Kawasaki Zephyr 1100, ZR 1100 Service Manual

Page 1

ZR1100 ZEPHYR 1100

Motorcycle Service Manual

First Edition (2) : Dec. 26, 1991 (M)

Page 2

LIST OF ABBREVIATIONS

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

Read OWNER'S MANUAL before operating.

Page 3

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 motorcycle:

•Follow the Periodic Maintenance Chart in the Service Manual.
Be alert for problems and non-scheduled maintenance.
•Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
•Follow the procedures in this manual carefully. Don't take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new parts installed.

How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.

The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.

The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations.

If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

AWARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

ACAUTION

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

Page 4

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 particular interest for more efficient and convenient operation.
Indicates a procedural step or work to be done.
Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
★ Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

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

Page 5

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.

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake 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 carburetion 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 and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, 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..."

(Continued on next page.)

Page 6

NOTE

The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows:
- 1. Tampering does not include the temporary 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 exceeded.
  - b. Use of replacement parts 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 standards.
  - 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 intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

Page 7

Quick Reference Guide

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

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.

Page 8

General Information

Before Servicing	1-2
Model Identification	1-4
General Specifications	1-5
Periodic Maintenance Chart	1-7
Technical Information	1-9
Maintenance Free Battery	1-9
(I) Construction	1-9
(II) Main Features	1-9
(III) Principle of Sealing Structure	1-9
(IV) Filling the Battery with Electrolyte	1-10
(V) Initial Charge	1-12
(VI) Precautions	1-12
(VII) Interchangeability with Ordinary Battery	1-12
Torque and Locking Agent	1-13
Special Tools and Sealant	1-17
Cable, Wire and Hose Routing	1-23
Evaporative Emission Control System (California Model)	1-26

Page 9

1-2 GENERAL INFORMATION

Before Servicing

Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings.

(2) Battery Ground

Remove the ground (-) lead from the battery before performing any disassembly operations on the motorcycle. This prevents:

(a) the possibility of accidentally turning the engine over while partially disassembled.
(b) sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) 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 evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated.

(4) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.

(5) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads.

(6) Edges

Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.

(7) High-Flash Point Solvent

A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(8) Gasket, O-Ring

Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.

(9) Liquid Gasket, Non-Permanent Locking Agent

Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue).

(10) Press

A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly.

(11) Ball Bearing and Needle Bearing

Do not remove any ball or needle bearings that are pressed in unless it is necessary. If they are removed, replace them with new ones.

When installing a bearing, press it in with the marked side facing out using a suitable driver until it is bottomed. Bearings should be pressed into place by pushing evenly the bearing race which is affected by friction.

Page 10

(12) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.

(13) Seal Guide

A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction.

(14) Circlip, Retaining Ring

Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more.

(15) Cotter Pin

Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.

Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.

Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS₂) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants.

(17) Electrical Wires

All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color.

Wire (cross-section)	Name of Wire Color
Red Wire Strands Yellow Red	Yellow/Red

(18) Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed.

(19) Inspection

When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones.

Abrasion	Crack	Hardening	Warp
Bent	Dent	Scratch	Wear
Color change	Deterioration	Seizure

(20) Specifications

Specification terms are defined as follows:

"Standards": Show dimensions or performances which brand-new parts or systems have.

"Service Limits": Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

Page 11

1-4 GENERAL INFORMATION

Model Identification

ZR1100-A1 Left Side View:

ZR1100-A1 Right Side View:

Page 12

GENERAL INFORMATION 1-5

General Specifications

ltems		ZR1100-A1
Dimensions:
Overall length		2,170 mm, (FG)(ST)(GR)(IT)(NR)(SD) 2,200 mm
Overall width		790 mm
Overall height		1,115 mm
Wheelbase		1,500 mm
Road clearance		130 mm
Seat height		795 mm
Dry weight		242 kg
Curb weight:	Front	127 kg
	Rear	135 kg
Fuel tank capacity		19.0 L
Performance:
Minimum turning r	adius	2.9 m
Engine:
Туре		4-stroke, DOHC, 4-cylinder
Cooling system		Air-cooled
Bore and stroke		73.5 x 62.6 mm
Displacement		1,062 mL
Compression ratio		9.1
Maximum horsepor	wer	68.4 kW (93 PS) @8,000 r/min (rpm),
		(FR) 66.3 kW @8,000 r/min (rpm) (UTAC's norm)
		(SD) 53.7 kW (73 PS) @8,000 r/min (rpm)
		(ST) 53.7 kW (73 PS) @6,000 r/min (rpm)
Maximum torque		88.3 N-m (9.0 kg-m, 65.1 ft-lb) @7,000 r/min (rpm)
		(FR)
		(SD) 77.5 N-m (7.9 kg-m, 57.1 ft-lb) @6,000 r/min (rpm)
		(ST) 85.3 N-m (8.7 kg-m, 62.9 ft-lb) @6,000 r/min (rpm)
Carburetion system		Carburetors, Keihin CVK34 ×4
Starting system		Electric starter
Ignition system		Battery and coil (transistorized)
Timing advance		Electronically advanced (digital igniter)
Ignition timing		From 2.5° BTDC @1,000 r/min (rpm) to
		25" BTDC @3,500 r/min (rpm)
		(ST) From 2.5° BTDC @1,100 r/min (rpm) to

Spark plug	a second second	NGK CK9E OF ND UZZESK-N
Cylinder numbering	g method
Firing order		1-2-4-3
valve timing:	Onen
Inlet	Open
	Close	200°
E. In a visit	Duration
Exnaust	Close	37° ATDC
	Duration	280°
Lubrication evetors	Duration	Forced lubrication (wet sump with cooler)
Engine oil
Grade		SE or SE class
Viecosity		SAF10W-40 10W-50 20W-40 or 20W-50
Canacity		501
Capacity

Page 13

1-6 GENERAL INFORMATION

Items		ZR1100-A1
Drive Train:
Primary reduction s	system:
Type		Chain and gear
Reduction ratio		1.706 (99/58)
Clutch type		Wet multi disc
Transmission:
Туре		5-speed, constant mesh, return shift
Gear ratios:	1st	2.500 (40/16)
	2nd	1.666 (35/21)
2	3rd	1.291 (31/24)
	4th	1.074 (29/27)
	5th	0.931 (27/29)
Final drive system:
Туре		Chain
Reduction ratio		3.000 (48/16), (AR)(ST) 2.812 (45/16)
Overall drive rati	ю	4.767 @Top gear, (AR)(ST) 4.469 @Top gear
Frame:
Туре		Tubular, double cradle
Caster (rake angle)	)	27°
Trail		110 mm
Front tire:	Туре	Tubeless
	Size	120/70-18 59V, 110/80 V18 V240, or 110/80 V18
		(AS)(CN) 120/70-18 59V or 110/80 V18 V240
Rear tire:	Туре	Tubeless
	Size	160/70-17 73V, 160/70 VB17 V240, or 160/70 VB17
		(AS)(CN) 160/70-17 73V or 160/70 VB17 V240
Front suspension:	Туре	Telescopic fork
	Wheel travel	130 mm
Rear suspension:	Туре	Swing arm
	Wheel travel	110 mm
Brake type:	Front	Dual discs
	Rear	Single disc
Electrical Equipme	ent:
Battery		12 V 14 Ah
Headlight:	Type	Semi-sealed beam

Headlight:	Туре	Semi-sealed beam
	Bulb	12 V 60/55 W (quartz-halogen)
Tail/brake light		12 V 5/21 W x2
Alternator:	Туре	Three-phase AC
	Rated output	35 A/13.5 V @5,000 r/min (rpm)

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

(AR) : Austrian Model

(AS) : Australian Model

(CN) : Canadian Model

(FG) : German Model

(FR) : French Model

(GR) : Greek Model (IT) : Italian Model (NR) : Norwegian Model (SD) : Swedish Model (ST) : Swiss Model

Page 14

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.

	FREQUENCY	Whichev comes fi	er rst			tC	DON	NETE	R REA	ADING
				04		*%				ALCH
OPERATION		Every	1/8	5/4	5		2/2	Vi	2/3
Spark plug clea	ın*			۲	۲		٠	٠	•	3.4.E
Spark plug che	ck*			٠	٠	٠	۲	٠	٠	mr.k
Valve clearance	check*		٠		٠		٠		•
Air suction valve -	check*			۲	٠	۲	٠	٠	٠
Air cleaner elemer	nt clean		٠		٠		٠
Air cleaner elemer	nt replace	5 cleanir	ngs				٠
Throttle grip play	check*		٠		٠		۲		٠
Idle speed chec	ck*		٠	۲	۲	٠	٠	٠	۲
Carburetor synchr	onization check*		٠	۲	۲	۲	٠	٠	٠
Fuel system ch	eck*				٠		٠		۲
Cylinder head bol	t tightness check*		۲		۲		۲		٠
Evaporative emiss check*	ion control system (CA)		•	۲	٠	٠	٠	٠	٠
Engine oil char	nge	year	٠		٠		۲		٠
Oil filter replace	9		٠		٠		۲		٠
Oil screen clear	٦		٠		٠		۲		۲
Air cleaner oil dra	in reservoir check*			۲	٠	٠	٠	٠	٠
Fuel hose repla	се	4 years
Clutch fluid level	check*	month	٠	۲	٠	٠	٠	٠	۲
Clutch fluid cha	ange	2 years					٠
Clutch master cyli dust seal re	nder cup and place	2 years
Clutch slave cylin	der piston seal replace	2 years
Clutch hose rep	place	4 years
Drive chain wear	- check*			٠	٠	٠	٠	٠	٠
Drive chain lub	ricate	300 km
Drive chain slack	check*	800 km
Brake lining or pa	d wear check*			٠	٠	٠	٠	۲	٠
Brake fluid level -	- check*	month	٠	٠	٠	٠	٠	٠	٠
Brake fluid cha	nge	2 years					٠

Page 15

1-8 GENERAL INFORMATION

FREQUENCY	Whichev comes fi	rer rst	300¥	00		DDOM	METE	RRE	ADING
Brake hose replace	4 years
Brake pad wear check*	month		•	٠	٠	٠	٠	٠	N-8297
Brake master cylinder cup and dust seal replace	2 years
Caliper piston seal and dust seal replace	2 years								in and the
Brake light switch check*		٠	٠	٠	٠	٠		•
Steering check*		٠	٠	٠	٠	٠	٠	٠	a segurar a da
Steering stem bearing lubricate	2 years				6	٠
Front fork oil change								•
Tire wear check*			٠	٠	٠	٠	٠	•
Swing arm pivot lubricate				٠	-		1.01	•	e a constant
General lubrication perform			۲	۲		٠	٠	•	tome clearly
Nut, bolt, and fastener tightness check*		٠					101		1.1.1.1.21.21

(†): For higher odometer readings, repeat at the frequency interval established here.

(*): Replace, add, adjust, clean, or torque if necessary.

(CA) : California Model

Page 16

Technical Information

Maintenance Free Battery

A maintenance free battery is installed in this model. The maintenance free battery is a sealed type, and so it is not necessary to check the electrolyte level and top-up the electrolyte.

(I) Construction

[A] Terminal (lead allov)
[B] Seal cap
[C] Lid
[D] Positive plate (lead and lead allov)
[E] Pole (lead allov)
[F] Separator
[G] Negative plate (lead and lead allov)
[H] Containe
[1] Viewed from A A
[]] Safatu yahuo
[K] Filter

(II) Main Features

1) Maintenance free...... It is not necessary to check the electrolyte level and top-up the electrolyte.

2) No electrolyte leakage ...... As the electrolyte is retained firmly in the special separators, there is no free electrolyte in the battery.

3) Instant activation system...... It can be used instantly after filling only the electrolyte without initial charge.
4) Safety construction ....................................
5) Compact and high performance ...... No presence of free electrolyte allows the battery to be made lower in height, thus resulting in enhanced volume efficiency. Moreover, gas being absorbed inside the battery eliminates the need for a gas exhaust tube.

6) Strong charge/discharge characteristics .... It can amply withstand deep charge/discharge cycles.

(III) Principle of Sealing Structure

A lead-acid battery operates under the following chemical reaction:

(+) PbO2	+	2H2SO4	+	(-) Pb	Discharge ↓	(+) PbSO4	+	2H2O +	(-) PbSO4
(Lead peroxide) Positive active		(Sulfuric acid) Electrolyte		(Spongy lead) Negative active	Charge	(Lead sulfate Positive activ	e) e	(water) Electrolyte	(Lead sulfate) Negative active
material				material		material			material

Normally in an ordinary lead-acid battery when it comes to an end of a charge, where the lead sulfate being a discharge product returns to lead peroxide and spongy lead, the charge current flowing thereafter is used exclusively to decompose electrolytically water from the electrolyte, thus resulting in generation of hydrogen gas from the negative plate and oxygen gas from the positive plate. The gases so generated are released out of the battery, causing the amount of electrolyte decreased to require occasional water replenishment.

A maintenance free battery, however, is so designed that, when it is overcharged, even if the positive plate is fully charged, the negative plate remains not fully turned to spongy lead. Therefore, even when the positive plate is overcharged generating oxygen gas, the negative plate is no fully charged, hence generating no hydrogen gas.

Moreover, the oxygen gas generated from the positive plate immediately reacts with the charged active material on the negative plate, and returns to water, with the ultimate result of no water loss.

Page 17

1 10 CENERAL INCORMATION

Pb Negative active material (charged state)	+ 1/2 O ₂ - Oxygen generated from positive plate	→ (PbO) Negative active material
(PbO)	+ H2SO4 Electrolyte	→ PbSO4 Negative active material (charged state)	+	H2O Water

Thus, the negative plate is made as not to get fully charged. Even if the overcharge continues, the oxygen gas generated inside the battery is absorbed by the negative plate a process called oxygen cycle, which keeps water loss theoretically at nil, and allows the battery to be sealed.

(IV) Filling the Battery with Electrolyte

Do not remove the sealing tape [A] sealing the filler opening [B] until just before use.

Be sure to use the dedicated electrolyte container for correct electrolyte volume.

• Check to see that there is no peeling, tears or holes in the sealing tape • Keep the battery level and peal off the sealing tape.

•Take the electrolyte container [A] out of the vinyl bag.
If the electrolyte is cold, 0°C (32°F) or less, warm it up to 5°C (41°F)
Cut off the black colored section [B] underneath the connection strip [C] using nippers.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medical attention if severe

•Turn the container upside down and gently insert it into the filler openings ensuring that it is upright
•To fill the battery, simply cut open the bulge [A] on the bottom of each bottle.
O Leave the container this way for 5 minutes or longer.
Be certain that all the electrolyte has flowed out.

ACAUTION

Fill until the container is completely emptied

Page 18

NOTE

○ If there is any electrolyte left in the container, tap the sides of the container lightly or cut open the bulge(s) again to spread the opening(s).

AWARNING

Do not tap the container near the openings at the top or pump the container body to flow out the electrolyte forcefully. The electrolyte may spout out from the openings of the container.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medical attention if severe.

Let the battery sit for 20 minutes. During this time, the electrolyte permeates the separators and the gas generated by chemical reaction is released.
•After filling, insert the manifold type seal cap [A] attached to the opposite side of the terminals, into the filler openings so that the top of the battery and the seal cap are flush with one another.

NOTE

ODo not hammer this cap. Press down evenly with both hands.

ACAUTION

Once the seal cap has been installed after filling the battery, never remove it, nor add any water or electrolyte.

Page 19

(V) Initial Charge

While a maintenance free battery can be used after only filling with electrolyte, a battery may not be able to start an engine in the cases shown in the table below, where an initial charge is required before use.


Condition requiring initial charge	Charging method
At low temperatures (lower than 0°C)	1.4 A × 2 ~ 3 hours
Battery has been stored in high temperature and humidity.
Seal has been removed, or broken - peeling, tear or hole.	1.4 A × 15 ~ 20 hours
Battery as old as 2 years or more after manufacture. Battery manufacturing date is printed on battery top.
Example) 12 01 3 A Day Month Year Mfg. location

(VI) Precautions

1) No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that.

2) Refreshing charge

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give a refresh charge (see Electrical System chapter).

When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.

ACAUTION

This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery's performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap during refresh charge.

If by chance an excessive amount of gas is generated due to overcharging, the safety valve operates to keep the battery safe.

3) When you do not use the motorcycle for months

Give a refresh charge before you store the motorcycle and store it with the negative lead removed. Give a refresh charge every six months during storage.

4) Battery life

If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it. (Provided, however, the vehicle's starting system has no problem.)

AWARNING

Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.

No fire should be drawn near the battery, or no terminals should have the tightening loosened.

The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medical attention if severe.

(VII) Interchangeability with Ordinary Battery

A maintenance free battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace a maintenance free battery only on a motorcycle which was originally equipped with a maintenance free battery.

Be careful, if a maintenance free battery is installed on a motorcycle which had an ordinary battery as original equipment, the maintenance free battery's life will be shortened.

Page 20

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten it to the specified torque.

Letters used in the "Remarks" column mean:

G : Apply high temperature grease to the threads.
L : Apply a non-permanent locking agent to the threads.
LG : Apply liquid gasket to the threads.
O : Apply engine oil to the threads and shaft portion.
R : Replace parts
S : Tighten the fasteners following the specified sequence.
SS : Apply silicone sealant (Kawasaki Bond : 56019-120) to the threads.
Si : Apply silicone grease.

Fastener		Remarks
	N-m	kg-m	ft-lb
Fuel System:
Carburetor Holder Bolts	13	1.3	9.5
Fuel Tap Plate Screws	0.8	0.08	7 in-lb
Fuel Tap Diaphragm Cover Screws	1.0	0.1	9 in-lb
Engine Top End:
Cylinder Head Cover Bolts	9.8	1.0	7.0
Spark Plugs	18	1.8	13.0
Cylinder Head Bolts (M11, New)	49	5.0	36	S
Cylinder Head Bolts (M11)	47	4.8	35	S
Cylinder Head Bolts (M8 Front)	25	2.5	18.0
Cylinder Head Allen Bolts(M8 Rear)	20	2.0	14.5
Camshaft Cap Bolts	12	1.2	8.5	S
Camshaft Sprocket Bolts	15	1.5	11.0	L
Carburetor Holder Bolts	13	1.3	9.5	L
Oil Pipe Holder Bolts	11	1.1	8.0	L
Camshaft Chain Tensioner
Mounting Bolts	11	1.1	8.0
Camshaft Chain Tensioner Cap Bolt	5.4	0.55	48 in-lb
Oil Pipe Banjo Bolts	25	2.5	18.0
Oil Pipe Retainer Bolt	11	1.1	18.0
Clutch:
Starter Lockout Switch Mounting Bolt	1.2	0.12	10 in-lb
Clutch Hub Nut	130	13.5	98	R
Clutch Hub Bolts	11	1.1	8.0	L
Clutch Spring Bolts	11	1.1	8.0
Clutch Cover Damper Plate Bolts	9.8	1.0	7.0	L
Clutch Cover Bolts	11	1.1	8.0
Clutch Bleed Valve	5.9	0.6	52 in-lb	Si
Clutch Lever Pivot Bolt	1.0	0.1	9 in-lb
Clutch Lever Pivot Bolt Locknut	5.9	0.6	52 in-lb
Clutch Reservoir Cap Screws	1.5	0.15	13 in-lb
Clutch Master Cylinder Clamp Bolts	11	1.1	8.0
Clutch Hose Banjo Bolts	25	2.5	18.0
Engine Lubrication System:				-
Oil Cooler Pipe Mounting Bolts	11	1.1	8.0

Page 21

1-14 GENERAL INFORMATION

Fastener	Aling grant -	Remarks
end these rule and the fire and the lists and	N-m	kg-m	ft-lb
Oil Passage Plugs Oil Pressure Switch	18 15	1.8 1.5	13.0 11.0	SS
Banjo Bolt (M14) Oil Pump Gear Holder Screws Oil Pump Mounting Bolts	34 5.4 12	3.5 0.55 1.2	25 48 in-Ib 8.5	L
Oil Pump Bracket Bolts Oil Pressure Relief Valve	12 15 25	1.2 1.5 2.5	8.5 11.0	L
Engine Oil Drain Plug Oil Pipe Banjo Bolt (M6)	29 7.8	3.0 0.8	22 69 in-lb
Banjo Bolts (M8) Oil Pipe Clamp Bolt Oil Pipe Holder Bolts	12 11 11	1.2 1.1 1.1	8.5 8.0 8.0	L
Banjo Bolt Holder Bolt Oil Pan Bolts	11	1.1 1.1	8.0 8.0	L (3)
Oil Pan Nozzle Oil Filter Mounting Bolt Oil Screen Mounting Screws	2.9 20 5.4	0.3 2.0 0.55	26 in-16 14.5 48 in-1b	n e migros de la Servicio de la composición
Engine Removal/Installation:			105
Engine Bracket Bolts Engine Mounting Bolts Engine Mounting Nuts	23 39 39	2.3 4.0 4.0	16.5 29 29	a an' shipes Shine ng 1
Down Tube Mounting Bolts	39	4.0	29
Crankshaft/Transmission: Upper Crankcase M8 Bolts	27 12	2.8	20 8 5	n, Karlan († 1997) 1917 - Dan († 1997)
Lower Crankcase M10 Bolts Lower Crankcase M6 Bolts	39 12	4.0	29 8.5	S
Connecting Rod Big End Cap Nuts Return Spring Pin External Shift Mechanism Cover Bolts	28 20 11	2.9 2.0 1.1	21 14.5 8.0	L L (1)
Neutral Switch Shift Pedal Mounting Bolt	15 34	1.5 3.5	11.0 25
Starter Clutch Holder Bolts Shift Drum Pin Plate Screw	12	1.8	8.5	L L
Shift Drum Bearing Holder Bolts Crankshaft Main Bearing Cap Bolts	13 39	1.3 4.0	9.5 29	. Ц _алана с
Balancer Shaft Clamp Bolt Starter Motor Idle Gear Shaft Holder Bolt	5.9 11	0.6	52 in-lb 8.0	L
Alternator Shaft Bearing Holder Bolts Alternator Shaft Coupling Bolt	11 25	1.1 2.5	8.0 18.0	L
Side Stand Switch Mounting Bolts Left Engine Cover Bolts	- 11	- 1.1	- 8.0	L
Left Engine Cover Damper Plate Bolts Positioning Lever Nuts Oil Pipe Banio Bolt (M6)	9.8 11 7.8	1.0 1.1	7.0 8.0	L
Separator Mounting Screw Pickup Coil Cover Bolts	5.4 11	0.55	48 in-lb 8.0
Pickup Coil Cover Damper Plate Bolts Breather Cover Bolts	9.8 11	1.0 1.1	7.0 8.0	L

Page 22

Fastener		Remarks
	N-m	kg-m	ft-lb
Wheels/Tires: Front Axle Clamp Bolts Front Axle Rear Axle Nut	23 88 110	2.3 9.0 11.0	16.5 65 80
Final Drive: Engine Sprocket Nut	98	10.0	72
Torque Link Nuts Chain Adjuster Clamp Bolts Rear Coupling Studs	32 39 -	3.3 4.0 -	24 29 -	L(Planted side)
Brakes: Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Front Brake Reservoir Cap Screws Front Master Cylinder Clamp Bolts Eropt Brake Light Switch Mounting Screws	1.0 5.9 1.5 11 1 2	0.1 0.6 0.15 1.1 0.12	9 in-lb 52 in-lb 13 in-lb 8.0 10 in-lb
Brake Hose Banjo Bolts Caliper Mounting Bolts Caliper Bleed Valves Brake Disc Mounting Bolts Front Caliper Assembly Bolts Brake Pedal Mounting Bolt Push Rod Locknut Rear Master Cylinder Mounting Bolts Rear Brake Reservoir Mounting Bolt Torque Link Nuts	25 34 7.8 23 21 34 18 23 6.9 32	2.5 3.5 0.8 2.3 2.1 3.5 1.8 2.3 0.7 3.3	18.0 25 69 in-lb 16.5 15.0 25 13.0 16.5 61 in-lb 24
Suspension: Front Fork Top Plugs Front Fork Clamp Bolts Front Fork Bottom Allen Bolts Front Axle Clamp Bolts Swing Arm Pivot Nut Chain Adjuster Clamp Bolts Rear Shock Absorber Lower Mounting Bolts	23 20 61 23 93 39 39	2.3 2.0 6.2 2.3 9.5 4.0 4.0	16.5 14.5 45 16.5 69 29 29	L G
Steering: Handlebar Clamp Bolts Steering Stem Head Nut Front Fork Clamp Bolts Steering Stem Locknut	27 59 20 4.9	2.8 6.0 2.0 0.5	20 43 14.5 43 in-Ib	S
Frame: Panel Mounting Bolts	27	2.8	20
Electrical System: Starter Motor Terminal Nut Front Brake Light Switch Mounting Screws Spark Plugs Starter Motor Retaining Bolts Starter Motor Mounting Bolts Alternator Cover Bolts Alternator Mounting Bolts	4.9 1.2 18 4.9 11 11 25	0.5 0.12 1.8 0.5 1.1 1.1 2.5	43 in-lb 10 in-lb 13.0 43 in-lb 8.0 8.0 18.0	L

Page 23

1-16 GENERAL INFORMATION

Fastener		Torque	0.000111	Remarks
	N-m	kg-m	ft-lb
Alternator Coupling Bolts (M6)	15	1.5	11.0	participation (all 196
Oil Pressure Switch	15	1.5	11.0	SS
Ignition Timing Rotor Bolt	25	2.5	18.0
Pickup Coil Stator Mounting Screws	2.9	0.3	26 in-Ib
Pickup Coil Cover Bolts	11	1.1	8.0	dana a P
Pickup Coil Cover Damper Plate Bolts	9.8	1.0	7.0	L
Neutral Switch	15	1.5	11.0
Side Stand Switch Mounting Bolts	-	-	-	L
Battery Ground Lead Terminal Bolt	5.1	0.52	45 in-lb
Starter Motor Terminal Mounting Nut	11	1.1	8.0

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.

General Fasteners

Threads dia.			Torque
(mm)		N-m	kg-m	ft-lb
5	1.1.1.1.1.1.1.1.1.1.1.1.1.1.1.1.1.1.1.1.	3.4 ~ 4.9	0.35 ~ 0.50	30 ~ 43 in-lb
6	0.001	5.9 ~ 7.8	0.60 ~ 0.80	52 ~ 69 in-lb
8	2.81	14~19	1.4 ~ 1.9	10.0 ~ 13.5
10	35	25 ~ 34	2.6 ~ 3.5	19.0 ~ 25
12	5 C T	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

Page 24

Special Tools and Sealant

Steering Stem Bearing Driver: 57001-137

Inside Circlip Pliers: 57001-143

Outside Circlip Pliers: 57001-144

Piston Base, Ø8: 57001-147

Valve Guide Reamer, 07: 57001-162

Valve Guide Arbor, φ7: 57001-163

Oil Pressure Gauge, 10 kg/cm²: 57001-164

Page 25

1-18 GENERAL INFORMATION

Valve Spring Compressor Assembly: 57001-241

Bearing Puller Adapter: 57001-317

Piston Pin Puller Assembly: 57001-910

Hand Tester: 57001-983

Fuel Level Gauge: 57001-1017

Fork Cylinder Holder Adapter: 57001-1057

Oil Seal & Bearing Remover: 57001-1058

Rim Protector: 57001-1063

Page 26

Page 27

Page 28

Page 29

Kawasaki Bond (Silicone Sealant): 56019-120

Kawasaki Bond (Liquid Gasket - Silver): 92104-002

Page 30

Cable Wire and Hose Bouting

1. Brake Hose
2. Diode
3. Speedometer Cable
4. Throttle Cable
5. Right Handlebar Switch Lead 6. Meter Assembly Lead
7. Ignition Switch Lead 8. Clutch Hose
9. Left Handlebar Switch Lead
10. Choke Cable
11. Chassis Ground
12. Harness (Run over throttle cables, and under choke cable, 19. Right Turn Signal Light Lead
- and outside clutch Hose.)
13. Horn Lead (Run outside of 21. Boost Sensor Hose cables.)
14. Clamp
15. Ignition Coil Lead

16. Heat Shield
17. Boost Sensor
18. Band
20. Left Turn Signal Light Lead

Page 31

1-24 GENERAL INFORMATION

1. To Right Handlebar Switch 12. To Left Turn Signal Light 23. To Pickup Coil
2. To Left Handlebar Switch 13. To Junction Box
3. Clutch Hose
4 Band
5. Chassis Ground 6. White Mark
7. Battery
8. Clamp
9. To Fuel Level Sensor
10 Main Harness
21. # 3, # 5 Ignition Coil 11. To Right Turn Signal Light 22. # 4, # 6 Ignition Coil

14. To Tail Light

16. To Headlight

18. To Horn

15. To Meter Assembly

17. To Ignition Switch

19. #1, #7 Ignition Coil

20. # 2, # 8 Ignition Coil

24. To Rear Brake Light Switch 35. Alternator
- 25. To Battery Minus Terminal 36. To Diode
- 26. To IC Igniter
- 27. To Side Stand Switch
- 28. To Neutral Switch
- 29 To Alternator
- 30. To Turn Signal Relay
- 31. To Starter Relay
- 32. To Battery Plus Terminal
- 33. Starter Motor

34. Neutral Switch
37. Turn Signal Relay
38. Starter Relay
39. IC Igniter
40 Throttle Cable
41 Front
42. Choke Cable
43. Oil Pressure Switch
44. To Oil Pressure Switch

Page 32

9. Clamp
10. Fuel Tap Vacuum Hose
11. Hose Guide
Hose
18. Boost Sensor Hose
19. To Air Cleaner
20. Frame

(CN) : Canadian Model
(AS) : Australian Model

Page 33

Evaporative Emission Control System (California Model)

1. Fuel Return Hose (Red) 2. Vacuum Hose (White)

3. Purge Hose (Green) 4. Breather Hose(Blue)
5. Breather Hose(yellow)
6. Canister

7. Separator 8. Catch Tank 9. Fuel Tap 10. Clamp 11. Air Cleaner 12. Fuel Tank

13. Carburetor 14. Vacuum Switch Valve 15 T-Type Fitting 16. Main Harness 17. Throttle Cable 18. Boost Sensor

Page 34

Fuel System

Exploded View2-2
Specifications2-4
Throttle Grip and Cables2-5
Free Play Inspection2-5
Free Play Adjustment2-5
Cable Installation Notes2-5
Cable Lubrication2-5
Choke Cable2-6
Free Play Inspection2-6
Free Play Adjustment2-6
Installation Notes2-6
Lubrication2-6
Carburetors2-7
Idle Speed Inspection2-7
Idle Speed Adjustment2-7
Synchronization Inspection2-7
Synchronization Adjustment2-8
Service Fuel Level Inspection2-8
Service Fuel Level Adjustment2-9
Fuel System Cleanliness Inspection2-10
Removal2-10
Installation Notes2-11
Disassembly/Assembly Notes2-11
Separation/Assembly Notes2-12


Cleaning	2-13
Inspection	2-13
Air Cleaner	2-15
Housing Removal	2-15
Housing Installation Notes	2-15
Element Removal	2-15
Element Installation	2-15
Element Cleaning and Inspection	2-16
Oil Draining	2-17
Fuel Tank
Removal
Installation Notes
Inspection
Cleaning	.2-19
Fuel Tap Removal	.2-20
Fuel Tap Installation Notes	2-20
Fuel Tap Inspection
Evaporative Emission Control System
(California Model Only)
Parts Removal/Installation Notes
Hose Inspection
Separator Inspection
Separator Operation Test	.2-22
Canister Inspection	2-22
	the factor

Page 35

2-2 FUEL SYSTEM

Exploded View

1. Jet Needle
2. Pilot Screw
3. Main Jet
4. Pilot Jet
5. Needle Jet
6. Needle Jet Holder
7. Plug
T1 : 0.8 N-m (0.08 kg-m, 7 in-lb)
T2 : 1.0 N-m (0.1 kg-m, 9 in-lb)
T3 : 13 N-m (1.3 kg-m, 4.5 ft-lb) ST : Swiss Model
US: U.S. Model
G : Apply grease.
L : Apply a non-permanent locking agent to the threads.
O : Apply oil.

Page 36

Page 37

2-4 FUEL SYSTEM

Specifications

ltem	Standard
Throttle Grip and Cables: Throttle grip free play	2 ~ 3 mm
Choke Cable: Choke cable free play	2 ~ 3 mm
Carburetors:
Make, type	Keihin, CVK 34
Main jet	# 1, # 4 cyl.: # 98
Main air ict	# 2, # 3 cyl.: # 100 # 100

Pilot iot	# 25
Pilot air iet	# 150
Pilot screw	2 turns out
Starter jet	# 45
Idle speed	1.000 +50 r/min (rpm) (ST) 1.100 +50 r/min (rpm)
Carburetor synchronization vacuum	Less than 2.7 kPa (2 cmHq) difference
	between any two carburetors
Service fuel level	-0.5 + 1 mm
(above the bottom edge of the carburetor body)
Float height	17 ± 2 mm

(ST) : Swiss Model

Special Tool – Fuel Level Gauge: 57001-1017 *Pilot Screw Adjuster, A: 57001-1239 Vacuum Gauge & Tachometer: 57001-1291 *Pilot Screw Adjuster, C: 57001-1292 Pressure Cable Luber: k56019-021

(*): You may use which every tool you like.

Page 38

Throttle Grip and Cables

Free Play Inspection

Check the throttle grip free play [A].
★ If the free play is incorrect, adjust the throttle cable.

Throttle Grip Free Play Standard: 2 ~ 3 mm

Free Play Adjustment

Loosen the locknut [A].
Turn the adjuster [B] until the proper amount of free play can be obtained.
Tighten the locknut securely.
★If the proper amount of free play cannot be obtained by using the adjuster only, use the adjuster in the middle part of the accelerator cable.
Loosen the locknut, and screw the adjuster, at the upper end of the accelerator cable, all the way in.
Tighten the locknut securely.
Remove the fuel tank (see Fuel Tank Removal).
Loosen the locknut [A] at the middle part of the accelerator cable.
Turn the adjuster [B] until the proper amount of throttle grip free play is obtained.
Tighten the locknut securely.
★If the proper amount of free play can not be obtained in the adjustable range of the lower adjuster, use the adjuster at the upper end of the accelerator cable again.

Cable Installation Notes

Install the throttle cables in accordance with the Cable Routing section in the General Information chapter.
Install the lower ends of the throttle cable in the cable bracket on the carburetor after installing the upper ends of the throttle cable in the grip.
After installation, adjust each cable properly.

AWARNING

Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.

Cable Lubrication

Whenever the cable is removed, and in accordance with the Periodic Maintenance Chart (see General Information chapter), do the following. • Apply a thin coating of grease to the cable lower ends.

Apply a triff coating of grease to the cable lower ends I ubricate the cable with a penetrating rust inhibitor.

Special Tool – Pressure Cable Luber: k56019-021 [A]

Page 39

2-6 FUEL SYSTEM

Choke Cable

Free Play Inspection

Check that the choke inner cable slides smoothly by moving the choke lever [A] to the front and rear.
★If there is any irregularity, check the choke cable play [B].

Push the choke lever all the way to the front.
Check choke cable free play.

O Determine the amount of choke cable play at the choke lever. Pull the choke lever until the starter plunger lever [A] at the carburetor contacts with the starter plunger [B]; the amount of choke lever lower end travel is the amount of choke cable play.

★If the free play is incorrect, adjust the choke cable.

Choke Cable Free Play [C] Standard: 2 ~ 3 mm

Free Play Adjustment

Remove the fuel tank (see Fuel Tank Removal).
Loosen the locknut [A], and turn the adjuster [B] until the cable has the proper amount of free play.
Tighten the locknut securely

Installation Notes

Install the choke cable in accordance with the Cable Routing section in the General Information chapter.
After installation, adjust the cable properly

AWARNING

Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding condition.

Lubrication

Whenever the choke cable is removed, lubricate the choke cable as follows:

Apply a thin coating of grease to the cable upper end.
Lubricate the cable with a penetrating rust inhibitor.

Special Tool - Pressure Cable Luber: k56019-021 [A]

Page 40

Carburetors

Idle Speed Inspection

• Start the engine and warm it up thoroughly.

•With the engine idling, turn the handlebar to both sides.
★If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these conditions before riding (see Cable Routing in the General Information chapter).

AWARNING

Operation with Improperly adjusted, incorrectly routed, or damaged cables could result in an unsafe riding condition.

Check idle speed.

★ If the idle speed is out of the specified range, adjust it.

Idle Speed

Standard:

1,000 ± 50 r/min (rpm) (Swiss Model) 1,100 ± 50 r/min (rpm)

Idle Speed Adjustment

Start the engine and warm it up thoroughly.
•Turn the adjusting screw [A] until the idle speed is correct.
Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.

Synchronization Inspection

•Set the motorcycle on its center stand.
Start the engine and warm it up thoroughly.
Check idle speed.
Remove the fuel tank. (see Fuel Tank Removal)
Supply fuel to the carburetors with an auxiliary fuel tank.
Pull the vacuum hoses off, and attach the vacuum gauge [A] to the fittings [B] on the carburetors.

Special Tool – Vacuum Gauge & Tachometer: 57001-1291

• Start the engine and let it idle to measure the carburetor intake vacuum.

★If the vacuum is incorrect, adjust the synchronization.

Carburetor Synchronization Vacuum

Standard:

Less than 2.7 kPa (2 cmHg) difference between any two carburetors.

Page 41

Synchronization Adjustment

Turn the adjusting screw to synchronize the carburetors.
O First synchronize the left two and then the right two carburetors by means of the left and right adjusting screws [A, C]. Then synchronize the left two carburetors and the right two carburetors using the center adjusting screw [B].
★If the carburetor synchronization cannot be obtained by using the adjusting screws, check for dirt or blockage, and then check the pilot screw settings.

Special Tool – Pilot Screw Adjuster, A: 57001-1239 or Pilot Screw Adjuster, C: 57001-1292

• Check the carburetor synchronization again.

NOTE

Do not turn the pilot screws carelessly during carburetor synchronization. You may cause poor running at low engine speed.
Check idle speed.

Service Fuel Level Inspection

AWARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

Remove the carburetors, and hold them upright on a stand (see Carburetor Removal).
Prepare an auxiliary fuel tank and connect the fuel hose to the carburetors.
Prepare a fuel hose (6 mm in diameter and about 300 mm long).
Connect the fuel level gauge [A] to the carburetor float bowl with the fuel hose.

Special Tool - Fuel Level Gauge: 57001-1017

Hold the gauge [A] vertically against the side of the carburetor body so that the "zero" line [B] is several millimeters higher than the bottom edge of the carburetor body.
Feed fuel to the carburetor, then turn the carburetor drain plug [C] out a few turns.
Wait until the fuel level in the gauge settles.
Keeping the gauge [A] vertical, slowly lower the gauge until the "zero" line [B] is even with the bottom edge [D] of the carburetor body.

NOTE

Do not lower the "zero" line below the bottom edge of the carburetor body. If the gauge is lowered and then raised again, the fuel level measured shows somewhat higher than the actual fuel level. If the gauge is lowered too far, dump the fuel into a suitable container and start the procedure over again.
Read the fuel level [E] in the gauge and compare to the specification. Screw in the carburetor drain plug.

Page 42

Stop feeding and remove the fuel level gauge.

★If the fuel level is incorrect, adjust it (see Service Fuel Level Adjustment).

Service Fuel Level (above the bottom edge of the carburetor body) Standard: -0.5 +1 mm

Service Fuel Level Adjustment

AWARNING

Remove the carburetor, and drain the fuel into a suitable container.
Remove the float bowl.
Drive out the pivot pin [A] and remove the float [B].
Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

Float Height Standard:

17 + 2 mm

NOTE

O Do not push the needle rod [A] in during the float height measurement [B].

•Assemble the carburetor, and recheck the fuel level.

★ If the fuel level cannot be adjusted by this method, the float or the float valve is damaged.

Page 43

Fuel System Cleanliness Inspection

AWARNING

Connect a suitable hose to the fitting at the bottom of each carburetor float how!
Run the lower ends of the hoses into a suitable container.
•Turn the fuel tap to the PRI position.
Turn out each drain plug [A] a few turns and drain the float bowls.
Check to see if water or dirt comes out.
Tighten the drain plugs and turn the fuel tap to the ON position.
★If any water or dirt appears during the above inspection, clean the fuel system (see Carburetor Cleaning and Fuel Tank Cleaning).

Removal

AWARNING

• Remove:

Seat Side Cover

Fuel Tank
Air Cleaner Rear Housing
Choke Cable Lower End
Slide the spring band [A], and turn up the air cleaner ducts [B].

Loosen the clamps, and pull the carburetors off the holders.
Slide the carburetor assembly to the right.
Remove the throttle cable lower ends.
Take out the carburetor assembly.
Stuff pieces of lint-free, clean cloth into the carburetor holders and the intake ducts to keep dirt out of the engine and air cleaner.

Page 44

Installation Notes

Route the cables, harness, and hoses correctly (see General Information chapter).
Tighten the clamps for the carburetor holders at the position shown in the figure.

Check fuel leakage from the carburetors.

Adjust the following items if necessary. Idle Speed Carburetor Synchronization Throttle Cable Choke Cable

Disassembly/Assembly Notes

AWARNING

For the US and Swiss models, remove the pilot screw plug as follows: Punch a hole in the plug and pry there with an awl or other suitable tool.

Turn in the pilot screw and count the number of turns until it seats fully but not tightly, and then remove the screw. This is to set the screw to its original position when assembling.
After installing the upper chamber cover, check that the vacuum piston slides up and down smoothly without binding in the carburetor bore.

ACAUTION

During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm.

•Turn in the pilot screw [A] fully but not tightly, and then back it out the same number of turns counted during disassembly.
For the US and Swiss models, install the pilot screw plug as follows:
O Install a new plug [B] in the pilot screw hole, and apply a small amount of a bonding agent [C] to the circumference of the plug to fix the plug.

ACAUTION

Do not apply too much bonding agent to the plug or the pilot screw itself may be fixed.

Page 45

2-12 FUEL SYSTEM

•Turn the carburetor body upside-down, and drop the needle jet [A] into place so that the smaller diameter end [B] of the jet goes in first.

• Carefully screw in the needle jet holder. It will seat against the needle jet, pushing the end of the jet into the carburetor bore.

CAUTION

Do not force the needle jet holder [A] and main jet [B] or overtighten them. They could be damaged requiring replacement.

• Slip the needle through the hole in the center of the vacuum piston, and put the spring seat [A] on the top of the needle. Turn the seat so that it does not block the hole [B] at the bottom of the vacuum piston.

Separation/Assembly Notes

• Read the WARNING in the Carburetor Disassembly/Assembly Notes.

The center lines of the carburetor bores must be parallel both horizontally and vertically. If they are not, loosen the mounting screws and align the carburetors on a flat surface. Retighten the mounting screws.
After assembling the choke mechanism, check to see that the choke shaft slides right to left smoothly without abnormal friction.

ACAUTION

Fuel mixture trouble could result if the starter does not seat properly in its rest position after the choke lever is returned.

•Visually synchronize the throttle (butterfly) valves.
O Check to see that all throttle valves open and close smoothly without binding when turning the pulley.
OVisually check the clearance [A] between the throttle valve and the carburetor bore in each carburetor.
★If there is a difference between any two carburetors, turn the balance adjusting screw(s) [B] to obtain the same clearance.

Page 46

Cleaning

AWARNING

Clean the carburetors in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash- point solvents to clean the carburetors.

ACAUTION

Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure, and the vacuum piston diaphragms may be damaged.

Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage to or deterioration of the parts.

The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high flash-point cleaning solution safe for plastic parts.

Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

Disassemble the carburetor.
Immerse all the metal parts in a carburetor cleaning solution.
Rinse the parts in water.
•When the parts are clean, dry them with compressed air.
Blow through the air and fuel passages with compressed air.
Assemble the carburetor.

Inspection

AWARNING

Remove the carburetors.

Before disassembling the carburetors, check the fuel level (see Fuel Level Inspection).
★If the fuel level is incorrect, inspect the rest of the carburetor before correcting it.
Move the choke shaft left and release it to check that the starter plungers move smoothly and return by spring tension.
★If the starter plungers do not work properly, replace the carburetors.
Turn the throttle cable pulley to check that the throttle butterfly valves [A] move smoothly and return by spring tension.
★If the throttle valves do not move smoothly, replace the carburetors.

Page 47

2-14 FUEL SYSTEM

Disassemble the carburetors.
Clean the carburetors.
Check that the O-rings on the float bowl and drain plug and the diaphragm on the vacuum piston are in good condition.
★If any of the O-rings or diaphragms are not in good condition, replace them.
Check the plastic tip [A] of the float valve needle [B]. It should be smooth, without any grooves, scratches, or tears.
★If the plastic tip is damaged [C], replace the needle.
Push in the rod [D] in the other end of the float valve needle and then replace it.
★If it does not spring out, replace the needle.
Check the tapered portion [A] of the pilot screw [B] for wear or damage.
★If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it.

Check that the vacuum piston [A] moves smoothly in the carburetor body. The surface of the piston must not be excessively worn.
★If the vacuum piston does not move smoothly, or if it is very loose in carburetor body, replace the carburetor.

Page 48

FUEL SYSTEM 2-15

Air Cleaner

Housing Removal

Remove:
- Seat
- Side Covers
- Fuel Tank
Remove the mounting bolt [A], and take off the rear housing [B]. Remove the front housing mounting bolt [C].
Remove the front housing mounting bolt [C].

Remove:

Carburetors [A]
Air Cleaner Drain Hose Upper End [B]
Engine Breather Hose Lower End [C]
Air Hose [D] for vacuum Switch Valve
Take off the front housing [E] toward the front.

Housing Installation Notes

Route the cable, harness and hoses correctly (see General Information chapter).
Fit the O-ring [A] of the rear housing in place.
Install the tabs [B] of the rear housing into the eyes [C] of the front housing.

Element Removal

Remove:

Seat
Fuel Tank
Air Cleaner Rear Housing Mounting Bolt Air Cleaner Intake Duct Mounting Screws
Remove the intake duct [A].
Take out the element [B].

Element Installation • Element installation is the reverse of removal.

Page 49

Element Cleaning and Inspection

In dusty areas, the element should be cleaned more frequently than the recommended interval.
OAfter riding through rain or on muddy roads, the element should be cleaned immediately.
Since repeated cleaning opens the pores of the foam in the element, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

AWARNING

Clean the element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.

• Remove the air cleaner element from the frame.

Clean the element in a bath of high flash-point solvent, and then dry it with compressed air or by shaking it.
After cleaning, saturate a clean, lint-free towel with SE class SAE 30 oil and apply the oil to the element by tapping the element outside with the towel.

•Visually check the element [A] for tears or breaks. Check the sponge gasket [B] also, and the plastic frame.
★ If the element or gasket has any tears or breaks, replace the element.
★ If the element frame is damaged or distorted, replace it.

• Repeated cleaning opens the pores of the foam in the element. Replace the element according to the Periodic Maintenance Chart (see General Information chapter).

Page 50

Oil Draining

A drain hose [A] is connected to the bottom of the air cleaner A drain nose [A] is connected to the bottom of the an housing, to drain oil accumulated at the bottom of the housing.

Visually check the catch tank at the middle of the drain hose if the oil
★ If any oil accumulates in the tank or the hose, drain it by taking off the plug [B] at the lower end of the drain hose.

AWARNING

Be sure to reinstall the plug in the drain hose after draining. Oil on be sure to reinstant the plug in the drain hose after draining. On on tires will make them slipperv and can cause an accident and injurv.

Page 51

2-18 FUEL SYSTEM

Fuel Tank

Removal

AWARNING

ACAUTION

For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister's vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

Remove:

Seat Side Covers Fuel Tank Mounting Bolts [A]

•Turn the fuel tap to the ON or RES position.

• Pull the fuel hoses and vacuum hose off the tap.

• Disconnect the fuel level sensor lead connector [A].

• Pull the overflow drain hose [B] at the fuel level sensor assembly.

• Remove the fuel tank [C].

• Drain the fuel tank.

O Place a suitable container under the fuel tank.

OTurn the fuel tap to the PRI position to drain the fuel into the container.

Installation Notes

Read the above WARNING.
Check the rubber dampers [A] on the frame.
★If the dampers are damaged or deteriorated, replace them.

Page 52

Route the hoses and leads correctly (see General Information chapter). Be sure the hoses are clamped securely to prevent leaks.

Inspection

•Visually inspect the gaskets on the tank and cap for any damage.
★ Replace the gaskets if they are damaged.
Remove the hose(s) from the fuel tank, and open the tank cap.
Check to see if the breather and water drain pipes (also the fuel return pipe for the California model) in the tank are not clogged. Check the tank cap breather also.
★If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air.

ACAUTION

Do not apply compressed air to the air vent holes [A] on the tank cap. This could cause damage and clogging of the labyrinth in the cap.

Cleaning

AWARNIN

Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash point solvents to clean the tank.

• Remove the fuel tank and drain it.

Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.
Pour the solvent out of the tank.
Remove the fuel tap from the tank (see Fuel Tap Removal).
Clean the fuel tap filter screens in a high flash point solvent.
Pour high flash point solvent through the tap in all lever positions.
Dry the tank and tap with compressed air.
Install the tap in the tank.
Install the fuel tank.

Page 53

2-20 FUEL SYSTEM

Fuel Tap Removal

Remove the fuel tank and drain it.

Remove the mounting bolts [A] with nylon flat washers and take out the fuel tap.

Fuel Tap Installation Notes

Be sure the O-ring is in good condition to prevent leaks.
Be sure to clamp the fuel hoses to the tap to prevent leaks.
Be sure the nylon washers are in good condition to prevent leaks.
Do not use steel washers in place of the nylon washers, because they will not seal the bolts properly and fuel will leak.

Fuel Tap Inspection

Remove the fuel tap.

Check the fuel tap filter screens [A] for any breaks or deterioration.
★If the fuel tap screens have any breaks or are deteriorated, they may allow dirt to reach the carburetor, causing poor running. Replace the fuel tap.
★If the fuel tap leaks, or allows fuel to flow when it is at ON or RES position without engine running, replace the damaged gasket [B] or O-ring [C].

Page 54

Evaporative Emission Control System (California Model Only)

The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.

Parts Removal/Installation Notes

AWARNING

ACAUTION

If gasoline, solvent, water or any other liquid enters the canister, the canister's vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

•To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.
Connect the hoses according to the diagram of the system. Make sure they do not get pinched or kinked.
- [A] Fuel Return Hose (Red)
- [B] Vacuum Hose (White)
- [C] Purge Hose (Green)
- [D] Breather Hose (Blue)
- [E] Breather Hose (Yellow)
- [F] Canister
- [G] Separator
- [H] Catch Tank
- [I] Plug
- [J] Clamp
- [K] Air Cleaner
- [L] Vacuum Switch Valve
- [M] Boost Sensor

Hose Inspection

Check that the hoses are securely connected. Replace any kinked, deteriorated or damaged hoses.

Separator Inspection

Disconnect the hoses from the liquid/vapor separator, and remove the separator from the motorcycle.
•Visually inspect the separator for cracks and other damage.
★If the separator has any cracks or is badly damaged, replace it with a new one.

Page 55

Separator Operation Test

WARNING

Connect the hoses to the separator, and install the separator on the motorcycle.
Disconnect the breather hose from the separator, and inject about 20 mL of gasoline into the separator through the hose fitting.
Disconnect the fuel return hose from the fuel tank.
Run the open end of the return hose into the container level with the tank top
Start the engine, and let it idle.
★If the gasoline in the separator comes out of the hose, the separator works well. If it does not replace the separator with a new one.

Canister Inspection

Remove the canister, and disconnect the hoses from the canister.
•Visually inspect the canister for cracks and other damage.
★ If the canister has any cracks or bad damage, replace it with a new one.

NOTE

• The canister is designed to work well through the motorcycle's life without any maintenance if it is used under normal conditions.

Page 56

ENGINE TOP END 3-1

Engine Top End


Exploded View	3-2
Specifications	3-4
Clean Air System	3-6
Air Suction Valve Removal	3-6
Air Suction Valve Installation Note	3-6
Air Suction Valve Inspection	3-6
Vacuum Switch Valve Removal	3-6
Vacuum Switch Valve Installation Note	3-7
Vacuum Switch Valve Test	3-7
Clean Air System Hose Inspection	3-7
Air Intake Duct	3-8
Removal	3-8
Cylinder Head Cover	3-9
Removal	3-9
Installation Notes	3-9
Camshaft Chain Tensioner	3-11
Removal	3-11
Installation Notes	3-11
Camshaft, Camshaft Chain	3-12
Camshaft Removal	3-12
Camshaft Installation Notes
(Including Camshaft
Chain Timing Procedure)	3-1 2
Camshaft and Sprocket Assembly	3-13
Cam Wear	3-14
Camshaft Journal/Camshaft
Bearing Wear	3-14
Camshaft Chain Wear	3-14
Cylinder Head	3-15
Cylinder Compression Measurement	3-15
Removal	3-15


Installation Notes	3-16
Assembly
Cylinder Head Warp
Cylinder Head Cleaning
Valves
Clearance Inspection
Clearance Adjustment
Removal	3-21
Installation
Guide Removal	3-21
Guide Installation	3-22
Seat Inspection	3-22
Seat Repair	3-23
Seat Cutter Operation Care:	3-23
Marks Stamped on the Cutte	r: 3-23
Operating Procedures:	3-24
Valve-to-Guide Clearance Meas	urement
(Wobble Method)	3-25
Valve Seat Repair	3-26
Cylinder Piston	3-27
Bemoval	3-27
Installation Notes	3-27
Cylinder Assembly	3-29
Cylinder Wear	3-29
Piston Wear	3_29
Boring Honing	3_29
Piston Ring, Piston Ring Groov	e Wear 3-30
Piston Ring End Gan	3-30
Exhaust Pine Muffler	2 21
Removal	2_21
Installation Notes	2 21

Page 57

Exploded View

1. Arrow points to the front.
2. Closed coil end faces toward the valve seat.
3. RN marked side faces up.
4. UP marked side faces up.
5. R marked side faces up.
T1 : 12 N-m (1.2 kg-m, 8.5 ft-lb)
T2 : 13 N-m (1.3 kg-m, 9.5 ft-lb)
T3 : 25 N-m (2.5 kg-m, 18.0 ft-lb)
T4 : 5.4 N-m (0.55 kg-m, 48 ft-lb)
T5 : 15 N-m (1.5 kg-m, 11.0 ft-lb)
T6 : 9.8 N-m (1.0 kg-m, 7.0 ft-lb)
T7 : 18 N-m (1.8 kg-m, 13.0 ft-lb)
T8 : 49 N-m (5.0 kg-m, 36 ft-lb)

T9 : 47 N-m (4.8 kg-m, 35 ft-lb)
T10: 20 N-m (2.0 kg-m, 14.5 ft-lb)
T11: 11 N-m (1.1 kg-m, 8.0 ft-lb)
LG : Apply liquid gasket.
L : Apply a non-permanent locking agent to the threads.
M : Apply molybdenum disulfide grease.
O: Apply engine oil to the surface.
S : Follow the specific tightening sequence.
SS : Apply silicone sealant (Kawasaki Bond: 56019-120) to the circumference of each plug.

Page 58

Page 59

3-4 ENGINE TOP END

Specifications

ltem		Standard	Service Limit
Clean Air System:
Vacuum Switch Valve Closing Pressure (O	pen → Close)	57 ~ 65 kPa (430 ~ 490 mm Hg)
Camshaft, Camshaft Chain:
Cam height:	Inlet	36.934 ~ 37.066 mm	36.83 mm
	Exhaust	36.534 ~ 36.666 mm	36.43 mm
Camshaft bearing oil clearance		0.058 ~ 0.101 mm	0.19 mm
Camshaft journal diameter		23.920 ~ 23.942 mm	23.89 mm
Camshaft bearing inside diameter		24.000 ~ 24.021 mm	24.08 mm
Camshaft runout		Not more than 0.03 mm TIR	0.1 mm TIR
Camshaft chain 20-link length		158.76 ~ 159.18 mm	161.10 mm
Cylinder Head:
Cylinder compression		(Usable range)
		825 ~ 1275 kPa (8.4 ~ 13.0 kg/cm ² ,
		119 ~ 185 psi) @320 r/min (rpm)
Cylinder head warp			0.05 mm
Valves:
Valve clearance (when cold):	Inlet	0.10 ~ 0.19 mm
	Exhaust	0.15 ~ 0.24 mm
Valve head thickness:	Inlet	1.0 mm	0.5 mm
Makes store hand	Exhaust	1.0 mm	0.7 mm
Valve stem bend	I. I. I	Not more than 0.015 mm TIR	0.05 mm TIR
valve stem diameter:	Inlet	6.965 ~ 6.980 mm	6.95 mm
Valve quide inside diameter	Exhaust	0.955 ~ 0.970 mm	0.94 mm
Valve/valve quide clearance (wobble meth	od): Inlet	0.05 ~ 0.12 mm	0.25 mm
	Exhaust	0.07 ~ 0.12 mm	0.25 mm
Valve seating surface outside diameter	Inlet	37.9 ~ 38.1 mm	0.24 mm
	Exhaust	32.9 ~ 33.1 mm
Valve seating surface width		0.8 ~ 1.2 mm
Valve seat cutting angle		32°, 45°, 60°
Valve spring free length:	Inner	36.7 mm	35.0 mm
	Outer	38.7 mm	37.1 mm
Cylinder, Piston:
Cylinder inside diameter		73.500 ~ 73.512 mm	73.60 mm
Piston diameter		73.442 ~ 73.457 mm	73.29 mm
Piston/cylinder clearance		0.043 ~ 0.065 mm
Oversize pistons and rings		+ 0.5 mm and + 1.0 mm
Piston ring/groove clearance:	Тор	0.05 ~ 0.09 mm	0.19 mm
Distantia	Second	0.03 ~ 0.07 mm	0.17 mm
riston ring groove width	Гор	0.84 ~ 0.86 mm	0.94 mm
	Second	0.82 ~ 0.84 mm	0.92 mm
Diston ving thickness		2.01 ~ 2.03 mm	2.11 mm
Piston ring thickness:	op & Second	0.77 ~ 0.79 mm	0.70 mm
	Second	0.20 ~ 0.30 mm	0.60 mm
	Second	0.50 ~ 0.45 11111	0.75 mm

Page 60

Special Tool - Piston Ring Pliers: 57001-115 Piston Base 08: 57001-147 Valve Guide Beamer, 07: 57001-162 Valve Guide Arbor, $7: 57001-163 Compression Gauge: 57001-221 Valve Spring Compressor Assembly: 57001-241 Piston Pin Puller Assembly: 57001-910 Valve Spring Compressor Adapter, 029.5: 57001-1078 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, $$\Phi 67 $\sim $$\Phi 79: 57001-1097$ Valve Seat Cutter, 45° - Φ35: 57001-1116 Valve Seat Cutter, 45° - Φ41.5: 57001-1117 Valve Seat Cutter, 32° - Φ35: 57001-1121 Valve Seat Cutter, 32° - Φ38.5: 57001-1122 Valve Seat Cutter, 60° – Φ41: 57001-1124 Valve Seat Cutter Holder, 07: 57001-1126 Valve Seat Cutter Holder Bar: 57001-1128 Spark Plug Wrench, Hex 16: 57001-1262 Vacuum Gauge & Tachometer: 57001-1291 Compression Gauge Adapter, M10 X 1.0: 57001-1317

Sealant – Kawasaki Bond (Silicone Sealant): 56019-120 Kawasaki Bond (Liquid Gasket – Silver): 92104-002

Valve Head Thickness

Page 61

3-6 ENGINE TOP END

Clean Air System

Air Suction Valve Removal

Remove:

Seat

Side Covers
Fuel Tank
Pull off the hoses from the air suction valves.
Unscrew the valve cover bolts.
Open the cover [A], and take out the air suction valve [B].

Air Suction Valve Installation Note

• Replace the gasket [A] with a new one, and install the air suction valve.

Air Suction Valve Inspection

The air suction valve is essentially a check valve which allows fresh air to flow from the air cleaner into the exhaust port. Any air that has passed the air suction valve is prevented from returning to the air cleaner.

Remove the air suction valves.
Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage.
★If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder, or heat damage.
★If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly.
★ If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly clean with a high flash-point solvent.

ACAUTION

Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.

Vacuum Switch Valve Removal

• Remove:

Seat Side Covers Fuel Tank Air Intake Duct

Spark Plug Caps
Pull off the hoses from the air suction valve cover, air cleaner, and carburetor vacuum hose joint.

Take off the vacuum switch valve [A] with the hoses.

Page 62

Vacuum Switch Valve Installation Note

Install the vacuum switch valve so that the air hole [A] faces downwards.
Route the hoses correctly (see General Information chapter).

Vacuum Switch Valve Test

Using the vacuum gauge and a syringe, inspect the vacuum switch operation as follows:

Remove the vacuum switch valve.
Connect the vacuum gauge [A] and syringe [B] to the vacuum hoses as shown.

Special Tool - Vacuum Gauge & Tachometer: 57001-1291

Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum rises to 57 ~ 65 kPa (430 ~ 490 mm Hg), it should stop air flow. When the vacuum is high enough, the air cannot flow through the valve.
★If the vacuum switch valve does not operate as described, replace it with a new one.

NOTE

• To check air flow through the vacuum switch valve, just blow through the air cleaner hose.

Vacuum Switch Valve Closing Pressure (Open → Close) Standard: 57 ~ 65 kPa (430 ~ 490 mm Hg)

Clean Air System Hose Inspection

Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the air cleaner housing, vacuum switch valve, #1 and #4 carburetors, and air suction valve covers.
★If they are not, correct them. Replace them if they are damaged.

Page 63

3-8 ENGINE TOP END

Air Intake Duct

Removal

Bemove: Seat

Side Covers Fuel Tank
Air Suction Valve Covers [A]
•Unscrew the duct mounting bolts [B] and bracket mounting bolts [C], and take off the air intake ducts [D].

Page 64

Cylinder Head Cover

Removal

Remove the cylinder head cover bolts, and take off the cover and the gasket.

Perform the following if the engine is on the frame.
O Remove: Seat Side Covers Fuel Tank Ignition Coils Air Intake Ducts Vacuum Switch Valve and Hoses Air Suction Valves Cylinder Head Cover Assembly Allen Bolts [A] Cylinder Head Cover Bolts [B]
Pry the points [A] to split the head cover halves apart with the head cover assembly lifted. There are four knock pins [B] on the left and right of the mating surfaces.

Installation Notes

Replace the cylinder head rubber plugs [A] with new ones.
Apply silicone sealant [B] to the circumference of each plug.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Replace the cylinder head cover rubber gasket [A] with a new one.
Install the rubber gasket with the groove [B] facing the cylinder head.

Page 65

3-10 ENGINE TOP END

If the left and right covers are separated, assemble them with the bolts and knock pins [A].
Apply liquid gasket [B] to the mating surfaces of the head cover halves.
Apply non-permanent locking agent to the threads of cylinder head cover assembly bolts.

Install the cylinder head cover.
Apply silicone sealant to the mating surfaces at the areas shown [A]. Tighten the cover bolts.

Torque - Cylinder Head Cover Bolts : 9.8 N-m (1.0 kg-m, 7.0 ft-lb)

Page 66

Camshaft Chain Tensioner

ACAUTION

This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below:

When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in "Installation Notes".

Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.

Remove the carburetors.
Remove: Cap Bolt [A] Copper Washer [B] Spring [C] Guide Pin [D]
Remove the mounting bolts [E], and take off the chain tensioner.

Installation Notes

Release the stopper [A], and push the push rod [B] into the tensioner body [C].

Replace the gasket with a new one.
Install the tensioner body with the arrow [A] on it pointing downwards.

Torque – Camshaft Chain Tensioner Mounting Bolts [B] : 11 N-m (1.1 kg-m, 8.0 ft-lb)

Install the guide pin, spring, copper washer and cap bolt.
- Torque Camshaft Chain Tensioner Cap Bolt : 5.4 N-m (0.55 kg-m, 48 in-lb)

Page 67

3-12 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft Removal

Remove:

Cylinder Head Cover Camshaft Chain Tensioner Camshaft Caps [A]

Disengage the camshaft chain [B] from the camshaft sprockets, and remove the camshafts [C].

NOTE

Use a screwdriver or wire to keep the chain from falling down into the cylinder block.
Stuff a clean cloth into the chain tunnel to keep any parts from falling into the crankcase.

ACAUTION

The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.

Camshaft Installation Notes (Including Camshaft

Chain Timing Procedure)

Apply engine oil to all cam parts. If the camshafts and/or cylinder head are replaced with new ones, apply a thin coat of molybdenum disulfide grease to the new cam part surfaces.
•The exhaust camshaft [A] differs from the inlet camshaft [B]. The exhaust camshaft has an EX mark [C] and the inlet camshaft has an IN mark [D]. Be careful not to mix up these shafts.

Apply engine oil to the camshaft bearing portion.

• Install the camshafts so that the notched ends [A] of the camshafts are on the right side [B] of the engine.

Remove the pickup coil cover.
•Turn the crankshaft until the TDC mark [A] for the #1 and #4 pistons on the timing rotor is aligned with the timing mark [B] on the crankcase.

ACAUTION

Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.

Page 68

• Engage the camshaft chain with the camshaft sprockets as shown.

NOTE

• Pull the tension side (exhaust side) of the chain taut to install the chain.

○Align the EX timing mark [A] on the exhaust camshaft sprocket [B] with the cylinder head upper surface [C], pull the chain [D] taut and fit it onto the sprocket.
Pull the chain taut and fit it onto the inlet camshaft sprocket [E] so that the IN timing mark [F] on the sprocket aligns with the cylinder head upper surface and points between the 39th and 40th pins which start with the pin above the EX timing mark as shown.
Install the camshaft caps.

ACAUTION

The camshaft caps are machined with the cylinder head. So, if a cap is installed in the wrong location, the camshaft may seize because of improper oil clearance in the bearings.

• Match the number [A] on the camshaft caps with the number [B] on the cylinder head. The arrow [C] on the cap points forward.

• First tighten down the two camshaft cap bolts (#1 and #2 bolts in the figure) evenly to seat the camshafts in place, then tighten all bolts following the specified tightening sequence.

Torque - Camshaft Cap Bolts : 12 N-m (1.2 kg-m, 8.5 ft-lb)

Camshaft and Sprocket Assembly The inlet and exhaust sprockets are identical.

Use the specified bolt holes: Bolt Holes for Inlet Camshaft [A] Bolt Holes for Exhaust Camshaft [B]

• Apply a non-permanent locking agent to the threads of the camshaft sprocket bolts and tighten them.

Torque - Camshaft Sprocket Bolts : 15 N-m (1.5 kg-m, 11.0 ft-lb)

Page 69

3-14 ENGINE TOP END

Cam Wear

Remove the camshafts.

Measure the height [A] of each cam with a micrometer.
* If the cams are worn down past the service limit, replace the camshafts.

Cam Height

Camshaft Journal/Camshaft Bearing Wear

Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A].

NOTE

Tighten the camshaft cap bolts to the specified torque (see Camshaft Installation).
Do not turn the camshaft when the plastigage is between the journal and camshaft cap.
★If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Bearing Oil Clearance Standard: 0.058 ~ 0.101 mm Service Limit: 0.19 mm

★If the camshaft journal diameter is less than the service limit (see Specifications), replace the camshaft with a new one and measure the clearance again.
★If the clearance is still beyond the limit, replace the cylinder head unit.

Camshaft Chain Wear

Hold the chain taut with a force of about 5 kg, and measure a 20-link length. Since the chain may wear unevenly, take measurement at several places.
★ If any measurement exceeds the service limit, replace the chain. Also, replace the camshaft sprockets and crankshaft when the chain is replaced.

Camshaft Chain 20-Link Length

Standard:	158.76 ~ 159.18 mm
Service Limit:	161.1 mm

Page 70

ENGINE TOP END 3-15

Cvlinder Head

Cylinder Compression Measurement

Warm up the engine thoroughly.
Stop the engine, and remove one of the spark plugs from each cylinder.

Special Tool - Spark Plug Wrench, Hex 16: 57001-1262

• Measure the cylinder compression.

OUsing the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising; the compression is the highest reading obtainable.

Special Tool - Compression Gauge: 57001-221 [A]

Compression Gauge Adapter, M10 X 1.0: 57001-1317

NOTE

OBe sure the battery is fully charged.
OBe sure no air leaks out of the cylinder head gasket.

Cylinder Compression Usable Range : 825 ~ 1275 kPa (8.4 ~ 13.0 kg/cm², 119 ~ 185 psi) @320 r/min (rpm)

O Repeat the measurement for the other cylinder.
★If cylinder compression is higher than the usable range, check the following:
- Carbon build-up on the cylinder head combustion chamber and the piston crown.
- (2) Cylinder head gasket is not the original part.
- (3) Valve stem oil seals and/or piston rings are damaged.
★If cylinder compression is lower than the usable range, check the following:
- (1) Condition of the valve seat is wrong.
- (2) Valve clearance is too small.
- (3) Piston/cylinder clearance is excessive.
- (4) Cylinder head is warped and/or head gasket is damaged.
- (5) Piston ring/piston ring groove clearance is excessive.

Removal

Remove:

Carburetor Assembly Cylinder Head Cover
Camshaft Chain Tensioner
Canadiant offant renai
Oil Pipe Holder Bolts [A]
Oil Pipes
Oil Pipe Banjo Bolts [B]
Oil Pipe Retainer Bolt [C]
Exhaust Pipe, Muffler

• Remove the cylinder head bolts.

• Lift off the cylinder head [A], and remove the gasket.

NOTE

• Tap up lightly the cylinder head with a rubber mallet [B] to separate from the cylinder.

Page 71

3-16 ENGINE TOP END

Installation Notes

Replace the cylinder head gasket with a new one.
Apply a molybdenum disulfide lubricant (grease or oil type, either will do) to both upper and lower sides of all washers and to the threads of the M11 bolts (except #2 bolt in the figure).
Apply silicone sealant to the threads of the #2 bolt in the figure.
Install the M11 (164 mm length) bolts at #1, 2, 3, 4, 9, 10, 11 and 12 in the figure with the thinner washers.
Install the M11 (140 mm length) bolts at #5 and 7 with thicker washers and at #6 and 8 with thinner washers.
•Tighten the M11 bolts following the tightening sequence. Tighten them first to about one half of the specified torque, and then tighten them to the specified torque.

Torque – Cylinder Head M11 Bolts : 47 N-m (4.8 kg-m, 35 ft-lb) (New Bolts) : 49 N-m (5.0 kg-m, 36 ft-lb)

•Tighten the M8 cylinder head bolts (#13 and 14 bolts in the figure).
- Torque Cylinder Head M8 Bolt (front) : 25 N-m (2.5 kg-m, 18.0 ft-lb) Cylinder Head M8 Allen Bolt (rear) : 20 N-m (2.0 kg-m, 14.5 ft-lb)
Install the oil pipe in the cylinder head.
Apply non-permanent locking agent to the threads of the oil pipe holder bolts and tighten them.

Torque - Oil Pipe Holder Bolts : 11 N-m (1.1 kg-m, 8.0 ft-lb)

Install new washers on each side of the oil pipe fittings, and tighten the banjo bolts, and oil pipe retainer bolt.
- Torque Oil Pipe Banjo Bolts : 25 N-m (2.5 kg-m, 18.0 ft-lb) Oil Pipe Retainer Bolt : 11 N-m (1.1 kg-m, 8.0 ft-lb)

Assembly

Install the rubber dampers [A] between the fins [B] as shown.
- C1 Front
- [D] About 60 mm
- [E] About 40 mm
- [F] Right and Left Both Sides of the Cylinder Head

Page 72

Cylinder Head Warp

Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and the head.
★ If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.

Cylinder Head Warp Service Limit: 0.05 mm

Cylinder Head Cleaning
Remove the cylinder head.
Remove the valves (see Valve Removal).
Wash the head with a high flash-point solvent.
Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool.

Page 73

3-18 ENGINE TOP END

Valves

Clearance Inspection

NOTE

• Valve clearance must be checked when the engine is cold (at room temperature).

• Remove:

Cylinder Head Cover

Using a thickness gauge, measure the valve clearance between the cam and the valve lifter.
O Using a wrench on the timing rotor nut, turn the crankshaft clockwise until the TDC mark [A] for the #1 and #4 pistons on the rotor is aligned with the timing mark [B] on the crankcase and the cam lobe is pointing away from the valve lifter at the end of the compression stroke.
O When positioning #4 piston TDC at the end of the compression stroke: Inlet valve clearance of #2 [A] and #4 [B] cylinders Exhaust valve clearance of #3 [C] and #4 [D] cylinders

O When positioning #1 piston TDC at the end of the compression stroke: Inlet valve clearance of #1 [A] and #3 [B] cylinders Exhaust valve clearance of #1 [C] and #2 [D] cylinders
★If the valve clearance is not within the specified range, first record the clearance, and then adjust it.

Valve Clearance (When cold) Standard: IN : 0.10

IN : 0.10 ~ 0.19 mm EX : 0.15 ~ 0.24 mm

Clearance Adjustment

Remove the camshaft [A] (see Camshafts Removal).
Remove the valve lifter [B].
Remove the shim [C].
Referring to the Valve Clearance Adjustment Chart, select a new shim which brings valve clearance within the specified range, and replace the original shim with the selected new one.

OWhen installing the shim, face the marked side [A] toward the spring retainer [B]. At this time, apply high temperature grease to the shim or the spring retainer to keep the shim in place during camshaft installation.

ACAUTION

Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage.

Page 74

VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE

										DBC	ENT	CH11	10									-
P	ART No. (92025-)	1090	1091	1092	1093	1094	1095	1096	1097	1098	1099	1100	1101	1102	1103	1104	1105	1106	1107	1109	1100	1110	1111	1112	1112	1114
F	MARK	200	205	210	215	220	225	230	235	240	245	250	255	260	265	270	275	280	285	290	295	300	305	310	315	320
Т	HICKNESS (mm)	2.00	2.05	2.10	2.15	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20

	0.00 ~ 0.04		/	2.00	2.05	2.10	2.15	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10
	0.05 ~ 0.09		2.00	2.05	2.10	2.15	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15
e	0.10 ~ 0.19								SPE	CIFI	ED C	LEAR	RANC	E/N	о сн	ANG	E RE	QUIF	ED
ldu	0.20 ~ 0.23	2.05	2.10	2.15	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
xar	0.24 ~ 0.28	2.10	2.15	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
Ш	0.29 ~ 0.33	2.15	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/
L	≥ 0.34 ~ 0.38	2.20	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
	0.39 ~ 0.43	2.25	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/
	0.44 ~ 0.48	2.30	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/
	0.49 ~ 0.53	2.35	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
	0.54 ~ 0.57	2.40	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/
Z	0.59 ~ 0.63	2.45	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
M	0.64 ~ 0.68	2.50	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
RE	0.69 ~ 0.73	2.55	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/
SU	0.74 ~ 0.78	2.60	2.65	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/
EA	0.79 ~ 0.83	2.65	3.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20		/	11	ISTA		IE SI	HIM	OFT	HIS .	THIC	KNES	S (m	im)
Σ	0.84 ~ 0.88	2.70	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
1CE	0.89 ~ 0.93	2.75	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
AA	0.94 ~ 0.98	2.80	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
AF	0.99 ~ 1.03	2.85	2.90	2.95	3.00	3.05	3.10	3.15	3.20
CLE	1.04 ~ 1.08	2.90	2.95	3.00	3.05	3.10	3.15	3.20
E	1.09 ~ 1.13	2.95	3.00	3.05	3.10	3.15	3.20
ALI	1.14 ~ 1.18	3.00	3.05	3.10	3.15	3.20
>	1.19 ~ 1.23	3.05	3.10	3.15	3.20
	1.24 ~ 1.28	3.10	3.15	3.20
	1.29 ~ 1.33	3.15	3.20		/
	1.34 ~ 1.38	3.20







1.	Measure the o	leara	ince	(wł	nen e	engi	ne is	col	d).
2.	Check present	t shir	n siz	ze.		-
3	Match cleara	ince	in	verti	cal	col	umn	wi	th r	orese	ent	shim	n siz	ze ii	n
0.	horizontal col	umn
Λ	Inetall the chir	n en	ecifi	ed w	here	e the	line	s int	erse	ct.	This	shin	n wil	l giv	е
4.	motan the sim	ii op	John		inon									0

the proper clearance.

Example : Present shim is 2.70 mm. Measured clearance is 0.35 mm. Replace 2.70 mm shim with 2.90 mm shim.

NOTE

If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.
Apply engine oil to the valve lifter and install it.
Install the camshaft (see Camshaft Installation).
Remeasure the valves that were adjusted, and readjust if necessary.

Page 75

3-20 ENGINE TOP END

VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE

	PRESENT SHIM Example –
PART No. (92025-)	1090 1091 1092 1093 1094 1095 1096 1097 1098 1099 1090 1101 100 1101 1102 1103 1104 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114
MARK	200 205 210 220 220 230 230 245 240 245 250 260 265 270 270 280 280 290 290 300 305 310 315 320
THICKNESS (mm)	2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20

0.00 ~ 0.04	2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05
0.05 ~ 0.09	2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10
0.10 ~ 0.14	2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.80 2.90 2.95 3.00 3.05 3.10 3.15
	SPECIFIED CLEARANCE/NO CHANGE REQUIRED
G 0.25 ~ 0.28	2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.29 ~ 0.33	2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.34 ~ 0.38	2.16 2.20 2.25 2.30 2.36 2.30 2.36 2.40 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
→ 0.39 ~ 0.43	2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.76 2.80 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.44 ~ 0.48	2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.49 ~ 0.53	2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.54 ~ 0.58	2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
5 0.59 ~ 0.63	2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.64 ~ 0.68	2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.69 ~ 0.73	2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
○ 0.74 ~ 0.78	2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
Q 0.79 ~ 0.83	2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
≥ 0.84 ~ 0.88	2.65 3.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
U 0.89 ~ 0.93	2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.94 ~ 0.98	2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0.99 ~ 1.03	2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
₩ 1.04 ~ 1.08	2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20
0 1.09 ~ 1.13	2.90 2.95 3.00 3.05 3.10 3.15 3.20
1.14 ~ 1.18	2.95 3.00 3.05 3.10 3.15 3.20
S 1.19 ~ 1.23	3.00 3.05 3.10 3.15 3.20
1.24 ~ 1.28	3.05 3.10 3.15 3.20
1.29 ~ 1.33	3.10 3.15 3.20
1.34 ~ 1.38	3.15 3.20
1.39 ~ 1.43	3.20

1. Measure the clearance (when engine is cold).
2. Check present shim size.
3. Match clearance in vertical column with present shim size in horizontal column.
4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
Example : Present shim is 2.80 mm. Measured clearance is 0.40 mm. Replace 2.80 mm shim with 3.00 mm shim.

NOTE

O If there is no clearance, select a shim which is several sizes smaller and then measure the clearance.
Apply engine oil to the valve lifter and install it.
Install the camshaft (see Camshaft Installation).
Remeasure the valves that were adjusted, and readjust if necessary.

Page 76

Removal

Remove the cylinder head (see Cylinder Head Removal).
Remove the valve lifter and the shim.
Remove the split keepers while compressing the valve spring.
Special Tool Valve Spring Compressor Assembly: 57001-241 [A] Valve Spring Compressor Adapter, 029.5: 57001-1078
- [B]

Remove:
- Spring Retainer
- Outer Valve Spring
Inner Valve Spring
Remove the valve.

Installation

Replace the oil seal [C] with a new one.
Apply a thin coat of molybdenum disulfide grease to the valve stem, and install the valve [A].
Check the following:
- (1) Valve moves smoothly up and down in the guide.
- (2) Valve seats properly in the valve seat.
Install the inner valve spring [D] and the outer valve spring [E] with their closed coil ends toward the spring seat [B].
Put the spring retainer [F] on the springs, and fit the split keepers [G] between the retainer and the stem while compressing the valve spring.

Special Tool – Valve Spring Compressor Assembly: 57001-241 Valve Spring Compressor Adapter, Φ29.5: 57001-1078

• Install the shim [H] with its marked side toward the spring retainer.

NOTE

○Apply high temperature grease to the shim or the spring retainer to keep the shim in place during camshaft installation.
Apply engine oil to the valve lifter [I] and install it.

Guide Removal

Remove the valve.
Remove the oil seal.
Remove the spring seat.
Remove the valve guide from the top of the cylinder head.

NOTE

○ Heat the area around the valve guide to about 120 ~ 150°C (248 ~ 302°F).

Special Tool – Valve Guide Arbor, 07: 57001-163 [A]

Page 77

3-22 ENGINE TOP END

Guide Installation • Distinguish the valve guide. Inlet Valve Guide......Short [A] Exhaust Valve Guide......Long [B]

• Drive the valve guide in from the top of the cylinder head until the circlip stops the guide from going in too far.

NOTE

Apply engine oil to the valve guide outer surface. Heat the area around the valve guide hole to about 120 ~ 150°C (248 ~ 302°F).

Special Tool - Valve Guide Arbor, 07: 57001-163

• Ream the valve guide even if the old guide is reused.

Special Tool - Valve Guide Reamer, 07: 57001-162 [A]

Seat Inspection

• Remove the valve.

Check the valve seating surface [A] between the valve [B] and valve seat [C].
O Measure the outside diameter [D] of the seating pattern on the valve seat.
★ If the outside diameter is too large or too small, repair the seat (see Seat Repair).

Valve Seating Surface Outside Diameter Standard: Inlet 37.9 ~ 38.1 mm Exhaust 32.9 ~ 33.1 mm

O Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with a vernier caliper.
★If the width is too wide, too narrow or uneven, repair the seat (see Seat Repair).

Valve Seating Surface WidthStandard:Inlet, Exhaust0.8 ~ 1.2 mm

Page 78

Seat Repair

Repair the valve seat with the valve seat cutters.
Special Tool Valve Seat Cutter Holder, Φ7: 57001-1126 Valve Seat Cutter Holder Bar: 57001-1128 [For Inlet Valve Seat] Valve Seat Cutter, 45° Φ41.5: 57001-1117 Valve Seat Cutter, 32° Φ38.5: 57001-1122 Valve Seat Cutter, 60° Φ41: 57001-1124 [For Exhaust Valve Seat] Valve Seat Cutter, 45° Φ35: 57001-1116 Valve Seat Cutter, 32° Φ35: 57001-1121 Valve Seat Cutter, 32° Φ41: 57001-1124 [For Exhaust Valve Seat]

★ If the manufacturer's instructions are not available, use the following procedure.

Seat Cutter Operation Care:

1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.

NOTE

Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.

NOTE

Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer of engine oil before storing.

Marks Stamped on the Cutter:

The marks stamped on the back of the cutter [A] represent the following.

60°	Cutter angle [B]
37.5Ф	Outer diameter of cutter [C]

Page 79

Operating Procedures

Clean the seat area carefully.
Coat the seat with machinist's dye.
Fit a 45° cutter into the holder and slide it into the valve guide.
Press down lightly on the handle and turn it right or left. Grind the seating surface only unit it is smooth.

ACAUTION

Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.

Measure the outside diameter of the seating surface with a vernier caliper.
★If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range.
★If the outside diameter of the seating surface is too large, make the 32° grind described below.
★If the outside diameter of the seating surface is within the specified range, measure the seat width as described below.
Grind the seat at a 32° angle until the seat O.D. is within the specified range.
OTo make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide.
OTurn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.

ACAUTION

The 32° cutter removes material very quickly. Check the seat outside diameter frequency to prevent overgrinding.

After making the 32° grind, return to the seat O.D. measurement step above.
•To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat.
★If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat O.D. measurement step above.
★ If the seat width is too wide, make the 60° grind described below.
★If the seat width is within the specified range, lap the valve to the seat as described below.
Grind the seat at a 60° angle until the seat width is within the specified range.
To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide.
OTurn the holder, while pressing down lightly.
O After making the 60° grind, return to the seat width measurement step above.
Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above.
Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
O Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve.
O Repeat the process with a fine grinding compound.
- [A] Lapper
- [B] Valve Seat
- [C] Valve
•The seating area should be marked about in the middle of the valve face.

Widened width of engagement by machining with 45° cutter

Page 80

★If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment).

Valve-to-Guide Clearance Measurement (Wobble Method)

If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.

Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular it as close as possible to the cylinder head mating surface.
Move the stem back and forth [C] to measure valve/valve guide clearance.
Repeat the measurement in a direction at a right angle to the first.
★ If the reading exceeds the service limit, replace the guide.

NOTE

• The reading is not actual valve/valve guide clearance because the measuring point is above the guide.

Valve/Valve Guide Clearance (Wobble Method)

	Standard	Service Limi
Inlet	0.05 ~ 0.12 mm	0.25 mm
Exhaust	0.07 ~ 0.14 mm	0.24 mm

Page 81

3-26 ENGINE TOP END

Page 82

ENGINE TOP END 3-27

Cylinder, Piston

Removal

Cylinder Head Cylinder

• Remove the snap ring from one side of each piston pin hole.

NOTE

Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase.
Remove the piston by pushing the piston pin out the side from which the snap ring was removed.

Special Tool - Piston Pin Puller Assembly: 57001-910 [A]

• Remove the piston rings.

Special Tool - Piston Ring Pliers: 57001-115 [A]

O Remove the oil ring with your thumbs.

Installation Notes

Do not mix up the top and second rings: Install the top ring [A] so that the "R" mark [B] faces up. Install the second ring [C] so that the "RN" mark [D] faces up.

Install the oil ring:

First install the expander in the piston oil ring groove so that the expander ends [A] butt together, never overlap.
O Install the upper and lower steel rails. There is no UP or DOWN to the rails. They can be installed either way.

Page 83

Apply engine oil to the inside of the connecting rod small end.
Install the piston so that the arrow on the top points toward the front.

ACAUTION

Be sure to replace the piston pin snap ring with a new one. When installing the snap ring, compress it only enough to install it and no more.

Fit the snap ring so that the ring opening [A] does not coincide with the notch [B] in the edge of the piston pin hole.

• Position the piston ring openings as follows:

Top Ring – Front [A] Second Ring – Rear [B] Upper Steel Rail – About 30° of angle to the left [C] Expander – Rear [D] Lower Steel Rail – About 30° of angle to the right [E]

• Replace the cylinder base gasket with a new one. • Install the gasket with UP [A] marked side facing up.

Apply molybdenum disulfide grease to the front and rear surface of the piston skirt.
Apply engine oil to the piston rings and the cylinder bores.
★If a new cylinder is installed, apply molybdenum disulfide grease to its bores.

• Hold the pistons level.

Special Tool - Piston Base, 08: 57001-147 [A]

•Install the cylinder while compressing the piston rings.

Special Tool – Piston Ring Compressor Grip: 57001-1095 [A] Piston Ring Compressor Belt, Φ67 ~ Φ79: 57001-1097

Page 84

Cylinder Assembly

Install the rubber dampers [A] between the fins [B] as shown.

[C] About 20 mm

ONo dampers are required at the position indicated as [F] where the displacement is embossed
O Install the dampers on the other faces of the cylinder at the same

Cylinder Wear

Since there is a difference in cylinder wear in different directions take a side-to-side and a front-to-back measurement at each of the 3 locations (total of 6 measurements) shown in the figure.
★ If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder will have to be bored to oversize and then honed.

Cylinder Inside Diameter

Standard:

73.500 ~ 73.512 mm Service Limit: 73.60 mm

Piston Wear

• Measure the outside diameter of each piston 5 mm [A] up from the bottom of the piston at a right angle to the direction of the piston pin. ★If the measurement is under service limit, replace the piston.

Piston Diameter Standard:

Service Limit: 73.29 mm

73.442 ~ 73.457 mm

Boring, Honing

When boring and honing a cylinder, note the following:

OThere are two sizes of oversize pistons available. Oversize pistons

require oversize rings.

Oversize Pistons and Rings
1.0 mm Oversize

OBefore boring a cylinder, first measure the exact diameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the rebore diameter. However, if the amount of boring necessary would make the inside diameter greater than 1.0 mm, the cylinder block must be replaced.

Page 85

3-30 ENGINE TOP END

O Cylinder inside diameter must not vary more than 0.01 mm at any point.
OBe wary of measurements taken immediately after boring since the heat affects cylinder diameter.
O In the case of a rebored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm and the service limit for the piston is the oversize piston original diameter minus 0.15 mm. If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder.

Piston Ring, Piston Ring Groove Wear

• Check for uneven groove wear by inspecting the ring seating.

★The rings should fit perfectly parallel to groove surfaces. If not, the piston must be replaced.
With the piston rings in their grooves, make several measurements with a thickness gauge to determine piston ring/groove clearance.

Piston Ring/G	roove Clearance
	Standard	Service Limit
Тор	0.05 ~ 0.09 mm	0.19 mm
Second	0.03 ~ 0.07 mm	0.17 mm

Piston Ring End Gap

Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low.
Measure the gap [B] between the ends of the ring with a thickness gauge.

Piston Ring End Gap

Standard		Service Limit
Тор	0.20 ~ 0.30 mm	0.60 mm
Second	0.30 ~ 0.45 mm	0.75 mm

Page 86

Exhaust Pipe, Muffler

Removal

Loosen the muffler clamp bolts [A].
Remove the mounting bolts [B], and take off the mufflers.

Loosen the exhaust pipe holder nuts [A]. Remove the exhaust pipe assembly from the engine.

Installation Notes

Check the gaskets for signs of damage.
★If necessary, replace the gaskets with new ones.
•Tighten the exhaust pipe holder nuts evenly.
Tighten the muffler clamp bolts and mounting bolts securely.
Thoroughly warm up the engine, wait until the engine cools down, and then retighten the clamp bolts and the holder nuts.
★If the exhaust pipe covers are removed, install the cover clamps as far as it can be set rear end on the muffler and position the clamp shown degrees.
- [A] Exhaust Pipe Covers
- [B] Front Clamps
- [C] 10 ~ 15°
- [D] Exhaust Pipes

Page 87

Clutch


Exploded View	4-2
Specifications	4-3
Clutch Lever	4-4
Lever Position Adjustment	4-4
Clutch Fluid	4-5
Level Inspection	4-5
Change	4-5
Bleeding the Clutch Line	4-6
Clutch Master Cylinder	4-8
Removal	4-8
Installation Notes	4-8
Disassembly
Assembly Notes
Inspection (Visual Inspection)	4-9
Clutch Slave Cylinder	4-10
Removal	4-10
Installation Notes
Disassembly	4-10
Assembly Notes
Inspection (Visual Inspection)	4-11
Clutch
Removal	4-12
Installation Notes	4-12
Spring Plate Free Play Measurement	4-14
Spring Plate Free Play Adjustment	4-15
Clutch Plate Wear, Damage Inspection	4-15
Clutch Plate Warp Inspection	4-15
Clutch Spring Free Length Measurement	4-16
Clutch Housing Finger Inspection	4-16
Sub Clutch Hub Spline Inspection	4-16
Damper Cam Inspection	4-16

Page 88

Exploded View

1. Starter Lockout Switch

T1 : 130 N-m (13.5 kg-m, 98 ft-lb)
T2 : 11 N-m (1.1 kg-m, 8.0 ft-lb)
T3 : 9.8 N-m (1.0 kg-m, 7.0 ft-lb) T4 : 5.9 N-m (0.6 kg-m, 52 in-lb)
T5 : 1.2 N-m (0.12 kg-m, 10 in-lb)
T6 : 1.5 N-m (0.15 kg-m, 13 in-lb)
T7 : 25 N-m (2.5 kg-m, 18.0 ft-lb)

T8 : 1.0 N-m (0.1 kg-m, 9 in-lb)

: Apply high temperature grease.
: Apply molybdenum disulfide grease.
O : Apply engine oil to the surface.
L : Apply a non-permanent locking agent.
R : Replace parts.
Si : Apply silicone grease.
S : Follow the specific tightening sequence.

Page 89

Specifications


	ltem	Standard	Service Limit
Clutch Lever: Lever position			(Adjustable Range) 1 ~ 4
Clutch Fluid:
Grade		D.O.T.4
Brand (recomm	ended)	Castrol Girling-Universal
		Castrol GT (LMA)
		Castrol Disc Brake Fluid
		Check Shock Premium Heavy Duty
Clutch:
Spring plate free	e play	(Usable range)
(with origina	I friction plates)	0.15 ~ 0.75 mm
		(Usable range)
(with all new	r friction plates)	0.05 ~ 0.35 mm
Friction and ste	el plates warp	Not more than 0.2 mm	0.3 mm
Spring free leng	Ith	39.4 mm	37.9 mm

Special Tool – Inside Circlip Pliers: 57001-143 Clutch Holder: 57001-1243

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Page 90

4-4 CLUTCH

Clutch Lever

Lever Position Adjustment

The adjuster has 4 positions so that the clutch lever position can be adjusted to suit the operator's hand.

Push the lever forward and turn the adjuster [A] to align the number with the triangular mark [B] on the lever holder.
OThe distance from the grip to the released lever is minimum at Number 4 and maximum at Number 1.

Page 91

Clutch Fluid

Since the clutch fluid is the same as the brake fluid, refer to Brake Fluid section in Brakes chapter for further details.

Level Inspection

In accordance with the Periodic Maintenance Chart, inspect the clutch fluid level in the clutch fluid reservoir.

Check that the clutch fluid level in the clutch fluid reservoir [A] is above the lower level line [B].

NOTE

O Hold the reservoir horizontal by turning the handlebar when checking clutch fluid level.
★ If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B].

Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Mixing different types and brand of fluid lowers the fluid boiling point and could cause the clutch to be ineffective. It may also cause the rubber clutch parts to deteriorate.

Recommended Clutch Fluid

Grade: D.O.T.4

Brand : Castrol Girling-Universal Castrol GT (LMA) Castrol Disc Brake Fluid Check Shock Premium Heavy Duty

Change Remove the clutch slave cylinder cover [A].

Level the clutch fluid reservoir.
Remove the reservoir cap.
Remove the rubber cap from the bleed valve [A] on the clutch slave cylinder.
Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.

Page 92

4-6 CLUTCH

Install the reservoir cap.
Change the clutch fluid as follows:

Repeat this operation until fresh clutch fluid comes out from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].
2. Apply the clutch lever and hold it [B].
3 Close the bleed valve [C]
4. Release the clutch lever [D].

NOTE

The fluid level must be checked several times during the fluid changing and replenished as necessary. If the fluid in the reservoir runs completely out any time during fluid changing, air bleeding must be done since air will have entered the line.
Remove the clear plastic hose.
Tighten the bleed valve, and install the rubber cap.

Torque - Clutch Bleed Valve : 5.9 N-m (0.6 kg-m, 52 in-lb)

After changing the fluid, check for fluid leakage around the fittings.
★If necessary, bleed the air from the line.

Bleeding the Clutch Line

AWARNING

Be sure to bleed the air from the clutch line whenever clutch lever action feels soft or spongy after the clutch fluid is changed, or whenever a clutch line fitting has been loosened for any reason.

Remove the reservoir cap, and fill the reservoir to the upper level line in the reservoir with fresh fluid.
•With the reservoir cap off, slowly pump the clutch level several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.
O Bleed the air completely from the master cylinder by this operation.
Install the reservoir cap.
•Attach a clear plastic hose to the bleed valve on the clutch slave cylinder, and run the other end of the hose into a container.
Bleed the clutch line as follows:
Repeat this operation until no more air can be seen coming out into the plastic hose.
- 1. Pump the clutch lever a few times until it becomes hard, then hold it squeezed [A].
- 2. Quickly open and close the bleed valve [B].
- 3. Release the clutch lever [C].

Page 93

NOTE

The fluid level must be checked often during the bleeding operation and replenished with fresh fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.
OTap the clutch hose lightly from the clutch slave cylinder to the reservoir for more complete bleeding.
Bemove the clear plastic hose.
Tighten the bleed valve, and install the rubber cap.

Torque - Clutch Bleed Valve : 5.9 N-m (0.6 kg-m, 52 in-lb)

Check the fluid level.
After bleeding is done, check for fluid leakage around the fittings.

Page 94

4-8 CLUTCH

Clutch Master Cylinder

CAUTION

Clutch fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with wet cloth.

Removal

Disconnect the starter lockout switch connector [A].
Pull back the dust cover, and remove the banjo bolt [A] to disconnect the clutch hose from the master cylinder.
Unscrew the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, clutch lever, and starter lockout switch installed.

Installation Notes

Install the clutch master cylinder so that the mating surface [A] of the switch housing is aligned with the mating surface [B] of the master cylinder clamp to level the reservoir.
OThe master cylinder clamp must be installed with the arrow mark [C] upward.
OTighten the upper clamp bolt first, and then the lower clamp bolt. There will be a gap at the lower part of the clamp after tightening.
- Torque Clutch Master Cylinder Clamp Bolts : 11 N-m (1.1 kg-m, 8.0 ft-lb) [D]
Replace the washers that are on each side of the hose fitting with new ones.
•Torque the clutch hose banjo bolt.

Torque - Clutch Hose Banjo Bolt : 25 N-m (2.5 kg-m, 18.0 ft-lb)

• Bleed the clutch line (see Bleeding the Clutch Line).

Disassembly

Remove the master cylinder.
Remove the reservoir cap and diaphragm, and pour the clutch fluid into a container.
Unscrew the locknut and pivot bolt, and remove the clutch lever.
Push the dust cover out of place, and remove the circlip.

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the piston [A], secondary cup [B], primary cup [C], and return spring [D].

Page 95

ACAUTION

Do not remove the secondary cup from the piston since removal will damage it.

Assembly Notes

Before assembly, clean all parts including the master cylinder with clutch fluid or alcohol.

ACAUTION

Use only disc brake/clutch fluid, isopropyl alcohol, or ethyl alcohol, for cleaning parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the cylinder.

Apply clutch fluid to the parts removed and to the inner wall of the cylinder. Take care not to scratch the piston or the inner wall of the cylinder.
Check to see that the piston return spring pushes back the piston to its rest position when the spring is compressed.
Install the push rod with the dust seal fitted into the groove.
OThe push rod round end must be faced inwards.
Use a new flat washer on each side of the hose fitting.
Tighten the banjo bolt.

Torque - Clutch Hose Banjo Bolt : 25 N-m (2.5 kg-m, 18.0 ft-lb)

• Fill the clutch fluid into the clutch line and bleed the clutch line (see Change and Bleeding the Clutch Line).

Inspection (Visual Inspection)

Check that there are no scratches, rust or pitting on the inside of the master cylinder and on the outside of the piston.
★ If the master cylinder or piston shows any damage, replace them.
Inspect the primary cup and secondary cup.
★If a cup is worn, damaged, softened (rotted), or swollen, the piston assembly should be replaced to renew the cups.
★ If fluid leakage is noted at the clutch lever, the piston assembly should be replaced to renew the cups.
Check the dust cover for damage.
★ If it is damaged, replace it.
Check that the relief and supply ports are not plugged.
★ If the small relief port becomes plugged, the clutch will slip. Blow the ports clean with compressed air.
Check the piston return spring for any damage.
★ If the spring is damaged, replace it.

Page 96

4-10 CLUTCH

Clutch Slave Cylinder

Removal

• Squeeze the clutch lever [A] and hold it with a band [B].

NOTE

• Holding the clutch lever keeps the piston from coming out.

ACAUTION

If the clutch slave cylinder is removed and left alone, the piston will be pushed out by the spring and the clutch fluid will drain out.

Remove the clutch slave cylinder cover.
Remove the clutch slave cylinder mounting bolts [A] and remove the cylinder [B] from the engine with the hose.
Perform the following if the clutch slave cylinder is to be disassembled. O Bemove the clutch slave cylinder cover.
O Loosen the clutch hose banio bolt [C] on the clutch slave cylinder.
O Remove the clutch slave cylinder mounting bolts and take off the cylinder
O Remove the banjo bolt and free the cylinder from the hose.

ACAUTION

Immediately wipe up any clutch fluid that spills. It may damage painted surfaces.

Installation Notes

Replace the washers on each side of the clutch hose fitting with new ones.

Torque - Clutch Hose Banjo Bolt : 25 N-m (2.5 kg-m, 18.0 ft-lb)

Apply non-permanent locking agent to the two shorter slave cylinder mounting bolts [A].
Check the fluid level in the clutch fluid reservoir, and bleed the air in the clutch line.
Check the clutch operation.

Disassembly

Remove the banjo bolt and pour the fluid into a container.
Using compressed air [A], remove the piston.
O Cover the cylinder opening with a clean, heavy cloth [B].
O Face the opening downwards.
O Remove the piston by lightly applying compressed air to where the clutch line fits into the slave cylinder.

ACAUTION

If the fluid seal is removed from the piston, replace the seal with a new one. Removal would damage the seal.

To avoid serious injury, never place your fingers or palm in front of the cylinder opening. If you apply high compressed air to the cylinder, the piston may injure your hand or fingers.

Page 97

Assembly Notes

Before assembly, clean all parts including the cylinder with clutch fluid or alcohol.

ACAUTION

Apply clutch fluid to the outside of the piston and the fluid seal, and push the piston into the cylinder by hand. Take care that neither the cylinder nor the piston gets scratched.
- [A] Cylinder
- [B] Piston
- [C] Fluid Seal
[D] Spring
Install the cylinder (see Installation Notes).

Inspection (Visual Inspection)

•Visually inspect the piston and cylinder surfaces.
Replace the cylinder and piston if they are badly scored or rusty.
★ Replace the fluid seal under any of the following conditions: fluid leakage around the piston or the seal is stuck to the cylinder.
Check the piston spring for any damage.
★ If the spring is damaged, replace it.

Page 98

4-12 CLUTCH

Clutch

Removal

Remove: Engine Oil (drain) Clutch Cover

Remove the parts in order from the clutch assembly. Clutch Spring Bolts [A], Washer, and Springs Clutch Spring Plate [B], Shim, Thrust Bearing, and Pusher [C]

Friction Plates and Steel Plates Clutch Hub Nut

Special Tool - Clutch Holder: 57001-1243 [A]

Torque Limiter Spring [B] Sub Clutch Hub [C]

Toothed Washer [A] Clutch Hub [B]

Thrust Washer Clutch Housing Bearing Collar [A] Needle Bearing [B] Clutch Housing [C] Oil Pump Drive Gear Spacers

NOTE

The clutch housing bearing collar can easily be removed by installing clutch cover bolts [D] into the collar tapping holes and pulling them. The clutch housing can be removed after removing the bearing collar.

Installation Notes

Install the spacers on the drive shaft [A] with the smaller spacer [B] located inside.

Page 99

Install the oil pump drive gear [A]. Fit the projections [B] of the gear into the grooves [C] in the clutch housing.

•Engage cam followers [A] (Clutch Hub) with the cams [B] (Sub Clutch Hub).

Replace the clutch hub nut with a new one. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut : 130 N-m (13.5 kg-m, 98 ft-lb)

Install the friction plates and steel plates, starting with a friction plate and alternating them.
O Install the last friction plate [A] fitting the tangs in the grooves in the housing as shown.

ACAUTION

If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.

Apply engine oil to the thrust bearing.
Apply molybdenum disulfide grease to the rubbing portion of clutch spring plate pusher.

Page 100

4-14 CLUTCH

Install the clutch spring plate with the shim, thrust bearing and pusher assembled.

Torque - Clutch Spring Bolts : 11 N-m (1.1 kg-m, 8.0 ft-lb)

Replace the cover gasket with a new one.
Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Spring Plate Free Play Measurement

Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel "spongy" or pulsate when pulled.

Remove oil from the clutch plates.
Hold an extra drive shaft in a vise and install the following clutch parts on the shaft.
- [A] Spacers
- [B] Oil Pump Drive Gear
- [C] Clutch Housing Bearing and Collar
- [D] Clutch Housing
- [E] Thrust Washer
- [F] Clutch Hub
- [G] Sub Clutch Hub
- [H] Friction Plates
- [I] Steel Plates
- [J] Spring Plate

•To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate.
Move the clutch housing gear back and forth [C]. The difference between the highest and lowest gauge readings is the amount of free play.