Kawasaki W800 Service Manual

W800

Quick Reference Guide

General Information 1 j

Periodic Maintenance 2 j

Fuel System (DFI) 3 j

Engine Top End 4 j

Clutch 5 j

Engine Lubrication System 6 j

Engine Removal/Installation 7 j

Crankshaft/Transmission 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.

Wheels/Tires 9 j

Final Drive 10 j

Brakes 11 j

Suspension 12 j

Steering 13 j

Frame 14 j

Electrical System 15 j

Appendix 16 j

W800

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/Motorcycle & Engine 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.

LIST OF ABBREVIATIONS

ABDC after bottom dead cente

AC alternating current m meter(s)

ATDC after top dead center min minute(s)

BBDC before bottom dead center N newton(s)

BDC bottom dead center Pa pascal(s)

BTDC before top dead center PS horsepower

°C degree(s) Celsius psi pound(s) per square inch

DC direct current r revolution

F farad(s) rpm revolution(s) per minute

°F degree(s) Fahrenheit TDC top dead center

ft foot, feet

in. inch(es) Ω ohm(s)

ampere(s)

gram(s)

hour(s)

TIR total indicator reading

liter(s)

pound(s)

volt(s)

watt(s)

COUNTRY AND AREA CODES

AU Austria MY Malaysia

BR Brazil SEA-B3 Southeast Asia B3

CA Can

CAL California

CH Switzerland

DE Germany

GB United Kingdom

ada

US Uni

WVTA (FULL)

GB WVTA (FULL H)

WVTA (78.2)

ted States

WVTA Model (Full Power)

WVTA Model with Honeycomb Catalytic Converter (Left Side Traffic, Full Power)

WVTA Model with Honeycomb Catalytic Converter (78.2 Kw Power)

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 symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more symbols which will help you distinguish different types of information.

NOTE

NOTE indicates information that may help

○

or g uide you in the operation or service of

the vehicle.

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

1-2 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 flash-point solvent when cleaning parts. High flash-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, cotter pins or self-locking nuts 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.

All of the tightening torque values are for use with dry, solvent - cleaned threads unless otherwise indicated. If a fastener which should have dry, clean threads gets contaminated with lubricant, etc., applying even the specified torque could damage it.

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 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, c lean 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

EJ800AB Left Side View

GENERAL INFORMATION 1-7

EJ800AB Right Side View

Frame Number Engine Number

1-8 GENERAL INFORMATION

General Specifications

Items EJ800AB ∼ AG

Dimensions

Overall Length 2 190 mm (86.22 in.)

Overall Width 790 mm (31.1 in.)

Overall Height 1 075 mm (42.32 in.)

Wheelbase

Road Clearance 125 mm (4.92 in.)

Seat Height 790 mm (31.1 in.)

Curb Mass 217 kg (478 lb)

Front 100 kg (220 lb)

Rear 117kg(258lb)

Fuel Tank Capacity 14 L (3.7 US gal.)

Performance

Minimum Turning Radius 2.7 m (8.9 ft)

Engine

Type 4-stroke, SOHC, 2-cylinder

Cooling System Air-cooled

Bore and Stroke 77.0 × 83.0 mm (3.03 × 3.27 in.)

Displacement 773 cm³ (47.2 cu in.)

Compression Ratio 8.4 : 1

Maximum Horsepower

Maximum Torque

Fuel System FI (Fuel Injection) KEIHIN TTK34 × 2

Fuel Type:

Minimum Octane Rating:

Research Octane Number (RON) 91

Starting System Electric start

Ignition System Battery and coil (transistorized)

Timing Advance

Ignition Timing

Spark Plug NGK CR8E

Cylinder Numbering Method Left to right, 1-2

Firing Order 1-2

Valve Timing:

Intake:

Open 25° BTDC

Close 55° ABDC

Duration 260°

Exhaust:

Open 55° BBDC

Close 25° ATDC

Duration 260°

Lubrication System Forced lubrication (wet sump)

Engine Oil:

Type

1 465 mm (57.68 in.)

35 kW (48 PS) @6 500 r/min (rpm)

60 N·m (6.1 kgf·m, 44 ft·lb) @2 500 r/min (rpm)

Electronically advanced (digital igniter)

0° BTDC @1 200

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

r/min (rpm)

GENERAL INFORMATION 1-9

General Specifications

Items EJ800AB ∼ AG

Viscosity SAE 10W-40

Capacity 3.2L(3.4USqt)

Drive Train

Primary Reduction System:

Type Gear

Reduction Ratio 2.095 (88/42)

Clutch Type Wet multi disc

Transmission:

Type 5-speed, constant mesh, return shift

Gear Ratios:

1st 2.353 (40/17)

2nd 1.591 (35/22)

3rd 1.240 (31/25)

4th

5th

Final Drive System:

Type Chain drive

Reduction Ratio 2.467 (37/15)

Overall Drive Ratio 4.403 at Top gear

Frame

Type Tubular, Double cradle

Caster (Rake Angle) 27°

Trail 108 mm (4.06 in.)

Front Tire:

Type TT100GP G

Size 100/90-19 M/C 57H

Rim Size J19 × 2.15

Rear Tire:

Type TT100GP

Size 130/80-18 M/C 66H

Rim Size J18M/C × MT2.75

Front Suspension:

Type Telescopic fork

Wheel Travel 130 mm (5.12 in.)

Rear Suspension:

Type Swingarm, shock absorber

Wheel Travel 106 mm (4.17 in.)

Brake Type:

Front Single disc

Rear Drum

Electrical Equipment

Battery 12 V 10 Ah (10 HR)

Headlight:

Type Semi-sealed beam

1.000 (28/28)

0.852 (23/27)

1-10 GENERAL INFORMATION

General Specifications

Items EJ800AB ∼ AG

Bulb 12 V 60/55 W (quartz-halogen)

Brake/Tail Light 12 V 21/5 W

Alternator:

Type

Maximum Output 14 V-18 A @7 000 r/min (r

Specifications are subject to change without notice, and may not apply to every country.

Three-phase AC

pm)

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 =

L × 0.8799 =

L × 2.113 = pint (US)

L × 1.816 = pint (IMP)

mL × 0.03381 = oz (US)

mL × 0.02816 = oz (IMP)

mL × 0.06102 = cu in.

qt (US)

qt (IMP)

Units of Length:

km × 0.6214 = mile

m × 3.281 = ft

mm × 0.03937 = in.

Units of Torque:

N·m × 0.1020 = kgf·m

N·m × 0.7376 = ft·lb

N·m × 8.851 = in·lb

kgf·m × 9.807 = N·m

kgf·m × 7.233 = ft·lb

kgf·m × 86.80 = in·lb

Units of Pressure:

kPa × 0.01020 = kgf/cm²

kPa × 0.1450 = psi

kPa × 0.7501 = cmHg

kgf/cm² × 98.07 = kPa

kgf/cm² × 14.22 = psi

cmHg×1.333=kPa

Units of Speed:

km/h

× 0.6214 = mph

Units of Force:

N × 0.1020 = kg

N × 0.2248 = lb

kg ×9.807=N

kg ×2.205=lb

Units of Temperature:

Units of Power:

kW ×1.360=PS

kW ×1.341=HP

PS × 0.9863 = HP

× 0.7355 = kW

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent................. 2-5

Specifications .................................... 2-10

Special Tools ..................................... 2-12

Periodic Maintenance Procedures..... 2-13

Fuel System.................................... 2-13

Air Cleaner Element Cleaning...... 2-13

Throttle Control System

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

Engine Vacuum Synchronization

Inspection.................................. 2-14

Idle Speed Inspection .................. 2-17

Idle Speed Adjustment................. 2-17

Fuel Hose and Pipe Inspection

(fuel leak, damage, installation

condition)................................... 2-17

Engine Top End .............................. 2-18

Valve Clearance Inspection ......... 2-18

Valve Clearance Adjustment........ 2-19

Air Suction System Damage

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

Clutch.............................................. 2-23

Clutch Operation Inspection......... 2-23

Wheels/Tires................................... 2-24

Tire Air Pressure Inspection......... 2-24

Wheel/Tire Damage Inspection.... 2-25

Tire Tread Wear Inspection.......... 2-25

Wheel Bearing Damage

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

Spoke Tightness and Rim Runout

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

Final Drive....................................... 2-28

Drive Chain Lubrication Condition

Inspection.................................. 2-28

Drive Chain Slack Inspection ....... 2-28

Drive Chain Slack Adjustment ..... 2-29

Wheel Alignment

Inspection/Adjustment............... 2-30

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

Chain Guide Wear Inspection ...... 2-31

Brake System ................................. 2-32

Brake Fluid Leak Inspection......... 2-32

Brake Hose Damage and

Installation Condition

Inspection.................................. 2-32

Brake Fluid Level Inspection........ 2-32

Brake Pad Wear Inspection ......... 2-33

Brake Operation Inspection ......... 2-33

Brake Pedal Free Play Inspection 2-33 Brake Pedal Free Play

Adjustment ................................ 2-34

Brake Lining Wear Inspection ...... 2-34

Brake Light Switch Operation

Inspection .................................. 2-34

Suspensions ................................... 2-35

Front Forks/Rear Shock Absorber

Operation Inspection................. 2-35

Front Forks Oil Leak Inspection ... 2-36 Rear Shock Absorbers Oil Leak

Inspection .................................. 2-36

Swingarm Pivot Lubrication ......... 2-36

Steering System ............................. 2-36

Steering Play Inspection .............. 2-36

Steering Play Adjustment............. 2-37

Steering Stem Bearing

Lubrication................................. 2-37

Electrical System ............................ 2-38

Lights and Switches Operation

Inspection .................................. 2-38

Headlight Aiming Inspection ........ 2-40

Sidestand Switch Operation

Inspection .................................. 2-41

Engine Stop Switch Operation

Inspection .................................. 2-42

Others............................................. 2-42

Chassis Parts Lubrication ............ 2-42

Bolts, Nuts and Fasteners

Tightness Inspection ................. 2-44

Replacement Parts ......................... 2-45

Air Cleaner Element

Replacement............................. 2-45

Fuel Hose Replacement .............. 2-45

Engine Oil Change....................... 2-47

Oil Filter Replacement ................. 2-48

Brake Hose Replacement ............ 2-49

Brake Fluid Change ..................... 2-50

Master Cylinder Rubber Parts

Replacement............................. 2-51

Caliper Rubber Parts

Replacement............................. 2-52

Spark Plug Replacement ............. 2-53

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to k eep 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

ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Fuel System

* ODOME TER READING

× 1 000 km

(× 1 000 mile)

See

Page

Air cleaner element - clean

Throttle c ontrol system (play, smooth return, no dra

Engine vacuum synchronization inspect

Idle speed - inspect

Fuel leak (fuel hose and pipe) inspect

Fuel hose and pipe damage inspect

Fuel hose and pipe installation condition - inspect

Engine Top End

Valve clearance - inspect

Air suction system damage inspect

Clutch

Clutch operation (play, disengagement, en

-inspect

Wheels and Tires

g) - inspect

gagement)

year

• • •

• • • •

• • •

• • • •

• • •

• • • •

2-13

2-14

2-17

2-18

2-23

Tire air pressure - inspect year

Wheel/tire damage - inspect

Tire tread wear, abnormal wear inspect

Wheel bearing damage - inspect year

Spoke tightness and rim runout inspect

Final Drive

Drive chain lubrication condition inspect #

Drive chain slack - inspect # Every 1 000 km (600 mile) 2-28

Drive chain wear - inspect #

Chain guide wear - inspect

Brakes

Brake fluid leak - inspect year

Brake hose damage - inspect year

• • • • • • •

Every 600 km (375 mile) 2-28

• • • • • •

• • • • • • •

• • •

2-24

2-25

2-26

2-31

2-32

Periodic Maintenance Chart

PERIODIC MAINTENANCE 2-3

FREQUENCY Whichever

comes

first

1 6 12 18 24 30 36

ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Brake hose installation condition inspect

Brake fluid level - inspect

Brake pad wear - inspect #

Brake operation (effectiveness, play, no drag) - inspect

Brake lining wear - inspect

Brake light switch operation inspect

Suspension

Front forks/rear shock absorbers operation (damping and smooth stroke) - inspect

Front forks/rear shock absorbers oil leak - inspect

year

months

year

• • • • • • •

• • • • • •

• • • • • • •

• • • • • •

• • • • • • •

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

• • •

See

Page

2-32

2-33

2-34

2-35

2-36

Swingarm pivot - lubricate

Steering

Steering play - inspect year

Steering stem bearings - lubricate 2 years

Electrical System

Lights and switches operation inspect

Headlight aiming - inspect year

Sidestand switch operation inspect

Engine stop switch operation inspect

Others

Chassis parts - lubricate

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.

year

• • • •

• • •

• • • •

•

2-36

2-37

2-38

2-40

2-41

2-42

2-44

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts

FREQUENCY Whichever

comes

first

ITEM Every (0.6) (7.5) (15) (22.5) (30)

Air cleaner element # - replace 2 years 2-45

Fuel hose - replace 5 years 2-45

* ODOMETER READING

× 1 000 km

(× 1 000 mile)

1 12 24 36 48

See

Page

Engine oil # - change year

Oilfilter-replace year

Brake hose - replace 4 years 2-49

Brake fluid - change 2 years

Rubber parts of master cylinder and caliper replace

Spark plug - replace

#: 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.

4 years

• • • • •

• •

• • • •

2-47

2-48

2-50

2-51,

•

2-52

2-53

PERIODIC MAINTENANCE 2-5

Torque and L ocking Agent

The following tables list the tightening torque for the major fasteners requiring use of a

non-permanent locking agent or silicone sealant etc.

All of the values are for use with dry solvent - cleaned threads unless otherwise indicated.

Letters used in the “Remarks” column mean:

CP: Bolt with copper-plated washer.

G: Apply grease.

HL: Apply high-lock agent to the threads.

L: Apply a non-permanent locking agent.

Lh: Left-hand Threads

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement parts S: Follow the specified tightening sequence.

Si: Apply silicone grease.

SS: Apply silicone sealant.

Fastener

Fuel System

Fuel Reserve Switch Screws

Fuel Pump Bolts 9.8 1.0 87 in·lb L

Throttle Cable Plate Bolt 5.9 0.60 52 in·lb

Delivery Pipe Mounting Screws 3.43 0.35 30 in·lb

Engine Temperature Sensor 9.8 1.0 87 in·lb

Oxygen Sensor 25 2.5 18

Crankshaft Sensor Bolts

Speed Sensor Mounting Bolt

Vehicle-down S

Engine Top End

Spark Plug Hole Holder Cover Bolts 7.8 0.8 69 in·lb

Cylinder Head Cover Bolts 9.8 1.0 87 in·lb

Bevel Gear Cover Bolts

Air Suction Valve Cover Bolts

Cylinder Head

Cylinder Head Bolts (Used Bolts) 47 4.8 35 MO, S

Spark Plugs 13 1.3 115 in·l b

Spark Plug Hole Pipes 120 12.2 89 L

Camshaft Cap Bolts (8 mm) 25 2.5 18 S

Camshaft Cap Bolts (6 mm) 12 1.2 106 in·lb S

Oil Fitting Bracket Bolts 12 1.2 106 in·lb L

Oxygen Sensor 25 2.5 18

Muffler Bracket Bolts 21 2.1 15

Rocker Shaft Bolts 12 1.2 106 in·lb L

Camshaft Locating Plate Bolts

Driven Bevel Gear Bolts

Bevel Gea

Gear Case 98 10 72 L

ensor Mounting Bolts

Bolts (New Bolts)

r Mounting Nuts

N·m kgf·m ft·lb

2.1 0.21 19 in·lb

7.8 0.80 69 in·lb L

4.5 0.46 40 in·lb

4.0 0.40 35 in·lb

3.9 0.4 35 in·lb L

12 1.2 106 in·lb L

49 5.0 36

12 1.2 106 in·lb

20 2.0 15 L

59 6.0 44 R

Torque

Remarks

MO, S

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Bevel Gear Case Locknuts 20 2.0 15

Bevel Gear Case Bolts

Bevel Gear Oil Passage Nozzle

Bevel Gear Holder Scre

Bearing Holder Allen Bolts 7.8 0.8 69 in·lb L

Locknut Stop Screw 2.1 0.2 1.5 L

Clutch

Clutch Lever Holder Bolts

Clutch Hub Nut

Clutch Spring Bolts

Clutch Cover Damper Plate Bolts 12 1.2 106 in·lb L

Clutch Cable Lower Holder Bolts 12 1.2 106 in·lb L

Clutch Release Case Mounting Bolt (L = 80 mm) 12 1.2 106 in·lb

Clutch Release Case Mounting Bolt (L = 70 mm) 12 1.2 106 in·lb

Release Shaft Locating Bolt 9.8 1.0 87 in·lb

Release Lever Clamp Bolt 12 1.2 106 in·lb

Clutch Cover Bolts (M6, L = 25) 12 1.2 106 in·lb

Clutch Cover Bolts (M6, L = 50) 12 1.2 106 in·lb

Clutch Cover Bolt (M6, L = 70) 12 1.2 106 in·lb L

Engine Lubrication System

Oil Fitting Bracket Bolts (L = 20 mm)

Oil Fitting Br

Oil Filler Cap 1.5 0.15 13 in·lb (Hand tighten)

Oil Filter Cap Bolts 12 1.2 106 in·lb L

Oil Filter 17 1.7 13

Oil Filter Passage Pipe 25 2.5 18 SS

Oil Pressure Relief Nozzle 3.4 0.35 30 in·lb

Oil Passage Nozzle 3.4 0.35 30 in·lb

Oil Pressure Switch Plug 20 2.0 15 L

Oil Pressure Switch 15 1.5 11 SS

Oil Pump Cover Bolts 9.8 1.0 87 in·lb L

Oil Pump Gear Bolt

Oil Pipe Plate Bolt

Oil Pressu

Oil Drain Plug 29 3.0 21

Oil Pan Bolts 12 1.2 106 in·lb L(2)

Engine Removal/Installation

Engine Bracket Bolts (L = 60 mm) 34 3.5 25

Engine Bracket Bolts (L = 16 mm) 25 2.5 18

Engine Mo

Lower Engine Mounting Nut 59 6.0 44 R

acket Bolt (L = 25 mm)

re Relief Valve

unting Nuts

N·m kgf·m ft·lb

12 1.2 106 in·lb

3.5 0.36 31 in·lb

4.9 0.5 43 in·lb L

7.8 0.80 69 in·lb

145 14.8 107 R

9.8 1.0 87 in·lb

12 1.2 106 in·lb L

9.8 1.0 87 in·lb L

15 1.5 11 HL

44 4.5 32 R

Torque

Remarks

Torque and L ocking Agent

PERIODIC MAINTENANCE 2-7

Fastener

Crankshaft/Transmission

Connecting Rod Big End Cap Nuts

Breather Cap Bolts 12 1.2 106 in·lb

Starter Motor Clutch Bolts

Breather Plate Screws

External Shift Mecha 35 mm)

Neutral Switch Screws 3.9 0.40 35 in·lb L

External Shift Mechanism Cover Bolts (M6, L = 25 mm)

Return Spring Pin

Rear Engine Cover B

Rear Engine Cover Bolts (M6, L = 22 mm) 12 1.2 106 in·lb

Upper Crankcase Bolts (M8, L = 73 mm) 29 3.0 21 CP (1)

Upper Crankcase Bolt (M6, L = 45 mm) 20 2.0 15

Upper Crankcase Bolt (M6, L = 70 mm) 20 2.0 15

Upper Crankcase Bolts (M6, L = 117 mm) 20 2.0 15

Upper Crankcase Bolts (M8, L = 50 mm) 29 3.0 21

Lower Crankcase Bolts (M9, L = 130 mm) 41 4.2 30 S, MO

Lower Crankcase Bolts (M9, L = 110 mm) 41 4.2 30 S, MO

Lower Crankcase Bolt (M9, L = 90 mm) 41 4.2 30 S, MO

Lower Crankcase Bolts (M6, L = 45 mm)

Lower Crankcase Bolts (M8, L = 73 mm)

Lower Crankca

Lower Crankcase Bolt (M8, L = 60 mm) 29 3.0 21 S, MO

Shift Drum Cam Bolt 12 1.2 106 in·lb L

Shift Drum Bearing H older Screw 4.9 0.50 43 in·lb S, L

Shift Drum Bearing Holder Bolt 12 1.2 106 in·lb S, L

Gear Positioning Lever Bolt 12 1.2 106 in·lb L

Wheels/Tires

Spoke Nipples 5.2 0.53 46 in·lb

Front Axle Clamp Bolt 20 2.0 15

Front Axle Nut 98 10 72

Rear Axle Nut 98 10 72

Final Drive

Engine Sprocket Cover Bolts 12 1.2 106 in·lb L

Engine Sprocket Nut 147 15 108 MO

Rear Sprocket Nuts 59 6.0 44 R

Brakes

Brake Reservoir Cap Screws 1.5 0.15 13 in·lb

Brake Lever Pivot Bolt 1.0 0.10 9in·lb Si

Brake Leve

Master Cylinder Clamp Bolts 11 1.1 97 in·lb S

r Pivot Bolt Locknut

nism Cover Bolts (M6, L =

olts (M6, L = 30 mm)

se Bolt (M6, L = 32 mm)

N·m kgf·m ft·lb

see the

text

34 3.5 25 L

4.9 0.50 43 in·lb L

12 1.2 106 in·lb

12 1.2 106 in·lb L

42 4.3 31 L

12 1.2 106 in·lb

20 2.0 15

29 3.0 21

20 2.0 15

5.9 0.60 52 in·lb

Torque

Remarks

← ← MO

S, MO, CP (1)

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Fastener

Front Brake Light Switch Screw 1.2 0.12 11 i n · lb

Brake Hose Banjo Bolts 25 2.5 18

Brake Disc Mounting Bolts 23 2.3 17

Caliper Mounting Bolts

Bleed Valve 7.8 0.80 69 in·lb

Brake Pedal Bolt (EJ800AB) 25 2.5 18

Brake Pedal Bolt (EJ800AC ∼) 34 3.5 25

Torque Link Bolt 34 3.5 25

Torque Link Nut 34 3.5 25

Cam Lever Bolt

Suspension

Front Fork Top Plugs 23 2.3 17

Front Fork Clamp Bolts (Upper) 20 2.0 15

Front Axle Clamp Bolt

Front Fork Bottom Allen Bolts 30 3.1 22 L

Front Fork Clamp Bolts (Lower) 29 3.0 21

Rear Shock Absorber Nuts 59 6.0 44

Rear Shock Absorber Bolts 44 4.5 32

Swingarm Pivot Shaft Nut 98 10 72

Torque Link Bolt 34 3.5 25

Torque Link Nut 34 3.5 25

Steering

Handlebar Clamp Bolts 25 2.5 18 S

Steering Stem Head Nut 49 5.0 36

Front Fork Clamp Bolts (Upper) 20 2.0 15

Steering Stem Nut 4.9 0.50 43 in·lb

Front Fork Clamp Bolts (Lower) 29 3.0 21

Frame

Rear View Mirror Locknut (Upper) 30 3.1 22 G, Lh

Rear View Mirror Nut (Lower) 30 3.1 22

Sidestand Switch Bolt 8.8 0.9 78 in·lb L

Sidestand Bolt 44 4.5 32

Sidestand Nut 44 4.5 32 R

Front Step Mounting Bolts 59 6.0 44

Center Stand Bolt 44 4.5 32

Grab Rail Bolts 25 2.5 18

Electrical System

Tail/Brake Light Mounting Nuts

Starter Motor Terminal Locknut

Starter Motor

Starter Motor Through Bolts 4.9 0.50 43 in·lb

Starter Motor Cable Terminal Nut 4.9 0.50 43 in·lb

One-Way Clutch Mounting Allen Bolts 34 3.5 25 L

Mounting Bolts

N·m kgf·m ft·lb

34 3.5 25

19 1.9 14

20 2.0 15

5.9 0.60 52 in·lb

11 1.1 97 in·lb

9.8 1.0 87 in·lb L

Torque

Remarks

Torque and L ocking Agent

PERIODIC MAINTENANCE 2-9

Fastener

Stator Coil Bolts 12 1.2 106 in·lb L

Alternator Rotor Bolt 155 15.8 114

Alternator Lead Holding Plate Bolts 7.8 0.80 69 in·lb L

Crankshaft Sensor Bracket Bolt (L = 45 mm) 12 1.2 106 in·lb L

Crankshaft Sensor Bracket Bolts (L = 40 mm) 12 1.2 106 in·lb L

Crankshaft Sensor Bolts 7.8 0.80 69 in·lb L

Crankshaft Sensor Lead Guard Plate Bolts 10 1.0 89 in·lb L

Oil Pressure Switch

Speed Sensor Mounting Bolt

Neutral Switch Scre

Alternator Cover Bolts (M6, L = 35 mm) 12 1.2 106 in·lb (L, 2)

Alternator Cover Bolts (M6, L = 40 mm) 12 1.2 106 in·lb

Alternator Cover Bolts (M6, L = 45 mm) 12 1.2 106 in·lb

Front Brake Light Switch Screw 1.2 0.12 11 in·lb

Spark Plugs 13 1.3 115 in·l b

Sidestand Switch Bolt 8.8 0.9 78 in·lb L

Fuel Reserve Switch Screws 2.1 0.21 19 in·lb

Oxygen Sensor 25 2.5 18

N·m kgf·m ft·lb

15 1.5 11

4.5 0.46 40 in·lb L

3.9 0.40 35 in·lb L

Torque

Remarks

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads Diameter

(mm)

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 23.0 ∼ 33.0 165 ∼ 240

N·m

Torque

kgf

·m

ft·

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit

Fuel System (DFI)

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

Idle Speed 1200±50r/min(rpm)

Throttle Body Vacuum 21.3 ∼ 26.7 kPa (160 ∼ 200 mmHg) at idle

speed (for reference)

Engine Synchronization Vacuum

Air Cleaner Element

Engine Top End

Valve Clearance:

Exhaust

Intake

Clutch

Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) –––

Engine Lubrication System

Engine Oil:

Type

Viscosity

Capacity 2.7 L (2.9 US qt) (when filter is not removed)

Level

Wheels/Tires

Tread Depth:

Front

Rear

Air Pressure (When Cold):

Front

Rear

Rim Runout:

Front:

Axial

Radial

Rear:

Axial

Radial

Less than 2.4 kPa (18 mmHg) difference between both cylinders

Polyurethane Foam –––

0.14 ∼ 0.19 mm (0.0055 ∼ 0.0075 in.)

0.08 ∼ 0.13 mm (0.0031 ∼ 0.0051 in.)

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

2.9 L (3.1 US qt) (when filter is removed)

3.2 L (3.4 US qt) (when engine is completely dry)

Between upper and lower level lines (Wait 2 ∼ 3 minutes after idling or running)

4.4 mm (0.17 in.) 1 mm (0.04 in.)

7.4 mm (0.29 in.) 2 mm (0.08 in.) up to 130km/h (80 mph)

3 mm (0.12 in.) over

130km/h (80 mph)

200 kPa (2.0 kgf/cm², 2 8 psi)

Up to 97.5 kg (215 lb) load: 225 kPa (2.25 kgf/cm², 32 psi)

Over 97.5 kg (215 lb) load: 250 kPa (2.50 kgf/cm², 36 psi)

TIR 0.7 mm (0.03 i n.) or less TIR 2.0 mm (0.08 in.)

TIR 1 mm (0.04 in.) or less TIR 2.0 mm (0.08 in.)

TIR 0.8 mm (0.03 i n.) or less TIR 2.0 mm (0.08 in.)

TIR 1.2 mm (0.05 i n.) or less TIR 2.0 mm (0.08 in.)

–––

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