radius 2.7 m (8.9 ft)
Engine
Type
Cooling System
Bore And Stroke 62.0× 41.2 mm (2.5 × 1.6 in.)
Displacement 249 cm³ (15.2 cu in.)
Compression Ratio 11 . 6
Maximum Horsepower 23.4 kW (31.8 PS) @11 000 r/min (rpm),
Maximum Torque 22.0 N·m (2.24 kg·m, 16.2 ft·lb) @9 500 r/min (rpm),
Carburetion System Carburetor, Keihin CVK 30× 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
Ignition Timing From 10° BTDC @1 300 r/min (rpm)
Spark Plug NGK CR8E or ND U24ESR-N
Cylinder Numbering Method Left to Right, 1-2
Firing Order
Valve Timing:
Inlet
Open 36° BTDC
Close 56° ABDC
Duration 272°
Exhaust
Open 61° BBDC
Close 31° ATDC
Duration 272°
82 kg (181 lb)
87 kg (192 lb)
4-stroke, DOHC, 2-cylinder
Liquid-cooled
35° BTDC @4 000 r/min (rpm)
1-2
GENERAL INFORMATION 1-9
General Specifications
Items EX250J8F
Lubrication System Forced ubrication (wet sump)
Engine Oil:
Grade API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity
Capacity 1.7 L (1.80 US qt)
Drive Train
Primary Reduction System:
Type Gear
Reduction Tatio 3.087 (71/23)
Clutch Type
Transmission:
Type 6-speed, constant mesh, return shift
Gear Ratios:
1st 2.600 (39/15)
2nd 1.789 (34/19)
3rd
4th
5th
6th 0.893 (25/28)
Final Drive System:
Type Chain drive
Reduction Ratio 3.214 (45/14) (AU) 3.071 (43/14)
Overall Drive Ratio 8.859 @Top gear (AU) 8.466 @Top gear
Frame
Type Tubular, diamond
Caster (Rake Angle) 26°
Trail 82 mm (3.2 in.)
Front Wheel:
Tire Type Tubeless
Tire Size 100/70-17M/C 54H
Rim Size 17 × 2.75
Rear Wheel:
Tire Type Tubeless
Tire Size 130/70-17M/C 62H
Rim Size 17 × 3.50
Front suspension:
Type Telescopic fork
Wheel Travel 120 mm (4.7 in.)
Rear Suspension:
Type Swingarm (uni-trak)
Wheel Travel 130 mm (5.1 in.)
SAE10W-40
Wet multi disc
1.409 (31/22)
1.160 (29/25)
1.000 (27/27)
1-10 GENERAL INFORMATION
General Specifications
Items EX250J8F
Brake Type:
Front Single disc
Rear Single disc
Electrical Equipment
Battery 12 V 6 Ah
Headlight:
Type Semi-sealed beam
Bulb:
High
Low
Tail/brake Light 12 V 5/21 W
Alternator:
Type Three-phase AC
Rated Output 19 A @5 000 r/min (rpm), 14 V
12 V 55 W + 55 W (quartz-halogen)
12 V 55 W (quartz-halogen)
Specifications are subject to change without notice, and may not apply to every country.
AU: Austral
ia Model
Unit Conversion Table
GENERAL INFORMATION 1-11
Prefixes for Units:
Prefix Symbol Power
mega M × 1 000 000
kilo k ×1000
centi c ×0.01
milli m × 0.001
micro µ × 0.000001
Units of Mass:
kg ×2.205=lb
g × 0.03527 = oz
Units of Volume:
L × 0.2642 = gal (US)
L × 0.2200 = gal (imp)
L × 1.057 = qt (US)
L × 0.8799 = qt (imp)
L×2.113=
L × 1.816 =
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp)
mL × 0.06102 = cu in
pint (US)
pint (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 =
N·m × 8.851 = in·lb
kgf·m × 9.807 = N·m
kgf·m × 7.233 = ft·lb
kgf·m × 86.80 = in·lb
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 Force:
N × 0.1020 = kg
N × 0.2248 = lb
kg ×9.807=N
kg ×2.205=lb
Units of Temperature:
Units of Speed:
km/h
× 0.6214 = mph
Units of Power:
kW ×1.360=PS
kW ×1.341=HP
PS × 0.7355 = kW
PS × 0.9863 = HP
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-3
Torque and Locking Agent...................................................................................................... 2-6
Specifications ......................................................................................................................... 2-11
Special Tools .......................................................................................................................... 2-13
Periodic Maintenance Procedures.......................................................................................... 2-14
Fuel System ......................................................................................................................... 2-14
Air Cleaner Element Cleaning........................................................................................... 2-14
Air Cleaner Element Installation........................................................................................ 2-15
Throttle Control System Inspection................................................................................... 2-15
Choke Operation Inspection ............................................................................................. 2-17
Engine Vacuum Synchronization Inspection..................................................................... 2-17
Idle Speed Inspection ....................................................................................................... 2-18
Idle Speed Adjustment...................................................................................................... 2-18
Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... 2-19
Evaporative Emission Control System (California Model) ................................................... 2-19
Evaporative Emission Control System Inspection ............................................................ 2-19
Cooling System.................................................................................................................... 2-20
Coolant Level Inspection................................................................................................... 2-20
Radiator Hose Damage and Installation Condition Inspection.......................................... 2-21
Coolant Filter Cleaning (Australia Model) ......................................................................... 2-21
Air Suction System .............................................................................................................. 2-21
Air Suction System Damage Inspection............................................................................ 2-21
Engine Top End ................................................................................................................... 2-22
Valve Clearance Inspection .............................................................................................. 2-22
Valve Clearance Adjustment............................................................................................. 2-23
Clutch................................................................................................................................... 2-26
Clutch Operation Inspection.............................................................................................. 2-26
Wheels/Tires........................................................................................................................ 2-27
Air Pressure Inspection..................................................................................................... 2-27
Wheel/Tire Damage Inspection......................................................................................... 2-27
Tire Tread Wear, Abnormal Wear Inspection .................................................................... 2-27
Wheel Bearing Damage Inspection .................................................................................. 2-28
Drive Train ........................................................................................................................... 2-29
Drive Chain Lubrication Condition Inspection ................................................................... 2-29
Drive Chain Slack Inspection ............................................................................................ 2-29
Drive Chain Slack Adjustment .......................................................................................... 2-30
Wheel Alignment Inspection ............................................................................................. 2-31
Drive Chain Wear Inspection ............................................................................................ 2-31
Chain Guide Inspection..................................................................................................... 2-32
Brake System ...................................................................................................................... 2-32
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-32
Brake Hose and Pipe Damage and Installation Condition Inspection............................... 2-32
Brake Operation Inspection .............................................................................................. 2-32
Brake Fluid Level Inspection............................................................................................. 2-33
Brake Pad Wear Inspection .............................................................................................. 2-33
Brake Light Switch Operation Inspection .......................................................................... 2-34
Suspensions ........................................................................................................................ 2-34
Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-34
Front Fork Oil Leak Inspection .......................................................................................... 2-35
Rear Shock Absorber Oil Leak Inspection ........................................................................ 2-35
2
2-2 PERIODIC MAINTENANCE
Rocker Arm Operation Inspection..................................................................................... 2-35
Tie-Rod Operation Inspection ........................................................................................... 2-35
Swingarm Pivot Lubrication .............................................................................................. 2-36
Steering System ..................................................................................................................2-36
Steering Play Inspection ................................................................................................... 2-36
Steering Play Adjustment.................................................................................................. 2-36
Steering Stem Bearing Lubrication ................................................................................... 2-37
Electrical System ................................................................................................................. 2-37
Lights and Switches Operation Inspection........................................................................ 2-37
Headlight Aiming Inspection ............................................................................................. 2-39
Sidestand Switch Operation Inspection ............................................................................ 2-40
Engine Stop Switch Operation Inspection......................................................................... 2-41
Others.................................................................................................................................. 2-42
Chassis Parts Lubrication ................................................................................................. 2-42
Bolts, Nuts and Fasteners Tightness Inspection............................................................... 2-43
Replacement Parts .............................................................................................................. 2-44
Air Cleaner Element Replacement.................................................................................... 2-44
Fuel Hose Replacement ................................................................................................... 2-44
Coolant Change ................................................................................................................ 2-44
Radiator Hose and O-ring Replacement ........................................................................... 2-46
Engine Oil Change............................................................................................................ 2-47
Oil Filter Replacement ...................................................................................................... 2-47
Brake Hose and Pipe Replacement .................................................................................. 2-48
Brake Fluid Change .......................................................................................................... 2-48
Master Cylinder Rubber Parts Replacement .................................................................... 2-50
Caliper Rubber Parts Replacement .................................................................................. 2-51
Spark Plug Replacement .................................................................................................. 2-52
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY Whichever
comes
first
1 6 12 18 24 30 36
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)
Fuel System
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
See
Page
Air cleaner element - clean
Throttle control system (play, smooth
return, no drag) - inspect
Choke operation - inspect year
Engine vacuum synchronization - inspect
Idle speed - inspect
Fuel leak (fuel hose and pipe) - inspect year
Fuel hose and pipe damage - inspect year
Fuel hose and pipe installation condition inspect
Evaporative Emission Control System
(CAL)
Evaporative emission control system
function - inspect
Cooling System
Coolant level - inspect
Coolant leak (radiator hose and pipe) inspect
Radiator hose damage - inspect year
Radiator hose installation condition inspect
Coolant filter - clean year
Air Suction System
year
year
year
year
• • •
• • • •
• • • •
• • •
• • • •
• • • •
• • • •
• • • •
• • • • • • •
• • • •
• • • •
• • • •
• • • •
2-14
2-15
2-17
2-17
2-18
2-19
2-19
2-19
2-19
2-20
2-21
2-21
2-21
Air suction system damage - inspect
Engine Top End
Valve clearance - inspect
Clutch
Clutch operation (play, disengagement,
engagement) - inspect
Wheels and Tires
Tire air pressure - inspect year
Wheel/tire damage - inspect
Tire tread wear, abnormal wear - inspect
Wheel bearing damage - inspect year
Drive Train
Drive chain lubrication condition - inspect # Every 600 km (400 mile) 2-29
• • • •
• • •
• • •
• • •
• • •
• • •
• • •
2-21
2-22
2-26
2-27
2-27
2-27
2-28
2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
1 6 12 18 24 30 36
INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24)
Drive chain slack - inspect # Every 1 000 km (600 mile) 2-29
Drive chain wear - inspect #
Drive chain guide wear - inspect
Brake System
Brake fluid leak (brake hose and pipe) inspect
Brake hose and pipe damage - inspect year
Brake hose and pipe installation condition
- inspect
Brake operation (effectiveness, play, no
drag) - inspect
Brake fluid level - in
Brake pad wear - inspect #
Brake light switch operation - inspect
Suspensions
Front forks/rear shock absorber operation
(damping and smoot
Front forks/rear shock absorber oil leak inspect
spect
h stroke) - inspect
year
year
year
6 months
year
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • • •
• • • • • • •
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
• • •
• • •
• • • • • •
• • •
• • •
See
Page
2-31
2-32
2-32
2-32
2-32
2-32
2-33
2-33
2-34
2-34
2-35
Rocker arm operation - inspect
Tie-rods operation - inspect
Swingarm pivot - lu
Steering System
Steering play - inspect year
Steering stem bearings - lubricate
Electrical System
Lights and switches operation - inspect year
Headlight aiming - inspect year
Sidestand switch operation - inspect year
Engine stop switch operation - inspect year
Others
Chassis parts - lubricate year
Bolts and nuts tightness - inspect
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
bricate
• • • •
2years
• • • •
• • •
• • •
•
•
• • •
• • •
• • •
• • •
• • •
2-35
2-35
2-36
2-36
2-37
2-37
2-39
2-40
2-41
2-42
2-43
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY
Whichever
comes
first
PERIODIC MAINTENANCE 2-5
* ODOMETER READING
× 1 000 km
(× 1 000 mile)
1 12 24 36 48
See
Page
CHANGE/REPLACE ITEM
Air cleaner element #
Fuel hose 4 years
Coolant 3 years
Radiator hose and O-ring 3 years
Engine oil #
Oil filter year
Brake hose and pipe 4 years
Brake fluid 2 years
Rubber parts of master cylinder and caliper 4 years
Spark plug
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
Every
2 years 2-44
(0.6) (7.5) (15) (24) (30)
•
•
•
year
• • • • •
• • • • •
•
• •
•
• • • •
2-44
2-44
2-46
2-47
2-47
2-48
2-48
2-50
2-52
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is
applied, the bolts and nuts could loosen and fall out. If too much torque is applied, the threads could
be sheared off.
To tighten a bolt or a nut, or to check their torque, loosen the bolt or nut one-half turn before tightening it to the specified torque.
Letters used in the “Remarks” column mean:
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent to the threads.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
R: Replacement Parts
S: Tighten the fasteners following the specified sequence.
Si: Apply silicone grease.
SS: Apply silicone sealant.
Fastener
Fuel System
Fuel Tap Mounting B
Fuel Gauge Mounting Bolts 6.9 0.7 61 in·lb
Air Cleaner Housing Cap Bolts 2.5 0.25 22 in·lb
Air Cleaner Housing Screws 1.15 0.12 10 in·lb
Air Cleaner Housing Mounting Bolts 9.8 1.0 87 in·lb
Air Cleaner Housing Clamp Screws 2.0 0.2 18 in·lb
Separate Bracket Bolt 9.8 1.0 87 in·lb
Cooling System
Water Temperature Switch 7.5 0.76 66 in·lb SS
Thermostat Cover Bolts 9.8 1.0 87 in·lb
Thermostat Housing Mounting Bolts 9.8 1.0 87 in·lb
Radiator Fan Switch 23.5 2.4 17
Radiator Bolt
Radiator Cap Bracket Bolt 9.8 1.0 87 in·lb
Water Pipe Bolts 9.8 1.0 87 in·lb
Water Hose Clamp Screws 1.5 0.15 13 in·lb
Drain Bolt 9.8 1.0 87 in·lb
Water Pump Cover Bolts 9.8 1.0 87 in·lb
Water Pump Bol
Reserve Tank Cap – – – Hand-Tighten
Reserve Tank Bolts 9.8 1.0 87 in·lb
Reserve Tank Bracket Bolt 9.8 1.0 87 in·lb
Engine Top End
Cylinder Head Cover Bolts
Camshaft Spro
Chain Tensioner Cap Bolt 5.0 0.5 44 in·lb
Air Suction Cover Bolts 9.8 1.0 87 in·lb
Vacuum Switch Valve Bracket Bolts 9.8 1.0 87 in·lb
Rear Camshaft Chain Guide Bolt-Lower 17 1.7 13
s
olts
ts
cket Bolts
N·m kgf·m ft·lb
2.5 0.25 22 in·lb
9.8 1.0 87 in·lb
9.8 1.0 87 in·lb
9.8 1.0 87 in·lb
15 1.5 11 L
Torque
Remarks
Torque and Locking Agent
PERIODIC MAINTENANCE 2-7
Fastener
Chain Tensioner Mounting Bolts 9.8 1.0 87 in·lb
Camshaft Cap Bolts 12 1.2 106 in·lb S
Camshaft Cap Bolts 12 1.2 106 in·lb S
Cylinder Head Bolt (M6) 12 1.2 106 in·lb MO, S
Cylinder Head Bolts (M8) 24.5 2.5 18 MO, S
Water Passage Plugs 20 2.0 15 L
Carburetor Holder Clamp Screws 2.0 0.2 18 in·lb
Water Drain Bolt 5.9 0.6 52 in·lb
Muffler Body Rear Cover Bolts
Muffler Body Mounting Bolt 30 3.1 22
Muffler Body Clamp Bolt 17 1.7 13
Muffler Cover Bolts 9.8 1.0 87 in·lb
Muffler Cover Clamp Screw 6.9 0.70 61 in·lb
Exhaust Pipe Mounting Bolt 9.8 1.0 87 in·lb
Exhaust Pipe Holder Nuts 12 1.2 104 in·lb
Clutch
Clutch Lever Holder Clamp Bolts 8.8 0.9 78 in·lb
Clutch Spring Bolts 8.8 0.9 78 in·lb
Clutch Hub Nut
Oil Filler Plug
Clutch Cover Bolts
Engine Lubrication System
Oil Hose Banjo Bolts 19.6 2.0 14.5
Oil Pressure Relief Valve 15 1.5 11 L
Crankcase Oil Passage Plug 15 1.5 11
Oil Passage Plugs for Oil Pump 20 2.0 15 L
Oil Pipe Banjo Bolts 12 1.2 104 in·lb
Oil Drain Bolt 19.6 2.0 14.5
Oil Pressure Switch 15 1.5 11 SS
Oil Pressure Switch Terminal Bolt 1.5 0.15 13 in·lb
Oil Filter Mounting Bolts
Oil Breather Mounting Bolts
Oil Pump Mounting Bolts
Oil Screen Cover Bolts 9.8 1.0 87 in·lb
Plug 19.6 2.0 14.5
Breather Bolt 9.8 1.0 87 in·lb
Engine Removal/Installation
Engine Mounting Bracket Bolts and Nuts 64 6.5 47
Engine Mounting Nuts 64 6.5 47
Crankshaft/Transmission
Oil Breather Mounting Bolts 9.8 1.0 87 in·lb L
Crankcase Bolts 6 12 1.2 104 in·lb
Crankcase Bolts 8 (L = 90)
N·m kgf·m ft·lb
9.8 1.0 87 in·lb L
132 13.5 97.4
– – – Hand-Tighten
9.8 1.0 87 in·lb
19.6 2.0 14.5
9.8 1.0 87 in·lb L
9.8 1.0 87 in·lb L
24 2.4 18
Torque
Remarks
MO, S
2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Crankcase Bolts 8(L=73) 19 1.9 14 MO, S
Starter Motor Clutch Bolts
Connecting Rod Big End Cap Nuts
Shift Drum Bearing Hol
Shift Drum Pin Plate Bolt 9.0 0.9 80 in·lb L
Neutral Switch 15 1.5 11
External Shift Mechanism Return Spring Pin 19.6 2.0 14.5 L
Shift Drum Positioning Bolt 24.5 2.5 18
Shift Lever Link Bolt 12 1.2 104 in·lb
Front Tie-Rod Locknut (Left-Hand Threads) 7.0 0.7 62 in·lb
Rear Tie-Rod Locknut (Right-Hand Threads) 7.0 0.7 62 in·lb
Shift Pedal Mounting Bolt 25 2.5 18
Wheels/Tires
Front Axle Nut 88 9.0 65
Rear Axle Nut 98 10.0 72
Final Drive
Engine Sprocket Cover Bolts 9.8 1.0 87 in·lb
Engine Sprocket Nut 127 13 94 MO
Rear Sprocket Nuts 59 6.0 44
Rear Sprocket Studs
Brakes
Brake Lever Pivot
Bleed Valve 5.5 0.55 49 in·lb
Front Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S
Brake Disc Mounting Bolts 27 2.8 20 L
Brake Hose Banjo Bolts 25 2.5 18
Front Caliper Mounting Bolts
Front Brake Ligh
Brake Lever Pivot Bolt 1.0 0.1 9in·lb
Front Reservoir Cap Screws 1.5 0.15 13 in·lb
Reservoir Mounting Bolt 6.9 0.7 61 in·lb
Bleed Valve 5.5 0.55 49 in·lb
Brake Pedal Pivot Bolt 8.8 0.9 78 in·lb L
Push Rod Locknut 18 1.8 13
Brake Disc Mounting Bolts 27 2.8 20 L
Brake Hose Banjo Bolts 25 2.5 18
Rear Master Cylinder Mounting Bolts 25 2.5 18
Rear Caliper Mounting Bolts 25 2.5 18
Suspension
Front Fork Clamp Bolts (Upper) 21 2.1 15
Front Fork Top Plugs 23 2.3 16.5
Front Fork Clamp Bolts (Lower) 30 3.1 22
Front Fork Bottom Allen Bolts 20 2.0 15 L
tSwitchScrew
der Bolt
Bolt Locknut
N·m kgf·m ft·lb
34.3 3.5 25 L
27.5 2.8 20
12 1.2 104 in·lb L
– – – L
5.9 0.6 52 in·lb
25 2.5 18
1.0 0.1 9in·lb
Torque
Remarks
MO
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