Kawasaki Brute Force 750 Service manual

BRUTE FORCE 750 4×4i

KVF 750 4×4

All Terrain Vehicle

Service Manual

Property of www.SmallEngineDiscount.com - Not for Resale


Quick Reference Guide

General Information

Periodic Maintenance

Fuel System

Cooling System

Engine Top End

Converter System

Recoil Starter

Engine Lubrication System

Engine Removal/Installation

Crankshaft/Transmission

Wheels/Tires

Final Drive

Brakes

Suspension

Steering

Frame

Electrical System

Appendix

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.


14 j

15 j

16 j

17 j

18 j

9 j

10 j

11 j

12 j

13 j

1 j

2 j

3 j

4 j

5 j

6 j

7 j

8 j


BRUTE FORCE 750 4×4i

KVF 750 4×4

All Terrain Vehicle

Service Manual

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

Company/Kawasaki Heavy Industries, Ltd., Japan.

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

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

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


© 2004 Kawasaki Heavy Industries, Ltd.

Second Edition (1) : Jul. 6, 2004

h

L ft g

A

ABDC

AC

ATDC

BBDC

BDC

BTDC

°C

DC

F

°F

LIST OF ABBREVIATIONS

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) Celcius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)

Pa

PS r psi lb m min

N

V

W

Ω rpm

TDC

TIR pounds(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)

Read OWNER’S MANUAL before operating.


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

California Air Resources Board.

1. Crankcase Emission Control System

A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow

-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner.

Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase.

2. Exhaust Emission Control System

The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics.

The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atmosphere.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser..."

NOTE

○

The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows:

1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded.

b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle.

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.


PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

(US MODEL only)

To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.


Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop.

However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.

For the duration of the warranty period,

we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

•

Follow the Periodic Maintenance Chart in the

Service Manual.

•

Be alert for problems and non-scheduled maintenance.

•

Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool

Catalog or Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.

•

Follow the procedures in this manual carefully. Don’t take shortcuts.

•

Remember to keep complete records of maintenance and repair with dates and any new parts installed.

Guide shows you all of the product’s system and assists in locating their chapters.

Each chapter in turn has its own comprehensive Table of Contents.

For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the

Table of Contents on the first page of the chapter to find the Ignition Coil section.

Whenever you see these WARNING and

CAUTION symbols, heed their instructions!

Always follow safe operating and maintenance practices.

WARNING

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

CAUTION

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

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

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

How to Use This Manual

In this manual, the product is divided into

Property of www.SmallEngineDiscount.com - Not for Resale the manual’s chapters. The Quick Reference instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.


GENERAL INFORMATION 1-1

General Information

Table of Contents

Before Servicing .....................................................................................................................

Model Identification.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1-2

1-7

1-8

1-11

1


1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Battery Ground

Before completing any service on the vehicle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive

(+) terminal of the battery then the negative (–) wire to the negative terminal.

Edges of Parts

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

Solvent

Use a high-flush point solvent when cleaning parts. High

-flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.



Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.


Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals,

Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service

Manual, follow the procedures given.




Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Often, the tightening sequence is followed twice initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance.

Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used

O-rings when re-assembling.

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a

Non-Permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.



Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.


Ball Bearing and Needle Bearing

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

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

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.




Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.


Model Identification

KVF750-A1 Left Side View


KVF750-A1 Right Side View

The KVF750–B1 is a camouflage-surface-treated model and identical to the KVF750–A1, the base model, in every other aspect: controls, features, and specifications.



General Specifications

Items

Dimensions

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance:

Seat Height

Dry Mass

Curb Mass:

Front

Rear

Fuel Tank Capacity

Performance

Minimum Turning Radius

Engine

Type

Cooling System

Bore and Stroke

Displacement

Compression Ratio

Maximum Horsepower

Maximum Torque

Carburetion System

Starting System

Ignition System

Timing Advance

Ignition Timing

2 192 mm (86.30 in.)

1 177 mm (46.34 in.)

1 249 mm (49.17 in.)

1 283 mm (50.51 in.)

269 mm (10.59 in.)

935 mm (36.81 in.)

274 kg (604 lb), (EUR) 274.5 kg (605 lb)

147.5 kg (325 lb), (EUR) 148 kg (326 lb)

149 kg (329 lb)

19.5 L (5.2 US gal)

3.2 m (10.5 ft)

KVF750-A1, B1

4-stroke, SOHC, V2-cylinders

Liquid-cooled

85 × 66 mm (3.35 × 2.60 in.)

749 mL (45.7 cu in.)

8.8 : 1

37.4 kW (50.9 PS) @6 500 r/min (rpm), (US) -

60.7 N·m (6.2 kgf·m, 45 ft·lb) @5 000 r/min (rpm)

Carburetor, Keihin CVKR-34

Electric Starter & Recoil Starter

Digital DC-CDI

Electronically advanced

From 5° BTDC @1 150 r/min (rpm) to 28° BTDC @5 000 r/min (rpm)

NGK CR7E, DENSO U22ESR-N

Front to rear, 1-2

1-2

Spark Plug

Cylinder Numbering Method

Firing Order

Valve Timing:

Inlet:

Open

Close

Duration

Exhaust:

Open

Close

20° BTDC

44° ABDC

244°

44° BBDC

20° ATDC

Duration 244°

Lubrication Aystem Forced lubrication (wet sump)




Items KVF750-A1, B1

Engine oil:

Type

Viscosity

Capacity

Drive Train

Primary Reduction System:

Type

Reduction Ratio

Transmission:

Type

Gear Ratios:

Forward:

High

Low

Reverse

Final Drive System:

Type

Reduction Ratio

Overall Drive Ratio:

Forward:

High

Low

Reverse

Front Final Gear Case Oil:

Type

API SF or SG

API SH or SJ with JASO MA class

SAE 10W-40

2.6 L (2.75 US qt)

Belt converter

3.122

∼

0.635

2-speed and reverse

3.098 (30/26 × 29/18 × 20/12)

4.833 (36/20 × 29/18 × 20/12)

4.028 (16/12 × 18/16 × 29/18 × 20/12)

Shaft 2WD/4WD

4.375 (35/8)

42.32

∼

8.61

66.02

∼

13.43

55.01

∼

11.19

Viscosity

Capacity

Rear Final Gear Case Oil:

API SF or SG


SAE10W-40

0.40 L (0.42 US qt)

Type

Capacity

Frame

Type

Caster (Rake Angle)

Camber

King Pin Angle

Trail

Tread:

MOBIL FLUID 424, CITGO TRANSGARD TRACTOR

HYDRAULIC FLUID, or EXXON HYDRAUL 560

0.72 L (0.76 US qt)

Double tubular

5.5°

0°

11°

28 mm (1.10 in.)

Front 915 mm (36.23 in.)

Rear 875 mm (34.45 in.)




Items

Front tire:

Type

Size

Rear tire:

Type

Size

Suspension:

Front:

Type

Wheel Travel

Rear:

Type

Wheel Travel

Brake:

Front

Rear

Parking Brake

Electrical Equipment

Battery

Headlight:

Type

Bulb

Tail/brake Light:

Bulb

Reverse Light:

Bulb

Alternator:

Type

Rated Output

Tubeless

AT25 × 8 – 12

Tubeless

AT25 × 10 – 12

Double Wishbone

171 mm (6.73 in.)

Double Wishbone

200 mm (7.87 in.)

KVF750-A1, B1

Disc × 2

Enclosed wet multi-plate

Enclosed wet multi-plate

12 V 12 Ah

Semi-sealed beam

12 V 40/40 W × 2

12 V 5/21 W

(EUR) 12V 10W

Three - phase AC

24.2 A, 14 V @6 000 r/min (rpm)

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

US: United States Model

EUR: Europe Model


Unit Conversion Table

Prefixes for Units:

Prefix mega kilo centi milli micro

Symbol

M k c m

µ

Power

× 1 000 000

× 1 000

× 0.01

× 0.001

× 0.000001

Units of Mass:

kg g

×

×

2.205

=

0.03527

= lb oz

Units of Volume:

L

L

L

L

L

L mL

×

×

×

×

×

×

×

0.2642

0.2200

1.057

0.8799

2.113

1.816

=

0.03381

=

=

=

=

=

= mL mL

×

×

0.02816

=

0.06102

= gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

Units of Force:

N × 0.1020

N kg kg

×

×

×

0.2248

9.807

2.205

Units of Temperature

=

=

=

= kg lb

N lb


Units of Length:

km × 0.6214

= m mm

×

×

3.281

=

0.03937

= mile ft in

Units of Torque:

N·m

N·m

N·m kgf·m kgf·m kgf·m

×

×

×

×

×

×

0.1020

=

0.7376

=

8.851

=

9.807

=

7.233

86.80

=

= kgf·m ft·lb in·lb

N·m ft·lb in·lb

Units of Pressure:

kPa kPa kPa kgf/cm² × kgf/cm² × cmHg ×

×

×

×

0.01020

=

0.1450

=

0.7501

=

98.07

14.22

1.333

=

=

= kgf/cm² psi cmHg kPa psi kPa

Units of Speed:

km/h × 0.6214

= mph

Units of Power:

kW kW

PS

PS

×

×

×

×

1.360

=

1.341

=

0.7355

=

0.9863

=

PS

HP kW

HP



PERIODIC MAINTENANCE 2-1

Periodic Maintenance

2


Periodic Maintenance Chart ..............

Torque and Locking Agent.................

Specifications ....................................

Special Tools .....................................

Periodic Maintenance Procedures.....

Fuel System....................................

Throttle Lever Free Play

Inspection..................................


Adjustment ................................

Choke Lever Free Play

Inspection..................................


Adjustment ................................

Idle Speed Inspection ..................

Idle Speed Adjustment.................

Fuel System Cleanliness

Inspection..................................

Air Cleaner Element Cleaning and

Inspection..................................

Air Cleaner Draining.....................

Fuel Hose and Connection

Inspection..................................

Fuel Hose Replacement ..............

Cooling System...............................

Radiator Cleaning ........................

Radiator Hose and Connection

Inspection..................................

Coolant Change ...........................

Engine Top End ..............................

Valve Clearance Inspection .........

Valve Clearance Adjustment........

Spark Arrester Cleaning...............

Converter System ...........................

Drive Belt Inspection ....................

Drive Belt Deflection Inspection ...

Drive Belt Deflection Adjustment .

Actuator Lever (Engine Brake

Control Lever) Assembly

Inspection..................................

Engine Lubrication System .............

Engine Oil Change.......................

2-14

2-14

2-14

2-15

2-15

2-16

2-16

2-17

2-17

2-18

2-18

2-19

2-19

2-20

2-20

2-23

2-23

2-24

2-24

2-25

2-25

2-25

2-26

2-3

2-5

2-11

2-13

2-14

2-14

2-27

2-27

2-27

Variable Differential Control Lever

Play Inspection..........................


Play Adjustment ........................

Front Final Gear Case Oil

Change......................................

Rear Final Gear Case Oil Change

Universal Joint Lubrication...........

Brakes.............................................

Front Brake Pad Wear Inspection

Front Brake Hoses and

Connections Inspection.............

Front Brake Hose Replacement...

Brake Fluid Level Inspection........

Brake Fluid Change .....................

Front Brake Master Cylinder

Piston Assembly and Dust Seal

Replacement .............................

Front Brake Caliper Piston Seal

and Dust Seal Replacement .....

Rear Brake Plates Replacement..

Rear Brake Lever Free Play

Inspection..................................

Brake Pedal Free Play Inspection

Rear Brake Lever and Pedal Free

Play Adjustment ........................

Steering ..........................................

Steering Inspection ......................

Electrical System ............................

Spark Plug Cleaning/Inspection...

Spark Plug Gap Inspection ..........

Brake Light Switch Inspection......

Brake Light Timing Adjustment ....

Drive Belt Failure Detection

System Inspection.....................

Joint Boots Inspection.....................

Front Axle/Knuckle Joint Boot

Inspection..................................

Front Propeller Shaft Boot

Inspection..................................

Tie-rod End Boot Inspection ........

Rear Propeller Shaft Joint Boot

2-29

2-29

2-30

2-31

2-32

2-32

2-32

2-32

2-33

2-33

2-34

2-34

2-34

2-35

2-35

2-35

2-35

2-36

2-36

2-36

2-36

2-36

2-37

2-37

2-37

2-39

2-39

2-39

2-39

Oil Filter Replacement .................

Wheels/Tires ...................................

2-28

Inspection..................................

Rear Axle/Stabilizer Joint Boot

2-39


Tire Inspection .............................

2-28

Inspection..................................

2-39

Final Drive.......................................

2-29

General Lubrication ........................

2-40

2-2 PERIODIC MAINTENANCE

Lubrication ...................................

Bolts and Nuts Tightening...............

2-40

2-41

Tightness Inspection ....................

2-41



Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY First

Service

Regular Service

After 10 hrs. or

100 km

(60 mi.) of use

Every

10 days or

200 km

(120 mi.) of use

Every

30 days or

600 km

(360 mi.) of use

Every 90 days, 1 700 km (1 100 mi.) or when belt indicator light turns on (100 hrs of use) whichever comes first

Every year of use

See page

OPERATION

ENGINE

Converter drive belt wear - inspect *

Converter drive belt deflection - inspect *

Drive belt failure detection system function

- inspect *

Engine brake control lever - inspect *

•

•

•

•

2-25

2-25

2-37

2-27

Air cleaner - inspect *

Throttle lever play - inspect

Choke lever play - inspect

• •

• •

• •

2-17

2-14

2-14

Idle speed - inspect

Valve clearance - inspect

•

2-15

•

2-23

2-16 Fuel system cleanliness - inspect *

Engine oil - change *

Oil filter - replace *

•

•

•

•

•

•

•

•

2-27

2-28

Spark plug - clean and gap

Spark arrester - clean

2-36

•

2-24

2-18 Fuel hoses and connections - inspect

•

Fuel hose - replace 4 years 2-18

Radiator - clean*

Radiator hoses and connections - check*

• •

2-19

•

2-20

2-20 Coolant - change* 2 years

CHASSIS

Joint boots - inspect *

Rear brake pedal and lever play - inspect *

• •

• • every 10 000 km (6 000 mi.)

2-39

2-35

Rear brake plates - replace * 2-35

Bolts and nuts - tighten

Front brake pad wear - inspect *

Brake light switch - inspect *


Steering - inspect

Differential control lever play - inspect

•

•

•

• •

• •

•

•

•

2-41

2-32

2-37

2-36

2-29


Periodic Maintenance Chart

OPERATION

Tire wear - inspect *

FREQUENCY

Front and rear final gear case oil - change

First

Service

Regular Service

After 10 hrs. or

100 km

(60 mi.) of use

Every

10 days or

200 km

(120 mi.) of use

Every

30 days or

600 km

(360 mi.) of use

Every 90 days, 1 700 km (1 100 mi.) or when belt indicator light turns on (100 hrs of use) whichever comes first

•

•

Every year of use

See page

•

2-28

2-30

2-31

Rear propeller shaft universal joint lubrication

General lubrication *

Front brake fluid level - inspect

Front brake fluid - change

Front brake hoses and connections inspect

Front brake master cylinder piston assembly and dust seal - replace

Front brake caliper piston seal and dust seal - replace

Front brake hose - replace

•

•

•

2 years

2 years

•

•

•

2-32

2-40

2-33

2-34

2-32

2-34

2-34

4 years 2-33

*: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy loads or pulling a trailer.

•

: Clean, adjust, lubricate, torque, or replace parts as necessary.



Torque and Locking Agent

The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket.

Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

L: Apply a non-permanent locking agent.

LB: Apply a non-permanent locking agent (Three Bond TB2471, Blue).

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1).

R: Replacement Parts

S: Follow the specific tightening sequence.

SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

St: Stake the fasteners to prevent loosening.

TB: Apply a non-permanent locking agent (Three Bond TB1363A, Red).

Fastener

N·m

Torque kgf·m ft·lb

Remarks

Fuel System

Idle Adjusting Screw Bracket Bolt

Element Cover Screw

Element Holder Screws

Clamp Bracket Bolt

Fuel Pump Mounting Nuts

Fuel Tap Plate Screws

Fuel Tap Mounting Bolts

Fuel Tap Cover Screws

Fuel Tap Bracket Bolts

Fuel Level Sensor Mounting Bolts

Cooling System

Radiator Mounting Bolts

Radiator Fan Switch

Radiator Fan Assembly Bolts

Thermostat Housing Cover Bolts

Coolant Temperature Warning Light Switch

Air Bleeder Bolt

Water Pump Cover Bolts

Coolant Drain Plug

Water Pump Impeller

Water Pipe Mounting Bolts

Engine Top End

Rocker Case Bolts 55 mm (2.2 in.)




8.8

3.5

3.5

9.8

7.8

0.8

4.9

9.8

7.8

2.0

6.9

8.8

8.8

8.8

8.8

18

4.9

8.8

7.8

8.8

8.8

9.8

9.8

9.8

0.90

0.35

0.35

1.0

0.80

0.08

0.50

1.0

0.80

0.20

0.90

1.8

0.50

0.90

0.70

0.90

0.90

0.90

0.80

0.90

0.90

1.0

1.0

1.0

78 in·lb

31 in·lb

31 in·lb

87 in·lb

69 in·lb

7 in·lb

43 in·lb

87 in·lb

69 in·lb

18 in·lb

78 in·lb

13

43 in·lb

78 in·lb

61 in·lb

78 in·lb

78 in·lb

78 in·lb

69 in·lb

78 in·lb

78 in·lb

87 in·lb

87 in·lb

87 in·lb

SS

S

S

S

S

Cylinder Head Bolts (M10), first torque

Cylinder Head Bolts (M10), final torque

25

49

2.5

5.0

18

36

S, MO

S

Cylinder Head Bolts (M6) 9.8

1.0

87 in·lb



Fastener

Valve Adjusting Cap Bolts


Rocker Shaft Bolts

Valve Adjusting Screw Locknuts

Chain Tensioner Mounting Bolts

Chain Tensioner Cap Bolt

Position Plate Bolts

Intermediate Shaft Chain Guide Bolts

Intermediate Shaft Chain Tensioner Bolts

Camshaft Splocket Bolts

Cylinder Bolts 40 mm (1.6 in.)

Cylinder Bolts 30 mm (1.2 in.)

Front Cylinder Camshaft Chain Guide Bolt

Rear Cylinder Camshaft Chain Guide Bolt

Exhaust Pipe Cover Bolts

Muffler Clamp Bolts

Muffler Mounting First Nuts

Muffler Mounting Second Nuts

Muffler Cover Bolts


Drive Pulley Bolt

Driven Pulley Nut

Drive Pulley Cover Bolt

Ramp Waight Nuts

Spider

Joint Duct Bolts

Converter Cover Bolts

Engine Brake Actuator Mounting Bolts

Recoil Starter

Recoil Starter Mounting Bolts


Oil Filter

Oil Pressure Switch

Oil Pipe Bolts

Engine Drain Plug

Oil Pressure Relief Valve

Oil Pump Bolts

Chain Guide Bolts

Oil Pump Drive Chain Tensioner Bolt

Oil Filter Mounting Bolts


Engine Bracket Mounting Bolts

9.8

9.8

20

20

8.8

8.8

8.8

12

8.8

8.8

15

31

8.8

N·m

8.8

8.8

20

12

8.8

22

93

93

13

6.9

275

8.8

8.8

8.8

5.9

15

8.8

8.8

25

18

15

8.8

20

25

1.5

72

0.60

1.8

1.5

0.90

2.0

1.5

0.90

0.90

2.5

2.5

0.15

7.3

9.5

9.5

1.3

0.70

28

0.90

0.90

0.90

ft·lb

78 in·lb

78 in·lb

14

104 in·lb

78 in·lb

16

78 in·lb

78 in·lb

78 in·lb

104 in·lb

87 in·lb

87 in·lb

14

14

78 in·lb

78 in·lb

11

23

78 in·lb

0.90

0.90

0.90

1.2

1.0

1.0

2.0

2.0

Torque kgf·m

0.90

0.90

2.0

1.2

0.90

2.2

0.90

0.90

1.5

3.2

0.90

Remarks

L

S

S

69

69

113 in·lb

61 in·lb

203

78 in·lb

78 in·lb

78 in·lb

52 in·lb

13

11

78 in·lb

14

11

78 in·lb

78 in·lb

18

18

13 in·lb

53

R, Lh

Lh

S

S

L

R

SS

L

L(15 mm)



Fastener

Engine Mounting Bolt

Engine Mounting Nut


Connecting Rod Big End Cap Nuts

Engine Drain Plug

Crankcase Bolts (M8) 75 mm (2.95 in.)


Crankcase Bolt (M8) 110 mm (4.33 in.)



Bearing Position Plate Screws

Grip Hold Nut

Shift Lever Assembly Bracket Bolts

Tie-rod End Front Locknut

Tie-Rod End Rear Locknut

Tie-rod End Nut

Shift Lever Assembly Nut

Tie-rod End Bolt

Shift Shaft Positioning Bolt

Shift Shaft Spring Bolt

Shift Shaft Cover Bolts

Tie-rod End Locknut

Neutral Position Switch

Reverse Position Switch

Wheel/Tires

Tie-rod Locknuts

Tie-rod End Nuts

Wheel Nuts (First Torque)

Wheel Nuts (Final Torque)

Front Axle Nuts

Rear Axle Nuts

Final Drive

(Output Bevel Gears)

Output Driven Bevel Gear Housing Bolts

Output Drive Bevel Gear Housing Bolts

Bearing Holder

Bevel Gear Holder Nut

Bearing Holder

Output Shaft Holder Nut

Rotor Mounting Bolts

(Front Final Gear Case)

Variable Differential Control Shift Shaft Lever Bolt

N·m

62

62

9.8

20

20

9.8

25

4.9

9.8

20

9.8

25

8.8

20

15

15

34

20

20

20

20

9.8

9.8

37

42

15

76

197

265

26

26

137

157

118

157

12

8.8

8.8

L

L

L

L

Torque kgf·m

6.3

6.3

0.50

1.0

2.0

1.0

1.0

2.0

2.0

1.0

2.5

2.5

0.90

2.0

1.5

1.5

3.5

2.0

2.0

2.0

2.0

1.0

1.0

3.8

4.3

1.5

7.8

20

27

ft·lb

46

46

25

14

14

14

14

87 in·lb

87 in·lb

43 in·lb

87 in·lb

14

87 in·lb

87 in·lb

14

14

87 in·lb

18

18

78 in·lb

14

11

11

27

31

11

56

145

195

Remarks

MO

S

S

S, L(1)

L

Lh

L

S

S

2.7

2.7

14

16

12

16

1.2

0.90

0.90

20

20

101

116

87

116

104 in·lb

78 in·lb

78 in·lb



Fastener

Front Final Gear Case Left Cover Bolts (M6)

Ring Gear Bolts

Front Final Gear Case Center Cover Bolts (M6)


Front Final Gear Case Oil Filler Cap

Pinion Gear Bearing Holder Nut

Pinion Gear Bearing Holder

Front Final Gear Case Coupling Nut

Front Final Gear Case Oil Drain Plug

2WD/4WD Actuator Mounting Bolts

Variable Differential Control Cable Locknut

Variable Differential Control Lever Bolt

Front Final Gear Case Nuts

(Rear Final Gear Case)

Rear Final Gear Case Front Cover Bolts

Gasket Screws



Rear Final Gear Case Right Cover Bolts (M12)



Rear Final Gear Case Oil Filler Cap

Rear Final Gear Case Oil Drain Plug

Bracket Bolts

Rear Final Gear Case Nuts

Brakes

Reservoir Cap Screws

Brake Lever Pivot Bolt

Brake Lever Pivot Bolt Locknut

Master Cylinder Clamp Bolts

Bake Hose Banjo Bolt

Brake Caliper Mounting Bolts

Bleed Valves

Brake Disc Mounting Bolts

Caliper Holder Shaft

Pad Mounting Bolts


Gasket Screws

Suspension

Front Shockabsorber Mounting Nuts

Front Knuckle Joint Nuts

Rear Shockabsorber Mounting Nuts

0.15

0.60

0.60

0.92

2.5

2.5

0.55

3.8

1.7

1.7

–

–

2.4

0.13

16

14

9.5

5.0

2.4

3.0

1.3

6.0

7.3

14

2.5

1.5

1.0

1.7

–

6.0

Torque kgf·m

1.0

5.8

1.0

2.4

3.0

13

ft·lb

87 in·lb

42

87 in·lb

17

22

94

101

18

11

87 in·lb

12

–

43

Remarks

L

LB

L

L

St

L

L, S

L

3.5

4.3

3.0

3.5

25

31

22

25

L

L

L

L

L

TB

S

L

L

L

13 in·lb

53 in·lb

53 in·lb

80 in·lb

18

18

48 in·lb

27

13

13

–

–

17

11 in·lb

116

101

69

36

17

22

113 in·lb

43

53

1.5

6.0

6.0

9.0

25

25

5.4

37

17

17

–

–

93

49

24

29

24

13

157

137

13

59

72

34

42

29

34

137

25

15

9.8

17

–

59

N·m

9.8

57

9.8

24

29

127



Fastener

Stabilizer Holder Bolts

Stabilizer Joint Nuts

Rear Suspension Arm Pivot Nuts

Rear Knuckle Mounting Nuts

Steering

Handlebar Holder Bolts

Steering Stem Clamp Bolts

Tie-rod End Nuts

Tie-rod Locknuts

Steering Stem Bearing Joint Bolts

Steering Stem Bottom End Nut

Front Knuckle Joint Nuts

Master Cylinder Clamp Bolts


Frame

Front Guard Bolts

Front Carrier Bolts, L=50 mm (2.0 in.)

Front Carrier Bolts, L=70 mm (2.8 in.)

Front Carrier Bracket Bolts

Rear Carrier Bolts, L=14 mm (0.6 in.)

Rear Carrier Bolts, L=41 mm (1.6 in.)

Rear Carrier Bracket Bolts

Footboard Bracket Bolts

Hitch Bracket Bolts


Starter Motor Mounting Bolts

Starter Motor Terminal Nut

Starter Motor Terminal Locknut

Starter Motor Bolts

Starter Motor Clutch Bolts

Alternator Stator Bolts

Crankshaft Sensor Mounting Bolts

Alternator Cover Plugs

Alternator Rotor Bolt

Alternator Cover Bolts

Spark Plugs


Engine Brake Actuator Mounting Bolts

Forward/Reverse Detectring Sensor Mounting Bolt

Speed Sensor Mounting Bolt

N·m

23

48

48

48

Reverse Position Switch

Ignition Coil Mounting Bolts

37

23

62

29

29

25

42

9.0

–

37

25

25

32

54

54

42

37

82

8.8

15

8.8

15

127

8.8

13

9.8

15

8.8

34

13

5.9

18

8.8

4.9

6.9

4.9

13

0.90

1.3

1.0

0.90

1.5

0.90

1.5

1.5

0.90

0.90

0.50

0.70

0.50

3.5

1.3

0.60

1.8

3.8

2.5

2.5

3.3

5.5

5.5

4.3

3.8

8.3

3.0

2.5

4.3

3.8

2.3

6.3

3.0

0.92

–

Torque kgf·m

2.3

4.8

4.8

4.8

ft·lb

17

35

35

35

27

17

46

22

22

18

31

80 in·lb

–

Remarks

S

L

L

L

L,S

78 in·lb

43 in·lb

61 in·lb

43 in·lb

25

113 in·lb

52 in·lb

13

94

78 in·lb

113 in·lb

87 in·lb

78 in·lb

11

78 in·lb

11

11

78 in·lb

27

18

18

24

40

40

31

27

60



Fastener

Radiator Fan Switch

Coolant Temperature Warning Light Switch

Oil Pressure Switch

Oil Pressure Switch Terminal Bolt

Regulator/Rectifier Mounting Bolts

Fuel Level Sensor Mounting Bolts

N·m

18

6.9

15

1.5

8.8

2.0

Torque kgf·m

1.8

0.70

1.5

0.15

0.90

0.20

ft·lb

13

61 in·lb

11

13 in·lb

78 in·lb

18 in·lb

Remarks

SS

SS

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

Basic Torque for General Fasteners of Engine Parts

Threads dia.

Mark of Torque mm (in.)

6 (0.24)

6 (0.24)

6 (0.24)

8 (0.31)

8 (0.31)

10 (0.39)

10 (0.39)

5 (0.20) bolt head

9T

7T

4T

7T

4T

7T

4T

4T

N·m

12

∼

15

7.8

∼

9.8

3.9

∼

4.9

18

∼

22

10

∼

14

39

∼

44

20

∼

24

2.2

∼

2.6

kgf·m

1.2

∼

1.5

0.8

∼

1.0

0.4

∼

0.5

1.8

∼

2.2

1.0

∼

1.4

4.0

∼

4.5

2.0

∼

2.4

0.22

∼

0.27

ft·lb

104

∼

130 in·lb

69

∼

87 in·lb

35

∼

43 in·lb

13

∼

16

87

∼

122 in·lb

29

∼

33

14

∼

17

19

∼

23 in·lb

Basic Torque for General Fasteners of Frame Parts

Threads dia.

mm (in.)

5 (0.20)

6 (0.24)

8 (0.31)

10 (0.39)

12 (0.47)

14 (0.55)

16 (0.63)

18 (0.71)

20 (0.79)

N·m

3.4

∼

4.9

5.9

∼

7.8

14

∼

19

25

∼

34

44

∼

61

73

∼

98

115

∼

155

165

∼

225

225

∼

325

Torque kgf·m

0.35

∼

0.5

0.6

∼

0.8

1.4

∼

1.9

2.6

∼

3.5

4.5

∼

6.2

7.4

∼

10.0

11.5

∼

16.0

17.0

∼

23.0

23

∼

33 ft·lb

30

∼

43 in·lb

52

∼

69 in·lb

10.0

∼

13.5

19.0

∼

25

33

∼

45

54

∼

72

83

∼

115

125

∼

165

165

∼

240



Specifications

Item

Fuel System



Idle Speed

Air Cleaner Element Oil

Cooling System

Coolant:

2

∼

3 mm (0.08

∼

0.12 in.) about 3 mm (0.12 in.)

1 150 ± 50 r/min (rpm)

High-quality foam air filter oil

– – –

– – –

Standard

Type (Recommended)

Color

Mixed Ratio

Freezing Point

Viscosity

Capacity

Permanent type antifreeze

Green

Soft water 50%, Coolant 50%

−35°C (−31°F)

2.2 L (2.3 US qt.) Total Amount

Engine Top End

Valve Clearance:

Exhaust

Inlet


0.20

∼

0.25 mm (0.0079

∼

0.0098 in.)

0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

Belt Width

Belt Deflection

29.7

∼

30.3 mm (1.169

∼

1.193 in.)

22

∼

27 mm (0.87

∼

1.06 in.)

Actuator Lever Guide Shoe Wear – – –


Engine Oil:

Type API SF or SG


SAE10W-40

2.1 L (2.2 US qt)

(When filter is not removed)

2.2 L (2.3 US qt)

(When filter is removed)

2.6 L (2.7 US qt)

(When engine is completely dry)

Wheels/Tires

Tire Tread Depth:

Front

Rear

Standard tire:

Front

Rear

AT 25 × 8-12

DUNLOP, KT191, Tubeless

AT 25 × 10-12


Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

28.0 mm (1.102 in.)

– – –

6 mm (0.24 in.)

– – –

– – –

– – –

– – –

– – –

– – –

3 mm (0.12 in.)

4 mm (0.16 in.)

– – –

– – –

– – –

– – –



Specifications

Item

Final Drive

Front Final Gear Case:

Gear Case Oil:

Type

Viscosity

Oil Level

Capacity

Rear Final Gear Case:

Gear Case Oil:

Type

Standard

API SF or SG

API SH or SJ of JASO MA class

SAE 10W-40

Filler opening bottom

0.40 L (0.42 US qt)

MOBIL Fluid 424, CITGO

TRANSGARD TRACTOR

HYDRAULIC FLUID, or EXXON

HYDRAUL 560


0.72 L (0.76 US qt)

Oil level

Capacity

Brakes

Front Brake Fluid:

Type

Front Disc Brake:

Pad Lining Thickness

Rear Brake Lever, Pedal and

Cables:


Brake Pedal Free Play


Spark Plug Gap

Rear Brake Light Switch Timing

DOT 3 or DOT 4

4 mm (0.16 in.)

1

∼

2 mm (0.04

∼

0.08 in.)

15

∼

25 mm (0.6

∼

1.0 in.)

0.7

∼

0.8 mm (0.028

∼

0.032 in.)

ON after 10 mm (0.4 in.) of pedal travel

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

1 mm (0.04 in.)

– – –

– – –

– – –

– – –


Special Tools

Oil Filter Wrench:

57001-1249


Filler Cap Driver:

57001-1454

Carburetor Drain Plug Wrench, Hex 3:

57001-1269

Pulley Holder Attachment:

57001-1472

Flywheel & Pulley Holder:

57001-1343



Periodic Maintenance Procedures

Fuel System

Throttle Lever Free Play Inspection

•

Check that the throttle lever [A] moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle lever does not return properly, check the throttle cable routing, lever free play, and cable damage.

Then lubricate the throttle cable.

•

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increases, check the throttle lever free play and the cable routing.

•

Stop the engine and check the throttle lever free play [B].

If the free play is not within the specified range, adjust the cable.

Throttle Lever Free Play

Standard: 2

∼

3 mm (0.08

∼

0.12 in.)

Throttle Lever Free Play Adjustment

•

Remove the handle cover (see Multifunction Meter Unit

Removal in the Electrical System chapter).

•

Slide the rubber cover off the adjuster at the throttle case.

•

Loosen the locknut [A] and turn the throttle cable upper adjuster [B] until the cable has proper amount of play.

•

Tighten the locknut and reinstall the rubber cover.

If the free play cannot be adjusted by using the upper cable adjuster, remove the left side cover (see Frame chapter) and then use the cable adjusting nuts [A] at the lower end of the throttle cable and make the necessary free play.

Choke Lever Free Play Inspection

•

Check if the choke lever [A] returns properly and if the inner cable slides smoothly.

•

Make sure that the choke lever returns to its released position all the way.

•

To determine the amount of choke cable play at the lever, pull the choke lever to the left until feeling the operation of the lever tough; the amount of choke lever is equivalent to that of cable play.

•

The proper amount of play ranges about 3 mm (0.12 in.) at the choke lever.

If the free play is not within the specified range, adjust the cable.


Choke Lever Free Play [B]

Standard: about 3 mm (0.12 in.)


Choke Lever Free Play Adjustment

•

Remove:

Handlebar Cover Screws [A]


•

Remove:


Handlebar Cover Front [B]

•

Loosen the locknut [A] of the choke cable.

•

Turn the adjuster [B] until the cable has proper amount of play.

•

Tighten the locknut securely.

Idle Speed Inspection

•

Start the engine and warm it up thoroughly.

•

With the engine idling, turn the handlebar to both sides to check for any changes in the idle speed.

If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted incorrectly routed, or damaged. Be sure to correct any of these conditions before riding.

WARNING

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

•

Check idle speed with a suitable tachometer.

If the idle speed is out of the specified range, adjust it (see

Idle Speed Adjustment).

Idle Speed

Standard: 1 150 ± 50 r/min (rpm)




Idle Speed Adjustment

•

Start the engine and warm it up thoroughly.

•

Turn the idle 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.

Fuel System Cleanliness Inspection

WARNING

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 check valve [A] at the end of the carburetor overflow hose [B].

•

Run the lower end of the carburetor overflow hose to a suitable container.

•

Turn out the carburetor drain plugs [A] a few turns and drain the fuel system.

Special Tool - Carburetor Drain Plug Wrench, Hex 3 [B] :

57001-1269

•

Check to see if water or dirt comes out.

•

Tighten the drain plugs.

If any water or dirt appears during the above inspection, clean the fuel system (carburetor, fuel pump, fuel tank, fuel hose).



Air Cleaner Element Cleaning and Inspection

NOTE

○

In dusty areas, the element should be cleaned more frequently than the recommended interval.

○

After riding through rain or muddy terrains, the element should be cleaned immediately.

○

Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

WARNING

Clean the element in a well-ventilated area, and take care that there are no sparks 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 a low-flash point solvent to clean the foam element.

•

Remove the air cleaner element (see Fuel System chapter).

•

Clean the element [A] in a bath of high-flash point solvent.


•

Squeeze it dry in a clean towel [A]. Do not wring the element or blow it dry; the element can be damaged.

•

Inspect the element for damage.

If it is torn, punctured, or hardened, replace it.

•

After cleaning, saturate the element with a high-quality foam-air-filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element.

Air Cleaner Draining

•

If any water or oil accumulates in the tube, drain it by taking off the tube plug [A]. After draining, be sure to install the tube plug and clamp firmly.




Fuel Hose and Connection Inspection

○

The fuel hoses are designed to be used throughout the vehicle life without any maintenance, however, if the vehicle is not properly handled, the pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

•

Check that the hoses are securely connected and clamps are installed correctly.

•

When installing the fuel hoses, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.

•

When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.

Replace the hose if it has been sharply bent or kinked.

•

Fit the fuel hose [A] onto the fitting fully and install the plate clamp [B] beyond the raised rib [C].

1

∼

2 mm (0.0039

∼

0.0078 in.) [D]

○

The hose end must reach the fillet [E] or be as near as possible to the step [F].

○

Fit the fuel pump inlet hoses onto the Y-joint fully until each end of the inlet hose touches the second raised rib.

Fuel Hose Replacement

WARNING

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:

Right Side Cover (see Frame chapter)

Electric Parts Case (see Frame chapter)

Rear Fender (see Frame chapter)

•

Turn the fuel tap to the ON position.



•

Remove:

Clamps [A]

Fuel Hoses [B]

•

Replace the fuel hoses with new ones.

•

When installing the fuel hose, route the hose according to Cable, Wire, and Hose Routing section in Appendix chapter.

•

When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed.

•

Fit the fuel hose onto the pipe fully and install the clamps beyond the raised rib (see Fuel Hose and Connection Inspection).


Cooling System

Radiator Cleaning

CAUTION

Clean the radiator screen and the radiator in accordance with the Periodic Maintenance Chart.

In dusty areas, they should be cleaned more frequently than the recommended interval.

After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately.

•

Remove:

Front Guard (see Frame chapter)

Front Fender (see Frame chapter)

Radiator Screen Mounting Screws [A]

Radiator Screen [B]

•

Clean the radiator screen in a bath of tap water, and then dry it with compressed air or by shaking it.

•

Clean the radiator.

CAUTION

When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage.

Keep the steam gun away more than 0.5 m (20 in.) from the radiator core [A].

Hold the steam gun perpendicular to the core surface.

Run the steam gun following the core fin direction.




Radiator Hose and Connection Inspection

○

The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.

•

Check that the hoses are securely connected and clamps are tightened correctly.

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down.

Coolant on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the frame, engine, or wheels.

Since coolant is harmful to the human body, do not use for drinking.

•

Remove:

Left Footboard (see Frame chapter)


Radiator Cover Screws [A] and Collars

•

Remove:


Radiator Cover [B]



•

Remove:

Clamp [A]

Reserve Tank Screws [B]

Reserve Tank [C] with Hose

•

Remove the reserve tank cap, and pour the coolant into a container.


•

Place a container under the drain plug [A] at the bottom of the water pump [B], then remove the drain plug.

•

Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first step. Then push and turn it further in the same direction and remove the cap.

•

The coolant will drain from the radiator and engine.

•

Place a container under the drain plug [A] at the front cylinder, then remove the drain plug.

•

Place a container under the drain plug [A] at the rear cylinder, then remove the drain plug.




•

Tighten the drain plug.

Torque - Coolant Drain Plug: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Support the vehicle on a stand or the jack so that the front wheels are off the ground. This makes air bleeding easier.

•

Fill the radiator up to the radiator filler neck [A] with coolant.

NOTE

○

Pour in the coolant slowly so that the air in the engine and radiator can escape.

CAUTION

Soft or distilled water must be used with the antifreeze in the cooling system.

If hard water is used in the system, it causes scale accumulation in the water passages, considerably reducing the efficiency of the cooling system.

Water and Coolant Mixture Ratio (when shipping)

Soft Water: 50%

Coolant:

Freezing Point:

Total Amount:

50%

−35°C (−31°F)

2.2 L (2.3 US qt)

NOTE

○

Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.

•

Bleed the air from the cooling system as follows.

○

Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant.

○

Tap the radiator hoses to force any air bubbles caught inside.

○

Stop the engine and add coolant up to the radiator filler neck.

•

Install the radiator cap.

•

Remove the reserve tank cap.

•

Fill the reserve tank up to the F mark [A] with coolant and install the cap.

•

Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine.

•

Check the coolant level in the reserve tank after the engine cools down.

If the coolant level is lower than the low level line, add coolant to the full level line.

CAUTION

Do not add more coolant above the full level line.



Engine Top End

Valve Clearance Inspection

NOTE

○

Check the valve clearance only when the engine is cold

(at room temperature).


•

Remove:

Left Side Cover (see Frame chapter)

Battery Case (see Frame chapter)

Valve Adjusting Caps [A]

Recoil Starter (see Recoil Starter chapter)

•

Remove the timing inspection plug [A].

Special Tool - Filler Cap Driver [B]: 57001-1454

•

Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until “T-F” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the front cylinder head.

•

Measure the clearance for all four valves, one at a time between the end of the valve stem and the adjusting screw [A] with the thickness gauge [B].

Valve Clearance (when cold)

Exhaust: 0.20

∼

0.25 mm (0.0079

∼

0.0098 in.)

Inlet: 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

If the valve clearance is not correct, adjust it (see Valve

Clearance Adjustment).




•

Then, turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt until “T-R” mark [A] on the alternator rotor aligns with the notch [B] as shown: the end of the compression stroke in the rear cylinder head.

•

Measure the clearance for all four valves, one at a time between the end of the valve stem and the adjusting screw with the thickness gauge.

Valve Clearance (when cold)

Exhaust: 0.20

∼

0.25 mm (0.0079

∼

0.0098 in.)

Inlet: 0.10

∼

0.15 mm (0.0039

∼

0.0059 in.)

If the valve clearance is not correct, adjust it (see Valve

Clearance Adjustment).

Valve Clearance Adjustment

•

Remove the valve adjusting caps.

•

Loosen the locknut and turn the adjusting screw until the clearance is correct.

•

Hold the adjusting screw [A] from turning and tighten the locknut [B].

Torque - Valve Adjusting Screw Locknuts: 12 N·m (1.2

kgf·m, 104 in·lb)

•

Recheck the clearance.

If the clearance is incorrect, repeat the adjustment procedure.

If the clearance is correct, perform the adjustment procedure on the other valve.

Spark Arrester Cleaning

WARNING

To avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.

•

Remove the drain plug [A] on the muffler.

•

In an open area away from combustible materials, start the engine with the transmission in neutral.

•

Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler.

WARNING

Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death.

•

Stop the engine.

•

Install the drain plug.





Drive Belt Inspection

Inspection of the drive belt is required at least every 90 days of vehicle use (average 12 mile/day) not to exceed 1

700 km (1 100 mile) or belt indicator light turn on (100 hours of use) counted by the hour meter. More frequent inspection is necessary if the vehicle is subjected to hard usage.

WARNING

Neglect, abuse, or failure to maintain the transmission can result in a severely worn or damaged drive belt locking up the transmission and wheels. This can cause the operator to lose control and have an accident resulting in injury or death.

•

Remove the torque converter cover (see Converter System chapter).

•

Measure the width [A] of the belt at several locations with a pair of suitable straightedges [B] as shown.

If any measurements exceed the service limit, replace the belt.

Belt Width

Standard: 29.7

∼

30.3 mm (1.169

∼

1.193 in.)

Service Limit: 28.0 mm (1.102 in.)

•

Check the belt [A] for abnormal wear [B].

○

Measure the width [C] of the belt at abnormal wear point.

If any measurements exceed 0.5 mm (0.02 in.), replace the belt.

○

When using the belt of large abnormal wear, the drive belt failure detection switch could be activated.

•

Check the belt for cracks, breaks, or peeling.

If necessary, replace the belt with a new one.

Belt [A]

Crack [B]

Broken [C]

Peeling [D]

NOTE

○

Whenever the belt is replaced, inspect the drive and the driven pulleys.

Drive Belt Deflection Inspection

•

Remove the torque converter cover (see Converter System chapter).

•

Put the transmission in neutral and rotate the driven pulley by hand to make sure the belt is shifted all the way to the top of the driven pulley.




•

Measure the belt deflection [A] as shown:

○

Place a straightedge [B] on top of the belt between the drive pulley [C] and the driven pulley [D].

○

Use a ruler to push the belt away from the straightedge.

Push hard, but with no more force than 59 N (6 kgf, 13 lb).

Belt Deflection

Standard: 22

∼

27 mm (0.87

∼

1.06 in.)

If the belt deflection is not within the specified range, adjust the deflection by adding or removing spacers on the fixed sheave of the driven pulley.

•

When adjusting the deflection, less is better than more.

Less deflection will maintain better performance for more time as the belt width decreases by normal wear, which causes the deflection to increase with usage.

Drive Belt Deflection Adjustment

•

Disassemble the driven pulley (see Converter System chapter).

If the belt deflection is more than 27 mm (1.06 in.), remove the spacers to decrease it.

○

The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.3 mm (0.051 in.) change in belt deflection.

If the adjustment cannot be done within the specified range even if the shim is removed, replace the drive belt.

If the belt deflection is less than 22 mm (0.87 in.), add the spacers [A] to increase it.

○

The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness equals about 1.6 mm (0.063 in.) change in belt deflection.

NOTE

○

When using the plural spacers, install the thick spacer to the movable sheave side and thin spacer to the fixed sheave side.

Spacers

Part No.

92026-0034

92026-1569

92026-1617

92026-1565

92026-1570

Thickness

0.3 mm (0.012 in.)

0.6 mm (0.024 in.)

0.8 mm (0.032 in.)

1.0 mm (0.039 in.)

1.4 mm (0.055 in.)



•

Assemble the driven pulley (see Converter System chapter).

•

With the transmission in neutral, rotate the driven pulley to allow the belt to return to the top of the sheaves before measuring the belt deflection.

•

Measure the belt deflection again and repeat the above procedures until it is within the standard range.

•

Using the flywheel & pulley holder and pulley holder attachment, tighten the driven pulley nut.

Special Tools - Flywheel & Pulley Holder: 57001-1343

Pulley Holder Attachment: 57001-1472

Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)


Actuator Lever (Engine Brake Control Lever)

Assembly Inspection

•

Measure the width [A] of the plastic guide shoe [B] of the actuator lever assembly.

If the guide contact area width is greater than the service limit, replace the actuator lever assembly.

Actuator Lever Guide Shoe

Service Limit: 6 mm (0.24 in.)


Engine Oil Change

•

Support the vehicle so that it is level side to side and front

• to back after warming up the engine.

Remove the engine drain plug [A] to drain the oil.

○

The oil in the filter can be drained by removing the filter

(see Oil Filter Change).

•

Replace the drain plug gasket with a new one.

•

Tighten:

Torque - Engine Drain Plug: 20 N·m (2.0 kgf·m, 14 ft·lb)

•

Pour in the specified type and amount of oil.

Engine Oil

Type: API SF or SG

API SH or SJ with JASO MA class

Viscosity:

Amount:

SAE 10W-40

2.1 L (2.2 US qt)

(When filter is not removed)

2.2 L (2.3 US qt)

(When filter is removed)

2.6 L (2.7 US qt)

(When engine is completely dry)

NOTE

○

Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in



Oil Filter Replacement

•

Drain the engine oil.

•

Remove the oil filter [A] with the oil filter wrench [B].

Special Tool - Oil Filter Wrench: 57001-1249

•

Replace the filter with a new one.

•

When installing the oil filter, be careful of the following.

○

Apply oil to the gasket [A] before installation.

○

Tighten the filter with the oil filter wrench.

Special Tool - Oil Filter Wrench: 57001-1249

Torque - Oil Filter: 18 N·m (1.8 kgf·m, 13 ft·lb)

○

Pour in the specified type and amount of oil.

Wheels/Tires

Tire Inspection

•

Examine the tire for damage and wear.

If the tire is cut or cracked, replace it.

○

Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement.

○

Remove any foreign objects from the tread.

After removal, check for leaks with a soap and water solution.

•

Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurements at several places.

If any measurements are less than the service limit, replace the tire.

Tire Tread Depth

Service Limit:

Front:

Rear:

3 mm (0.12 in.)

4 mm (0.16 in.)

Standard Tire

Front: AT 25 × 8 - 12

DUNLOP, KT191, Tubeless

Rear: AT 25 × 10 - 12

DUNLOP, KT195, Tubeless



Final Drive

Variable Differential Control Lever Play Inspection

•

Pull the variable differential control lever [A] towards the handlebar grip [B] with a spring scale until it reads 30 N

(3 kgf, 7 lb) of force.

○

The differential control in the front final gear case must be locked, then the clearance [C] between the control lever and grip should be 20 mm (0.8 in.).

If the clearance is not the specified length, adjust the cable.

Differential Control Lever Lock Position Length

Standard: 20 mm (0.8 in.)


Variable Differential Control Lever Play Adjustment

•

Remove:


•

Remove:


Handlebar Cover Front [B]

•

Loosen the locknut [A] of the differential control cable.

•

Turn the adjuster [B] until the cable has proper amount of play.

•

Tighten the locknut securely.




Front Final Gear Case Oil Change

•

Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle.

•

Park the vehicle so that it is level, both side-to-side and front-to-rear.

•

Remove the front side cover (see Frame chapter).

•

Place an oil pan beneath the front final gear case and remove the drain plug [A].

WARNING

When draining or filling the final gear case, be careful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent.

•

After the oil has completely drained out, install the drain plug with a new aluminum gasket, and tighten it.

Torque - Oil Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb)

•

Fill the gear case up to the bottom of filler opening with the oil specified below.

Front Final Gear Case Oil

Type: API SF or SG

API SH or SJ with JASO MA class

Viscosity: SAE 10W-40

Capacity: 0.40 L (0.42 US qt)

NOTE

○

Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the chart.

•

Be sure the O-ring [A] is in place, and tighten the filler cap

[B].

○

Apply grease to the O-ring.

Torque - Oil Filler Cap: 29 N·m (3.0 kgf·m, 22 ft·lb)



Rear Final Gear Case Oil Change

•

Warm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle.

•


•

Place an oil pan beneath the rear final gear case and remove the drain plug [A].

WARNING

When draining or filling the final gear case, be careful that no oil gets on the tire or rim because oil will deteriorate the tire. Clean off any oil that inadvertently gets on them with a high-flash point solvent.

•

After the oil has completely drained out, install the drain plug with a new aluminum gasket.

Torque - Oil Drain Plug: 13 N·m (1.3 kgf·m, 113 in·lb)

•

Fill the final gear case up to the bottom of filler opening with the oil specified below.

Final Gear Case Oil

Type: MOBIL FLUID 424,

CITGO TRANSGARD TRACTOR

HYDRAULIC FLUID or EXXON HYDRAUL

560

Capacity: 0.72 L (0.76 US qt)

○

Do not use mixing the above oils.

•

Be sure the O-ring [A] is in place, and tighten the filler cap

[B].

○







Universal Joint Lubrication

•

Remove:

Rear Propeller Shaft (see Final Drive chapter)

•

Force grease into the grease nipples [A] until the grease comes out from the nipple, and wipe off any excess grease.

[B] Grease Gun

Brakes

Front Brake Pad Wear Inspection

•

Check the lining thickness [A] of the pads in each caliper.

If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set.

Pad Lining Thickness

Standard: 4 mm (0.16 in.)


Front Brake Hoses and Connections Inspection

•

Inspect the brake hose and fittings for deterioration, cracks and signs of leakage.

○

The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.

Replace the hose if any cracks [B] or bulges [C] are noticed.

•

Tighten any loose fittings.



Front Brake Hose Replacement

•

Pump the brake fluid out of the line as explained in the

Brake Fluid Change.

•

Remove the banjo bolts at both ends of the brake hose, and pull the hose off the vehicle.

•

Immediately wipe up any brake fluid that spills.

CAUTION

Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.

•

Use a new flat washer for each side of the hose fittings.

•

Install the new brake hose in its place (see Appendix chapter), and tighten the banjo bolts.

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Brake Fluid Level Inspection

•

Position the reservoir horizontal, and check that the fluid level in the reservoir is higher than the lower level line [A].

If the fluid level is lower than the lower level line, check for fluid leakage of the brake line, and add the fluid as follows:


○

Remove the reservoir cap, and fill the reservoir to the upper level line [A] in the reservoir with the same type and brand of the fluid that is already in the reservoir. And then install the reservoir cap.

WARNING

Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified.

•

Tighten:

Torque - Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)




Brake Fluid Change

•

Remove the reservoir cap and the rubber cap on the bleed valve.

•

Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a container.

•

Fill the reservoir with new brake fluid.

•

Change the brake fluid as follows:

○

Open the bleed valve [A].

○

Apply the brake lever and hold it [B].

○

Close the bleed valve [C].

○

Release the brake lever [D].

•

Check the fluid level in the reservoir often, replenishing it as necessary.

NOTE

○

If the fluid in the reservoir runs completely out any time during fluid changing, air will enter the line, and the system must be bled.

•

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

WARNING

Do not mix two brands of fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are not known.

•

Tighten:

Torque - Bleed Valves: 5.4 N·m (0.55 kgf·m, 48 in·lb)

•

Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.

If necessary, bleed the air from the brake line (see Brake

Line Air Bleeding section in Brakes chapter).

WARNING

If the brake lever has a soft or "spongy feeling" when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, bleed the air from the brake line immediately.

Front Brake Master Cylinder Piston Assembly and

Dust Seal Replacement

•

Refer to the Master Cylinder section in the Brakes chapter for Front Brake Master Cylinder Piston Assembly and

Dust Seal Replacement.

Front Brake Caliper Piston Seal and Dust Seal

•

Replacement

Refer to the Caliper section in the Brakes chapter for Front



Rear Brake Plates Replacement

•

Replace the steel plates and friction plates in accordance with the specified interval (see Rear Final Gear Case section in the Final Drive chapter).

•

Rear Brake Lever Free Play Inspection

Check the rear brake lever free play [A].

○

Pull the rear brake lever lightly until the brake is applied.

If the play is incorrect, adjust it.

Rear Brake Lever Free Play

Standard: 1

∼

2 mm (0.04

∼

0.08 in.)


•

Brake Pedal Free Play Inspection

Check the brake pedal free play [A].

○

Depress the brake pedal lightly by hand until the brake is applied.

If the free play is incorrect, adjust it.

Brake Pedal Free Play

Standard: 15

∼

25 mm (0.6

∼

1.0 in.)

Rear Brake Lever and Pedal Free Play Adjustment

NOTE

○

Since the rear brake lever and pedal free play adjustments affect each other, make them at the same time.

Rear Brake Lever:

•

Loosen the knurled locknut [A] and turn the adjuster [B] at the rear brake lever in as far as it will go.

•

Tighten the locknut.

•

Turn the brake lever adjuster [A] at the rear end of the brake cable until the rear brake lever has the correct amount of play.

Brake Pedal:

•

Turn the brake pedal adjuster [B] at the rear end of the brake cable until the brake pedal has the correct amount of play.

•

Operate the pedal a few times to see that it returns to its rest position immediately upon release.

•

Rotate the rear wheels to check for brake drag.

•

Check braking effectiveness.

If there is any doubt as to the conditions of the brake, check the brake parts for wear or damage.




Steering

Steering Inspection

•

Turn the handlebar left and right, and check the steering action.

If the steering action is not smooth, or if the steering binds or catches before the stop, lubricate the steering stem bearing.

NOTE

○

The cables and wires will have some effect on the steering action which must be taken into account.

•

Check the steering action again.

If steering stem bearing lubrication does not remedy the problem, inspect the steering stem for straightness, steering stem clamps, and tie-rod bearings.

If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts.

•

Tighten loose bolts and nuts to the specified torque (see

Steering chapter), and check the steering action again.

If the steering action does not change by tightening the bolts and nuts, inspect the steering stem clamps, steering stem bearings, tie-rod bearings, and steering knuckle joints.


Spark Plug Cleaning/Inspection

•

Remove the spark plug (see Electrical System chapter).

•

Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a wire brush or other suitable tool.

If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its equivalent.

Spark Plug Gap Inspection

•

Measure the gap [A] with a wire-type thickness gauge.

If the gap is incorrect, carefully bend the side electrode

[B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

0.7

∼

0.8 mm (0.028

∼

0.032 in.)



Brake Light Switch Inspection

•

Turn on the ignition switch.

•

Check the operation of the rear brake light switch by depressing the brake pedal.

If it does not as specified, adjust the brake light timing.

Brake Light Timing

Standard: On after about 10 mm (0.4 in.) of pedal travel [A]


Brake Light Timing Adjustment

•

Remove the right hootboard (see Frame chapter).

•

Adjust the brake light switch [A] up or down. To change the switch position, turn the adjusting nut [B].

CAUTION

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

Drive Belt Failure Detection System Inspection

•

Remove:

Seat (see Frame chapter)

•

Check the drive belt failure detection system according to following chart.






Joint Boots Inspection

Front Axle/Knuckle Joint Boot Inspection

•

Visually inspect the front axle joint boots [A].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boot or front axle assembly (see Final

Drive chapter).

•

Visually inspect the knuckle joint boots [B].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the knuckle (see Steering Knuckle section in Steering chapter).


Front Propeller Shaft Boot Inspection

•

Visually inspect the boots [A] of the front propeller shaft.

If damage, tear or deterioration is found, replace the boots

(see Front Propeller Shaft section in Final Drive chapter).

Tie-rod End Boot Inspection

•

Visually inspect the tie-rod end boots [A] of the tie-rods.

If the boot is torn, worn, deteriorated, or leaks grease, replace the tie-rod end (see Steering chapter).

Rear Propeller Shaft Joint Boot Inspection

•

Visually inspect the boots [A] of the rear propeller shaft.

If the joint boot is torn, worn, or deteriorated, replace the joint boot and check the propeller shaft (see Rear Propeller Shaft section in Final Drive chapter).

Rear Axle/Stabilizer Joint Boot Inspection

•

Visually inspect the rear axle joint boots [A].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boot or rear axle assembly (see Final

Drive chapter).

•

Visually inspect the stabilizer joint boots [B].

If the joint boot is torn, worn, deteriorated, or leaks grease, replace the stabilizer joint (see Suspension chapter).




General Lubrication

Lubrication

•

Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.

•

Lubricate the points listed below with indicated lubricant.

NOTE

○

Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.

Cables: Lubricate with Cable Lubricant

Brake Cables

Throttle Cable

Choke Cables

Variable Differential Control Cable

•

Lubricate the cables by seeping the oil between the cable and housing.

○

The cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant.

•

With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing.

If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.

Points: Lubricate with Grease.

Throttle Inner Cable Ends [A]

Choke Cable Lower End

Brake Cable Ends

Variable Differential Control Cable Ends



Slide Points: Lubricate with Grease.

Brake Lever

Brake Pedal Pivot Shaft

Throttle Lever Shaft

Bolts and Nuts Tightening

Tightness Inspection

•

Check the tightness of the bolts and nuts listed here in accordance with the Periodic Maintenance Chart. Also, check to see that each cotter pin is in place and in good condition.

If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence.

Refer to the appropriate chapter for torque specifications.

If torque specifications are not listed in the appropriate chapter, see the Basic Torque Table (see Torque and

Locking Agent). For each fastener, first loosen it by 1/2 turn, then tighten it.

If cotter pins are damaged, replace them with new ones.

Bolts, Nuts, and Fasteners to be checked

Wheels:

Front Axle Nuts and Cotter Pins

Rear Axle Nuts and Cotter Pins

Wheel Nuts

Brakes:

Front Brake Master Cylinder Clamp Bolts

Brake Lever Pivot Bolt

Brake Lever Pivot Nut

Front Brake Caliper Mounting Bolts

Brake Pedal Cotter Pin

Steering/Suspension:

Handlebar Clamp Bolts

Stem Clamp Bolts

Stem Bearing Housing Bolts

Tie-rod End Nuts and Cotter Pins

Tie-rod Adjusting Sleeve Locknuts

Shock Absorber Mounting Bolts and Nuts

Suspension Arm Pivot Bolts

Steering Knuckle Pivot Nuts and Cotter Pins

Engine:

Engine Mounting Bolts

Engine Mounting Bracket Bolts

Exhaust Pipe Holder Nuts

Muffler Mounting Bolts

Muffler Clamp Bolt

Front Final Drive:

Gear Case Bracket Bolts

Others:

Footboard Mounting Bolts

Throttle Mounting Bolts

Carrier Mounting Bolts




FUEL SYSTEM 3-1

Fuel System

Exploded View...................................

Specifications ....................................

Special Tools .....................................

Throttle Lever and Cable ...................


Inspection..................................


Adjustment ................................

Throttle Case

Removal/Disassembly...............

Throttle Case

Assembly/Installation ................

Throttle Cable Installation ............

Throttle Case Inspection ..............

Throttle Cable Lubrication and

Inspection..................................

Choke Lever and Cable.....................


Inspection..................................


Adjustment ................................

Choke Lever and Cable Removal

Choke Lever and Cable

Installation .................................

Choke Cable Lubrication and

Inspection..................................

Carburetor .........................................

Idle Speed Inspection ..................

Idle Speed Adjustment.................

Pilot Screw Adjustment ................

Service Fuel Level Inspection ......

Service Fuel Level Adjustment ....

Carburetor Synchronization

Inspection..................................


3-8

3-8

3-9

3-9

3-9

3-10

3-10

3-10

3-10

3-11

3-11

3-12

3-12

3-12

3-12

3-12

3-14

3-14

3-2

3-6

3-7

3-8

3-8

3-8

Carburetor Synchronization

Adjustment ................................

Fuel System Cleanliness

Inspection..................................

Carburetor Removal.....................

Carburetor Installation..................

Carburetor Disassembly ..............

Carburetor Assembly ...................

Carburetor Separation .................

Carburetor Joining .......................

Carburetor Cleaning.....................

Carburetor Inspection ..................

Air Cleaner.........................................

Air Cleaner Element Removal......

Air Cleaner Element Installation...

Air Cleaner Element Cleaning and

Inspection..................................

Air Cleaner Housing Removal......

Air Cleaner Housing Installation...

Fuel Tank ...........................................

Fuel Tank Removal ......................

Fuel Tank Installation ...................

Fuel Tank Cleaning ......................

Fuel Tap Removal ........................

Fuel Tap Installation .....................

Fuel Tap Inspection......................

Fuel Tap Cleaning ........................

Fuel Pump .........................................

Fuel Pump Removal ....................

Fuel Pump Removal ....................

Fuel Pump Installation .................

Fuel Pump Inspection ..................

3-15

3-15

3-15

3-17

3-17

3-19

3-20

3-20

3-21

3-22

3-24

3-24

3-24

3-30

3-31

3-32

3-33

3-33

3-33

3-34

3-34

3-24

3-24

3-26

3-28

3-28

3-29

3-30

3-30

3


3-2 FUEL SYSTEM

Exploded View


Exploded View

No.

Fastener

1 Idle Adjusting Screw Bracket Bolt

2. Choke Lever

3. Choke Cable

4. Throttle Cable

5. Throttle Lever

6. Jet Needle

7. Pilot Jet

8. Main Jet

9. Needle Jet

10. Pilot Screw

11. Priming Pump

12. Air Temperature Sensor

G: Apply grease.

O: Apply engine oil.

CA: Canada Model

FUEL SYSTEM 3-3

N·m

8.8

Torque kgf·m

0.90

ft·lb

78 in·lb

Remarks


3-4 FUEL SYSTEM

Exploded View


FUEL SYSTEM 3-5

Exploded View

No.

Fastener

1 Element Cover Screw

2 Element Holder Screws

3 Clamp Bracket Bolt

4 Fuel Pump Mounting Nuts

5 Fuel Tap Plate Screws

6 Fuel Tap Mounting Bolts

7 Fuel Tap Cover Screws

8 Fuel Tap Bracket Bolts

9 Fuel Level Sensor Mounting Bolts

N·m

3.5

3.5

9.8

7.8

0.8

4.9

9.8

7.8

2.0

10. Fuel Pump

11. Insert the fuel breather tube end into the hole of the right frame.

AD: Apply adhesive agent.

G: Apply grease.

R: Replacement Part

W: Apply water or soap and water solution.

Torque kgf·m

0.35

0.35

1.0

0.80

0.08

0.50

1.0

0.80

0.20

ft·lb

31 in·lb

31 in·lb

87 in·lb

69 in·lb

7 in·lb

43 in·lb

87 in·lb

69 in·lb

18 in·lb

Remarks


3-6 FUEL SYSTEM

Specifications

Item

Throttle Case and Cable


Choke Lever and Cable


Carburetor

Make/Type

Main Jet:

Front

Rear

Main Air Jet

2

∼

Standard

3 mm (0.08

∼

KEIHIN, CVKR-34

0.12 in.) about 3 mm (0.12 in.)

#152

#158

#70

Needle Jet

Jet Needle:

Front

Rear

Pilot Jet

Pilot Air Jet

#6

NFKK

NFKL

#38

#100

Pilot Screw 2 1/4 turns out

Carburetor Synchronization vacuum less than 2.7 kPa (2 cmHg) difference between carburetors

Starter Jet #82

1 150 ±50 r/min (rpm) Idle Speed

Service Fuel Level:

Front

Rear

20.4 ±1 mm (0.80 ±0.04 in.) below the punch mark

19.5 ±1 mm (0.77 ±0.04 in.) below the punch mark

2.9 ±1 mm (0.11 ±0.04 in.) Float Height

Optional Parts:

Main Jet:

*Altitude

0

∼

1 200 m (0

∼

3 900 ft):

Front

Rear

1 200

∼

2 500 m (3 900

∼

8 200 ft):

Front

#152 (92063-1331)

#158 (92063-1344)

#145 (92063-1017)

Rear

2 500

∼

3 500 m (8 200

∼

11 500 ft):

Front

#152 (92063-1331)

Rear

3 500

∼

4 500 m (11 500

∼

14 800 ft):

Front

#142 (92063-1016)

#148 (92063-1324)

#135 (92063-1014)

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

Rear

Air Cleaner

#140 (92063-1013) – – –


Air Cleaner Element Oil High-quality foam air filter oil – – –

*: Refer to pg. 6-27 for high altitude setting in the converter system.

Special Tools

Fuel Level Gauge:

57001-1017

Pilot Screw Adjuster, A:

57001-1239

FUEL SYSTEM 3-7

Carburetor Drain Plug Wrench, Hex 3:

57001-1269

Vacuum Gauge:

57001-1369


3-8 FUEL SYSTEM

Throttle Lever and Cable

Throttle Lever Free Play Inspection

•

Refer to the Throttle Lever Free Play Inspection in the

Periodic Maintenance chapter.

Throttle Lever Free Play Adjustment

•

Refer to the Throttle Lever Free Play Adjustment in the


Throttle Case Removal/Disassembly

•

Remove the throttle case screws [A] and pull the case open.

•

Slide the cable adjuster dust cover out of place.

•

Remove the rubber cover [A].

•

Pull the cable tip [A] out of the throttle lever catch with the throttle lever opened.

•

•

Loosen the locknut [B] and unscrew the adjuster [C].

Disassemble the throttle case as follows:

○

Remove the throttle lever screw [D], lockwasher, and flat washer, and lift the throttle lever [E] and return spring from the case.

○

Pull the throttle control lever [F] out of the case.

Throttle Case Assembly/Installation

•

Lubricate the throttle case and cable before assembly/installation.

•

Be certain that the return spring is correctly installed on the throttle lever [A].


Throttle Lever and Cable

•

Swing the throttle control lever so that the carburetor throttle valve is fully open. Turn the throttle limiter screw [A] until it is spaced about 1 mm (0.04 in.) [B] away from the throttle lever stop [C]. Tighten the locknut [D].

NOTE

○

Refer to the Owner’s Manual for the function of the throttle limiter and adjustment procedure of it.

WARNING

Operation with an improperly assembled throttle case could result in an unsafe riding condition.

•

Check the throttle lever free play (see Throttle Lever Free

Play Inspection in Periodic Maintenance chapter).

Throttle Cable Installation

•

Lubricate the throttle cable before installation.

•

Route the cable correctly according to the Appendix chapter.

WARNING

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

•

Check the throttle cable (see Throttle Lever Free Play Inspection in Periodic Maintenance chapter).

Throttle Case Inspection

•

With the throttle cable disconnected from the throttle lever, the lever should move freely and return smoothly by spring.

If the lever is heavy, disassemble the throttle case, clean and lubricate the throttle case.

•

Examine the lever and case for cracks. Replace the case assembly if it is cracked.

Throttle Cable Lubrication and Inspection

•

Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart in the Periodic Maintenance chapter, lubricate the cable .

•

Refer to the General Lubrication in the Periodic Maintenance chapter for the cable lubrication and inspection.

FUEL SYSTEM 3-9


3-10 FUEL SYSTEM


Choke Lever Free Play Inspection

•

Refer to the Choke Lever Free Play Inspection in the Periodic Maintenance chapter.

Choke Lever Free Play Adjustment

•

Refer to the Choke Lever Free Play Adjustment in the


Choke Lever and Cable Removal

•

Remove the air cleaner housing (see Air Cleaner Housing

Removal).

•

Remove the carburetor from the carburetor holder (see

Carburetor Removal).

•

Remove the screws [A] and holder plates [B] from both carburetors.

•

Pull out the starter plungers.

•

Hold the starter plunger springs compressed, and free the choke cable lower ends [A] from the plungers [B].

•

Remove:

Choke Lever Mounting Screw [A], Plane Washer, and

Wave Washer

Switch Case Mounting Screws [B]

•

Free the choke cable upper end [A] from the choke lever

[B].



•

Pull off the retaining clip [A].

•

Fit the cable end [A] in the grommet [B], and free the cable from the switch case.

•

Pull the cable out of the vehicle.

Choke Lever and Cable Installation

•

Lubricate the choke cable before installation.

•

Install the wave washer, plane washer and screw in that order.

•

Route the choke cable according to the Appendix chapter.

WARNING

Operation with an incorrectly routed, or damaged cable could result in an unsafe riding condition.

Choke Cable Lubrication and Inspection

•

Whenever the choke cable is removed or in accordance with the Periodic Maintenance chart in the Periodic Maintenance chapter, lubricate the cable.

•

Refer to the General Lubrication in the Periodic Maintenance chapter for the cable lubrication and inspection

FUEL SYSTEM 3-11



Carburetor

Idle Speed Inspection

•

Refer to the Idle Speed Inspection in the Periodic Maintenance chapter.

Idle Speed Adjustment

•

Refer to the Idle Speed Adjustment in the Periodic Maintenance chapter.

Pilot Screw Adjustment

•

Adjust the pilot screw if necessary.

•

Remove the air cleaner cover (see Frame chapter).

•

Turn the carburetor pilot screw [A] all the way in until it seats lightly.

Special Tool - Pilot Screw Adjuster, A: 57001-1239 [B]

CAUTION

Do not overtighten the pilot screw or the carburetor body will be damaged and require replacement.

•

Back the pilot screw out the specified number of turns.

Carburetor Pilot Screw Setting

Standard: 2 1/4 turns out

Service Fuel Level Inspection

WARNING


•

Park the vehicle on a level surface.

•

Remove:

Side Covers (see Frame chapter)

Throttle Link Case Cover

Carburetor Drain Hose


Carburetor

•

Connect two suitable hoses [A] to the fuel level gauge [B] and the float chamber of the carburetors.

Special Tool - Fuel Level Gauge: 57001-1017

•

Mark the additional graduation [C] 15 mm (0.59 in.) higher than the top graduation [D].

•

Hold the gauge so that the additional graduation is placed slightly higher than the punch mark [E].

[F] Front Carburetor

[G] Rear Carburetor

•

Run the engine at idle speed.

•

Loosen the carburetor drain screw.

Special Tool - Carburetor Drain Plug Wrench, Hex 3:

57001-1269

•

Wait until the fuel level in the gauge settles.

•

Hold the gauge vertically and lower it slowly so that the additional graduation aligns with punch mark.

NOTE

○

Do not align the additional graduation on the gauge lower than the punch mark. If it is lowered and then raised, the gauge will show a fluid level that is higher than the actual level, which will require a remeasurement.

•

Read the fuel level [H].

If the fuel level is incorrect, adjust it.

Fuel Level

Standard:

Front

Rear

20.4 ±1 mm (0.80 ±0.04 in.) below the punch mark

19.5 ±1 mm (0.77 ±0.04 in.) below the punch mark



Stop the engine.

•

Tighten the drain screw.

•

Repeat the same procedure for the other carburetor.


Carburetor

Service Fuel Level Adjustment

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch to 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 drain the fuel.

•

Remove the float chamber.

•

Remove the screw [A].

•

Slide out the pivot pin [B] and remove the float [C].

•

Bend the tang [A] on the float arm very slightly to change the float height.

Float Height

Standard: 2.9 ±1 mm (0.11 ±0.04 in.)

○

Measure the float height [A] from the mating surface [B] of float by tilting the carburetor so that the tang of the float

[C] just touches the needle rod [D]. At this time, the float valve [E] rod must not be depressed.

○

Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

•

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.

Carburetor Synchronization Inspection

•

Remove:


Throttle Link Case Cover

•

Check idle speed.

•

Remove the front vacuum hose [A] and install the vacuum hose for vacuum gauge.


Carburetor

•

Remove the rear vacuum hose [A] and install the vacuum hose for vacuum gauge.


•

Connect:

Vacuum Gauge [A]

Special Tool - Vacuum Gauge: 57001-1369

•

Connect the fuel hose of a suitable fuel tank [B] to the carburetor.

•

Start the engine and read the intake vacuum of each carburetor when idling.

If the vacuum is out of the specified range, adjust it.

Carburetor Synchronization Vacuum

Standard: Less than 2.7 kPa (2 cmHg) difference between carburetors

Carburetor Synchronization Adjustment

•

Turn the adjust screw [A] to synchronize the carburetors.

If the carburetor synchronization cannot be obtained by using the adjusting screw, check for dirt or blockage, and then check the pilot screw settings.

Special Tool - Pilot Screw Adjuster, A: 57001-1239

•

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.

Fuel System Cleanliness Inspection

•

Refer to the Fuel System Cleanliness Inspection in the


Carburetor Removal

WARNING




Carburetor

•

Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)

•

Drain the fuel from the carburetors.

•

Remove:

Fuel Hose [A]

Heater and Ground Lead Connectors [B]

•

Remove:

Screws [A] and Throttle Link Case Cover [B]

•

Remove:

Locknut [A]

Throttle Cable Lower End [B]

•

Loosen the carburetor clamp screws [C].

•

Remove the carburetor out of the frame.

•

Remove:

Screw [A]

Holder Plate [B]

•

Remove:

Starter Plunger [A]


Carburetor

•

Remove:

Screw [A]

Holder Plate [B]

Starter Plunger

Carburetor Installation

•

Confirm the groove of the carburetor holder [A] fits on the projection [B] of the cylinder head.

•

Check fuel leakage from the carburetors.

WARNING

Fuel spilled from the carburetors is hazardous.

•

Adjust the idle speed (see Idle Speed Adjustment in Periodic Maintenance chapter).

•

Check the throttle cable (see Throttle Lever Free Play Inspection in Periodic Maintenance chapter).

Carburetor Disassembly

•

Remove the carburetors (see Carburetor Removal).

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch to 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.

NOTE

○

The carburetors can be disassembled in the joined state.




Carburetor

•

Remove the upper chamber cover [A], spring [B], and vacuum piston [C].

CAUTION

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

•

Remove the jet needle [D] from the vacuum piston. These can be detached together with the spring seat [E].

○

Do not remove the pilot screw if possible, synchronization of the carburetors is necessary if pilot screws are removed

(see Pilot Screw Adjustment).

•

Remove:

Screws [A]

Float Chamber [B]

•

Remove:

Screw [A]

Float Pivot Pin [B], Float [C], and Float Needle Valve

Pilot Jet [D]

Main Jet [E]

Starter Jet [F]

•

Remove:

Screws [A]

Coasting Enricher Cover [B]



Carburetor

•

Remove:

Diaphragm [A]

O-ring [B]

Carburetor Assembly

WARNING

Fuel spilled from the carburetors is hazardous.

CAUTION

Do not apply force to the jet or overtighten it, or this could damage the jet or the carburetor body, requiring replacement.

•

Install the float valve needle in the valve seat and hook the needle hanger [A] onto the float tang.

•

Insert the float pivot pin [B] into the pivot post and the float.

•

Tighten the screw [C].

•

Set the float to the standard height (see Service Fuel

Level Adjustment).

•

Insert the jet needle [A] into the hole in the center of the vacuum piston [B], and place the spring seat [C] over the needle.

•

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.

•

After installing the upper chamber cover, check that the vacuum piston slides up and down smoothly without binding in the carburetor bore.



Carburetor

•

Fit the projection [A] of the vacuum piston diaphragm in the recess [B] of the body.

•

After installing the upper chamber cover, check to make sure that the vacuum piston moves smoothly in the carburetor body.

Carburetor Separation

•

Remove:

Carburetor (see Carburetor Removal)

Screws [A]

Fuel Hose Fittings [B]

•

Remove:

Cotter Pins [A], Collars and Washers

Link Arm [B]

•

Remove:

Link Case Screws [A]

Link Case [B]

•

Separate the Carburetors.

Carburetor Joining

•

Install link case and tighten link case screws.

•

Apply grease to the link pins [A].

•

Install the link arm as shown.

Washers [B]

Collars [C]

Link Arm [D]

Cotter Pins [E]

•

Bend the ends of the cotter pins.

•

Install the fuel hose fittings, and tighten the screws.



Carburetor

•

Visually synchronize the throttle (butterfly) valves.

○

Check to see that all throttle valves open and close smoothly without binding when turning the pulley.

○

Visually check the clearance [A] between the throttle valve and the carburetor bore in each carburetor.

If there is a difference between two carburetors, turn the balance adjusting screw [A] to obtain the same clearance.

•

Install the carburetors (see Carburetor Installation).

•

Adjust the synchronization (see Synchronization Adjustment).

Carburetor Cleaning

WARNING

Clean the carburetor in a well-ventilated area and take care that there are no sparks 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 carburetor.

CAUTION

Do not use compressed air on an assembled carburetor, the float may be crushed by the pressure, and the vacuum piston diaphragm 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 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.



Carburetor

•

Disassemble the carburetor and clean all the metal parts in a carburetor cleaning solution.

•

Rinse the parts in water and dry them with compressed air.

•

Blow through the air and fuel passages with compressed air.

•

Remove the float valve, spray cleaning solution from the valve seating surface into the fuel passage, and clean the strainer (press-fitted) with compressed air [A].

•

Assemble the carburetor (see Carburetor Assembly).

Carburetor Inspection

WARNING


•

Remove the carburetor (see Carburetor Removal).

•

Before disassembling the carburetors, check the fuel level

(see Fuel Level Inspection).

•

Turn the throttle cable pulley [A] to check that the throttle butterfly valves [B] move smoothly and return back with the spring tension.

If the throttle valves do not move smoothly, replace the carburetor.


Carburetor

•

Disassemble the carburetors (see Carburetor Disassembly).

•

Clean the carburetor (see Carburetor Cleaning).

•

Check the vacuum piston diaphragm [A], and the O-rings

[B] on the float bowl, pilot screw, coasting enricher, and starter plunger cap.

If any of the diaphragm or O-rings are not in good condition, replace them.


•

Check the plastic tip [A] of the float valve needle. It should be smooth, without any grooves, scratches, or tears.

If the plastic tip is damaged [C], replace the float valve [B].

•

Push the rod [D] in the other end of the float valve needle and then release it [E].

If it does not spring out, replace the float valve.

•

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 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 the carburetor body, replace both the body and the vacuum piston.



Air Cleaner

Air Cleaner Element Removal

•

Remove:


Clips [A]

Air Cleaner Housing Cap [B]

•

Remove:

Element Cover Screw [A]

Element Cover [B]

Element [C]

•

After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner ducts to keep dirt out of the carburetor and engine.

WARNING

If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possibly causing an accident.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Air Cleaner Element Installation

•

Install:

Element

Element Cover

•

Tighten:

Torque - Element Cover Screw: 3.5 N·m (0.35 kgf·m, 31 in·lb)

Air Cleaner Element Cleaning and Inspection

•

Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter.

Air Cleaner Housing Removal

•

Remove:


Air Cleaner Housing Cap

Air Cleaner Element (see Air Cleaner Element Removal)



Air Cleaner

•

Remove:

Screws [A]

Element Holder [B]

Spark Arrester [C]

•

Remove:

Screw [A]

Air Intake Duct [B]

Air Cleaner Housing Bolt [C]

•

Remove:

Air Cleaner Housing Bolt [A]

•

Loosen the clamp screws [A].

•

Remove:

Breather Hose [A]



Air Cleaner

•

Remove:

Screw [A]

Carburetor Breather Tank [B]

Air Cleaner Housing [C]

Air Cleaner Housing Installation

•

Fit the projection [A] of the housing in the groove [B] of the joint duct [C] (front and rear), and tighten the clamp screws.

•

Install:

Dust Seal [A]

Air Cleaner Housing Cover [B]

[C] Inside

•

Install the air cleaner housing and joint duct on the carburetor.

•

Install:

Breather Hose and Clamp

Carburetor Breather Tank

•

Fit the joint duct on the fitting of the carburetor securely and tighten the clamp screws.

•

Tighten the air cleaner housing bolts.

•

Install the spark arrester [A] so that the swelling faces upward.


Air Cleaner

•

Apply the soap and water solution over the trim seal [A].


•

Install:

Element Holder

•

Tighten:

Torque - Element Holder Screws: 3.5 N·m (0.35 kgf·m, 31 in·lb)

•

Install:

Element (see Air Cleaner Element Installation)



Fuel Tank

Fuel Tank Removal

•

Remove:

Electrical Parts Case (see Frame chapter)


Storage Case [A] (Optional Part)

Check Valve Hose [B]

•

Remove:

Two Right Footboard Bolts [A]

•

Insert a thin driver [A] in the clamp [B] to clear its stopper, and slide the clamp forward.

•

Move the main harness [A] inside as shown.

•

Remove:

Fuel Level Sensor Lead Connector [B]

Vacuum Hose [C]

Fuel Hose [D]

Bolts [E]

Damper Bracket Bolt [F]

Damper Bracket [G]

•

Remove:

Fuel Tank [A] with Tank Case [B]


Fuel Tank

Fuel Tank Installation

•

Check the insulators [A] on the tank case.

If the insulators are damaged or deteriorated, replace them.


•

Check the rubber dampers [A] on the frame as shown.

If the dampers are damaged or deteriorated, replace them.

•

Install the fuel tank with case, and tighten the bolts.

•

Check the damper [A] on the damper bracket [B].

If the damper is damaged or deteriorated, replace it.

•

Tighten the damper bracket bolt.

•

Install the check valve so that the arrow [A] faces fuel tank.

[B] Black Color

[C] Blue Color

•

Install:

Hose [A]

Clamps [B]



Fuel Tank

•

Install:

Vacuum Hose [A] and Clamp [B]

Fuel Level Sensor Lead Connector

•

Install the removed parts.

Fuel Tank Cleaning

•

Remove the fuel tank and drain it (see Fuel Tank Removal).

•

Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.

WARNING

Clean the tank 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 tank. A fire or explosion could result.

•

Pour the solvent out the tank.

•

Dry the tank with compressed air.

•

Install the fuel tank (see Fuel Tank Installation).

Fuel Tap Removal

•

Remove:

Fuel Pump (see Fuel Pump Removal)

Fuel Tap Mounting Bolts [A]

Vacuum Hose [B]

Fuel Tap [C]

Fuel Tap Installation

•

Be sure the O-ring [A] is in good condition to prevent leakage.


Fuel Tank

•

Connect the fuel hoses to the fuel tap as follows.

Vacuum Hose [A]

Fuel Pump Hose [B]

•

Be sure to clamps [C] the fuel hoses to prevent leakage.


Fuel Tap Inspection

•

Check the fuel tap filter screen [A] for any breaks or deterioration.

If the filter screen has any break or is deteriorated, it may allow dirt to reach the carburetor, causing poor running.

Replace the fuel tap.

If the fuel tap leaks, replace the damaged gasket [A] or

O-rings [B].

•

Apply grease to the lever [A].

•

Tighten:

Torque - Fuel Tap Plate Screws [A]: 0.8 N·m (0.08 kgf·m, 7 in·lb)



Fuel Tank

Fuel Tap Cleaning

•

Remove:

Fuel Tap (see Fuel Tap Removal)

•

Clean the fuel tap filter screen in a high-flash point solvent.

WARNING

Clean the tap 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 tap. A fire or explosion could result.

•

Pour high-flash point solvent through the tap in PRI position.

•

Dry the fuel tap with compressed air.

•

Install the fuel tap (see Fuel Tap Installation).


Fuel Pump

Fuel Pump Removal

CAUTION

Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.

WARNING

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

Disconnect the battery (-) terminal.

To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold.

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

Fuel Pump Removal

•

Remove:

Electrical Parts Case (see Frame chapter)

Bolts [A]

Fuel Hose [B]

•

Remove:

Vacuum Hose [A]

Fuel Hose [B]


•

Remove:

Nuts [A] and Washers

Fuel Pump [B]



Fuel Pump

Fuel Pump Installation

•

Install:

Bracket [A]

Fuel Pump [B]

Washers [C] and Nuts [D]

•

Install:

Vacuum Hose [A]

Fuel Hose (Carburetor Side) [B]

Clamps [C]

•

Install:

Fuel Hose (Fuel Tap Side) [A]

Clamp [B]

Bolts [C]

Removed Parts

Fuel Pump Inspection

•

Remove the fuel pump (see Fuel Pump Removal).

If the hose connection areas [A] of the fittings are damaged, replace the fuel pump.

•

Blow the air to the outlet fitting [A], and make sure does not flow the blown air from the inlet fitting [B].

If the fuel pump does not operate as described, replace it with a new one.


Fuel Pump

•

Inhale the air to the inlet fitting [A], and make sure does not inhale the blown air from the outlet fitting [B].

If the fuel pump does not operate as described, replace it with a new one.




COOLING SYSTEM 4-1

Cooling System


Exploded View........................................................................................................................

Coolant Flow Chart.................................................................................................................

Specifications .........................................................................................................................

Special Tools & Sealant..........................................................................................................

Coolant ...................................................................................................................................

Coolant Deterioration Inspection.......................................................................................

Coolant Level Inspection...................................................................................................

Coolant Draining ...............................................................................................................

Coolant Filling ...................................................................................................................

Pressure Testing ...............................................................................................................

Water Pump............................................................................................................................

Water Pump Cover Removal ............................................................................................

Water Pump Cover Installation .........................................................................................

Water Pump Impeller Removal .........................................................................................

Water Pump Impeller Installation ......................................................................................

Water Pump Impeller Inspection .......................................................................................

Water Pump Leakage Inspection ......................................................................................

Mechanical Seal Replacement .........................................................................................

Radiator ..................................................................................................................................

Radiator Removal .............................................................................................................

Radiator Installation ..........................................................................................................

Radiator Fan Removal ......................................................................................................

Radiator Fan Installation ...................................................................................................

Radiator Inspection ...........................................................................................................

4-14

4-14

4-14

4-15

Radiator Cleaning .............................................................................................................

4-15

Radiator Cap Inspection ...................................................................................................

4-15

Thermostat .............................................................................................................................

Thermostat Removal.........................................................................................................

4-16

4-16

Thermostat Installation......................................................................................................

Thermostat Inspection ......................................................................................................

Radiator Fan Switch ...............................................................................................................

Radiator Fan Switch Removal ..........................................................................................

Radiator Fan Switch Installation .......................................................................................

Radiator Fan Switch Inspection ........................................................................................

Coolant Temperature Warning Light Switch ...........................................................................

Coolant Temperature Warning Light Switch Removal ......................................................

Coolant Temperature Warning Light Switch Installation ...................................................

Coolant Temperature Warning Light Switch Inspection ....................................................

4-16

4-16

4-18

4-18

4-18

4-18

4-19

4-19

4-19

4-19

4-10

4-10

4-11

4-11

4-11

4-13

4-13

4-8

4-8

4-9

4-10

4-10

4-10

4-2

4-4

4-6

4-7

4-8

4-8

4-8

4


4-2 COOLING SYSTEM

Exploded View



Exploded View

No.

Fastener

1 Radiator Mounting Bolts

2 Radiator Fan Switch

3 Radiator Fan Assembly Bolts

4 Thermostat Housing Cover Bolts

5 Coolant Temperature Warning Light Switch

6 Air Bleeder Bolt

7 Water Pump Cover Bolts

8 Coolant Drain Plug

9 Water Pump Impeller

10 Water Pipe Mounting Bolts

G: Apply grease.


N·m

8.8

18

4.9

8.8

6.9

8.8

8.8

8.8

7.8

8.8

Torque kgf·m

0.90

1.8

0.50

0.90

0.70

0.90

0.90

0.90

0.80

0.90

ft·lb

78 in·lb

13

43 in·lb

78 in·lb

61 in·lb

78 in·lb

78 in·lb

78 in·lb

69 in·lb

78 in·lb

Remarks

SS



Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion.

When the engine starts, the water pump (coupled with the oil pump) turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.

When coolant temperature is below 69.5

∼

72.5°C (157

∼

162°F), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.

When coolant temperature is more than 69.5

∼

72.5°C (157

∼

162°F), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 96

∼

100°C (205

∼

212°F), the radiator fan switch conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the temperature is below 91

∼

95°C (195

∼

203°F), the fan switch opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contract, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 14

∼

18 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 14

∼

18 psi).

When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.


Coolant Flow Chart


1. Radiator

2. Radiator Cap

3. Radiator Fan Switch

4. Radiator Fan

5. Coolant Temperature Warning Light Switch

6. Thermostat

7. Cylinder

8. Cylinder Head

9. Water Pump

10. Reserve Tank

White Painted Arrow: Cold Coolant


Specifications

Item

Coolant Provided when Shipping

Type

Color

Mixed Ratio

Freezing Point

Total Amount

Radiator Cap

Relief Pressure

Thermostat

Valve Opening Temperature

Valve Full Opening Lift

Standard

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Green

Soft water 50%, coolant 50%

−35°C (−31°F)

2.2 L (2.3 US qt) (reserve tank full level including radiator and engine)

93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 14

∼

18 psi)

69.5

∼

72.5°C (157

∼

162°F)

8 mm or more @85°C (185°F)

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –


Special Tools & Sealant

Bearing Driver Set:

57001-1129


Bearing Remover Head, 10 × 12:

57001-1266

Bearing Remover Shaft, 9:

57001-1265

Kawasaki Bond (Silicone Sealant):

56019-120



Coolant

Coolant Deterioration Inspection

•

Visually inspect the coolant in the reserve tank [A].

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.

If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

If the coolant gives off an abnormal smell, check for cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Coolant Level Inspection

NOTE

○

Check the level when the engine is cold (room or ambient temperature).

•

Check the coolant level in the reserve tank with the vehicle held perpendicularly.

Reserve Tank [A]

F (full) Mark [B]

L (low) Mark [C]

If the coolant level is lower than the L mark, Remove the reserve tank cap [A], then add coolant to the F mark [B].

CAUTION

For refilling, add the specified mixture of coolant and soft water.

Adding water alone dilutes the coolant and degrades its anticorrosion properties.

The diluted coolant can attach the aluminum engine parts. In an emergency, soft water can be added.

But the diluted coolant must be returned to the correct mixture ration within a few days.

If coolant must be added often, or the reserve tank has run completely dry; there is probably leakage in the cooling system. Check the system for leaks.

Coolant Draining

•

Refer to the Coolant Change in the Periodic Maintenance chapter.

Coolant Filling

•

Refer to the Coolant Change in the Periodic Maintenance chapter.


Coolant

Pressure Testing

•

Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator filler neck.

NOTE

○

Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.

•

Build up pressure in the system carefully until the pressure reaches 123 kPa (1.25 kgf/cm², 18 psi).

CAUTION

During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).

•

Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is alright.

If the pressure drops soon, check for leaks.




Water Pump

Water Pump Cover Removal

•

Drain the coolant (see Coolant Change in Periodic Maintenance chapter).

•

Remove:

Coolant Reserve Tank

Water Hose [A]

Water Pump Cover Bolts [B]

Water Pump Cover [C]

Water Pump Cover Installation

•

Install:

Knock Pins [A]

New Gasket [B]

•

Tighten:

Torque - Water Pump Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Water Pump Impeller Removal

•

Drain the coolant (see Coolant Draining).

•

Remove:

Water Pump Cover (see Water Pump Cover Removal)

•

Loosen the water pump impeller [A] counterclockwise.

Water Pump Impeller Installation

•

Apply a small amount of coolant on the sliding surface [A] of the mechanical seal and the sealing seat.

•

Install the impeller on the water pump shaft and tighten the impeller.

Torque - Water Pump Impeller: 7.9 N·m (0.80 kgf·m, 69 in·lb)


Water Pump

Water Pump Impeller Inspection

•

Visually inspect the impeller [A].

If the surface is corroded or the blades are damaged, replace the impeller.


Water Pump Leakage Inspection

•

Check the drainage catch tank [A] at the bottom of the water pump body for coolant leakage.

If there is a coolant leak, the mechanical seal in the pump could be damaged. Replace the mechanical seal with a new one (see Mechanical Seal Replacement).

Mechanical Seal Replacement

•

Remove:

Water Pump Impeller (see Water Pump Impeller Removal)

Alternator Cover (see Electrical System chapter)

•

Take the bearing [A] out of the alternator cover, using the bearing remover.

Special Tools - Bearing Remover Shaft, 9 [B]:

57001-1265

Bearing Remover Head, 10 × 12 [C]:

57001-1266

•

Press out the mechanical seal [A] and oil seal [B] from the inside of the alternator cover with the bearing driver set [C].

Special Tool - Bearing Driver Set: 57001-1129

CAUTION

If either the mechanical seal, oil seal, or the ball bearing is removed, make sure to replace all of them simultaneously with a new one.

Be careful not to block the inspection hole with the oil seal. If the inspection hole is blocked, the coolant may pass through the oil seal and flow into the crankcase.



Water Pump

•

Apply heat-resistance grease on the oil seal lip.

•

From outside the alternator cover, press and insert the oil seal [A] flush [B] in the direction as shown.


•

From inside the alternator cover, press and insert the ball bearing [A] until it is bottomed.


•

Using a suitable socket [A] and the bearing driver [B], press and insert a new mechanical seal [C] until its flange stops at the step [D] of the hole.


•

Clean the sliding surface of a new mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication.

•

Apply coolant to the surfaces of the rubber seal and sealing seat [A], and press the rubber seal [B] and sealing seat into the impeller by hand until the seat bottoms out.

•

Tighten the water pump impeller by turning the bolt clockwise.

Torque - Water Pump Impeller: 7.9 N·m (0.80 kgf·m, 69 in·lb)


Radiator

Radiator Removal

WARNING

The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN

UNTIL THE RADIATOR FAN CONNECTOR IS DIS-

CONNECTED. TOUCHING THE FAN BEFORE THE

CONNECTOR IS DISCONNECTED COULD CAUSE

INJURY FROM THE FAN BLADES.

•


•

Remove:

Radiator Cover (see Frame chapter)

Radiator Fan Motor Lead Connector [A]

Reserve Tank Hose [B]

Radiator Fan Switch Lead Connectors [C]

Radiator Hose [D]


•

Remove:

Radiator Hose [A]

Fan Motor Breather Hose [B]

•

Remove:

Radiator Bolts [A]

Radiator



Radiator

•

Pull the projections [A] out of from the dampers [B], and remove radiator [C].

CAUTION

Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.

Radiator Installation

•

Insert the projections of the radiator in the dampers.

•

Install:

Dampers [A]

Collars [B]

•

Tighten:

Torque - Radiator Mounting Bolts [C]: 8.8 N·m (0.90 kgf·m,

78 in·lb)

•

Connect:

Radiator Fan Motor Lead Connector [A]

•

Install the fan motor breather hose [B].

NOTE

○

Do not apply lubricant at fitting hose region.

•

Install:

Radiator Hoses [C]

Reserve Tank Hose [D]

Clamps [E]

•

Run the hoses according to the Cable, Wire, and Hose

Routing section in the Appendix chapter.

Radiator Fan Removal

•

Remove:

Radiator (see Radiator Removal)

Radiator Fan Assembly Bolts [A]

Fan Assembly [B]

Radiator Fan Installation

•

Install:

Radiator Fan

Radiator Fan Mounting Nut

•

Install:

Radiator Fan Assembly

•

Tighten:

Torque - Radiator Fan Assembly Bolts: 4.9 N·m (0.50 kgf·m,

43 in·lb)


Radiator

Radiator Inspection

•

Check the radiator core.

If there are obstructions to air flow, remove the radiator and remove obstructions.

If the corrugated fins [A] are deformed, carefully straighten them.

If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.

Radiator Cleaning

•

Refer to the Radiator Cleaning in the Periodic Maintenance chapter.

Radiator Cap Inspection

•

Check the condition of the top and bottom valve seals of the radiator cap.

If any one of them shows visible damage, replace the cap.

Bottom Valve Seal [A]

Top Valve Seal [B]

Valve Spring [C]

•

Install the cap [A] on a cooling system pressure tester [B].

NOTE

○

Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.

•

Watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The relief valve opens, indicated by the gauge hand flicks downward.

○

The relief valve must open within the relief pressure range in the table below and the gauge hand must remain within the specified range at least 6 second.

Radiator Cap Relief Pressure

Standard: 93

∼

123 kPa (0.95

∼

1.25 kgf/cm², 14

∼

18 psi)

If the cap cannot hold the specified pressure, or if it holds too much pressure, replace it with a new one.




Thermostat

Thermostat Removal

•


•

Remove:

Side Cover (see Frame chapter)

Coolant Temperature Warning Light Switch Lead Connector [A]

Water Pipe Bolt [B]

•

Remove:

Thermostat Housing Cover Bolts [A]

Thermostat Housing Cover [B]

Thermostat

Thermostat Installation

•

Install:

Thermostat [A]

•

Be sure to install the O-ring [B] on the housing cover.

•

Tighten:

Torque - Thermostat Housing Cover Bolts: 8.8 N·m (0.90

kgf·m, 78 in·lb)

Water Pipe Mounting Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Add coolant (see Coolant Change in Periodic Maintenance chapter).

Thermostat Inspection

•

Remove the thermostat, and inspect the thermostat valve

[A] at room temperature.

If the valve is open, replace the valve with a new one.


Thermostat

•

To check valve opening temperature, suspend the thermostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth.

NOTE

○

The thermostat must be completely submerged and the thermostat and thermometer must not touch the container sides or bottom.

•

Gradually raise the temperature of the water while stirring the water gently for even temperature.

If the measurement is out of the specified range, replace the thermostat.

Thermostat Valve Opening Temperature

69.5

∼

72.5°C (157

∼

162°F)




Radiator Fan Switch

Radiator Fan Switch Removal

CAUTION

The fan switch should never be allowed to fall on a hard surface. Such a shock to the part can damage it.

•


•

Remove:

Radiator Cover (see Frame chapter)

•

Disconnect the fan switch leads.

•

Remove the radiator fan switch [A].

Radiator Fan Switch Installation

•

Tighten:

Torque - Radiator Fan Switch: 18 N·m (1.8 kgf·m, 13 ft·lb)

•

Fill the coolant (see Coolant Change in Periodic Maintenance chapter).

Radiator Fan Switch Inspection

•

Refer to the Electrical System chapter.


Coolant Temperature Warning Light Switch

Coolant Temperature Warning Light Switch Removal

CAUTION

The coolant temperature warning light switch should never be allowed to fall on a hard surface.

Such a shock to the part can damage it.

•


•

Disconnect the switch lead connector [A].

•

Remove the switch [B].

Coolant Temperature Warning Light Switch Installation

•

Apply silicone sealant to the threads of the switch and tighten it.

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

Torque - Coolant Temperature Warning Light Switch: 6.9

N·m (0.70 kgf·m, 61 in·lb)

•

Fill the coolant (see Coolant Change in Periodic Maintenance chapter).

Coolant Temperature Warning Light Switch Inspection

•

Refer to the Electrical System chapter.




ENGINE TOP END 5-1

Engine Top End

Exploded View...................................

Specifications ....................................

Special Tools and Sealant .................

Camshaft Chain Tensioner ................

Camshaft Chain Tensioner

Removal ....................................

Camshaft Chain Tensioner

Installation .................................

Rocker Case......................................

Rocker Case Removal .................

Rocker Case Installation ..............

Rocker Arm Removal...................

Rocker Arm Installation................

Rocker Arm Inspection.................

Rocker Shaft Diameter

Measurement ............................

Camshaft ...........................................

Camshaft Removal ......................

Camshaft Installation ...................

Camshaft Assembly .....................

Cam Wear....................................

Camshaft Bearing Wear...............

KACR Inspection..........................

KACR Removal............................

KACR Installation.........................

Camshaft Chain Removal ............

Camshaft Chain Installation .........

Camshaft Chain Guide Wear .......

Cylinder Head....................................

Cylinder Compression

Measurement ............................

Cylinder Head Removal ...............

Cylinder Head Installation ............


5-2

5-8

5-11

5-13

5-13

5-19

5-20

5-20

5-20

5-21

5-21

5-22

5-23

5-23

5-24

5-24

5-25

5-28

5-29

5-13

5-15

5-15

5-16

5-17

5-18

5-18

5-29

5-30

5-30

Cylinder Head Cleaning ...............

Cylinder Head Warp.....................

Valves ................................................

Valve Clearance Inspection .........

Valve Clearance Adjustment........

Valve Removal .............................

Valve Installation ..........................

Valve Guide Removal ..................

Valve Guide Installation ...............

Valve-to-Guide Clearance

Measurement ............................

Valve Seat Inspection ..................

Valve Seat Repair (Valve

Lapping) ....................................

Cylinder and Piston ...........................

Cylinder Removal.........................

Piston Removal............................

Cylinder, Piston Installation..........

Cylinder Wear ..............................

Piston Wear .................................

Piston/Cylinder Clearance ...........

Piston Ring, Piston Ring Groove

Wear..........................................

Piston Ring Groove Width............

Piston Ring Thickness ................

Piston Ring End Gap ...................

Exhaust System.................................

Spark Arrester Cleaning...............

Muffler and Exhaust Pipe

Removal ....................................

Muffler and Exhaust Pipe

Installation .................................

Exhaust System Inspection..........

5-42

5-42

5-42

5-43

5-44

5-44

5-44

5-45

5-46

5-33

5-34

5-34

5-39

5-39

5-39

5-39

5-41

5-41

5-41

5-31

5-31

5-32

5-32

5-32

5-32

5-32

5-32

5-33

5


5-2 ENGINE TOP END

Exploded View



Exploded View

No.

Fastener

1 Rocker Case Bolts 55 mm (2.2 in.)




5 Cylinder Head Bolts (M10), First Torque

5 Cylinder Head Bolts (M10), Final Torque

6 Cylinder Head Bolts (M6)

7 Valve Adjusting Cap Bolts

8

9

10


Rocker Shaft Bolts

Valve Adjusting Screw Locknuts

N·m

8.8

9.8

9.8

9.8

25

49

9.8

8.8

8.8

20

12

Torque kgf·m

0.90

1.0

1.0

1.0

2.5

5.0

1.0

0.90

0.80

2.0

1.2

ft·lb

78 in·lb

87 in·lb

87 in·lb

87 in·lb

18

36

87 in·lb

78 in·lb

78 in·lb

14

104 in·lb

Remarks

S

S

S

S

S, MO

S

G: Apply grease.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1).


SS: Apply silicone sealant (Three Bond: TB1211F or GE SILICONES TRANSLUCENT RTV128).



Exploded View



Exploded View

No.

Fastener

1 Chain Tensioner Mounting Bolts

2 Chain Tensioner Cap Bolt

3 Position Plate Bolts

4 Intermediate Shaft Chain Guide Bolts

5 Intermediate Shaft Chain Tensioner Bolts

6 Camshaft Sprocket Bolts

7 Cylinder Bolts 40 mm (1.6 in.)

8 Cylinder Bolts 30 mm (1.2 in.)

9 Front Cylinder Camshaft Chain Guide Bolt

10 Rear Cylinder Camshaft Chain Guide Bolt

G: Apply grease.




N·m

8.8

22

8.8

8.8

8.8

12

9.8

9.8

20

20

Torque kgf·m

0.90

2.2

0.90

0.90

0.90

1.2

1.0

1.0

2.0

2.0

ft·lb

78 in·lb

16

78 in·lb

78 in·lb

78 in·lb

104 in·lb

87 in·lb

87 in·lb

14

14

Remarks

L



Exploded View


Exploded View

No.

Fastener

1 Exhaust Pipe Cover Bolts

2 Muffler Clamp Bolt

3 Muffler Cover Bolts

4 Muffler Mounting First Nuts

5 Muffler Mounting Second Nuts





N·m

8.8

8.8

8.8

20

31

Torque kgf·m

0.90

0.90

0.90

2.0

3.2

ft·lb

78 in·lb

78 in·lb

78 in·lb

14

23

Remarks

S

S



Specifications

Item Standard Service Limit

Rocker Case

Rocker Arm Inside Diameter

Rocker Shaft Diameter

12.000

∼

12.018 mm

(0.4724

∼

0.4731 in.)

11.983

∼

11.994 mm

(0.4718

∼

0.4722 in.)

12.05 mm

(0.474 in.)

11.96 mm

(0.471 in.)

Camshafts

Cam Height:

Exhaust

Inlet

35.363

∼

35.477 mm

(1.3922

∼

1.3967 in.)

35.622

∼

35.736 mm

(1.4024

∼

1.4069 in.)

35.26 mm

(1.388 in.)

35.52 mm

(1.398 in.)

Camshaft Bearing Clearance:

18

22

0.016

∼

0.052 mm

(0.0006

∼

0.0020 in.)

0.020

∼

0.062 mm

(0.0008

∼

0.0024 in.)

0.14 mm

(0.0055 in.)

0.15 mm

(0.0059 in.)

Camshaft Journal Diameter:

18

22

17.966

∼

17.984 mm

(0.7073

∼

0.7080 in.)

21.959

∼

21.980 mm

(0.8645

∼

0.8653 in.)

17.94 mm

(0.706 in.)

21.93 mm

(0.863 in.)

Camshaft Bearing Inside Diameter:

18

22

18.000

∼

18.018 mm

(0.7087

∼

0.7094 in.)

22.000

∼

22.021 mm

(0.8661

∼

0.8670 in.)

18.08 mm

(0.712 in.)

22.08 mm

(0.870 in.)

TIR 0.02 mm (0.0008 in.) or less TIR 0.1 mm (0.0039 in.) Camshaft runout

KACR (Kawasaki Automatic

Compression Release):

KACR Operating Engine Speed 760 ±30 r/min (rpm) – – –

Cylinder Head

Cylinder Compression (Usable

Range)

Electric Starter – – – 251

∼

456 kPa (2.56

∼

4.65

kgf/cm², 36

∼

66 psi) @ 380 r/min

(rpm)

– – – 0.05 mm (0.002 in.) Cylinder head warp

Valve

Valve Clearance:

Exhaust – – –

Inlet

0.20

∼

0.25 mm

(0.0079

∼

0.0098 in.)

0.10

∼

0.15 mm

(0.0039

∼

0.0059 in.)

– – –

Valve Head Thickness:

Exhaust

Inlet

0.8 mm (0.031 in.)

0.5 mm (0.020 in.)

0.5 mm (0.020 in.)

0.3 mm (0.012 in.)

Valve Stem Bend – – – TIR 0.05 mm (0.002 in.)


Specifications

Item

Valve Stem Diameter:

Exhaust

Inlet

Standard

4.955

∼

4.970 mm

(0.1951

∼

0.1957 in.)

4.975

∼

4.990 mm

(0.1959

∼

0.1965 in.)

Service Limit

4.94 mm

(0.1945 in.)

4.96 mm

(0.1953 in.)

Valve Guide Inside Diameter:

Exhaust

Inlet

5.000

∼

5.012 mm

(0.1969

∼

0.1973 in.)

5.000

∼

5.012 mm

(0.1969

∼

0.1973 in.)

5.08 mm

(0.20 in.)

5.08 mm

(0.20 in.)

Valve/Valve Guide Clearance

(Wobble Method):

Exhaust

Inlet

0.09

∼

0.17 mm

(0.0035

∼

0.0067 in.)

0.03

∼

0.11 mm

(0.0012

∼

0.0043 in.)

45°, 32°, 60°

0.37 mm

(0.0146 in.)

0.31 mm

(0.0122 in.)

– – – Valve Seat Cutting Angle

Valve Seating Surface:

Outside Diameter:

Exhaust

Inlet

25.2

∼

25.4 mm

(0.992

∼

1.000 in.)

29.4

∼

29.6 mm

(1.157

∼

1.165 in.)

– – –

– – –

Width:

Exhaust

Inlet

0.5

∼

1.0 mm

(0.02

∼

0.04 in.)

0.5

∼

1.0 mm

(0.02

∼

0.04 in.)

– – –

– – –

Valve Spring Free Length:

Exhaust 41.3 mm (1.626 in.) 39.5 mm (1.555 in.)

Inlet

Cylinder, Piston

41.3 mm (1.626 in.) 39.5 mm (1.555 in.)

Cylinder Inside Diameter

Piston Diameter

Piston/Cylinder Clearance

84.994

∼

85.006 mm

(3.3462

∼

3.3467 in.)

84.964

∼

84.979 mm

(3.3450

∼

3.3456 in.)

0.015

∼

0.042 mm

(0.0006

∼

0.0017 in.)

85.10 mm

(3.350 in.)

84.81 mm

(3.3390 in.)

– – –

Piston Ring/Groove Clearance:

Top

Second

0.04

∼

0.08 mm

(0.0016

∼

0.0032 in.)

0.03

∼

0.07 mm

(0.0012

∼

0.0028 in.)

0.18 mm

(0.0071 in.)

0.17 mm

(0.0067 in.)

Piston Ring Groove Width:

Top 1.03

∼

1.05 mm

(0.0405

∼

0.0413 in.)

1.13 mm



Specifications

Item

Second

Piston Ring Thickness:

Top

Second

Piston Ring End Gap:

Top

Second

Oil

Standard

1.02

∼

1.04 mm

(0.0402

∼

0.0409 in.)

0.97

∼

0.99 mm

(0.0382

∼

0.0390 in.)

0.97

∼

0.99 mm

(0.0382

∼

0.0390 in.)

0.20

∼

0.30 mm

(0.0079

∼

0.0118 in.)

0.30

∼

0.45 mm

(0.0118

∼

0.0177 in.)

0.20

∼

0.70 mm

(0.0079

∼

0.0276 in.)

Service Limit

1.12 mm

(0.0441 in.)

0.90 mm

(0.035 in.)

0.90 mm

(0.035 in.)

0.60 mm

(0.0236 in.)

0.75 mm

(0.0295 in.)

1.00 mm

(0.0394 in.)


Special Tools and Sealant

Outside Circlip Pliers:

57001-144


Valve Seat Cutter, 32° 28:

57001-1119

Compression Gauge, 20 kgf/cm²:

57001-221


57001-1123

Valve Spring Compressor Assembly:

57001-241

Valve Seat Cutter Holder Bar:

57001-1128

Piston Pin Puller Assembly:

57001-910

Valve Seat Cutter, 45° 27.5:

57001-1114


57001-1187


57001-1199




Valve Spring Compressor Adapter, 22:

57001-1202

Piston Pin Puller Adapter, 14:

57001-1211

Valve Guide Arbor, 5:

57001-1203

Valve Guide Reamer, 5:

57001-1204

Valve Seat Cutter Holder, 5:

57001-1208

Filler Cap Driver:

57001-1454

Compression Gauge Adapter, M10 × 1.0:

57001-1458


56019-120


Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

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

When removing the tensioner, do not take out the mounting bolts only partway.

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 “Camshaft Chain Tensioner Installation”.

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

•

Remove:

Cap Bolt [A] and Washer

Pin and Spring


•

Remove:

Tensioner Mounting Bolts [A]

Camshaft Chain Tensioner [B]

Camshaft Chain Tensioner Installation

•

Push the stopper [A] to release the ratchet and push the push rod [B] into the tensioner body.



Camshaft Chain Tensioner

•

Tighten:

Torque - Chain Tensioner Mounting Bolts: 8.8 N·m (0.90


•

Install:

Pin [A] and Spring [B]

Washer [C] and Chain Tensioner Cap Bolt [D]

•

Tighten:

Torque - Chain Tensioner Cap Bolt: 22 N·m (2.2 kgf·m, 16 ft·lb)


Rocker Case

Rocker Case Removal

Front Rocker Case

•

Remove:



Timing Inspection Plug [A]

Special Tool - Filler Cap Driver [B]: 57001-1454

•

Remove:

Valve Adjusting Caps

•

Using a wrench on the alternator bolt, turn the crankshaft counterclockwise until “T-F” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rocker arms: the end of the compression stroke.

CAUTION

Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case. The rocker arms could bend the valves.

•

Drain the coolant (see Coolant Change section in Periodic maintenance chapter).

•

Remove:

Thermostat and Water Pipes (see Cooling System chapter)

Front and Rear Propeller Shafts (see Final Drive chapter)

Air Cleaner Housing Mounting Bolts

Front Camshaft Chain Tensioner (see Camshaft Chain

Tensioner Removal)

Front Engine Mounting Bolt [A]

•

Loosen:

Rear Engine Mounting Bolt [B]

•

Remove:

Rocker Case Bolts [A]

•

Loosen:

Rocker Case Bolt [B]




Rocker Case

•

Insert a suitable bar [A] under the front of the engine.

•

Lift [A] the front of the engine to remove the bolt [B] of the front right side on the rocker case.

•

Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame.

Rear Rocker Case

•

Remove:

Front Rocker Case (see this section)

Torque Converter Cover Upper Air Duct

•

Using a wrench on the alternator bolt, turn the crankshaft

counterclockwise (270°) until “T-R” mark [A] is aligned with the notch [B] in the inspection window, and the cam lobes are pointing away from the rocker arms: the end of the compression stroke.

CAUTION

Be sure to position the crankshaft at TDC of the end of the compression stroke when removing or installing the rocker case. The rocker arms could bend the valves.

•

Remove:

Rear Camshaft Chain Tensioner (see Camshaft Chain

Tensioner Removal)

Rocker Case Bolts [A]

Rear Rocker Case [B]

•

Lift the rocker case clear of the dowel pins in the cylinder head and slide the rocker case out of the frame.

Rocker Case Installation

•

Check that the crankshaft is positioned at TDC and at the end of the compression stroke.

CAUTION

Be sure to position the crankshaft is at TDC of the


could bend the valves.

Rocker Case

•

Apply silicone sealant to the outer surface of the cap [A] and the cylinder head upper surface [B] as shown.

Sealant - Three Bond: TB1211F or GE SILICONES

TRANSLUCENT RTV128


•

Tighten the rocker case bolts following the tightening sequence shown.

Torque - Rocker Case Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

[1, 2, 3, 4] L = 55 mm (2.2 in.) with washers

Torque - Rocker Case Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

[5, 6] L = 130 mm (5.1 in.)

[A] L = 30 mm (1.2 in.)

[B] L = 25 mm (1.0 in.)

○

Lift the front of the engine to install the bolt of the front right side on the front rocker case.

•

Check the valve clearance and adjust it if necessary.

•

Apply grease to the O-ring [A].

•

Tighten:

Torque - Valve Adjusting Cap Bolts [B]: 8.8 N·m (0.90 kgf·m,

78 in·lb)

Rocker Arm Removal

•

Remove:

Rocker Case (see Rocker Case Removal)

Rocker Shaft Bolts [A]



Rocker Case

•

Using a M8 bolt [A], remove the rocker shaft [B].

•

Remove:

Rocker Arm [C]

Washers [D]

○

Mark and record the rocker arm location so it can be installed in the original position.

○

The rocker arms come off with the rocker shafts.

Rocker Arm Installation

•

Apply engine oil:

Rocker Shafts [A]

Hole in Rocker Arms [B]

•

Apply grease to the O-rings [C].

•

Install:

Wave Washers [D] (as shown)

Rocker Arms (as shown)

Rocker Shafts and O-rings

•

Tighten:

Torque - Rocker Shaft Bolts [E]: 20 N·m (2.0 kgf·m, 14 ft·lb)

Rocker Arm Inspection

•

Inspect the area [A] on the rocker arm where the cam rubs.

If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes.

•

Inspect the end of the valve clearance adjusting screws

[B] where it contacts the valve stem.

If the end of the adjusting screw is mushroomed or damaged in any way, or if the screw will not turn smoothly, replace it. Also inspect the end of the valve stem.

•

Measure the inside diameter [C] of the rocker arm with a dial bore gauge.

If the rocker arm inside diameter is larger than the service limit, replace it. Also check the rocker shaft diameter (see

Rocker Shaft Diameter Measurement).

Rocker Arm Inside Diameter

Standard: 12.000

∼

12.018 mm (0.4724

∼

0.4731 in.)



Rocker Case

Rocker Shaft Diameter Measurement

•

Measure the diameter [A] of the rocker shaft where the rocker arm pivots on it with a micrometer.

If the rocker shaft diameter is smaller than the service limit, replace it. Also check the rocker arm inside diameter

(see Rocker Arm Inspection).

Rocker Shaft Diameter


∼

11.994 mm (0.4718

∼

0.4722 in.)





Camshaft

Camshaft Removal

•

Remove:

Camshaft Chain Tensioners (see Camshaft Chain Tensioner Removal)

Rocker Cases (see Rocker Case Removal)

Camshafts [A]

•

Support the chain using a suitable tool.

Camshaft Installation

•


clockwise until “T-R” mark [A] is aligned with the notch

[B] in the inspection window.

•

The rear camshaft [A] has a groove [B].

•

First, install the rear camshaft.

•

Face the arrow [A] of the rear camshaft sprocket upward

(left side view).

•

Engage the rear camshaft chain with the rear camshaft sprocket.

•

Align the marks [B] on the weights with the rear cylinder head upper surface.

•


clockwise 270°.

○

Align the “T-F” mark [A] with the notch [B] in the inspection window.


Camshaft

•

Face the arrow [A] of the front camshaft sprocket upward

(right side view).

•

Engage the front camshaft chain with the front camshaft sprocket.

•

Align the marks [B] on the weights with the front cylinder head upper surface.


•

Install:

Rocker Cases (see Rocker Case Installation)

Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation)

•

Check the valve clearance (see Valve Clearance Inspection).

Camshaft Assembly

•

Install the KACR unit [A] (sprocket) on the camshaft so that the unit fits onto the camshaft pins [B].

•

Apply a non-permanent locking agent to the camshaft sprocket bolts [C].

•

Tighten:

Torque - Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)

Cam Wear

•

Remove the camshaft.

•

Measure the height [A] of the cam with a micrometer.

If the cams are worn past the service limit, replace the camshaft.

Cam Height

Standard:

Exhaust

Inlet

Service Limit:

Exhaust

Inlet

35.363

∼

35.477 mm (1.3922

∼

1.3967 in.)

35.622

∼

35.736 mm (1.4024

∼

1.4069 in.)

35.26 mm (1.388 in.)

35.52 mm (1.398 in.)



Camshaft

Camshaft Bearing Wear

○

The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be measured.

The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.

•

Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case.

•

Install the rocker case, tightening the bolts in the correct sequence to the specified torque (see Rocker Case Installation).

NOTE

○

Do not turn the camshaft when the plastigage is between the journal and rocker case.

•

Remove the rocker case and measure the plastigage width [A] to determine the clearance between the journal and the rocker case. Measure the widest portion of the plastigage.

Camshaft Bearing Clearance ( 18)

Standard: 0.016

∼

0.052 mm (0.0006

∼

0.0020 in.)


Camshaft Bearing Clearance ( 22)

Standard: 0.020

∼

0.062 mm (0.0008

∼

0.0024 in.)


If any clearance exceeds the service limit, measure the diameter of the camshaft journal.

Camshaft Journal Diameter ( 18)


∼

17.984 mm (0.7073

∼

0.7080 in.)


Camshaft Journal Diameter ( 22)


∼

21.980 mm (0.8645

∼

0.8653 in.)


If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the limit, replace the cylinder head and the rocker case.

CAUTION

The cylinder head and rocker case are machined as a set, and must be replaced as a set.


Camshaft

KACR Inspection

The Kawasaki Automatic Compression Release (KACR) momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting.

Due to the simplicity of the mechanism, no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism [A]: compression is not released during starting, and compression is released during running.

(1) If compression is not released during starting, the weights are not returning to their rest position.

•

Remove the camshaft (see Camshaft Removal).

•

Remove the KACR unit.

•

Visually inspect the spring.

If damaged, deformed, or missing, replace the spring.

•

Remove the spring and move the weights back and forth.

If the weights do not move smoothly, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary.

[A] Rest Position (compression is released)

[B] Weights

[C] Spring

(2) If compression is released while the engine is running, the weights are not swinging out.

•

Remove the spring and move the weights back and forth.

If the weights do not move easily from the retracted position, replace the KACR unit. Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary.

[A] Running Position (compression is not released)

[B] Weights

[C] Spring

KACR Removal

•

Remove:

Camshaft (see Camshaft Removal)

Camshaft Sprocket Bolts [A]

KACR Unit [B]




Camshaft

•

Remove:

Circlips [A]

Weights [B]

Spring [C]

NOTE

○

Do not remove the shaft [A] and pin [B].

○

If the parts are removed, they cannot be reinstalled.

KACR Installation

•

Install:

Weights

Circlips

Spring [A]

○

Hook the spring from the outside with the open side of the hook inwards.

•

Install:

KACR Unit

•

Hook the arms [B] on the pins.

•

Apply a non-permanent locking agent to the camshaft sprocket bolts [C] and tighten them.

Torque - Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)

Camshaft Chain Removal

•

Remove (left side view):

Rear and Front Camshafts (see Camshaft Removal)

Alternator Rotor (see Electrical System chapter)

Oil Pump (see Engine Lubrication System chapter)

Intermediate Shaft Chain Tensioner [A]

Circlip [B] and Washer

Special Tool - Outside Circlip Pliers: 57001-144

•

Remove:

Intermediate Shaft Chain Guides [C]

Position Plate Bolts [D] and Position Plate


Camshaft

•

Remove (right side view):

Torque Converter (see Converter System chapter)

•

Using a M6 bolt [A], pull out the cover [B].


•

Remove (left side view):

Circlip [A]


•

Remove:

Intermediate Shaft Sprocket [B]

Intermediate Shaft Drive Chain [C]

Rear Camshaft Chain [D]

Front Camshaft Chain (right side)

Camshaft Chain Installation

Rear Camshaft Chain

•

Align the key grooves [A] on the crankshaft with the embossed line [B] on the crankcase (left side view).

•

Face the arrow [A] of the rear camshaft sprocket upward.

•

Align the marks [B] on the weights with the rear cylinder head upper surface [C].

•

Place the rear camshaft chain [D] onto the rear camshaft sprocket.

•

Engage the camshaft and intermediate shaft chains on the intermediate shaft sprocket [A] and insert the intermediate shaft (left side view).

•

Align the punch marks [B] on the intermediate shaft and sprocket with the embossed mark [C] on the crankcase.



Camshaft

Front Camshaft Chain

•

Install the circlip [A].


•

Rotate the crankshaft clockwise 270°.

•

Align the key grooves [B] on the crankshaft with the embossed line [C] on the crankcase.

•

Move the intermediate shaft [A] to the left side of the engine.

•

Engage the front camshaft chain [B] with the sprocket on the intermediate shaft.

•

Install (left side view):

Position Plate [A]

•

Tighten:

Torque - Position Plate Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install:

Intermediate Shaft Chain Guide [A] (front)

•

Tighten:

Torque - Intermediate Shaft Chain Guide Bolts [B]: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

•

Install:

Intermediate Shaft Chain Guide [A] (Rear)

Washer [B]

Circlip [C]



Camshaft

•

Install the intermediate shaft chain tensioner [A] as follows:

•

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

•

Insert a wire [D] into the rod hole to hold the rod in place.


•

Install:

Intermediate Shaft Chain Tensioner [A]

•

Tighten:

Torque - Intermediate Shaft Chain Tensioner Bolts [B]: 8.8

N·m (0.90 kgf·m, 78 in·lb)

•

Remove the wire [C] to free the push rod.

•

Confirm that the punch mark [A] on the intermediate shaft sprocket (Right Side) is aligned with the embossed mark

[B] on the crankcase.

•

Face the arrow mark [A] upward.

•

Align the marks [B] on the weights with the front cylinder head upper surface [C].

•

Place the front camshaft chain on the front camshaft sprocket.

•

Apply grease to the O-ring [A] and install the cover [B] into the right side of the crankcase so that the tapped hole [C] faces outward.



Camshaft

•

Install:

Rocker Cases (see Rocker Case Installation)

Camshaft Chain Tensioners (see Camshaft Chain Tensioner Installation)

•

Check the valve clearances (see Valve Clearance Inspection).

Camshaft Chain Guide Wear

•

Visually inspect the rubber on the guides.

If the rubber is damaged, cut, or is missing pieces, replace the guide.



Cylinder Head

Cylinder Compression Measurement

NOTE

○

Use the battery which is fully charged.

•

Warm up the engine thoroughly, and stop the engine.

•

Remove the spark plug (see Electrical System chapter).

•

Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole.

Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221

Compression Gauge Adapter, M10 × 1.0:

57001-1458

•

Hold the throttle wide open and crank the engine with the electric starter or the recoil starter several times.

When the gauge stops rising, stop cranking and read the gauge.

Cylinder Compression (Usable Range)

Electric Starter: 251

∼

456 kPa (2.56

∼

4.65 kgf/cm², 36

∼

66 psi) @380 r/min (rpm)

The following table should be consulted if the obtainable compression reading is not within the usable range.

Problem

Cylinder compression is higher than usable range

Diagnosis

Carbon accumulation on piston, cylinder head, and in combustion chamber possibly due to damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke).

Incorrect cylinder head gasket thickness.

Damaged or missing compression release cam spring

Remedy (Action)

Remove the carbon deposits and replace damaged parts if necessary.

Replace the gasket with a standard part.

Replace the spring.

Cylinder compression is lower than usable range

Compression release weights do not move smoothly.

Gas leakage around cylinder head Replace damaged gasket and check

Bad condition of valve seating

Replace the compression release unit.

cylinder head warp.

Repair if necessary.

Incorrect valve clearance.

Adjust the valve clearance.

Incorrect piston/cylinder clearance Replace the piston and/or cylinder

Piston seizure.

Inspect the cylinder and liner and replace/repair the cylinder and/or piston as necessary.

Replace the piston and/or the piston rings.

Bad condition of piston ring and/or piston ring grooves

Compression release weights do not move smoothly

Replace the compression release unit



Cylinder Head

Cylinder Head Removal

•


•

Remove:

Carburetor (see Fuel System chapter)

Exhaust Pipe (see Engine Top End chapter)

Thermostat (see Cooling System chapter)

Spark Plug Cap [A]

Water Pipe Bolt [B]

Left Water Pipe [C]

•

Remove:

Water Pipe Bolts [A]

Right Water Pipe [B]

Vacuum Hoses [C]

Rocker Case (see Rocker Case Removal)

Camshaft (see Camshaft Removal)

•

Remove:

Cylinder Head Bolt (M6) [A]

Cylinder Head Bolts (M10) [B] and Washers

Cylinder Head [C] and Gasket

○

Lift the cylinder head to clear the dowel pins in the cylinder, and slide the cylinder head out of the frame.

Cylinder Head Installation

•

Apply oil to the O-rings on the oil pipe [A], and insert the pipe.

•

Install:

Camshaft Chain Guides [B]

Dowel Pins [C]

New Cylinder Head Gasket [D]

•

Tighten:

Torque - Front Cylinder Camshaft Chain Guide Bolt: 20

N·m (2.0 kgf·m, 14 ft·lb)

•

Apply molybdenum disulfide oil to the threads and seating surface of the cylinder head bolts and both sides of the washers.

•

Tighten the cylinder head bolts [A] following the tightening sequence as shown.

First Torque - Cylinder Head Bolts (M10): 25 N·m (2.5

kgf·m, 18 ft·lb)

Final Torque - Cylinder Head Bolts (M10): 49 N·m (5.0


Tighten the cylinder head bolts (M6) [B].


in·lb)

Cylinder Head

Cylinder Head Cleaning

•

Remove the cylinder head (see Cylinder Head Removal).

•

Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool.

•

Wash the head with a high-flash point solvent.

•

Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air.

Cylinder Head Warp

•

Clean the cylinder head (see Cylinder Head Cleaning).

•

Lay a straightedge across the lower surface of the cylinder head.

•

Use a thickness gauge [A] to measure the space between the straightedge [B] and the head at several locations.

Cylinder Head Warp


If the cylinder head is warped more than the service limit, replace it.

If the cylinder head is warped less than the service limit, repair the head by lapping the lower surface with emery paper secured to a surface plate (first No. 200, then No.

400).




Valves

Valve Clearance Inspection

•

Refer to the Valve Clearance Inspection in the Periodic

Maintenance chapter.

Valve Clearance Adjustment

•

Refer to the Valve Clearance Adjustment in the Periodic


•

Valve Removal

Remove the cylinder head (see Cylinder Head Removal).

○

Mark and record the valve location so it can be installed in the original position.

•

Using the valve spring compressor assembly, remove the valve.

Special Tools - Valve Spring Compressor Assembly: 57001

-241 [A]

Valve Spring Compressor Adapter, 22:

57001-1202 [B]

Valve Installation

•

Replace the valve stem oil seal.

If a new valve is to be used, check the valve-to-guide clearance (see this chapter).

If there is too little clearance, ream the valve guide (see

Valve Guide Installation).

If there is too much clearance, install a new valve guide

(see Valve Guide Removal and Valve Guide Installation).

•

Check the valve seat (see Valve Seat Inspection).

•

Apply a thin coat of molybdenum disulfide grease to the valve stem.

•

Install each spring so that the closed coil end faces downwards.

○

The green paint on the spring faces upwards.

Valve Stem [A]

Oil Seal [B]

Spring Seat [C]

Spring [D]

Retainer [E]

Split Keepers [F]

Closed Coil End [G]

Valve Guide Removal

•

Remove:

Valve (see Valve Removal)

Valve Stem Oil Seal

•

Hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.

Special Tool - Valve Guide Arbor, 5: 57001-1203


Valves

Valve Guide Installation

•

Lightly oil the valve guide outer surface.

•

Using the valve guide arbor [A], drive the valve guide [B] until its flange touches the cylinder head.

Special Tool - Valve Guide Arbor, 5: 57001-1203


•

Ream the valve guide with the valve guide reamer [A] , if may be necessary to ream the guide even if the old guide is reused.

Special Tool - Valve Guide Reamer, 5: 57001-1204

Valve-to-Guide Clearance Measurement

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 to it as close as possible to the cylinder head mating surface.

•

Move [C] the stem back and forth 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:

Exhaust

Inlet

0.09

∼

0.17 mm (0.0035

∼

0.0067 in.)

0.03

∼

0.11 mm (0.0012

∼

0.0043 in.)

Service Limit:

Exhaust 0.37 mm (0.0146 in.)

Inlet 0.31 mm (0.0122 in.)



Valves

Valve Seat Inspection

•

Remove the valve (see Valve Removal).

•

Check the valve seating surface [A] between the valve [B] and valve seat [C].

○

Coat the valve seat with machinist’s dye.

○

Push the valve into the guide.

○

Rotate the valve against the seat with a lapping tool.

○

Pull the valve out, and check the seating pattern on the valve head. It must be the correct width and even all the way around.

•

Measure the outside diameter [D] of the seating pattern on the valve seat.

If the outside diameter of the valve seating pattern is too large or too small, repair the seat (see Valve Seat Repair).

Valve Seating Surface Outside Diameter

Exhaust: 25.2

∼

25.4 mm (0.992

∼

1.000 in.)

Inlet: 29.4

∼

29.5 mm (1.157

∼

1.165 in.)

NOTE

○

The valve stem and guide must be in good condition, or this check will not be valid.

If the valve seating pattern is not correct, repair the seat

(see Valve Seat Repair).

•

Measure the seat width [E] of the portion where there is no build-up carbon (white portion) of the valve seat with vernier calipers.

If the width is too wide, too narrow or uneven, repair the seat (see Valve Seat Repair).

[F] Good

[G] Too Wide

[H] Too Narrow

[J] Uneven

Valve Seating Surface Width

Exhaust: 0.5

∼

1.0 mm (0.02

∼

0.04 in.)

Inlet: 0.5

∼

1.0 mm (0.02

∼

0.04 in.)

Valve Seat Repair (Valve Lapping)

•

Using the valve seat cutters [A], repair the valve seat.

Special Tools - Valve Seat Cutters:

Exhaust Valves:

Valve Seat Cutter, 45° 27.5: 57001-1114

Valve Seat Cutter, 32° 28: 57001-1119


Inlet Valves:




Holder and Bar:

Valve Seat Cutter Holder, 5: 57001-1208 [B]

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

Valves

Seat Cutter Operation Care

1. This valve seat cutter is developed to grind the valve seat 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]

37.5

....................... Outer diameter of cutter [C]


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 until it is smooth.

CAUTION

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.



Valves

Widened Width [A] of engagement by machining with

45° cutter

Ground Volume [B] by 32° cutter

32° [C]

Correct Width [D]

Ground Volume [E] by 60° cutter

60° [F]

•

Measure the outside diameter of the seating surface with vernier calipers.

If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.

Original Seating Surface [B]

NOTE

○

Remove all pittings of flaws from 45° ground surface.

○

After grinding with 45° cutter, apply thin coat of machinist’s dye to seating surface. This makes seating surface distinct and 32° and 60° grinding operation easier.

○

When the valve guide is replaced, be sure to grind with

45° cutter for centering and good contact.

If the outside diameter [A] 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 [B] until the seat O.D. is within the specified range.

○

To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide.

Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.

CAUTION

The 32° cutter removes material very quickly.

Check the seat outside diameter frequently to prevent overgrinding.

After making the 32° grind, return to the seat O.D. measurement step above.

•

To measure the seat width, use vernier calipers 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.


Valves

If the seat width is too wide, make the 60° [A] 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.

○

Turn the holder, while pressing down lightly.

○

After making the 60° grind, return to the seat width measurement step above.

Correct Width [B]

•

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.

○

Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve.

○

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.

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 in Periodic

Maintenance chapter).




Valves


Cylinder and Piston

Cylinder Removal

•

Remove:

Cylinder Head (see Cylinder Head Removal)

Oil Pipe [A]

Chain Guide [B]

Cylinder Bolts [C]

Cylinder [D]

Cylinder Base Gasket

Piston Removal

•

Remove the cylinder block (see Cylinder Removal).

•

Place a piece of clean cloth under the piston and remove the piston pin snap rings [A] from the outside of each piston.

CAUTION

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

•

Using the piston pin puller assembly (special tool), remove the piston pins.

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

Piston Pin Puller Adapter, 14 [B]: 57001

-1211

•

Remove the piston.

•

Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.

•

Remove the 3-piece oil ring with your thumbs in the same manner.


Cylinder, Piston Installation

NOTE

○

If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston rings.




NOTE

○

The oil ring rails have no “top” or “bottom”.

•

Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together.

•

Install the oil ring steel rails, one above the expander and one below it.

○

Spread the rail with your thumbs, but only enough to fit the rail over the piston.

○

Release the rail into the bottom piston ring groove.

•

Do not mix up the top ring and second ring.

•

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.

•

The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 30

∼

40° [F] of angle from the opening of the top ring.

Top Ring [A]

Second Ring [B]

Oil Ring Steel Rails [C]

Oil Ring Expander [D]

F mark [E] must be faced toward Front Side for front and rear pistons

Opening Positions [G]

•

Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit

[B] of the piston pin hole.

○

When installing the piston pin snap ring, compress it only enough to install it and no more.

•

Apply engine oil to the cylinder bore and, piston skirt.

•

Install:

Dowel Pins [A]

New Cylinder Base Gasket [B]



•

Install:

Cylinder

Clamp [A] (rear only)

•

Tighten:

Torque - Cylinder Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install:

Chain Guide [C]

•

Apply oil to the O-ring on the oil pipe [D], and insert the pipe.

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 three locations (total of six measurements) shown in the figure.

If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder.

10 mm (0.4 in.) [A]

60 mm (2.4 in.) [B]

20 mm (0.8 in.) [C]

Cylinder Inside Diameter


∼

85.006 mm (3.3462

∼

3.3467

in.), and less than 0.01 mm (0.0004

in.) difference between any two measurements.

Service Limit: 85.10 mm (3.350 in.), or more than 0.05

mm (0.0020 in.) difference between any two measurements.

Piston Wear

•

Measure the outside diameter [A] of each piston 5 mm

(0.20 in.) [B] 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


∼

84.979 mm (3.3450

∼

3.3456 in.)


Piston/Cylinder Clearance

•

Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance.

Piston/Cylinder Clearance

Standard: 0.015

∼

0.042 mm (0.0006

∼

0.0017 in.)





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, replace the piston and all the piston rings.

•

With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

Piston Ring/Groove Clearance

Standard:

Top

Second

0.04

∼

0.08 mm (0.0016

∼

0.0032 in.)

0.03

∼

0.07 mm (0.0012

∼

0.0028 in.)

Service Limit:

Top

Second

0.18 mm (0.0071 in.)

0.17 mm (0.0067 in.)

If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both.

•

Piston Ring Groove Width

Measure the piston ring groove width.

○

Use a vernier caliper at several points around the piston.

Piston Ring Groove Width

Standard:

Top

Second

1.03

∼

1.05 mm (0.0405

∼

0.0413 in.)

1.02

∼

1.04 mm (0.0402

∼

0.0409 in.)

Service Limit:

Top

Second

1.13 mm (0.0445 in.)

1.12 mm (0.0441 in.)

If the width of any of the two grooves is wider than the service limit at any point, replace the piston.

•

Piston Ring Thickness

Measure the piston ring thickness.

○

Use a micrometer to measure at several points around the ring.

Piston Ring Thickness

Standard:

Top

Second

0.97

∼

0.99 mm (0.0382

∼

0.0390 in.)

0.97

∼

0.99 mm (0.0382

∼

0.0390 in.)

Service Limit:

Top

Second

0.90 mm (0.035 in.)

0.90 mm (0.035 in.)

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

○

When using new rings in a used piston, check for un-


to the groove sides. If not, replace the piston.


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:

Top

Second

Oil

0.20

∼

0.30 mm (0.0079

∼

0.0118 in.)

0.30

∼

0.45 mm (0.0118

∼

0.0177 in.)

0.20

∼

0.70 mm (0.0079

∼

0.0276 in.)

Service Limit:

Top 0.60 mm (0.0236 in.)

Second

Oil

0.75 mm (0.0295 in.)

1.00 mm (0.0394 in.)

If the end gap of either ring is greater than the service limit, replace all the rings.




Exhaust System

This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.

Spark Arrester Cleaning

•

Refer to the Spark Arrester Cleaning in the Periodic Maintenance chapter.

Muffler and Exhaust Pipe Removal

•

Remove:


Left Side Cover (see Frame chapter)

Bolts [A]

Rear Exhaust Pipe Cover [B]

Bolts [C]

Middle Exhaust Pipe Cover [D]

•

Remove:

Bolts [A]

Front Exhaust Pipe Cover [B]

•

Remove:

Rear Exhaust Pipe Nuts [A]

•

Remove:

Muffler Clamp Bolt [A]

Muffler Mounting Bolts [B] and Washers

Muffler [C] and Rear Exhaust Pipe



Exhaust System

•

Remove:

Front Exhaust Pipe Nuts [A]

•

Move the front exhaust pipe rear end [A] under the fuel tank and remove the pipe forward.

Muffler and Exhaust Pipe Installation

•

If the muffler cover [A] is removed, tighten them.

Torque - Muffler Cover Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Replace the exhaust pipe gaskets [C] and clamp gasket

[D] with new ones.

•

Install (But do not tighten the following nuts and bolts.):

Front Exhaust Pipe [E], Clamp [F], Muffler and Nuts

Rear Exhaust Pipe [G] and Nuts

Muffler Mounting Bolts [H] and Washers [I]

•

Tighten:

Exhaust Pipe Nuts evenly

•

Tighten the muffler mounting first nut [M] (flange nut) and then the second nut [N].

○

Hold the first nut while tightening the second nut.

Torque - Muffler Mounting First Nuts: 20 N·m (2.0 kgf·m, 14 ft·lb)

Muffler Mounting Second Nuts: 31 N·m (3.2 kgf·m,

23 in·lb)

Muffler Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install:

Front Exhaust Cover [J]

Middle Exhaust Cover [K]

Rear Exhaust Cover [L]

Torque - Exhaust Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)



Exhaust System

Exhaust System Inspection

•

Before removing the exhaust system, check for signs of leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp.

If there are signs of leakage around the exhaust pipe gasket, it should be replaced. If the muffler-to-exhaust pipe joint leaks, tighten the clamp.

•

Remove the exhaust pipe and muffler (see Muffler and

Exhaust Pipe Removal).

•

Inspect the gasket for damage and signs of leakage.

If the gasket is damaged or has been leaking, replace it.

•

Check the exhaust pipe and muffler for dents, cracks, rust and holes.

If the exhaust pipe or muffler is damaged or has holes, it should be replaced for best performance and least noise.


CONVERTER SYSTEM 6-1



Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Torque Converter....................................................................................................................

Torque Converter Cover Removal ....................................................................................

Torque Converter Cover Installation .................................................................................

Torque Converter Cover Disassembly ..............................................................................

Actuator Lever (Engine Brake Control Lever) Assembly Inspection .................................

Torque Converter Cover Assembly ...................................................................................

Drive Belt ................................................................................................................................

Drive Belt Removal ...........................................................................................................

Drive Belt Installation ........................................................................................................

Drive Belt Deflection Inspection ........................................................................................

Drive Belt Deflection Adjustment ......................................................................................

Drive Belt Inspection .........................................................................................................

Drive Pulley ............................................................................................................................

Drive Pulley Removal........................................................................................................

Drive Pulley Disassembly .................................................................................................

Drive Pulley Inspection .....................................................................................................

Spider Shoe Side Clearance Adjustment..........................................................................

Drive Pulley Assembly ......................................................................................................

Drive Pulley Installation.....................................................................................................

Driven Pulley ..........................................................................................................................

Driven Pulley Removal......................................................................................................

Driven Pulley Disassembly ...............................................................................................

Driven Pulley Inspection ...................................................................................................

Driven Pulley Assembly ....................................................................................................

Driven Pulley Installation...................................................................................................

High Altitude Setting Information ............................................................................................

Specifications....................................................................................................................

6-13

6-13

6-14

6-14

6-14

6-15

6-17

6-11

6-11

6-13

6-13

6-13

6-13

6-18

6-19

6-21

6-21

6-21

6-22

6-23

6-25

6-27

6-27

6-2

6-6

6-7

6-9

6-9

6-10

6-10

6


6-2 CONVERTER SYSTEM

Exploded View



Exploded View

No.

Fastener

1 Drive Pulley Bolt

2 Driven Pulley Nut

3 Drive Pulley Cover Bolts

4 Ramp Weight Nuts

5 Spider

N·m

93

93

13

6.9

275

Torque kgf·m

9.5

9.5

1.3

0.70

28

ft·lb

69

69

113 in·lb

61 in·lb

203

Remarks

R, Lh

Lh

G: Apply grease.



WR: Apply grease (WR500-No.2 KYODO YUSHI, POWER LITE WR #2 KYODO YUSHI, or SERAN

-HV TOTAL FINA).



Exploded View


Exploded View

No.

Fastener

1 Converter Cover Bolts

2 Joint Duct Bolts

3 Engine Brake Actuator Mounting Bolts

G: Apply grease.


R: Replacement Part



N·m

8.8

8.8

8.8

Torque kgf·m

0.90

0.90

0.90

ft·lb

78 in·lb

78 in·lb

78 in·lb

Remarks

S

S



Specifications

Item

Torque Converter

Standard Service Limit

Actuator Lever Guide Shoe

Drive Belt

– – – 6 mm (0.24 in.)

Belt Width

Belt Deflection

29.7

∼

30.3 mm (1.169

∼

1.193 in.)

22

∼

27 mm (0.87

∼

1.06 in.)

28.0 mm (1.102 in.)

– – –

Drive Pulley

Shoe Side Clearance Up to 0.20 mm (0.008 in.) (in the text) – – –

Cover Bushing Inside Diameter 27.985

∼

28.085 mm (1.1018

∼

1.1057 in.) 28.12 mm (1.107 in.)

Sheave Bushing Inside 37.985

∼

38.085 mm (1.4955

∼

1.4994 in.) 38.12 mm (1.501 in.)

Diameter

Spring Free Length

Driven Pulley

60.4 mm (2.38 in.) – – –

40.000

∼

40.039 mm (1.5748

∼

1.5763 in.) 40.07 mm (1.578 in.) Sheave Bushing Inside

Diameter

Spring Free Length 99.5 mm (3.92 in.) – – –


Special Tools

Circlip Pliers:

57001-154

Flywheel & Pulley Holder:

57001-1343

Drive & Driven Pulley Holder:

57001-1412

Drive Pulley Puller Bolt:

57001-1429

Pulley Holder Attachment:

57001-1472


Drive & Driven Pulley Holder:

57001-1473

Drive Pulley Wrench:

57001-1474

Spring Holder Set:

57001-1483

Drive Pulley Measurement Tool:

57001-1498

Actuator Lever Measurement Tool:

57001-1499



Special Tools

Drive Pulley Holder:

57001-1520



WARNING

Excessive imbalance or operating rpm could cause torque converter pulley failure resulting in severe injury or death. The pulleys of the belt drive torque converter are precision balanced components designed to operate within certain rpm limits. Disassembly/assembly and servicing procedures of the pulley assemblies must be followed closely. Modifications to the engine or pulleys that increase rpm may cause failure.

CAUTION

Do not turn the ignition switch OFF position from

ON position, while the torque converter cover is removed.

If it is done, the learning control of Kawasaki Engine

Brake Control system works and the engine brake actuator works an error operation.

NOTE

○

If the drive belt failure detection system is activated by abnormal belt, the drive belt failure detection switch is damaged. Make sure to replace the torque converter cover (see Torque Converter Cover Removal/Installation).

Torque Converter Cover Removal

•

Confirm that the ignition switch is in OFF position.

•

Remove:


Clamp Screws [A] and Clamps

Rubber Air Duct [B]


•

Remove:

Actuator Lead Connector and Drive Belt Failure Detection Switch Lead Connector [A]

Torque Converter Cover Bolts [B]

Torque Converter Cover [C]




Torque Converter Cover Installation

•

Check the actuator lever assembly installation length (see

•

Torque Converter Cover Assembly).

Fit the trim seal into the converter cover.

○

Set the trim seal juncture in the area [A] when insert the trim seal in the cover.

[B] 10 mm (0.39 in.)

•

Check:

Drive Belt Failure Detection Switch (see Switch Inspection section in Electric System chapter)

•

Set [A] the switch lever [B] to the ON mark side [C].

Converter Cover [D]

Front [E]

NOTE

○

The failure detection system is activated when the switch is in the ON position. This is the normal running mode. Engine rpm is limited when the switch is in the

OFF position.

•

Tighten (loosely):

#3 Bolt

#1 and #2 Bolts

•

Press the cover downward and tighten the cover bolts following the tightening sequence as shown.

Torque - Converter Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

[A] Clamp

Torque Converter Cover Disassembly

•

Remove:

Torque Converter Cover (see Torque Converter Cover

Removal)

Engine Brake Actuator (see Electrical System chapter)

Circlip [A]

Spring [B]

Actuator Lever Assembly [C]



Actuator Lever (Engine Brake Control Lever)

Assembly Inspection

•

Refer to the Actuator Lever (Engine Brake Control Lever)

Assembly Inspection in the Periodic Maintenance chapter.

Torque Converter Cover Assembly

•

Install:

New Circlip

Spring

Actuator Lever Assembly

Engine Brake Actuator (see Electrical System chapter)

•

Measure the installation length [A] of the actuator lever assembly between the cover end [B] and resin tips [C] on the actuator lever assembly as follows:

Actuator Lever Assembly Installation Length


∼

150.47 mm (5.879

∼

5.924 in.)

○

Remove the trim seal.

○

Install the actuator lever measurement tool (plate [A] and rods [B]) on the torque converter cover [C] and tighten the two cover bolts.

Special Tool - Actuator Lever Measurement Tool: 57001

-1499

○

Set the rod ends on the resin tips [D].

○

Measure the recess length [E] between the plate and rods with Vernier calipers [F] or depth gauge.

Measurement Length [E]

Standard: 1.33

∼

2.47 mm (0.052

∼

0.097 in.)

If the measurement is less than 1.33 mm (0.052 in.), use the actuator lever assembly (13236-0046) of yellow paint.

If the measurement is more than 2.47 mm (0.097 in.), use the actuator lever assembly (13236-0047) of green paint.

If the length is not within the specified length after the actuator lever assembly is replaced, replace the torque converter cover, and install the actuator lever assembly

(13236-0048).





Actuator Lever Assemblies

Part Number Paint Color [A]

13236-0046

13236-0048

13236-0047

Yellow

None

Green

Length [B]

0.4 ±0.1 mm (0.016 ±0.004 in.)

1.0 ±0.1 mm (0.039 ±0.004 in.)

1.6 ±0.1 mm (0.063 ±0.004 in.)


Drive Belt

Drive Belt Removal

•

Remove the drive pulley [A] (see Drive Pulley Removal).


NOTE

○

Before removing, observe the direction the belt’s printed information [A] (such as manufacturer’s name) is facing so that it may be reinstalled on the pulleys to rotate in the same direction as originally installed.

•

Lift the drive belt [B] off the driven pulley [C].

Drive Belt Installation

NOTE

○

Be sure the printed information faces the same direction so the belt rotates in the same direction as originally installed. When installing a new belt, install it so the printed information [A] can be read from beside the vehicle.

•

Installation is basically the reverse of removal.

•

Loop the belt [B] over the driven pulley [C].

•

Install the drive pulley (see Drive Pulley Installation).

•

Put the transmission in neutral, and rotate the driven pulley to allow the belt to return to the top [A] of the sheaves, before measuring belt deflection.

Drive Belt Deflection Inspection

•

Refer to the Drive Belt Deflection Inspection in the Periodic Maintenance chapter.

Drive Belt Deflection Adjustment

•

Refer to the Drive Belt Deflection Adjustment in the Periodic Maintenance chapter.

Drive Belt Inspection

•

Refer to the Drive Belt Inspection in the Periodic Mainte-



Drive Pulley

Drive Pulley Removal

•

Remove the torque converter cover (see Torque Converter Cover Removal).

•

Remove the three cover bolts [A] and install the drive pulley holder [B].

Special Tool - Drive Pulley Holder: 57001-1520

•

Tighten the three cover bolts:

Torque - Drive Pulley Cover Bolts: 13 N·m (1.3 kgf·m, 113 in·lb)

•

Loosen the drive pulley bolt [C] (left-hand threads), holding the drive pulley with the drive pulley holder.

NOTE

○

The drive pulley bolt has left-hand threads. Turn the wrench clockwise for loosening.

•

Remove the drive pulley bolt, two washers, and the stepped washer, but do not remove the drive pulley holder yet.

•

Remove the drive pulley [A] from the crankshaft by screwing the drive pulley puller bolt [B] clockwise, while holding the drive pulley with the drive pulley holder [C].

Special Tool - Drive Pulley Puller Bolt: 57001-1429

Drive Pulley Disassembly

•

Hold the drive & driven pulley holder (57001-1473) [A] and the tapered guide of the holder (57001-1412) [B] in a vise so that the upper surface on the holder is 7 mm (0.28 in.)

[C] above the vise.

Special Tools - Drive & Driven Pulley Holder: 57001-1473

Drive & Driven Pulley Holder: 57001-1412

•

Set the pulley onto the pulley holder.

•

Remove:

Drive Pulley Cover Bolts [A]

Drive Pulley Cover [B]


Drive Pulley

•

Remove:

Spring [A]

Spacer

•

Put the drive pulley wrench [A] on the spider [B] and tighten the bolt [C].

Special Tool - Drive Pulley Wrench: 57001-1474

•

Turn the wrench clockwise and remove the spider with the movable sheave.

NOTE

○

The spider has left-hand threads.

Turn the wrench clockwise for loosening.

•

Remove:

Spider [A]

Shoes [B]

Nuts [C]

Ramp Weight Pin [D]

Ramp Weight [E]

Movable Sheave [F]

Fixed Sheave [G]


Drive Pulley Inspection

If the sheave surfaces [A] appear damaged, replace the sheaves.



Drive Pulley

If the cover bushing is damaged or worn, replace the drive pulley cover.

Cover Bushing Inside Diameter [A]


∼

28.085 mm (1.1018

∼

1.1057 in.)


If the sheave bushing is damaged or worn, replace it.

Sheave Bushing Inside Diameter [A]


∼

38.085 mm (1.4955

∼

1.4994 in.)


If the spider shoes [A] are damaged, replace them.

•

Check the spider shoe side clearance (see Spider Shoe

Side Clearance Inspection).

If the ramp weights [A] in the movable sheave are damaged or worn, replace them.

If the pins [B] are damaged or worn, replace them.

If the rollers [A] are damaged or worn, replace the spider

[B].

If the washers [C] are damaged or worn, replace the spider.


Drive Pulley

If the spring is worn or damaged, replace the spring.

Spring Free Length [A]

Standard: 60.4 mm (2.38 in.)


Spider Shoe Side Clearance Adjustment

•

Remove:

Drive Pulley (see Drive Pulley Removal)

Drive Pulley Cover and Spring (see Drive Pulley Disassembly)

•

Temporarily install the following parts on the movable sheave.

Dowel Pins (2)

Drive Pulley Cover

Two Bolts (at dowel pins)

○

Do not install the spring.

•

Turn the movable sheave counterclockwise.

•

Measure the resulting clearance [A] between the shoe [B] and the post [C] on the movable sheave at two positions as shown.

[D] Arrow Mark

Shoe Side Clearance

Standard: up to 0.20 mm (0.008 in.), and there must be kept a clearance which the movable sheave [E] moves smoothly until it touches the fixed sheave [F] with its own weight.

If the clearance is not the specified range, adjust it using the following shoes.

Standard Shoe

Adjustment Shoes

Part Number

49048-1090

49048-1087

49048-1088

49048-1089

49048-1091

49048-1092

49048-1093

49048-1094

49048-1095

Thickness

7.5 mm (0.295 in.)

7.2 mm (0.283 in.)

7.3 mm (0.287 in.)

7.4 mm (0.291 in.)

7.6 mm (0.299 in.)

7.7 mm (0.303 in.)

7.8 mm (0.307 in.)

7.9 mm (0.311 in.)

8.0 mm (0.315 in.)



Drive Pulley

If the clearance is not the specified range after the above shoes are replaced, use the spacer [A] (92026-0038) of the option part.

[B] Shoe

[C] Spider

[D] Post

[E] Clearance

Drive Pulley Assembly

•

Install the ramp weight [A] as shown.

•

Tighten:

Torque - Ramp Weight Nuts [B]: 6.9 N·m (0.70 kgf·m, 61 in·lb)

•

Check that the ramp weights swing smoothly.

•

Hold the fixed sheave [A] with the drive pulley holder [B] in a vise.

Special Tool - Drive & Driven Pulley Holder: 57001-1473

•

Clean the threads of the fixed sheave and spider.

•

Install:

Movable Sheave

Spider [A] and Shoes [B]

○

Align the arrow [C] on the spider with the arrow [D] on the movable sheave.

○

Insert the shoes so that the rubber side (black, small diameter) faces inward.

•

Put the drive pulley wrench [A] on the spider [B] and tighten the bolt [C].

Special Tool - Drive Pulley Wrench: 57001-1474

•

Turn the wrench counterclockwise for tightening.

Torque - Spider (left-hand threads): 275 N·m (28 kgf·m, 203 ft·lb)

•

Remove the drive pulley wrench.


Drive Pulley

•

Install the spacer.

•

Put the spring [A] in the groove of the spider.

•

Align the arrows [B] on the drive pulley cover and spider.

•

Install:

Dowel Pins [C]

Drive Pulley Cover

•

Tighten:


•

Clean the surface of the sheaves with an oil-less cleaning fluid.

Drive Pulley Installation

•

Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone.

Fixed Sheave Tapered Portion [A]

Crankshaft Tapered Portion [B]

WARNING

These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.

•

Install the drive pulley, stepped waster and two washers on the drive pulley bolt as shown.

Crankcase Side [A]

Stepped Washer [B]

Two Washers [C]

Bolt Head Side [D]


•

Remove the three cover bolts [A] and install the drive pulley holder [B].


•

Tighten:


Drive Pulley Bolt [C] (new, left-hand threads): 93

N·m (9.5 kgf·m, 69 ft·lb)



Drive Pulley

•

Remove the drive pulley holder and install three drive pulley cover bolts to the specified torque.

•

Adjust the installation length [A] of the drive pulley between the surface of the crankcase [B] and the collar [C] on the drive pulley as followings.

Drive Pulley Installation Length [A]


∼

150.95 mm (5.900

∼

5.943 in.)

○

Install the drive pulley measurement tool (legs [A] and plate [B]) on the crankcase [C].

Special Tool - Drive Pulley Measurement Tool: 57001-1498

○

Measure the length [D] between the plate and collar [E] with vernier calipers [F] or a depth gauge.

Measurement Length [D]

Standard: 14.55

∼

15.65 mm (0.573

∼

0.616 in.)

If the measurement is not within the specified range, adjust it according to following table.

Status Quo

Measurement

Length

Paint Color of Cover less than

14.55 mm

(0.573 in.) more than

15.65 mm

(0.616 in.)

Blue

No Paint

Red

Blue

No Paint

Red

Replacement Part

Replace Part

(Part Number)

Paint Color of Cover

Pulley Cover

(14041-1161)

Pulley Cover

(14041-1159)

No Paint

Red

Drive Pulley Assembly

(49093-0014)

Drive Pulley Assembly

(49093-0014)

Pulley Cover

(14041-1160)

Pulley Cover

(14041-1161)

Blue

No Paint

Drive Pulley Covers

Part Number

14041-1159

Paint Color [A]

Red

Length [B]

24.0 mm (0.945 in.)

14041-1160 Blue 25.4 mm (1.000 in.)

14041-1161 No Paint 24.7 mm (0.972 in.)

•

Measure the length again, after the drive pulley cover is replaces.

If the length is not within the specified length, replace the drive pulley assembly.


Driven Pulley

Driven Pulley Removal

•

Remove:

Torque Converter Cover (see Torque Converter Cover

Removal)

Drive Pulley (see Drive Pulley Removal)

Drive Belt (see Drive Belt Removal)

•

Using the flywheel & pulley holder [A] and attachments

[B], remove the driven pulley nut [C] and washers. (Nut has R/H threads.)


•

Remove:

Driven Pulley


Driven Pulley Disassembly

•

Hold the drive & driven pulley holder [A] in a vise.


•

Screw the guide bar [B] into the holder.

Special Tool - Spring Holder Set: 57001-1483

•

Put the driven pulley [C] on the guide bar.

•

Tighten the nut [D], and compress the spring with the spring holder [E].


•

Remove the circlip [A] with circlip pliers [B].

Special Tool - Circlip Pliers: 57001-154

•

Remove the nut and spring holder [C].


•

Remove:

Spring Seats [A]

Spring [B]

Thrust Plate [C]



Driven Pulley

•

Confirm the paint mark “0” [A] on the movable sheave [B] in alignment with the point [C] on the fixed sheave [D] for phase fit of the sheaves.

•

Wipe off the molybdenum disulfide grease.

•

Remove the four pins [A] with a thin standard tip screwdriver [B].

•

Remove the movable sheave from the fixed sheave.

•

Remove:

Spacer(s) [A] (for Drive Belt Deflection Adjustment)

Driven Pulley Inspection

If the sheave surfaces [A] appear damaged, replace the sheaves.

•

Replace the sheave with uneven wear on the belt contacting surfaces.

[A] Sheave Surface

[B] Straight Edge


Driven Pulley

If the sheave bushings [A] are damaged or worn, replace the movable sheave.

Sheave Bushing Inside Diameter


∼

40.039 mm (1.5748

∼

1.5763 in.)


•

Inspect seals for damage.

If seals are damaged, replace the movable sheave.


If the splines [A] are damaged or worn, replace the fixed sheave.

If the spring is damaged or worn, replace the spring.

Spring Free Length [A]

Standard: 99.5 mm (3.92 in.)

If the spring coils are distorted, replace the spring.

Driven Pulley Assembly

•

Clean off any grease or dirt on the movable and fixed sheaves, and dry them with a clean cloth.

•

Install:

Spacers [A] (for Drive Belt Deflection Adjustment, see

Periodic Maintenance chapter)

•

Apply grease to the oil seal lips [A].

•

Press the oil seals [B] in the movable sheave assembly so that the oil seal surface is flush [C] with the sleeve end.

•

Apply [D] grease WR500-No.2

(KYODO YUSHI),

POWER LITE WR #2 (KYODO YUSHI), or SERAN-HV

(TOTAL FINA) to the inner surfaces of the busings.



Driven Pulley

•

Align the paint mark “0” [A] on the movable sheave [B] with the point [C] on the fixed sheave [D] for phase fit of the sheaves.

○

In that case the opening [A] and hole [B] will be matched easily.

•

Apply grease WR500-No.2 (KYODO YUSHI), POWER

LITE WR #2 (KYODO YUSHI), or SERAN-HV (TOTAL

FINA) to the seating surface [A] of the pins, and insert them into the holes in the movable sheave.

•

Draw the movable sheave onto the fixed sheave, and apply grease of 1 g (0.035 oz) to all openings [A].

Grease - WR500-No.2 (KYODO YUSHI) or

POWER LITE WR #2 (KYODO YUSHI) or

SERAN-HV (TOTAL FINA)

NOTE

○

Do not heap up the grease out of the openings.

•

Check that the O-rings [A] are in good condition.

If any of the O-rings are damaged, replace them.

•

Apply grease to the O-rings.


Driven Pulley

•

Hold the drive & driven pulley holder in a vise.


•

Screw the guide bar into the holder.


•

Put the driven pulley [A] onto the guide bar.

•

Put the thrust plate [B] so that the alloy side (gray) faces the movable sheave.

•

Install:

Spring Seat [C]: 18.5 mm (0.728 in.)

Spring [D]

Spring Seat [E]: 9.3 mm (0.366 in.)

Circlip [F]

•

Tighten nut [A], and compress the spring with the spring holder [B].


•

Install a new circlip [C] with circlip pliers [D].

Special Tool - Circlip Pliers: 57001-154

•

Remove the driven pulley from the spring holder set.

•

Clean the surface of the sheaves with an oil-less cleaning fluid.

Driven Pulley Installation

•

Clean the transmission driven shaft [A].

•

Install:

Driven Pulley

NOTE

○

When engaging the spline on the driven pulley with the spline [B] on the shaft, do not damage the pulley’s spline. If any damage occurs, remove it with a file.

•

Clean the threads of the driven shaft and driven pulley ends to open the air vent passage. Wipe off any extra grease.

○

Wipe off any protruding grease [A].




Driven Pulley

•

Install two washers [A] on the shaft as shown.

Crankcase Side [B]

Bolt Head Side [C]

•

Using a flywheel & pulley holder [A] and attachments [B], tighten the driven pulley nut [C].



Torque - Driven Pulley Nut: 93 N·m (9.5 kgf·m, 69 ft·lb)



High Altitude Setting Information

Specifications

Altitude m (ft)

0

∼

1 200

(0

∼

3 900)

1 200

∼

2 500

(3 900

∼

8 200)

2 500

∼

3 500

(8 200

∼

11 500)

3 500

∼

4 500

(11 500

∼

14 800)

P/No. 39152-1081

(STD, C)

P/No. 39152-1088

(C1)

P/No. 39152-1088

(C1)

Drive Pulley

Ramp Weights

P/No. 39152-1081

(STD, C)

Spring Spacer

P/No. 92026-1603 t = 1 mm (0.04 in.)

P/No. 92026-1603 t = 1 mm (0.04 in.)

P/No. 92026-1603 t = 1 mm (0.04 in.)

P/No. 92026-1603 t = 1 mm (0.04 in.)

(qty)

Carburetor

Main Jet

(1) Front: #152 (P/No. 92063-1331)

(STD)

Rear: #158 (P/No. 92063-1344)

(STD)

(1) Front:

Rear:

#145 (P/No. 92063-1017)

#152 (P/No. 92063-1331)

(2) Front:

Rear:

(2) Front:

Rear:

#142 (P/No. 92063-1016)

#148 (P/No. 92063-1324)

#135 (P/No. 92063-1014)

#140 (P/No. 92063-1013)

C, C1: Identification Marks qty: quantity

•

Refer to the Drive Pulley section in this chapter and Carburetor section in the Fuel System chapter for the parts replacement.



RECOIL STARTER 7-1

Recoil Starter


Exploded View........................................................................................................................

Recoil Starter..........................................................................................................................

Recoil Starter Removal .....................................................................................................

Recoil Starter Installation ..................................................................................................

Recoil Starter Inspection...................................................................................................

7-2

7-4

7-4

7-4

7-4

7


7-2 RECOIL STARTER

Exploded View


Exploded View

No.

Fastener

1 Recoil Starter Mounting Bolts


RECOIL STARTER 7-3

N·m

5.9

Torque kgf·m

0.60

ft·lb

52 in·lb

Remarks

L


7-4 RECOIL STARTER

Recoil Starter

Recoil Starter Removal

•

Remove:

Recoil Starter Mounting Bolts [A]

Recoil Starter [B]

Recoil Starter Installation

•

Apply a non-permanent locking agent:

Recoil Starter Mounting Bolts

•

Tighten:

Torque - Recoil Starter Mounting Bolts: 5.9 N·m (0.60


Recoil Starter Inspection

•

Check the starter rope for excessive wear or fraying.


ENGINE LUBRICATION SYSTEM 8-1



Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools & Sealant..........................................................................................................

Engine Oil Flow Chart.............................................................................................................

Engine Oil and Oil Filter..........................................................................................................

Oil Level Inspection...........................................................................................................

Engine Oil Change............................................................................................................

Oil Filter Change ...............................................................................................................

Oil Screen Removal ..........................................................................................................

Oil Screen Cleaning ..........................................................................................................

Oil Pressure Measurement ...............................................................................................

Oil Pressure Relief Valve........................................................................................................

Oil Pressure Relief Valve Removal ...................................................................................

Oil Pressure Relief Valve Installation ................................................................................

Oil Pressure Relief Valve Inspection.................................................................................

Oil Pump.................................................................................................................................

Oil Pump Removal ............................................................................................................

Oil Pump Installation .........................................................................................................

Oil Pipe ...................................................................................................................................

Oil Pipe Removal ..............................................................................................................

Oil Pipe Installation ...........................................................................................................

8-9

8-9

8-10

8-10

8-10

8-12

8-12

8-12

8-7

8-7

8-8

8-8

8-9

8-9

8-2

8-4

8-5

8-6

8-7

8-7

8-7

8


8-2 ENGINE LUBRICATION SYSTEM

Exploded View



Exploded View

No.

Fastener

1 Oil Filter

2 Oil Pressure Switch

3 Oil Pipe Bolts

4 Engine Drain Plug

5 Oil Pressure Relief Valve

6 Oil Pump Bolts

7 Chain Guide Bolts

8 Oil Pump Drive Chain Tensioner Bolt

9 Oil Filter Mounting Bolt

10 Oil Pressure Switch Terminal Bolt

G: Apply grease.





N·m

18

15

8.8

20

15

8.8

8.8

25

25

1.5

Torque kgf·m

1.8

1.5

0.90

2.0

1.5

0.90

0.90

2.5

2.5

0.15

ft·lb

13

11

78 in·lb

14

11

78 in·lb

78 in·lb

18

18

13 in·lb

Remarks

R

SS

L

L (15 mm)



Specifications

Item

Engine Oil

Type

Viscosity

Capacity

Standard

API SF or SG


SAE 10W-40

2.1 L (2.2 US qt) (when filter is not removed)

2.2 L (2.3 US qt) (when filter is removed)

2.6 L (2.7 US qt) (when engine is completely dry)

Oil Pressure Measurement

Oil Pressure @4 000 r/min (rpm), Oil

Temperature 120°C (248°F)

430 kPa (4.4 kgf/cm², 62.6 psi)


Special Tools & Sealant

Oil Pressure Gauge, 10 kgf/cm²:

57001-164


Oil Filter Wrench:

57001-1249

Oil Pressure Gauge Adapter, PT 1/8:

57001-1033


56019-120



Engine Oil Flow Chart

1. Front Camshaft

2. Oil Filter

3. Crankshaft

4. Oil Pressure Switch

5. Oil Pipes

6. Oil Pump

7. Relief Valve

8. Transmission Idle Shaft

9. Oil Screen

10. Transmission Driven Shaft

11. Rear Camshaft

12. Breather Hose

13. To Air Cleaner



Engine Oil and Oil Filter

WARNING

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury.

Oil Level Inspection

•


•

If the oil has just been changed, start the engine, and run it for several minutes to fill the oil filter.

CAUTION

Allow the engine to idle for several minutes so that oil may reach all parts of the engine. Racing a "dry" engine may cause severe damage.

•

Stop the engine and wait several minutes for all the oil to drain back to the sump.

•

Unscrew the oil filler cap [A], wipe its dipstick [B] dry, and tighten it into the filler opening.

•

Unscrew the oil filler cap and check the oil level. The oil level should be between the upper (H) and lower (L) level lines [C].

If the level is too high, suck the excess oil out the filler hole with a syringe or other suitable device.

If the level is too low, add oil through the filler hole. Use the same type and make of oil that is already in the engine.

Engine Oil Change

•

Refer to the Engine Oil Change in the Periodic Maintenance chapter.

Oil Filter Change

•

Refer to the Oil Filter Change in the Periodic Maintenance chapter.

Oil Screen Removal

•

Split the crankcase (see Crankshaft/Transmission chapter).

•

Pull the oil screen [A] out of the crankcase.



Engine Oil and Oil Filter

Oil Screen Cleaning

•

Clean the oil screen [A] thoroughly whenever it is removed for any reason.

•

Clean the oil screen with a high-flash point solvent and remove any particles stuck to it.

WARNING

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

NOTE

○

While cleaning the screen, check for any metal particles that might indicate internal engine damage.

•

Check the screen carefully for any damage, holes, broken wires, or gasket pulling off.

If the screen is damaged, replace it.

Oil Pressure Measurement

NOTE

○

Measure the oil pressure after the engine is warmed up.

•

Remove the oil pressure switch, and attach the oil pressure gauge [A] and adapter [B].

Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164

Oil Pressure Gauge Adapter, PT 1/8: 57001

-1033

Oil Pressure

Standard: 430 kPa (4.4 kgf/cm², 62.6 psi) @4 000 r/min (rpm), 120°C (248°F) of oil temp.

If the oil pressure is much lower than the standard, inspect the relief valve, oil pump, and/or crankshaft bearing insert wear.

If the oil pressure is much higher than the standard, inspect the oil filter, oil screen, and other areas of the lubrication system for clogging.

•

Stop the engine.

•

Remove the oil pressure gauge and adapter.

WARNING

Take care against burns from hot engine oil that will drain through the oil passage when the gauge adapter is removed.

•

Apply silicone sealant to the oil pressure switch, and tighten it.

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

Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)



Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

•

Split the crankcase (see Crankcase Disassembly in the

Crankshaft/Transmission chapter).

•

Remove the oil pressure relief valve [A].

Oil Pressure Relief Valve Installation

•

See crankcase assembly (See Crankshaft/Transmission chapter).

•

Apply a non-permanent locking agent to the threads of oil pressure relief valve, and tighten it.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)

Oil Pressure Relief Valve Inspection

•

Remove the relief valve.

•

Using a wooden stick, push the inner valve to make sure that the valve [A] moves smoothly and that it returns to its original position by the force of the spring [B].

NOTE

○

The relief valve cannot be disassembled and it must be inspected in the assembled state.

If the valve movement is not smooth, wash the relief valve with high-flash point solvent, and use compressed air to remove any foreign particles from it.

WARNING

Clean the oil pressure relief valve in a well

-ventilated area, and take care that there is no spark or flame anywhere near the working area.

Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.

If the valve does not move smoothly even after washing it, replace the relief valve. The oil pressure relief valve is precision made with no allowance for replacement of individual parts.



Oil Pump

Oil Pump Removal

•

Remove:

Alternator Rotor and Starter Clutch Gear (see Electrical

System chapter)

Oil Pump Drive Chain Tensioner Bolt [A]

Chain Guide Bolt [B] and Collar

Chain Guide [C]

•

Remove:

Oil Pump Bolts [A]

Oil Pump Drive Chain [B] and Oil Pump Assembly [C]

•

Remove:

Circlip [A]

Inner Rotor [B]

Outer Rotor [C]

Oil Pump Drive Shaft [D]

Oil Pump Cover [E]

Oil Pump Installation

•

Apply engine oil:

Oil Pump Shaft

Inner and Outer Rotors

•

Install:

Oil Pump Drive Shaft

Oil Pump Cover

Inner Rotor

Outer Rotor

New Circlip

•

Check to see that the dowel pins [A] are in place.

•

Apply engine oil to the oil pump hole [B].



Oil Pump

•

Install the oil pump drive chain [A] with the oil pump assembly [B].

•

Tighten:

Torque - Oil Pump Bolts [C]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Install:

Chain Guide [A] and Collar [B]

•

Tighten:

Torque - Chain Guide Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Apply grease to the O-ring [A].

•

Install:

Pin [B]

Spring [C]

O-ring

Oil Pump Drive Chain Tensioner Bolt [D]

•

Tighten:

Torque - Oil Pump Drive Chain Tensioner Bolt: 25 N·m (2.5




Oil Pipe

Oil Pipe Removal

Engine Left Side Oil Pipe

•

Remove:

Alternator Cover (see Electrical System chapter)

Oil Pump (see Oil Pump Removal)

Oil Pipe Bolts [A]

Oil Pipes [B]

Engine Right Side Oil Pipe

•

Remove:

Drive Pulley (see Torque Converter chapter)

Plate Bolts [A]

Plate [B]

•

Remove:

Oil Pipe Bolt [A]

Oil Pipe [B]

Engine Inside Oil Pipe

•

Remove:

Cylinder Head (see Engine Top End chapter)

Oil Pipe [A]

Oil Pipe Installation

•

Replace the O-ring [A] with new ones if they are damaged.

•

Apply engine oil to the O-rings before installation.

•

Tighten:

Torque - Oil Pipe Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)


ENGINE REMOVAL/INSTALLATION 9-1



Exploded View........................................................................................................................

Engine Removal/Installation ...................................................................................................

Engine Removal................................................................................................................

Engine Installation.............................................................................................................

9-2

9-4

9-4

9-5

9


9-2 ENGINE REMOVAL/INSTALLATION

Exploded View


Exploded View

No.

Fastener

1 Engine Bracket Mounting Bolts

2 Engine Mounting Bolts

3 Engine Mounting Nut


N·m

72

62

62

Torque kgf·m

7.3

6.3

6.3

ft·lb

53

46

46

Remarks


9-4 ENGINE REMOVAL/INSTALLATION


Engine Removal

•

Remove:

Engine Oil (drain)

Coolant (drain)

Muffler and Exhaust Pipe (see Engine Top End chapter)

Footboards (see Frame chapter)

Carburetor (see Fuel System chapter)

Alternator Lead Connector [A]

Crankshaft Sensor Lead Connector [B]

Oil Pressure Switch Lead Connector [C]

•

Remove:

Water Pipe [A] and Thermostat Housing [B]

Air Rubber Duct [C]

Front Propeller Shaft [D]

•

Remove:

Ignition Coil [A] (rear)

Spark Plug Cap [B]

Shift Shaft Lever [C]

Vacuum Hoses [D]

Engine Brake Actuator Lead Connector [E]

Drive Belt Failure Detection Switch Lead Connector [F]

•

Remove:

Speed Sensor Lead Connector [A]

Rear Propeller Shaft [B]

•

Remove:

Water Pipe [A]

Spark Plug Cap [B]




•

Remove:

Coolant Reserve Tank [A]

Neutral Switch Lead Connector [B]

Reverse Switch Lead Connector [C]

Forward/Reverse Detecting Sensor Lead Connector [D]

Water Hose [E]

•

Remove:

Footboard Brackets [A]

Engine Mounting Bolts [B]

Engine Mounting Bracket [C]

•

Remove the engine [A] as shown.

Engine Installation

•

Install:

Engine

Engine Mounting Bolts (temporary)

Engine Bracket and Bolts

•

Tighten:

Torque - Engine Bracket Mounting Bolts: 72 N·m (7.3


Engine Mounting Bolt: 62 N·m (6.3 kgf·m, 46 ft·lb)

Engine Mounting Nut: 62 N·m (6.3 kgf·m, 46 ft·lb)



CRANKSHAFT/TRANSMISSION 10-1



Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools and Sealant ......................................................................................................

Crankcase ..............................................................................................................................

Crankcase Disassembly ...................................................................................................

Crankcase Assembly ........................................................................................................

Crankshaft/Connection Rod ...................................................................................................

10-13

Crankshaft Removal .........................................................................................................

10-13

Crankshaft Installation ......................................................................................................

10-13

Connecting Rod Removal .................................................................................................

10-13

Connecting Rod Installation ..............................................................................................

10-13

Crankshaft/Connecting Rod Cleaning...............................................................................

10-14

10-2

10-6

10-8

10-9

10-9

10-9

Connecting Rod Bend.......................................................................................................

10-14

Connecting Rod Twist .......................................................................................................

10-14

Connecting Rod Big End Side Clearance .........................................................................

10-15

Connecting Rod Big End Bearing/Crankpin Wear ............................................................

10-15

Crankshaft Runout ............................................................................................................

10-17

Crankshaft Main Bearing/Journal Wear ............................................................................

10-17

Transmission ..........................................................................................................................

10-18

Shift Lever Removal..........................................................................................................

10-18

Shift Lever Installation.......................................................................................................

10-19

Transmission Removal .....................................................................................................

10-21

Transmission Installation ..................................................................................................

10-22

Shift Fork Bending ............................................................................................................

10-24

Shift Fork/Gear and Shifter Groove Wear.........................................................................

10-24

Transmission and Shift Mechanism Inspection.................................................................

10-25

Ball Bearing, Needle Bearing, and Oil Seal............................................................................

10-27

Ball and Needle Bearing Replacement .............................................................................

10-27

Ball and Needle Bearing Wear..........................................................................................

10-27

Oil Seal Inspection ............................................................................................................

10-27

10


10-2 CRANKSHAFT/TRANSMISSION

Exploded View



Exploded View

No.

Fastener

Torque kgf·m

3.5

2.0

ft·lb

25

14

Remarks

1 Connecting Rod Big End Cap Nuts

2 Engine Drain Plug

3

4



N·m

34

20

20

20

20

9.8

2.0

2.0

2.0

1.0

14

14

14

87 in·lb

MO

S

S

S, L (1) 5 Crankcase Bolt (M8) 110 mm (4.33 in.)

6 Crankcase Bolts (M6) 40 mm (1.57 in.)

7 Crankcase Bolts (M6) 65 mm (2.56 in.) 9.8

1.0

87 in·lb L

8 Bearing Position Plate Screws 4.9

0.50

43 in·lb

9. Do not apply a non-permanent locking agent to this area (2

∼

3 mm, 0.08

∼

0.12 in.)

10. About 12 mm (0.47 in.)

11. White Mark: Face the mark backwards and align it with the crankcase mark.

12. Face the seal of the bearing to the left side (outward).

G: Apply grease.


LG: Apply liquid gasket (Kawasaki Bond: 92104-1063 or Three Bond 1216).


MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1).





Exploded View



Exploded View

No.

Fastener

1.0

2.5

2.5

0.90

2.0

1.5

1.5

Torque kgf·m

1.0

2.0

1.0

1.0

2.0

2.0

ft·lb

87 in·lb

14

87 in·lb

87 in·lb

14

14

87 in·lb

18

18

78 in·lb

14

11

11

Remarks

1 Grip Hold Nut

2 Shift Lever Assembly Bracket Bolts

3 Tie-rod End Front Locknut

4 Tie-rod End Rear Locknut

5 Tie-rod End Nut

6 Shift Lever Assembly Nut

7 Tie-rod End Bolt

8 Shift Shaft Positioning Bolt

9 Shift Shaft Spring Bolt

10 Shift Shaft Cover Bolts

11 Tie-rod End Locknut

12 Neutral Position Switch

13 Reverse Position Switch

N·m

9.8

20

9.8

9.8

20

20

9.8

25

25

8.8

20

15

15

Lh

L

14. Do not apply a non-permanent locking agent to this end.

G: Apply grease.






R: Replacement Part



Specifications

Item

Crankshaft, Connecting Rods

Connecting Rod Bend – – –

Standard

Connecting Rod Twist – – –

Connecting Rod Big End Side Clearance

Connecting Rod Big End Bearing Insert/Crankpin

Clearance

Crankpin Diameter:

Marking:

Connecting Rod Big End Inside Diameter:

Marking:

None

None

0.16

∼

0.46 mm

(0.0063

∼

0.0181 in.)

0.028

∼

0.052 mm

(0.0011

∼

0.0020 in.)

39.984

∼

40.000 mm

(1.5742

∼

1.5748 in.)

39.984

∼

39.992 mm

(1.5742

∼

1.57449 in.)

39.993

∼

40.000 mm

(1.57452

∼

1.5748 in.)

43.000

∼

43.016 mm

(1.6929

∼

1.6939 in.)

43.000

∼

43.008 mm

(1.6929

∼

1.69323 in.)

43.009

∼

43.016 mm

(1.69326

∼

1.6935 in.)

Connecting Rod Big End Bearing Insert

Thickness:

Brown

Yellow

Green

Connecting Rod Big End Bearing Insert Selection:

1.482

∼

1.486 mm

(0.05835

∼

0.05850 in.)

1.486

∼

1.490 mm

(0.05850

∼

0.05866 in.)

1.490

∼

1.494 mm

(0.05866

∼

0.05882 in.)

Con-rod Big End Bore

Diameter Marking

None

None

Crankpin Diameter

Marking

None

None

– – –

– – –

– – –

Bearing Insert

Size Color

Brown

Part Number

92028-1963

Yellow

Green

92028-1962

92028-1961

Service Limit

TIR 0.2/100 mm

(0.008/3.94 in.)

TIR 0.2/100 mm

(0.008/3.94 in.)

0.7 mm

(0.028 in.)

0.09 mm

(0.0035 in.)

39.97 mm

(1.5736 in.)

– – –

– – –

– – –

– – –

– – –

Crankshaft Runout

Crankshaft Main Journal Diameter

Crankshaft Main Bearing Bore Diameter

TIR 0.04 mm (0.0016 in.) or less

41.984

∼

42.000 mm

(1.6529

∼

1.6535 in.)

42.025

∼

42.041 mm

(1.6545

∼

1.6552 in.)

TIR 0.10 mm

(0.0039 in.)

41.96 mm

(1.652 in.)

42.08 mm

(1.6567 in.)


Specifications

Item

Transmission

Shift fork Ear Thickness

Shift Groove Width


Standard

5.9

∼

6.0 mm

(0.2322

∼

0.2362 in.)

6.05

∼

6.15 mm

(0.2382

∼

0.2421 in.)

Service Limit

5.8 mm

(0.228 in.)

6.25 mm

(0.2460 in.)





57001-144

Crankshaft Jig:

57001-1174


57001-1129



Crankcase

Crankcase Disassembly

•

Remove:

Engine (see Engine Removal/Installation chapter)

Starter Motor (see Electrical System chapter)

Oil Filter

Recoil Starter

Cylinder Blocks and Pistons (see Engine Top End chapter)

Intermediate Shaft and Chains (see Engine Top End chapter)

Right Crankcase Bolt (M6) [A]

Right Crankcase Bolts (M8) [B]

•

Remove:

Shift Shaft Positioning Bolt [A], Washer, Spring, and

Steel Ball

Left Crankcase Bolts (M6) [B]

Left Crankcase Bolts (M8) [C]

•

Wrap the teeth on the sprockets [A] by taping for protecting the bushing in the crankcase.

•

Using the pry points [B], split the crankcase halves.

•

Lift off the left crankcase half.

Crankcase Assembly

CAUTION

The right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.

NOTE

○

Be certain that all parts are cleaned thoroughly before assembly.

○

Blow through all oil passages with compressed air to clear any blockage in the crankcase halves and crankshaft.

WARNING

Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or plosion could result.


Crankcase

•

Press and insert the new ball bearings until they are bottomed.


[A] Ball Bearing

[B] Ball Bearing (sealed side towards crankcase)

•

Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole.

[C] Needle Bearing

[D] Needle Bearing (Insert it from outside.)

•

Apply engine oil to the bearings.

•

Install:

Oil Pressure Relief Valve [E] (see Engine Lubrication

System chapter)

•

Install:

Rear Cylinder Camshaft Chain Guide [A]

•

Tighten:

Torque - Rear Cylinder Camshaft Chain Guide Bolt [B]: 20

N·m (2.0 kgf·m, 14 ft·lb)

•

Press and insert the new ball bearings [A] until they are bottomed.


•

Press and insert the new needle bearings so that the bearing surfaces are flush with the end of the hole.

[B] Needle Bearing

[C] Needle Bearing (Insert it from outside.)

•

Apply engine oil to the bearings.

•

Install the ball bearing [A] so that the stepped side faces outside [B].

•

Install:

Plates [C]

•

Apply a non-permanent locking agent to the bearing position plate screws [D].

•

Tighten:

Torque - Bearing Position Plate Screws: 4.9 N·m (0.50




Crankcase

•

Be sure the following parts are in place in the right crankcase half.

Crankshaft

Transmission Shafts and Shift Rod [A]

Spacers [B]

Oil Tube [C]

Oil Screen [D]

O-ring (Apply Grease) [E]

Dowel Pins [F]

•

Apply liquid gasket [A] to mating surface of the left crankcase half.

Sealant - Kawasaki Bond: 92104-1063 or

Three Bond 1216

•

Apply a non-permanent locking agent to the area [C] (12 mm, 0.47 in.) except for the tip [D] (2

∼

3 mm, 0.08

∼

0.12

in.).

Left Crankcase Bolt (M8) [3]

•

Tighten the right and left crankcase bolts (M8) following the tightening sequence [1

∼

8].

Torque - Crankcase Bolts (M8): 20 N·m (2.0 kgf·m, 14 ft·lb)

[1, 2, 5, 6] L = 75 mm (2.95 in.)

[3, 4, 7, 8] L = 110 mm (4.33 in.)

•

Tighten:

Torque - Crankcase Bolts (M6): 9.8 N·m (1.0 kgf·m, 87 in·lb)

[A] L = 40 mm (1.57 in.)

[B] L = 65 mm (2.56 in.)

•

Grease the lip [A] of the oil seal [B] and press the seal 3 mm (0.12 in.) [C] inwards from the end of the boss.



Crankcase

•

Install the breather tube [A] on the crankcase fitting.

○

Align the white line on the tube with the mark [B] on the crankcase.

○

Face the open end of the clamp [C] towards the left side

[D] as shown.

•

Apply grease to the steel ball [A] and spring [B].

•

Install:

Steel Ball

Spring

Washer [C]

Shift Shaft Positioning Bolt [D]

•

Tighten:

Torque - Shift Shaft Positioning Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Check:

Crankshaft and driven shaft turn freely.

If any of the shafts do not turn freely, split the crankcase to locate the problem.



Crankshaft/Connection Rod

Crankshaft Removal

•

Split the crankcase (see Crankcase Disassembly).

•

Remove the crankshaft [A] from the crankcase using a press.

Crankshaft Installation

•

The left shaft [A] of the crankshaft is longer than the right shaft [B].

•

Apply engine oil to the both main journals.

•

Insert the right crankshaft tapered end (the shorter end) into the right crankcase using a press and two crankshaft jigs.

Special Tools - Crankshaft Jig: 57001-1174 × 2

Connecting Rod Removal

•

Remove the crankshaft (see Crankshaft Removal).

•

Remove the connecting rods [A] from the crankshaft.

NOTE

○

Mark and record the locations of the connecting rods and their big end caps [B] so that they can be installed in their original positions.

○

Remove the connecting rod big end nuts, and take off the rod and cap with the bearing inserts.

Connecting Rod Installation

CAUTION

If the connecting rods, bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage before assembling the engine to be sure the correct bearing inserts are installed.

•

Apply molybdenum disulfide oil:

Inner Surface [A] of Bearing Inserts

•

Face the “OUT” marks [B] of both connecting rods towards the outsides of the crankshaft.

•

Fit the connecting rod cap so that the grooves [C] of the cap and connecting rod are on the same side.




•

Apply molybdenum disulfide oil:

Threads [A] of Connecting Rod Big End Cap Bolts

Seating Surface [B] of Connecting Rod Big End Cap

Nuts [C]

•

Tighten:

Torque - Connecting Rod Big End Cap Nuts: 34 N·m (3.5


Crankshaft/Connecting Rod Cleaning

•

After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent.

•

Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.

Connecting Rod Bend

•

Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap.

•

Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end.

•

Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor

[B] through the connecting rod small end.

•

On a surface plate, set the big-end arbor on a V block [C].

•

With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend.

If connecting rod bend exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist

•

With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.

If connecting rod twist exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)




Connecting Rod Big End Side Clearance

•

Measure the side clearance of the connecting rod big end

[A].

○

Insert a thickness gauge [B] between the big end and either crank web to determine clearance.

Connecting Rod Big End Side Clearance

Standard: 0.16

∼

0.46 mm (0.0063

∼

0.0181 in.)


If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.

If clearance is too large after connecting rod replacement, the crankshaft also must be replaced.

Connecting Rod Big End Bearing/Crankpin Wear

•

Measure the bearing insert/crankpin [A] clearance with plastigage [B].

○

Tighten the big end cap nuts to the specified torque.



NOTE

○

Do not move the connecting rod and crankshaft during clearance measurement.

Connecting Rod Big End Bearing, Insert/Crankpin

Clearance

Standard: 0.028

∼

0.052 mm (0.0011

∼

0.0020 in.)


If the clearance is within the standard, no bearing insert replacement is required.

If the clearance is between 0.052 mm (0.0020 in.) and the service limit 0.09 mm (0.0035 in.), replace the bearing inserts [A] with inserts painted green [B]. Check insert/crankpin clearance with plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.

If the clearance exceeds the service limit, measure the diameter of the crankpin.

Crankpin Diameter


∼

40.000 mm (1.5742

∼

1.5748 in.)


If the crankpin has worn past the service limit, replace the crankshaft with a new one.




If the measured crankpin diameter [A] is not less than the service limit, but does not coincide with the original diameter marking on the crankshaft, make a new mark on it.

Crankpin Diameter Marks

None: 39.984

∼

39.992 mm (1.5742

∼

1.57449 in.)

: 39.993

∼

40.000 mm (1.57452

∼

1.5748 in.)

Crankpin Diameter Mark [B]: “ ” mark or no mark

•

Measure the connection rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter.

•

Tighten the big end nuts to the specified torque.



NOTE

○

The mark already on the big end should almost coincide with the measurement because of little wear.

Connecting Rod Big End Inside Diameter Marks

None: 43.000

∼

43.008 mm (1.6929

∼

1.69323 in.)

: 43.009

∼

43.016 mm (1.69326

∼

1.6935 in.)

Diameter Mark [A]: “ ” or no mark

•

Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding.

Size Color [B]

Big End Bearing Insert Selection

Con-rod Big

End Bore

Diameter Mark

Crankpin

Diameter Mark

None

None None

Bearing Insert

Size Color

Brown

Part Number

92028-1963

Yellow 92028-1962

None Green 92028-1961

•

Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage.




Crankshaft Runout

•

Measure the crankshaft runout.

If the measurement exceeds the service limit, replace the crankshaft.

Crankshaft Runout

Standard: TIR 0.04 mm (0.0016 in.) or less

Service Limit: TIR 0.10 mm (0.0039 in.)

Crankshaft Main Bearing/Journal Wear

•

Measure the diameter [A] of the crankshaft main journal.

Crankshaft Main Journal Diameter


∼

42.000 mm (1.6529

∼

1.6535 in.)


If any journal has worn past the service limit, replace the crankshaft with a new one.

•

Measure the main bearing bore diameter [A] in the crankcase halves.

Crankcase Main Bearing Bore Diameter


∼

42.041 mm (1.6545

∼

1.6552 in.)


If there is any signs of seizure, damage, or excessive wear, replace the crankcase halves as a set.



Transmission

Shift Lever Removal

•

Set the shift lever in the neutral position.

•

Remove:


Shift Shaft Lever Bolt [A]

•

Remove the shift shaft lever [B] from the shift shaft.

•

Remove:

Nut [A]

Shift Lever Assembly [B]

Front [C]

•

Remove:

Tie-rod End Bolt [A]

Tie-rod [B]

•

Remove:

Oil Seals [A]

Collar [B]



Transmission

Shift Lever Installation

•

Twist the tie-rod end [A] and tie-rod end locknut [B] to bottom of the screw and then turn back to dimension with

77° ±10° [C] as shown.

•

Tighten the locknut against the tie-rod end:

Torque - Tie-rod End Locknut: 20 N·m (2.0 kgf·m, 14 ft·lb)

•

Apply molybdenum disulfide grease:

Outside of Tie-rod End Collar [D]

•

Apply grease to the oil seals, and install them.

•

Tighten:

Torque - Tie-rod End Bolt [E]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Align the mark [A] on the shaft end with the slit [B] of the shift shaft lever.

•

Position the shift shaft lever end [C] on the boss-center

[D] of the crankcase.

•

Install:

Bracket [E]

Shift Lever Assembly Nut [F]

•

Tighten:

Torque - Shift Lever Assembly Nut: 20 N·m (2.0 kgf·m, 14 ft·lb)

Tie-rod End Nut [G]: 20 N·m (2.0 kgf·m, 14 ft·lb)



Transmission

•

Install:

Guide [A]

•

Tighten:

Torque - Shift Lever Assembly Bracket Bolts [B]: 20 N·m

(2.0 kgf·m, 14 ft·lb)

•

Set the lever assembly in the neutral position [C] while turning the tie-rod [D].

NOTE

○

Do not turn the shift shaft [E] when setting the lever assembly on neutral position.

○

Turn the tie-rod until the rod [F] of the shift lever assembly contact with the guide [G], and then the tie-rod can be turned until 1/8. At that time, the clearance [H] which can be made between the rod and the guide is 0 ~ –0.5 mm

(0 ~ –0.02 in.).

○

This clearance is a setting range for the neutral position.

○

Move the rod [F] to right and check it will be back to left smoothly.

•

Tighten:

Torque - Tie-rod End Rear Locknut [I]: 9.8 N·m (1.0 kgf·m,

87 in·lb)

•

Holding the rear tie-rod end, and tighten the front locknut

[J].

Torque - Tie-rod End Front Locknut: 9.8 N·m (1.0 kgf·m, 87 in·lb)

NOTE

○

The front locknut has left-hand threads.

○

Do not lean the tie-rod rear end after tightening the front locknut.

Right [K]

Wrong [L]

•

Check that the shift lever moves from right to left smoothly.

•

Install:

Spring [M]

Trim Seal [N]

•

Align the mark [O] of the grip [P] with the projection [Q] on the guide.

•

Tighten:

Torque - Grip Hold Nut [R]: 9.8 N·m (1.0 kgf·m, 87 in·lb)


Transmission


Transmission Removal

•

Split the crankcase (see Crankcase Disassembly).

•

Remove:

Shift Shaft Cover Bolts [A]

Shift Shaft Cover [B]

•

Remove:

Shift Shaft Spring Bolt [A]

Shift Shaft [B]

•

Remove:

Reverse Idle Shaft [A]

Spacer [B]

Reverse Drive Gear [C], Needle Bearing, and Spacer

Shifter [D]

Shift Rod [E]



Transmission

•

Remove:

Circlip [A]


•

Remove:

Spacer [A]

Idle Gear Assembly [B]

Washers and Spacer [C]

Low and High Gears [D]

•

Remove:

Needle Bearings [A]

•

Remove the driven shaft [B] from the crankcase using a press.

Transmission Installation

•

Insert the driven shaft in the crankcase until it is bottomed using a press.

•

Apply engine oil to the needle bearings and install them.

•

Install the following parts on the low gear [A].

Needle Bearings [B]

Spacer [C] (P/No. 92026-1599, 48.2 × 54.3 × 1.0)

High Gear [D]



Transmission

•

Install:

Idle Shaft [A] with Gear Assembly [B]

Spacer [C]

Spacer [D] (P/No. 92026-1599, 48.2 × 54.3 × 1.0)

•

Apply engine oil to the inner surface of the spacer [E].

•

Install the spacer [E] so that the stepped side [F] faces outward.

•

Install:

Spacer

Toothed Washer [A]

Circlip


•

Apply engine oil:

Shift Rod [A] and Shift Fork Ear [B]

Needle Bearing [C]

•

Install:

Shift Rod with Shifter

Spacer [D]

Needle Bearing

•

Install:

Reverse Drive Gear [A]

Spacer [B]

•

Install:

Reverse Idle Shaft [A]



Transmission

•

Apply molybdenum disulfide oil to the shift shaft [A].

•

Install:

Shift Shaft Spring Bolt [B]

Spring [C]

Guide [D]

•


Shift Shaft Spring Bolt

•

Tighten:

Torque - Shift Shaft Spring Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

When a new bushing [A] and oil seal [B] are installed in the shift shaft cover [C], press and insert the new bushing and oil seal so that their surfaces are flush with the end of the each hole.

•

Install:

Shift Shaft Cover

•

Tighten:

Torque - Shift Shaft Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Shift Fork Bending

•

Visually inspect the shift fork.

If the fork is bent, replace the shift rod with a new one.

A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.

[A] 90°

Shift Fork/Gear and Shifter Groove Wear

•

Measure the thickness of the shift fork ears [A], and measure the width [B] of the gear groove and shifter.

If the thickness of a shift fork ear is less than the service limit, the shift rod must be replaced.

Shift Fork Ear Thickness

Standard: 5.9

∼

6.0 mm (0.2322

∼

0.2362 in.)


If the groove is worn over the service limit, the shifter must be replaced.

Shifter Groove Width

Standard: 6.05

∼

6.15 mm (0.2382

∼

0.2421 in.)




Transmission

Transmission and Shift Mechanism Inspection

•

Visually inspect:

Gears

Dogs of Gear and Shifter

If they are damaged or worn excessively, replace them.



Transmission

1. Driven Shaft

2. Spacer (17.3 × 30 × 2.0)

3. Reverse Gear (12T)

4. Spacer (21.2 × 29 × 1.6)

5. Shifter

6. Snap Ring

7. Washer T = 1.5

8. Spacer (28.2 × 34.5 × 1.6)

9. Spacer (Hi and Low)

10. Spacer (48.2 × 54.3 × 1.0)

12. Drive Low Gear (20T)

13. Reverse Idle Shaft

14. Reverse Driven Gear (16T)

15. Reverse Driven Output Gear (16T)

16. Idle Shaft

17. Spacer (20.3 × 33 × 2.0)

18. Driven Output Gear (18T)

19. Driven Hi Gear (30T)

20. Driven Low Gear (36T)

21. Needle Bearing

11. Drive Hi Gear (26T)



Ball Bearing, Needle Bearing, and Oil Seal

Ball and Needle Bearing Replacement

CAUTION

Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.

•

Using a press or puller, remove the ball bearing and/or three needle bearings.

NOTE

○

In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.

CAUTION

Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.

•

Using a press and the bearing driver set [A], install the new ball bearing until it stops at the bottom of its housing.

○

Three new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole.


Ball and Needle Bearing Wear

CAUTION

Do not remove the bearings for inspection.

Removal may damage them.

•

Check the ball bearings.

○

Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.

○

Spin [A] the bearing by hand to check its condition.

If the bearing is noisy, does not spin smoothly, or has any

• rough spots, replace it.

Check the needle bearings.

○

The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a needle bearing, replace it.

Oil Seal Inspection

•

Inspect the oil seals.

Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.



WHEELS/TIRES 11-1

Wheels/Tires


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tool ............................................................................................................................

Wheel Alignment ....................................................................................................................

Steering Centering Inspection...........................................................................................

Steering Centering Adjustment .........................................................................................

Toe-in Inspection...............................................................................................................

Toe-in Adjustment .............................................................................................................

Wheels (Rims) ........................................................................................................................

Wheel Removal.................................................................................................................

Wheel Installation..............................................................................................................

Wheel (Rim) Inspection.....................................................................................................

Wheel (Rim) Replacement................................................................................................

11-10

Tires........................................................................................................................................

11-11

Tire Removal.....................................................................................................................

11-11

Tire Installation..................................................................................................................

11-11

Tire Inspection ..................................................................................................................

11-12

Front Hub................................................................................................................................

11-13

Front Hub Removal...........................................................................................................

11-13

Front Hub Installation........................................................................................................

11-13

Front Hub Disassembly/Assembly ....................................................................................

11-14

Rear Hub ................................................................................................................................

11-15

Rear Hub Removal ...........................................................................................................

11-15

Rear Hub Installation ........................................................................................................

11-15

Rear Hub Disassembly/Assembly.....................................................................................

11-16

11-7

11-7

11-9

11-9

11-9

11-9

11-2

11-4

11-5

11-6

11-6

11-6

11


11-2 WHEELS/TIRES

Exploded View


Exploded View

No.

Fastener

1 Tie-rod Locknuts

2 Tie-rod End Nuts

3 Wheel Nuts (First Torque)

3 Wheel Nuts (Final Torque)

4 Front Axle Nuts

5 Rear Axle Nuts



W: Apply water or soap and water solution.


N·m

37

42

15

76

197

265

Torque kgf·m

3.8

4.3

1.5

78

20

27

ft·lb

27

31

11

56

145

195

Remarks

S

S



Specifications

Item

Wheel Alignment

Toe-in of front wheels:

Tires

Standard tire:

Front

Standard

–10

∼

10 mm (–39

∼

0.39 in.) at 1G

Rear

AT 25 × 8-12


AT 25 × 10-12


Tire air pressure (when cold):

Front

Rear

Maximun tire air pressure

(to seat beads, when cold)

Tire tread depth:

Front

Rear

35 kPa (0.35 kgf/cm², 5.0 psi)

35 kPa (0.35 kgf/cm², 5.0 psi)

250 kPa (2.5 kgf/cm², 36 psi)

– – –

– – –

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

3 mm (0.12 in.)

4 mm (0.16 in.)


Special Tool

Jack:

57001-1238




Wheel Alignment

Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is the greater than B

(Front) as shown.

The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs.

Caster and camber are build-in and require no adjustment.

A (Rear ) - B (Front) = Amount of Toe-in

(Distance A and B are measured at axle height with the vehicle sitting on the ground, or at 1G.)

Steering Centering Inspection

•

Test ride the vehicle.

If the handlebar is straight when the vehicle is traveling in a straight line, go on to the Toe-in Inspection procedure.

Otherwise, go on to the Steering Centering Adjustment procedure.

Steering Centering Adjustment

•

Hold a straightedge [A] against the rear wheel rim on one side at axle height.

•

With the handlebar straight ahead, loosen the locknuts

[A] [B] and turn the tie-rod [C] until the front wheel on that side is parallel to the straightedge.

NOTE

○

The locknut [B] near the L mark [D] on the tie-rod has left-hand threads. Turn the wrench clockwise for loosening.

CAUTION

Adjust the tie-rod so that the visible thread length

[A] is even on both ends of the tie-rod, or the threads could be damaged.


Wheel Alignment

•

Repeat the straightedge procedure on the other side of the vehicle. Now the front wheels are parallel to each other and to the center line of the vehicle.

Front Wheel [A]

Vehicle Center Line [B]

Parallel each other [C]

Straightedges [D]

Rear Wheels [E]

•

Go on to the Toe-in Inspection procedure.

Toe-in Inspection

•

Apply a heavy coat of chalk or a paint line near the center of the front tires.

•

Using a needle nose scriber, make a thin mark near the center of the chalk coating while turning the wheel.

•

With the front wheels on the ground, set the handlebar straight ahead.

•

At the level of the axle height, measure the distance between the scribed or painted lines for both front and rear of the front tires.

•

Subtract the measurement of the front from the measurement of the rear to get the toe-in.

If the toe-in is not in the specified range, go on to the

Toe-in Adjustment procedure.

Toe-in of Front Wheels

Standard: –10

∼

10 mm (–0.39

∼

0.39 in.) at 1G

Toe-in Adjustment

•

Loosen the locknuts [A] [B] and turn the tie-rod [C] the same number of turns on both sides to achieve the specified toe-in.

NOTE

○

The locknut [B] near the L mark [D] on the tie-rod has left-hand threads. Turn the locknut clockwise for loosening.




Wheel Alignment

NOTE

○

The toe-in will be near the specified value, if the tie-rod length [A] is 393.3 mm (15.48 in.) on each tie-rod.

CAUTION

Adjust the tie-rod length so that the visible thread length [B] is even on both ends of the tie-rod. Uneven thread length could cause tie-rod damage.

•

Check the toe-in.

•

Tighten:

Torque - Tie-rod Locknuts: 37 N·m (3.8 kgf·m, 27 ft·lb)

•

Test ride the vehicle.


Wheels (Rims)

Wheel Removal

•

Loosen the wheel nuts [A].

•

Support the vehicle on a stand or a jack so that the wheels are off the ground.

Special Tool - Jack: 57001-1238

•

Remove:

Wheel Nuts

Wheel

Wheel Installation

•

Check the tire rotation mark [A] on the tire, and install the wheel accordingly.

NOTE

○

The direction of the tire rotation [B] is shown by an arrow on the tire sidewall.

•

Position the wheel so that the air valve [A] is toward the outside of the vehicle.

•

Wipe dry the taper surface of the rim.

•

Wipe dry the threads and the taper surface of the nuts.

•

First tighten the wheel nuts in a criss-cross pattern.

First Torque - Wheel Nuts: 15 N·m (1.5 kgf·m, 11 ft·lb)

•

Finally tighten the wheel nuts in a criss-cross pattern.

Final Torque - Wheel Nuts: 76 N·m (7.8 kgf·m, 56 ft·lb)

NOTE

○

The nuts are the self-locking type and must be replaced when they are worn and can be turned by hand after repeated removing and installing.

Wheel (Rim) Inspection

•

Examine both sides of the rim for dents [A]. If the rim is dented, replace it.




Wheels (Rims)

If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary.

Wheel (Rim) Replacement

•

Remove the wheel (see Wheel Removal).

•

Disassemble the tire from the rim (see Tire Removal).

○

Remove the air valve and discard it.

CAUTION

Replace the air valve whenever the tire is replaced.

Do not reuse the air valve.

Plastic Cap [A]

Valve Core [B]

Stem Seal [C]

Valve Stem [D]

Valve Seat [E]

Valve Opened [F]

•

Install a new air valve in the new rim.

○

Remove the valve cap, lubricate the stem with a soap and water solution, and pull the stem [A] through the rim from the inside out until it snaps into place.

CAUTION

Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.

•

Mount the tire on the new rim (see Tire Installation).

•

Install the wheel (see Wheel Installation).

•

Install the air valve cap.



Tires

Tire Removal

•

Remove the wheel.

•

Unscrew the valve core to deflate the tire.

○

Use a proper valve core tool [A].

•

Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water [A].

This helps the tire beads slip off the rim flanges.

CAUTION

Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire.

•

Remove the tire from the rim using a suitable commercially available tire changer.

NOTE

○

The tires cannot be removed with hand tools because they fit the rims tightly.

Tire Installation

•

Inspect the rim (see Wheel (Rim) Inspection).

•

Replace the air valve with a new one.

CAUTION

Replace the air valve with whenever the tire is replaced. Do not reuse the air valve.

•

Check the tire for wear and damage (see Tire Inspection in Periodic Maintenance chapter).

•

Lubricate the tire beads and rim flanges with a soap and water solution, or water.

WARNING

Do not use the lubricant other than a water and soap solution, or water to lubricate the tire beads and rim because it may cause tire separation.

•

Check the tire rotation mark [A] on the tire, and install the tire on the rim accordingly.

○

The tires should be installed on the rims so that each air valve is toward the outside of the vehicle.

NOTE

○

The direction of the tire rotation [B] is shown by an arrow on the tire sidewall.

•

•

Install the tire on the rim using a suitable commercially available tire changer.



Tires

•

Support the wheel rim [A] on a suitable stand [B] to prevent the tire from slipping off.

•

Inflate the tire until the tire beads seat on the rim.

Maximum Tire Air Pressure (to seat beads when cold)

Front and Rear: 250 kPa (2.5 kgf/cm², 36 psi)

WARNING

Do not inflate the tire to more than the maximum tire air pressure. Overinflation can explode the tire with possibility of injury and loss of life.

•

Check to see that rim lines [A] on both sides of the tire are parallel with the rim flanges [B].

If the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate

• the tire.

After the beads are properly seated, check for air leaks.

○

Apply a soap and water solution around the tire bead and check for bubbles.

•

Deflate the tire to the specified pressure.

•

Check the tire pressure using an air pressure gauge.

NOTE

○

Kawasaki provides the air pressure gauge (P/N 52005

-1082) with the owner’s tool kit.

Tire Air Pressure (when cold)

Front: 35 kPa (0.35 kgf/cm², 5.0 psi)

Rear: 35 kPa (0.35 kgf/cm², 5.0 psi)

•

Install the air valve cap.

•

Install the wheel (see Wheel Installation).

•

Wipe off the soap and water solution on the tire and dry the tire before operation.

WARNING

Do not operate the vehicle with the water and soap still around the tire beads. They will cause tire separation, and a hazardous condition may result.

Tire Inspection

•

Refer to the Tire Inspection in the Periodic Maintenance chapter.


Front Hub

Front Hub Removal

•

Remove:

Cap [A]

Cotter Pin [B] (cut)

•

Loosen the axle nut [C].

•

Remove the wheel (see Wheel Removal).

•

Remove the caliper by taking off the mounting bolts, and let the caliper hang free.

•

Remove the axle nut [A] and pull off the front hub [B] and brake disc.

•

Separate the brake disc from the front hub.

Front Hub Installation

•

Install the brake disc (see Brakes chapter).

•

Wipe dry the spline portion of the hub.

•

Wipe dry the threads and seating surface of the nuts.

•

Install the front wheel temporary.

•

Tighten:

Torque - Front Axle Nuts: 197 N·m (20 kgf·m, 145 ft·lb)

•

Remove the front wheel.

•

Insert a new cotter pin [A].

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [B] up to next alignment.

○

It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past the nearest hole.

•

Bend the cotter pin [A] over the nut.




Front Hub

Front Hub Disassembly/Assembly

If any hub bolt [A] is damaged, replace it.

•

Remove the hub bolt from hub [B] using a press.

•

Press the hub bolt using a press.


Rear Hub

Rear Hub Removal

•

Remove:

Cap [A]

Cotter Pin [B]

•

Loosen the axle nut [C].

•

Remove:

Wheel (see Wheel Removal)

Axle Nut [A]

Rear Hub [B]

Rear Hub Installation

•

Wipe dry the spline portion of the hub.

•

Wipe dry the threads and seating surface of the nuts.

•

Tighten:

Torque - Rear Axle Nuts: 265 N·m (27 kgf·m, 195 ft·lb)

•

Insert a new cotter pin [A].

NOTE

○

When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [B] up to next alignment.

○

It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past the nearest hole.

•

Bend the cotter pin [A] over the nut.




Rear Hub

Rear Hub Disassembly/Assembly

If any hub bolt [A] is damaged, replace it.

•

Remove the hub bolt from hub [B] using a press.

•

Press the hub bolt using a press.


FINAL DRIVE 12-1

Final Drive


Exploded View...................................

12-3

Specifications ....................................

12-10

Special Tools .....................................

12-11

Output Bevel Gears ...........................

12-14

Output Drive Bevel Gear

Removal ....................................

12-14


Installation .................................

12-14


Disassembly..............................

12-15


Assembly...................................

12-17

Output Driven Bevel Gear

Removal ....................................

12-17


Installation .................................

12-18


Disassembly..............................

12-18


Assembly...................................

12-19

Output Bevel Gears Adjustment ..

12-20

Bevel Gears Inspection................

12-24

Front Propeller Shaft .........................

12-25

Front Propeller Shaft Removal.....

12-25

Front Propeller Shaft Installation..

12-25

Front Axle ..........................................

12-26

Front Axle Removal .....................

12-26

Front Axle Installation ..................

12-26

Front Axle Joint Boot Inspection ..

12-26

Front Axle Joint Boot

Replacement .............................

12-26

Front Final Gear Case .......................

12-34

Front Final Gear Case Oil Level

Inspection..................................

12-34

Front Final Gear Case Oil

Change......................................

12-34


Play Inspection..........................

12-34


Play Adjustment ........................

12-34


Removal ....................................

12-34


Lubrication.................................

12-35


Inspection..................................

12-35

Front Final Gear Case Removal ..

12-35

Front Final Gear Case Installation 12-36

Front Final Gear Case

Disassembly..............................

12-37

Front Final Gear Case Coupling

Inspection..................................

12-39

Front Final Gear Case Assembly.

12-39

Oil Seal Installation ......................

12-43

Ring Gear Disassembly ...............

12-44

Ring Gear Assembly ....................

12-44

LSD Clutch Torque Inspection .....

12-45

Pinion Gear Unit Disassembly .....

12-45

Pinion Gear Unit Assembly ..........

12-46

Front Final Bevel Gear

Adjustment ................................

12-46

Bevel Gear Inspection..................

12-50

Differential Gear Inspection .........

12-50

Rear Propeller Shaft ..........................

12-52

Rear Propeller Shaft Removal .....

12-52

Rear Propeller Shaft Installation ..

12-52

Rear Propeller Shaft Joint Boot

Inspection..................................

12-53

Rear Propeller Shaft Inspection ...

12-53

Rear Axle...........................................

12-54

Rear Axle Removal ......................

12-54

Rear Axle Installation ...................

12-54

Rear Axle Joint Boot Inspection...

12-54

Rear Axle Joint Boot

Replacement .............................

12-55

Rear Final Gear Case........................

12-61

Rear Final Gear Case Oil Level

Inspection..................................

12-61

Rear Final Gear Case Oil Change 12-61

Rear Final Gear Case Removal...

12-61

Rear Final Gear Case Installation 12-62

Rear Final Gear Case

Disassembly..............................

12-62

Rear Final Gear Case Assembly .

12-64

12


Rear Final Gear Case Right



Rear Final Gear Case Front

Installation .................................

12-35

Cover Assembly ........................

12-65

12-2 FINAL DRIVE

Rear Final Gear Case Assembly .

12-65

Rear Final Bevel Gear

Adjustment ................................

12-68

Pinion Gear Unit Disassembly .....

12-72

Pinion Gear Unit Assembly ..........

12-72

Bearing and Oil Seal..........................

12-73

Ball or Needle Bearing Inspection 12-73

Oil Seal Inspection .......................

12-74


Exploded View

Blank page




Exploded View



Exploded View

No.

1

2

3

4

5

6

7

8

Fastener

Output Driven Bevel Gear Housing Bolts

Output Drive Bevel Gear Housing Bolts

Bearing Holder

Bevel Gear Holder Nut

Bearing Holder

Output Shaft Holder Nut

Rotor Mounting Bolts

Output Drive Bevel Gear Cover Bolts

N·m

26

26

137

157

118

157

12

8.8

Torque kgf·m

2.7

2.7

14

16

12

16

1.2

0.90

ft·lb

20

20

101

116

87

116

104 in·lb

78 in·lb

Remarks

L

L

L

L

G: Apply grease.







Exploded View



Exploded View

No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Ring Gear Bolts

Fastener

Variable Differential Control Shift Shaft Lever Bolt

Front Final Gear Case Left Cover Bolts (M6)



Front Final Gear Case Oil Filler Cap



Front Final Gear Case Coupling Nut

Front Final Gear Case Oil Drain Plug


Variable Differential Control Cable Locknut


Front Final Gear Case Nuts

N·m

8.8

9.8

57

9.8

24

29

127

137

25

15

9.8

17

–

59

G: Apply grease.


LB: Apply a non-permanent locking agent (Three Bond TB2471 Blue).





St: Stake the fasteners to prevent loosening.

1.0

1.7

–

6.0

13

14

2.5

1.5

Torque kgf·m ft·lb

Remarks

0.90

78 in·lb

1.0

87 in·lb L(4), S

5.8

1.0

2.4

3.0

42

87 in·lb

17

22

LB

L

L

St

L

94

101

18

11

87 in·lb

12

–

43

L, S

L



Exploded View



Exploded View

No.

1 Rear Final Gear Case Front Cover Bolts

2 Gasket Screws

3 Pinion Gear Bearing Holder Nut

4 Pinion Gear Bearing Holder

5 Rear Final Gear Case Right Cover Bolts (M12)



8 Rear Final Gear Case Oil Filler Cap

9 Rear Final Gear Case Oil Drain Plug

10 Bracket Bolts

11

Fastener

Rear Final Gear Case Nuts

N·m

24

1.3

157

137

93

49

24

29

13

59

59

G: Apply grease.



MF: Apply MOBIL FLUID 424 or equivalent oil.



TB: Apply a non-permanent locking agent (Three Bond 1363A, Red).

2.4

3.0

1.3

6.0

6.0

Torque kgf·m

2.4

0.13

16

14

9.5

5.0

ft·lb

17

11 in·lb

116

101

69

36

17

22

113 in lb

43

43

Remarks

L

L

L

L

L

TB



Specifications

Item

Output Bevel Gear Case

Output Bevel Gear Backlash

Standard

0.05

∼

0.11 mm (0.0020

∼

0.0043 in.)

(at output drive shaft spline)

Service Limit

– – –

Front Final Gear Case

Gear Case Oil (same engine oil):

Type

Viscosity

Oil Level

SAE 10W-40


– – –

– – –

Capacity 0.43 L (0.45 US qt) – – –

Coupling Bushing Inside Diameter 13.000

∼

13.018 mm (0.5118

∼

0.5125 in.) 13.048 mm

(0.5137 in.)

LSD Clutch Torque:

(when variable differential control lever is released.)

(when variable differential control lever is pulled in.)

Bevel Gear Backlash

15

∼

0.10

20 N·m (1.5

∼

∼

2.0 kgf·m, 11

0.20 mm (0.004

(at pinion gear spline)

∼

∼

0.008 in.)

14 ft·lb)

157 N·m (16 kgf·m, 116 ft·lb) or more

– – –

– – –

– – –

Rear Final Gear Case

Gear Case Oil:

API SF or SG


– – –

– – –

– – –

Type

MOBIL Fluid 424 or CITGO TRANSGARD

TRACTOR HYDRAULIC FLUID

Oil Level

Capacity

Rear Final Bevel Gear Backlash


0.9 L (0.95 US qt)

0.04

∼

0.17 mm (0.002

∼

0.007 in.)

(at pinion gear spline)

– – –

– – –

– – –


Special Tools

Bearing Puller:

57001-135

Steering Stem Bearing Driver:

57001-137

Inside Circlip Pliers:

57001-143


57001-144

Oil Seal & Bearing Remover:

57001-1058


57001-1129


Rotor Puller, M16/M18/M20/M22 × 1.5:

57001-1216

Pinion Gear Holder:

57001-1281

Socket Wrench:

57001-1363

Holder & Guide Arbor:

57001-1476



Special Tools

Socket Wrench, Hex 50:

57001-1478

Pinion Gear Holder, m1.0:

57001-1485

Output Shaft Holder & Spacer, m1.25:

57001-1479

Bearing Driver, 54.3:

57001-1488

Nut Holding Bolts:

57001-1481

Socket Wench:

57001-1482

Socket Wrench, Hex 41:

57001-1484

Gear Holder & Socket Wrench, Hex 24:

57001-1489

Hexagon Wench, Hex 41:

57001-1491

Oil Seal Driver,

57001-1505

18.5:


Special Tools

Oil Seal Driver, 70:

57001-1506

Output Shaft Holder:

57001-1570




Output Bevel Gears

Output Drive Bevel Gear Removal

•

Remove:

Oil Pipe [A] (Engine Left and Outside, see Engine Lubrication System chapter)

Output Drive Bevel Gear Cover Bolts [B]

Output Drive Bevel Gear Cover [C]

•

Remove:

Circlip [A]


•

Remove:

Output Drive Idle Gear [B]

•

Remove:

Output Drive Bevel Gear Housing Bolts [A]

Output Drive Bevel Gear Housing [B]

Output Drive Bevel Gear Installation

•

Install the output drive bevel gear housing.

•

Tighten:

Torque - Output Drive Bevel Gear Housing Bolts: 26 N·m

(2.7 kgf·m, 20 ft·lb)

•

Install the rotor [A] so that the projections [B] face outward.

•

Tighten:

Torque - Rotor Mounting Bolts [C]: 12 N·m (1.2 kgf·m, 104 in·lb)

•

Install:

Output Drive Idle Gear

New Circlip




•

Apply grease:

O-rings [A]

•

Install:

Output Drive Bevel Gear Cover [B]

•

Tighten:

Torque - Output Drive Bevel Gear Cover Bolts [C]: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

•

Install:

Forward/Reverse Detecting Sensor [A]

•

Tighten:

Torque - Forward/Reverse Detecting Sensor Mounting

Bolt: 15 N·m (1.5 kgf·m, 11 ft·lb)

Output Drive Bevel Gear Disassembly

•

Remove:

Output Drive Bevel Gear Housing [A] (see Output Drive

Bevel Gear Removal)

•

Look through the hole [B] in the housing.

•

Turn the bevel gear [C] until the groove of the output drive bevel gear holder nut is seen.

•

Tighten the nut holding bolts [A] (4) securely into the grooves [B] of the bevel gear holder nut [C] in the output drive bevel gear housing.

Special Tool - Nut Holding Bolts: 57001-1481

[D] Output Drive Bevel Gear Housing

[E] Outer Ball Bearing

[F] Inner Ball Bearing

[G] Bearing Holder

[H] Output Drive Bevel Gear





•

Hold the output drive bevel gear housing [A] in a vise.

•

Loosen the bevel gear [B] using an Allen wrench about four rotations.

•

Remove one nut holding bolt, and look at through the hole.

If the groove of the bevel gear holder nut is not seen, loosen the other three bolts.

•

Drive the gear shaft end using a copper mallet until the grooves of the bearing holder nut can be seen again.

•

Retighten the nut holding bolts (4) securely into the groove of the bevel gear holder nut in the output drive bevel gear housing.

Special Tool - Nut Holding Bolts: 57001-1481

•

Repeat the above procedure, and remove the bevel gear from the housing.

•

Remove the bearing holder [A] using the hexagon wrench

[B].

Special Tool - Hexagon Wrench, Hex 41: 57001-1491

○

If the holder seems too difficult to break free, apply heat to softer the locking agent.

•

Remove:

Outer Ball Bearing [A]

Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058

•

Remove:

Output Drive Bevel Gear Holder Nut

Inner Ball Bearing [A]

Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058



Output Drive Bevel Gear Assembly

•

Press the new inner ball bearing until it is bottomed.

Special Tool - Bearing Driver Set [A]: 57001-1129

•

Apply a non-permanent locking agent to the threads of the bearing holder [A] and tighten it so that the deep side

[B] faces outward.

Torque - Bearing Holder: 118 N·m (12 kgf·m, 87 ft·lb)

•

Press the output drive bevel gear until it is bottomed.

•

Apply a non-permanent locking agent to the threads of the bevel gear holder nut [A] and tighten it so that the projection side [B] faces outward.

Special Tool - Socket Wrench: 57001-1482 [C]

Torque - Bevel Gear Holder Nut: 157 N·m (16 kgf·m, 116 ft·lb)

•

Press the new outer ball bearing until it is bottomed.


Output Driven Bevel Gear Removal

•

Remove:

Swingarm (see Suspension chapter) and Front Propeller

Shaft (see Front Propeller Shaft Removal) or Engine

(see Engine Removal/Installation chapter)

Output Driven Bevel Gear Housing Bolts [A]

Output Driven Bevel Gear Housing [B]




•

Tap lightly the front end [A] of the output driven bevel gear shaft using a plastic mallet.

○

The output driven bevel gear shaft assembly comes off with the housing.

Output Driven Bevel Gear Installation

•

Apply grease:

O-ring [A]

•

Install the output driven bevel gear shaft assembly.

•

Tighten:

Torque - Output Driven Bevel Gear Housing Bolts: 26 N·m

(2.7 kgf·m, 20 ft·lb)

Output Driven Bevel Gear Disassembly

•

Remove:

Output Driven Bevel Gear Housing Assembly (see Output Driven Bevel Gear Removal)

Oil Seal

•

Hold the holder [A] in a vise, and set the housing assembly

[B] on the holder.

Special Tool - Output Shaft Holder: 57001-1570

•

Remove:

Output Shaft Holder Nut [A]

Special Tool - Socket Wrench [B]: 57001-1482

•

Remove the output shaft [A] from the housing [B] using a press.



•

Hold the housing assembly [A] with the holder [B] in a vise.

Special Tool - Holder & Guide Arbor: 57001-1476

•

Remove:

Bearing Holder [C]

Special Tool - Socket Wrench, Hex 50 [D]: 57001-1478

○


•

Remove:

Ball Bearing

Special Tool - Oil Seal & Bearing Remover: 57001-1058


•

Remove the output driven bevel gear [A] from the output shaft [B] using the bearing puller [C] and spacer [D].

Special Tools - Bearing Puller: 57001-135

Output Shaft Holder & Spacer, m1.25: 57001

-1479

Output Driven Bevel Gear Assembly

•

Press the new ball bearing until it is bottomed.

Special Tool - Bearing Driver Set [A]: 57001-1129

•

Hold the housing assembly [A] with the holder [B] in a vise.

Special Tool - Holder & Guide Arbor: 57001-1476




•

Apply a non-permanent locking agent to the threads of the bearing holder [A] and tighten it.

Special Tool - Socket Wrench, Hex 50 [B]: 57001-1478

Torque - Bearing Holder: 137 N·m (14 kgf·m, 101 ft·lb)

•

Hold the holder [A] in a vise, and set the output shaft [B] on the holder.

Special Tool - Output Shaft Holder: 57001-1570

•

Press the output driven bevel gear [C] using the driver [D] until it is bottomed.

Special Tool - Steering Stem Bearing Driver: 57001-137

•

Press the housing assembly [A] using the driver [B] until it is bottomed.

Special Tool - Steering Stem Bearing Driver: 57001-137

•

Apply a non-permanent locking agent to the threads of the output shaft holder nut [A] and tighten it so that the projection side [B] faces outward.

Special Tool - Socket Wrench: 57001-1482

Torque - Output Shaft Holder Nut: 157 N·m (16 kgf·m, 116 ft·lb)

•

Apply grease to the oil seal and press it so that it is flush with the end surface of the housing.

Output Bevel Gears Adjustment

The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.

When replacing any one of the backlash-related parts, be sure to check and adjust the backlash and tooth contact.

First adjust the backlash, and then tooth contact by replacing shims.

These two adjustments are of critical importance and must be carried out in the correct sequence, using the procedures shown.



Output Bevel Gear (Backlash-related Parts)


1. Ball Bearings

2. Drive Bevel Gear Shims

3. Output Drive Bevel Gear

4. Bearing Housings

5. Output Driven Bevel Gear

Drive Bevel Gear Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1311

92180-1312

92180-1313

92180-1314

92180-1351

92180-1352

Driven Bevel Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1307

92180-1308

92180-1309

92180-1310

92180-1349

92180-1350

6. Output Driven Shaft

7. Driven Bevel Gear Shims



Bevel Gear Backlash Adjustment

○

The amount of backlash is influenced by driven bevel gear position more than by drive bevel gear position.

•

Remove the output drive idle gear (see Output Drive

Bevel Gear Removal).

•

Set up a dial gauge [A] against the output drive shaft spline groove to check gear backlash.

○

To measure the backlash, turn the shaft clockwise and counterclockwise slightly so as not to move the mate gear.

A rod can be inserted through the lower hole of the housing and into contact with driven gear. This may help to hold it still. The difference between the highest and lowest gauge reading is the amount of backlash.

If the backlash is not within the limit, replace the shim(s) at the driven bevel gear.

Change the thickness a little at a time.

•

Recheck the backlash, and readjust as necessary.

Output Bevel Gear Backlash

Standard: 0.05

∼

0.11 mm (0.0020

∼

0.0043 in.) (at output drive shaft spline)

Tooth Contact Adjustment

○

Tooth contact location is influenced by drive gear position more than by driven gear position.

•

Clean any dirt and oil off the bevel gear teeth.

•

Apply checking compound to 4 or 5 teeth on the output driven bevel gear.

NOTE

○

Apply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear.

○

The checking compound must be smooth and firm with the consistency of tooth paste.

○

Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears.

•

Turn the output driven shaft for 3 or 4 turns in the drive and reverse (coast) directions, while creating a drag on the drive bevel gear shaft.

•

Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and a little closer to the toe of the tooth.

If the tooth contact pattern is incorrect, replace the shim(s) at the drive bevel gear and shim(s) at the driven bevel gear, following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary.


If the backlash is out of the standard range after changing shims, correct the backlash before checking the tooth contact pattern.


Example 1: Decrease the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or increase the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below. Repeat in 0.1 mm (0.004

in.) steps if necessary.


Example 2: Increase the thickness of the drive bevel gear shim(s) by 0.1 mm (0.004 in.), and/or decrease the thickness of the driven bevel gear shim(s) by 0.1 mm (0.004

in.) to correct the pattern shown below. Repeat in 0.1 mm

(0.004 in.) steps if necessary.




Bevel Gears Inspection

•

Visually check the bevel gears [A] for scoring, chipping, or other damage.

Replace the bevel gears as a set if either gear is damaged.


Front Propeller Shaft

Front Propeller Shaft Removal

•

Slip the O-ring clamps off the grooves on the small rubber boots [A], and then pull the boot.


•

Push the front propeller shaft [A] rearward, and remove the front end [B] from the front final gear case.

•

Remove the front propeller shaft from the vehicle.

Front Propeller Shaft Installation

•

Wipe off any old grease on the splines of the propeller shaft [A] and the coupling [B].

•

Inspect the splines of the propeller shaft and the coupling.

If the splines are twisted or damaged in any way, replace the parts as needed.

•

Apply molybdenum disulfide grease to all splines.

•

Replace the circlip [C] with a new one, if it is removed.

•

Wipe off any old grease on the splines of the shafts in the engine and front final gear case.

•

Inspect the O-rings on those shafts for damage.

If any doubt exists, replace the O-rings with new ones.

•

Apply molybdenum disulfide grease to the splines of the shafts on the output bevel gear and front final gear case.

•

First install the rear end, and then install the front end.

•

Slip the two O-ring clamps into the groove on the small rubber boot.

O-rings [D]

Boots [E]

Spring [F]

Spring Seat [G]

Front [H]



Front Axle

Front Axle Removal

•

Drain the front final gear case oil (see Front Final Gear

Case Oil Change in Periodic Maintenance chapter).

•

Remove:

Front Wheel (see Wheels/Tires chapter)

Knuckle (see Steering chapter)

•

Pull the front axle [A] in a straight line out of the front final gear case.

Front Axle Installation

•

Wipe the old grease off the splines of the axle and the gear case oil seal.

•

Visually inspect the splines of the axle.

If they are badly worn or chipped, replace the axle with a new one.

•

Apply molybdenum disulfide grease to the axle splines.

•

Apply grease to the gear case oil seal.

•

Insert the left axle so that the teeth [A] fit in the grooves

[B].

•

Tap [A] the end of the front axle lightly and install the front axle.

NOTE

○

The axle shaft must not come off easily.

Front Axle Joint Boot Inspection

•

Refer to the Front Axle Joint Boot Inspection in the Periodic Maintenance chapter.

Front Axle Joint Boot Replacement

Outboard Joint Boot Removal

•

Remove:

Front Axle (see Front Axle Removal)

Boot Bands [A]

•

Scrap the removed boot bands.

•

Slide the joint boot toward the inboard joint.


Front Axle

•

Tap the bearing housing [A] straight [B] with a plastic hammer to separate it from the shaft.

CAUTION

Do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft.

•

Remove:

Circlip [A]

Boot [B]

Small Band [C]


Outboard Joint Boot Installation

•

Clean the axle shaft by wiping off the used grease on it.

•

Wind the tape on the splines of the axle shaft in order to protect the joint boot.

•

Install:

New Small Band [A]

New Boot [B]

○

Apply the special grease slightly on the inside of the new boot small diameter, and install the boot on the axle shaft.

CAUTION

Only the special grease that is included with the boot kit can be applied to the boots.

•

Install:

New Circlip [C]

•

Apply the special grease slightly on the part [A] of the band installation in order to make easy to install the boot band.

•

Tighten the small boot band [B].



Front Axle

○

Tighten the boot band [A] and bend the tangs [B] securely to hold down the end of the band.

•

Place the special grease tube nozzle in the bore of the housing and squeeze the tube [A] until the grease comes out from the joint bearing.

•

Tap the shaft end [A] straight with a plastic hammer until it is locked by the circlip.

•

Squeeze all of the special grease [A] into the new boot

[B], and slide the boot onto the outboard joint [C].

•

Compress the axle assembly to the specified length while relieving the air pressure inside the inboard boot.

•

Hold the axle at this setting.

Standard Length of Assembling:

Right Front Axle: 178.6 mm (7.03 in.) [A]



Front Axle

Left Front Axle: 178.6 mm (7.03 in.) [A]

•

Open the edge [A] of the boot in order to equalize the air pressures.

•

Tighten the large band [A] and bend the tangs securely to hold down the end of the band.

Maximum Outside Diameter of Band: 80.2 mm (3.16 in.)

(After tightening the outside diameter)

Inboard Joint Boot Removal

•

Remove:

Front Axle (see Front Axle Removal)

Boot Bands [A]

•


•

Slide the joint boot toward the outboard joint [B].

•

Remove the retaining ring [A].

•

Separate to the axle shaft.



Front Axle

•

Remove the steel balls [A].

•

Slide the cage [B] toward the center of the axle.

•

Remove:

Circlip [A]

Special Tool - Outside Circlip Pliers [B]: 57001-144

•

Remove the inner race [A] using a suitable bearing remover [B].

•

Remove the inboard joint boot [C].

Inboard Joint Boot Installation

•


•

Install:

New Small Band [A]

New Inboard Joint Boot [B]

Cage [C]

•

Install the inner race [A] so that the flat side [B] faces outboard joint.


Front Axle

•

Press the inner race [A] using the cap [B] in the rotor puller set (57001-1216) until it is bottomed.

Special Tool - Rotor Puller, M16/M18/M20/M22 × 1.5: 57001

-1216


•

Install:

Circlip [A]


•

Slide the cage [B] on the inner race and install the steel balls [C].

•

Apply the special grease [A] to the steel balls and cage.

•

Squeeze about half a tube (30 grams) of the special grease [A] into the bearing cup [B].

•

Insert the balls and cage assembly in the bearing cup strongly.



Front Axle

•

Install the new retaining ring [A] so that the opening [B] is aligned with one of the projections [C].

•

Tighten the small band.

•

Squeeze the remaining special grease [A] into the inboard joint boot [B].

•


•



Right Front Axle: 161.1 mm (6.34 in.) [A]

Left Front Axle: 169.1 mm (6.66 in.) [A]

•

Open the edge of the boot in order to eqalize the air pressures.

•


Maximum Outside Diameter of Band: 69 mm (2.72 in.)



Front Axle

•

While the band is held at the diameter above, tap down the tangs [A] of the clamp.





Front Final Gear Case Oil Level Inspection

•


•

Remove the filler cap.

CAUTION

Be careful not to allow any dirt or foreign materials to enter the gear case.

•

Check the oil level. The oil level should come to the bottom of the filler opening [A].

If it is insufficient, first check the front final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that

• is already in the final gear case.

Be sure the O-ring is in place, and tighten the filler cap.

○



Front Final Gear Case Oil Change

•

Refer to the Front Final Gear Case Oil Change in the Periodic Maintenance chapter.

Variable Differential Control Lever Play Inspection

•

Refer to the Variable Differential Control Lever Play Inspection in the Periodic Maintenance chapter.

Variable Differential Control Lever Play Adjustment

•

Refer to the Variable Differential Control Lever Play Adjustment in the Periodic Maintenance chapter.

Variable Differential Control Lever Removal

•

Remove:

Handlebar Cover

Plate Bolt [A]

Cable Stopper Plate [B]

Variable Differential Control Lever Bolt [C], Washer and

Collar

Variable Differential Control Lever [D]

Variable Differential Control Cable Upper End

Variable Differential Control Lever Installation

•

Install:

Variable Differential Control Cable Upper End

Variable Differential Control Lever [A]

•

Apply a non-permanent locking agent to the variable differential control lever bolt [B].

•

Install:

Variable Differential Control Lever Bolt, Washer [C] and

Collar [D]

•

Tighten:

•

Install:

Cable Stopper Plate [E]

•

Plate Bolt [F]

Property of www.SmallEngineDiscount.com - Not for Resale able Differential Control Lever Play Inspection in Periodic



Variable Differential Control Cable Installation

•

Lubrication the variable differential control cable before installation.

•

Route the cable correctly according to the Appendix chapter.

WARNING

Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe operating condition.

•

Tighten:

Torque - Variable Differential Control Cable Locknut [A]: 17

N·m (1.7 kgf·m, 12 ft·lb)

•

Check the variable differential control lever play (see Variable Differential Control Lever Play Inspection in Periodic


Variable Differential Control Cable Lubrication

Whenever the variable differential control cable is removed, lubricate the cable as follows:

•

Apply a small amount of multi-purpose grease to the cable

(both ends).

•

Lubricate the cable with a penetrating rust inhibitor through the pressure cable luber.

Variable Differential Control Cable Inspection

•

With the variable differential control cable disconnected at both ends, the cable should move freely within the cable housing.

If the cable does not move freely after lubricating, if the cable is frayed, or if the housing is kinked, replace the cable.

Front Final Gear Case Removal

•

Drain the gear case oil (see Front Final Gear Case Oil

Change in Periodic Maintenance chapter).





•

Remove:


Front Wheels (see Wheels/Tires chapter)

Steering Stem (see Steering chapter)

Front Axles (see Front Axle Removal)

Right Upper Suspension Arm (see Suspension chapter)

Right Front Shock Absorber (see Suspension chapter)

Front Propeller Shaft (see Front Propeller Shaft Removal)

Actuator Lead Connector (disconnect)

Variable Differential Control Cable Lower End

Air Duct [A]

Brake Hose Joint Bolt [B]

•

Remove:

Front Final Gear Case Bolts [A]

•

Remove:

Bracket Bolts [A]

Bracket

•

Remove the rear final gear case [A] as shown.

Front Final Gear Case Installation

•

Install the gear case bolts from the vehicle left side.

Torque - Front Final Gear Case Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)

•


•

Fill the front final gear case with the specified oil (see

Front Final Gear Case Oil Change in Periodic Maintenance chapter).



Front Final Gear Case Disassembly

•

Remove:

Front Final Gear Case (see Front Final Gear Case Removal)

Variable Differential Control Shift Shaft Lever Bolt [A] and Nut [B]

Variable Differential Control Shift Shaft Lever [C]

2WD/4WD Actuator (see Electrical System chapter)

•

Hold the front final gear case with the gear holder & socket wrench [A] in a vise.

Special Tool - Gear Holder & Socket Wrench, Hex 24:

57001-1489

•

Remove:

Front Final Gear Case Coupling Nut [A]

Washer [B]

Front Final Gear Case Coupling [C]

Shifter [D]

Oil Seals [E]

•

Remove:

Front Final Gear Case Left Cover Bolts [A]

Front Final Gear Case Left Cover [B]

Variable Differential Control Shift Shaft

Spring

•

Remove:

Outer Disc [A]

Needle Bearing





•

Remove:

Housing [A] and Differential Disc Assembly [B]

Inner Disc

Needle Bearing

•

Remove:

Cam Plate [A]

•

Remove:

Steel Balls [A]

Gasket [B]

Dowel Pins [C]

Front Final Gear Case Center Cover Bolts (M6) [D]

Front Final Gear Case Center Cover Bolts (M8) [E]

Front Final Gear Case Center Cover [F]

•

Remove:

Ring Gear Assembly [A]

Shim(s) [B]

•

Hold the front final gear case right cover [A] in a vise, and remove the bearing holder using the socket wrench [B].

Special Tool - Socket Wrench, Hex 41: 57001-1484

○


•

Remove:




•

Remove:

Pinion Gear Unit [A]

Shim(s)

Front Final Gear Case Coupling Inspection

If the coupling bushing [A] is damaged or worn, replace the front final gear case coupling.

Front Final Gear Case Coupling Bushing Inside Diameter

[B]


∼

13.018 mm (0.5118

∼

0.5125 in.)


Front Final Gear Case Assembly

•

Install:

Ball Bearing [A]

Needle Bearing [B]

○

Press the ball bearing and needle bearing until they are bottomed.

•

Install:

Circlip [C]

Special Tool - Inside Circlip Pliers: 57001-143

•

Install:

Oil Seal [D]

○

Insert the oil seal so that the rubber surface is flush [E] with the end of hole.

○

Apply grease to the oil seal lip.

•

Visually check the pinion gear and ring gear for scoring, chipping, or other damage.

Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact.

•

Insert the pinion gear in the front final gear case right cover.





•

Install:

Ring Gear Assembly

•

Apply grease to the O-ring [A] on the front final gear case center cover.

•

Install:

Front Final Gear Case Center Cover [A]

•

Tighten the cover bolts following the tightening sequence as shown.

Torque - Front Final Gear Case Center Cover Bolts (M8)

[1, 3]: 24 N·m (2.4 kgf·m, 17 ft·lb)

Front Final Gear Case Center Cover Bolts (M6)

[2, 4]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Adjust the gear backlash and tooth contact pattern (see

Front Final Bevel Gear Adjustment).

•

Apply a non-permanent locking agent to the cover bolts, and tighten them to the specified torque in the tightening sequence [1

∼

4].

•

Apply a non-permanent locking agent to the pinion gear bearing holder [A], and tighten it so that the deep recess

[B] faces outward.


Torque - Pinion Gear Bearing Holder: 137 N·m (14 kgf·m,

101 ft·lb)

•

Install:

Dowel Pins [A]

New Gasket [B]

Steel Balls [C]



•

Install:

Cam Lever [A]

Needle Bearing [B]

•

Apply engine oil to the needle bearing.

•

Check the wear of the disc assembly as follows.

○

Measure the thickness of the inner disc [A].

•

Select the width [A] of the disc assembly [B] in accordance with the thickness of the inner disc, refer to the below table.

Thickness of Inner

Disc Assembly

Width [A] of Disc Assembly

2.4 mm (0.0945 in.) 16.7

∼

17.3 mm (0.6675

∼

0.6811 in.)

1.8 mm (0.0709 in.) 17.31

∼

17.9 mm (0.6815

∼

0.7047 in.)

1.2 mm (0.0472 in.) 17.91

∼

18.5 mm (0.7051

∼

0.7283 in.)

○

Measure the width of the disc assembly at three locations, and calculate average for three points.

NOTE

○

Be careful not to damage the facing surface [C] on the outer plates.

If the width is within the specified range, install the inner disc and disc assembly.

If the width is not within the specified range, replace the disc assembly.

•

Install:

Inner Disc [A]

Disc Assembly [B] and Housing [C]





•

Apply engine oil to the needle bearing [A].

•

Install:

Needle Bearing

Outer Disc [B]

•

Apply engine oil to the variable front differential control shaft [A].

•

Install the shaft and spring [B] in the front final gear case left cover [C] as shown.

•

Turn the shaft counterclockwise and insert the tab [A] of the shift shaft into the groove [B] of the cam plate.

•

Install:

Front Final Gear Case Left Cover [C]

•

Apply a non-permanent locking agent to the cover bolts [1

∼

4], and tighten them following the tightening sequence as shown.

Torque - Front Final Gear Case Left Cover Bolts (M6)

[1

∼

8]: 9.8 N·m (1.0 kgf·m, 87 ft·lb)

[1

∼

4] L = 60 mm (2.4 in.)

[5

∼

8] L = 30 mm (1.2 in.)

•

Apply grease to the oil seal lip [A].

•

Press the oil seal [B] in the coupling [C] to the specified position as shown.

[D] 1 mm (0.04 in.)

Special Tools - Oil Seal Driver, 18.5: 57001-1505

Driver Holder: 57001-1132

NOTE

○

57001-1132 is included in Bearing Driver Set, 57001

-1129.



•

Apply molybdenum disulfide grease to the spline [A] in the shifter [B] and inner surface [C] of the coupling.

•

Install the shifter and coupling on the pinion gear shaft [D].

•

Apply grease to the oil seal lip [E].

•

Press the oil seal [F] in the front final gear case so that the oil seal surface is flush [G] with the case end.

Special Tool - Oil Seal Driver, 70: 57001-1506

•

Hold the front final gear case with the gear holder & socket wrench [A] in a vise.

Special Tool - Gear Holder & Socket Wrench, Hex 24:

57001-1489


•

Install:

Washer [A]

Front Final Gear Case Coupling Nut [B]

•

Tighten:

Torque - Front Final Gear Case Coupling Nut: 25 N·m (2.5


•

Install the variable differential control shaft lever [A] on the shift shaft [B] so that the punch mark [C] on the lever aligns with the punch mark [D] on the shaft as shown.

[E] 45.8

∼

50.4 mm (1.803

∼

1.984 in.)

•

Tighten:

Torque - Variable Differential Control Shift Shaft Lever Bolt

[F]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Oil Seal Installation

•

Press the oil seal [A] in the front final gear case left cover

[B] to the dimension as shown.

[C] 4.6

∼

5.6 mm (0.18

∼

0.22 in.)




Ring Gear Disassembly

•

Remove:

Ring Gear Assembly (see Front Final Gear Case Disassembly)

Ring Gear Bolts [A]

Ring Gear [B]

•

Remove:

Differential Gear Case Cover [A]

Right Side Gear (16T) [B]

Pins [C]

Spider Gear Shaft [D]

Spider Gears (10T) [E]

Left Side Gear (16T) [F]

Left Differential Gear Case [G]

Ring Gear Assembly

•

Press the bearing [A] on the left differential gear case [B] until it is bottomed.

•

Apply engine oil [C] to the spider gears and the spider gear shaft.

•

Apply molybdenum disulfide grease [D] to the left side gear (16T) [E].

•

Install:

Left Side Gear (16T)

Spider Gears (10T) [F]

Spider Gear Shaft [G] and Pins [H]

•

Apply engine oil [A] to the spider gears.

•

Apply molybdenum disulfide grease [B] to the right side gear (16T) [C].

•

Install:

Right Side Gear (16T)

Differential Gear Case Cover [D]

Ring Gear [E]

•

Apply a non-permanent locking agent (Three Bond:

TB2471 Blue) to the ring gear bolts [F], and tighten them.

Torque - Ring Gear Bolts: 57 N·m (5.8 kgf·m, 42 ft·lb)

NOTE

○

Keep the ring gear assembly at more than 20°C (68°F) for six hours after tightening the bolts.



LSD Clutch Torque Inspection

If the vehicle has the following symptoms, check the LSD

(Limited Slip Differential) clutch torque.

-The handlebar is hard to turn.

-The front final gear case overheats.

-Abnormal noises come from the front final gear case when rounding a curve.

•

Ensure 2WD mode.

•

Support the vehicle so that the front wheels are off the ground.

•

Remove:

One Front Wheel (see Wheels/Tires chapter)

Front Axle Nut Cotter Pin

•

Secure the other-side front wheel from rotating.

•

Measure the clutch torque using a torque wrench [A]. Turn the wrench evenly.

○

The clutch torque is the mean torque reading during about a quarter turn of the wrench.

LSD Clutch Torque

(When variable differential control lever is released.)

Standard: 15

∼

20 N·m (1.5

∼

2.0 kgf·m, 11

∼

14 ft·lb)

LSD Clutch Torque

(When variable differential control lever is pulled in.)

Standard: 157 N·m (16 kgf·m, 116 ft·lb) or more

If the clutch torque is out of the specified range, check the width of the disc assembly (see Front Final Gear Case

Assembly).

NOTE

○

The correct type of oil must be installed.

Pinion Gear Unit Disassembly

•

Remove:

Pinion Gear Unit (see Front Final Gear Case Disassembly)

•

Pry open the staking of the pinion gear bearing holder nut with a small chisel.

•

Hold the pinion gear unit [A] with the pinion gear holder

[B] in a vise, and remove the pinion gear bearing holder nut [C].

Special Tool - Pinion Gear Holder, m1.0: 57001-1485

•

Remove the ball bearing only if required.

Special Tool - Bearing Puller: 57001-135





Pinion Gear Unit Assembly

○

The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set.

•

Visually inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a bearing, replace the bearing.

•

Be sure to check and adjust the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see Front Final Bevel Gear Adjustment).

•

Press the bearing on the pinion gear until it is bottomed.

•

Install the pinion gear bearing holder nut [A] so that the projection [B] faces outward.

•

Tighten:

Special Tool - Pinion Gear Holder, m1.0: 57001-1485

Torque - Pinion Gear Bearing Holder Nut: 127 N·m (13 kgf·m, 94 ft·lb)

•

Stake [C] the nut with a punch at three positions to secure it.

Front Final Bevel Gear Adjustment

The backlash (distance one gear will move back and forth without moving the mate gear) and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.

Above two adjustments are of critical importance and must be carried out following the correct sequence and method.

•

When any one of the backlash-related parts are replaced, check and adjust the bevel gear backlash, and tooth contact by replacing shims.

○

The amount of backlash is influenced by the ring gear position more than by the pinion gear position.

○

Tooth contact location is influenced by the pinion gear position more than by the ring gear position.



Front Final Gear Case (Backlash-related Parts)


1. Pinion Gear Shim(s)

2. Ring Gear Right Shim(s)

3. Ring Gear Left Shim(s)

4. Front Final Gear Case Center Cover

5. Front Final Gear Case Right Cover

6. Ball Bearings

7. Ring Gear

8. Ring Gear Assembly

9. Pinion Gear




1. Pinion Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.7 mm (0.028 in.)

0.8 mm (0.031 in.)

0.9 mm (0.035 in.)

1.0 mm (0.039 in.)

1.1 mm (0.043 in.)

1.2 mm (0.047 in.)

Part Number

92180-1408

92180-1409

92180-1410

92180-1411

92180-1412

92180-1413

92180-1414

92180-1415

92180-1416

2. Ring Gear Right Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.7 mm (0.028 in.)

0.8 mm (0.031 in.)

0.9 mm (0.035 in.)

1.0 mm (0.039 in.)

1.1 mm (0.043 in.)

1.2 mm (0.047 in.)

Parts Number

92180-1399

92180-1400

92180-1401

92180-1402

92180-1403

92180-1404

92180-1405

92180-1406

92180-1407

3. Ring Gear Left Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.7 mm (0.028 in.)

0.8 mm (0.031 in.)

0.9 mm (0.035 in.)

1.0 mm (0.039 in.)

1.1 mm (0.043 in.)

1.2 mm (0.047 in.)

Parts Number

92180-1390

92180-1391

92180-1392

92180-1393

92180-1394

92180-1395

92180-1396

92180-1397

92180-1398

Backlash Adjustment

•

Check and adjust the gear backlash when any of the backlash-related parts are replaced with new ones.

•


•

Assemble the front final gear case (see Front Final Gear

Case Assembly).

○

It is not necessary to install the variable front differential control unit.

○

Check the backlash during tightening of the front final gear case center cover bolts and stop tightening them immediately if the backlash disappears. Then, change the ring

Property of www.SmallEngineDiscount.com - Not for Resale and hold it in a vise so that the ring gear is lower than the pinion gear.


•

Mount a dial gauge [A] so that the tip of the gauge is against the splined portion [B] of the pinion gear shaft.

•

To measure the backlash, move the pinion gear shaft back and forth [C] while holding the front axle steady.

The difference between the highest and the lowest gauge reading is the amount of backlash.

○

Measure backlash at three locations equally spaced on the splines.

Front Final Bevel Gear Backlash

Standard: 0.10

∼

0.20 mm (0.004

∼

0.008 in.) (at pinion gear spline)

If the backlash is not within the limit, replace the pinion gear shims. To increase backlash, increase the thickness of the shim(s). To decrease backlash, decrease the thickness of the shim(s).

○


•



•


•

Apply checking compound to 4 or 5 teeth on the pinion gear.

NOTE

○


○

The checking compound must be smooth and firm, with the consistency of tooth paste.

○

Special compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use one of these for checking the bevel gears.

•

Assemble the front final gear case (see Front Final Gear

Case Assembly).

○

It is not necessary to install the variable front differential control unit.

•

Turn the pinion gear shaft [A] for one revolution in the drive and reverse (coast) direction, while creating a drag on the ring gear.

•

Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth.





○

The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe.

If the tooth contact pattern is incorrect, replace the ring gear shim(s), following the examples shown.

•

Then erase the tooth contact patterns and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.

NOTE

○

If the backlash is out of the standard range after changing the ring gear shim(s), change the pinion gear shim(s) to correct the backlash before checking the tooth contact pattern.

Bevel Gear Inspection

•

Visually check the bevel gears [A] for scoring, chipping, or other damage.

Replace the bevel gears as a set if either gear is damaged.

Differential Gear Inspection

•

Visually check the differential gears [A] for scoring, chipping, or other damage.

Replace the differential gears as a set if either gear is damaged.

•

Also, inspect the differential gear shaft [B], gear case [C], and cover [D] where the differential gears rub.

If they are scored, discolored, or otherwise damaged, replace them as a set.






Rear Propeller Shaft

Rear Propeller Shaft Removal

•

Remove:

Footboard (see Frame chapter)

•

Slide the rubber boots [A].

•

Push the front universal joint [B] rearward, and remove the front end [C] from the engine.

•

Remove the rear propeller shaft [A] from the vehicle.

Rear Propeller Shaft Installation

•

Wipe off any old grease:

Splines [A] of Propeller Shaft and Universal Joint

Output Shaft of Engine

Pinion Gear of Rear Final Gear Case

•

Inspect O-rings [B] and boots [C] for damage.

If any doubt exists, replace it with a new one.

•


Spline [A] and Inside [B] of Propeller Shaft [C]

•

Install:

Boots [D]


Rear Propeller Shaft

•


Spline [A] on Output Shaft of Engine

Spline [B] on Pinion Gear of Rear Final Gear Case

•

Install:

O-rings [C]

Spring [D]

Rear Universal Joint [E]

•

Align the front universal joint yoke [F] with the rear universal joint yoke [G] as shown.

•

Install the front end [H] of the propeller shaft.

•

Push the rear universal joint forward [I], and install the rear end [J] of the rear universal joint on the pinion gear of rear final gear case.

•

Install the rubber boots and fit the O-rings in the groove of the boots.


Rear Propeller Shaft Joint Boot Inspection

•

Refer to the Rear Propeller Shaft Joint Boot Inspection in the Periodic Maintenance chapter.

Rear Propeller Shaft Inspection

•

Remove the rear propeller shaft (see Rear Propeller Shaft

Removal).

•

Check that the universal joints [A] work smoothly without rattling or sticking.

If it does rattle or stick, the universal joint is damaged.

Replace the propeller shaft with a new one.

•

Visually inspect the splines [B] on the propeller shaft.

If they are badly worn, chipped, or loose, replace the propeller shaft.

•

Also, inspect the splines on the rear end of the output shaft and the pinion gear in the final gear case.

If splines are badly worn, chipped, or loose, replace the


Rear Axle

Rear Axle Removal

•

Drain the rear final gear case oil (see Rear Final Gear

Case Oil Change).

•

Remove:

Rear Wheels (see Wheels/Tires chapter)

Rear Knuckle (see Suspension chapter)

Upper Suspension Arm [A] (see Suspension chapter)

•

Pull the rear axle [A] in a straight line out of the rear final gear case.

Rear Axle Installation

•

Wipe off any old grease:

Splines [A] of Axle

Gear Case Oil Seal [B]

•

Visually inspect the splines of the axle.

If they are badly worn or chipped, replace the axle with a new one.

•

Apply molybdenum disulfide grease to the axle splines.

•

Apply grease top the gear case oil seal.

•

Tap [A] the end of the rear axle straight and install the rear axle.

NOTE

○

The axle shaft must not come off easily.

Rear Axle Joint Boot Inspection

•

Refer to the Axle Joint Boot Inspection in the Periodic



Rear Axle

Rear Axle Joint Boot Replacement

Outboard Joint Boot Removal

•

Remove:

Rear Axle (see Rear Axle Removal)

Boot Bands [A]

•


•

Slide the joint boot [B] toward the inboard joint.

•

Tap the bearing housing [A] straight [B] with a plastic hammer to separate it from the shaft.

CAUTION

Do not tap on the cage. Be careful not get hurt when the housing comes out. If the splined portion of shaft cracked or damaged during disassembling of outboard joint, do not reuse the shaft.

•

Remove:

Circlip [A]

Boot [B]

Small Band [C]


Outboard Joint Boot Installation

•

Clean the axle shaft by wiping off the used grease on it.

•


•

Install:

New Small Band [A]

New Boot [B]

○

Apply the special grease slightly on the inside of the new boot small diameter, and install the boot on the axle shaft.

CAUTION

Only the special grease that is included with the boot kit can be applied to the boots.

•

Install:

New Circlip [C]



Rear Axle

•

Apply the special grease slightly on the part [A] of the band installation in order to make easy to install the boot band.

•

Tighten the small boot band [B].

○

Tighten the boot band [A] and bend the tangs [B] securely to hold down the end of the band.

•

Place the special grease tube nozzle in the bore of the housing and squeeze the tube [A] until the grease comes out from the joint bearing.

•

Tap the shaft end [A] straight with a plastic hammer until it is locked by the circlip.

•

Squeeze all of the special grease [A] into the new boot

[B], and slide the boot onto the outboard joint [C].


Rear Axle

•


•



Outboard: 216.2 mm (8.51 in.) [A]

•

Open the edge of the boot in order to equalize the air pressures.

•




Inboard Joint Boot Removal

•

Remove:

Rear Axle (see Rear Axle Removal)

Boot Bands [A]

•


•

Slide the joint boot toward the outboard joint.

•

Remove the retaining ring [A].

•

Separate to the axle shaft.


•

Remove the steel balls [A].

•

Slide the cage [B] toward the outboard joint.



Rear Axle

•

Remove:

Circlip [A]

Special Tool - Outside Circlip Pliers [B]: 57001-144

•

Remove:

Inner Race [A]

Cage [B]

Inboard Joint Boot [C]

Boot Band [D]

Inboard Joint Boot Installation

•

Install:

New Small Band [A]

New Inboard Joint Boot [B]

Cage [C]

•

Install the inner race [A] so that the flat side [B] faces outboard joint.

•

Install:

Circlip [A]


•

Slide the cage [B] on the inner race and install the steel balls [C].


Rear Axle

•

Apply the special grease [A] to the steel balls and cage.


•

Squeeze about half a tube (30 grams) of the special grease [A] into the bearing cup [B].

•

Insert the balls and cage assembly in the bearing cup strongly.

•

Install the new retaining ring [A] so that the opening [B] is aligned with one of the projections [C].

•

Tighten the small band.

•

Squeeze the remaining special grease [A] into the inboard joint boot [B].



Rear Axle

•


•



Inboard: 174.6 mm (6.87 in.) [A]

•

Open the edge of the boot in order to eqalize the air pressures.

•

Tighten the large band [A].

○

Assemble it the same as the outboard joint boot, noting this setting;



•

While the band is held at the diameter above, tap down the tangs [A] of the band.



Rear Final Gear Case Oil Level Inspection

•


•

Remove the filler cap.

CAUTION

Be careful not to allow any dirt or foreign materials to enter the gear case.

•

Check the oil level. The oil level should come to the bottom of the filler opening [A].

If it is insufficient, first check the rear final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case.

•

Apply grease to the O-ring [B].

•

Be sure the O-ring is in place.


Rear Final Gear Case Oil Change

•

Refer to the Rear Final Gear Case Oil Change in the Periodic Maintenance chapter.

Rear Final Gear Case Removal

•

Remove:


Fuel Tank (see Fuel System chapter)


Rear Propeller Shaft (Rear Propeller Shaft Removal)

Rear Axles (see Rear Axle Removal)

Brake Cable Rear Ends

Brake Cam Lever

Rear Final Gear Case Bolts [A] and Washers (rear)

•

Remove:

Bracket Bolts [A]

Collars [B]

Bracket [C]





•

Remove the rear final gear case [A] as shown.

Rear Final Gear Case Installation

•

Install:

Rear Final Gear Case

Bracket [A]

Collars [B]

Bracket Bolts [C]

[D] Front

[E] Hole

Washers (rear side)

•

Apply a non-permanent locking agent (Three Bond

1363A, Red) to the rear final gear case nuts.

•

Tighten:

Torque - Rear Final Gear Case Nuts [F]: 72 N·m (7.3 kgf·m,

53 ft·lb)

Bracket Bolts: 59 N·m (6.0 kgf·m, 43 ft·lb)

•

Install:

Removed Parts (see applicable chapters)

Rear Final Gear Case Disassembly

•

Remove:

Rear Final Gear Case (see Rear Final Gear Case Removal)

Rear Final Gear Case Right Cover Bolts (M8) [A]

Rear Final Gear Case Right Cover Bolts (M10) [B]

Rear Final Gear Case Right Cover Bolts (M12) [C]

•

Using the pry points [A], remove the rear final gear case right cover [B].

[C] Arrow Marks

•

Remove:

Ring Gear

Shims



•

Remove:

Rear Final Gear Case Front Cover Bolts [A]

Rear Final Gear Case Front Cover Assembly [B]

•

Remove:

Gasket Screws [A]

Gasket [B]

•

Remove:

Set Pins [A] with Steel Plates [B] and Friction plates [C]


•

Remove:

Brake Cam Plate [A]

Brake Camshaft [B] and Spring

•

Remove:

Steel Balls [A]




•

Remove:

Pinion Gear Bearing Holder [A]

○

Hold the rear final gear case [A] in a vise, and remove the bearing holder using the socket wrench [B].


○


•

Remove:

Pinion Gear Unit [A]

Shim(s) [B]

•

Drill out the spring pin [A] with a drill bit of the 3 mm (0.12

in.) diameter and remove it.

•

Remove the needle bearing [B].

Rear Final Gear Case Assembly

[A] Rear Final Gear Case

•

Press:

Ball Bearing [B] (until bottomed)

Oil Seal [C] (until bottomed)


•

•

Apply Grease:

Oil Seal Lip

•

Press the face of the needle bearing [D] is flush with the end of the housing.

Insert the spring pin [E].




Rear Final Gear Case Right Cover Assembly

[A] Rear Final Gear Case Right Cover

•

Press:

Ball Bearing (until bottomed)

Special Tool - Bearing Driver, 54.3 [B]: 57001-1488

[A] Rear Final Gear Case Right Cover

[B] Ball Bearing

•

Press:

Oil Seal [C] (until bottomed)


•

Apply Grease:

Oil Seal Lips [D]

Rear Final Gear Case Front Cover Assembly

[A] Rear Final Gear Case Front Cover

•

Press:

Ball Bearing [B] (until bottomed)


•

Press the faces of the oil seals [C] are flush with the ends of the housing.

•

Apply Grease:

Oil Seal Lips

Rear Final Gear Case Assembly

•

Visually check the pinion gear [A] and ring gear [B] for scoring, chipping, or other damage.

Replace the bevel gear as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact.

•

Be sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced (see Rear Final Bevel Gear Adjustment).

•

Insert the shim(s) and pinion gear unit [A].

•

Apply a non-permanent locking agent to the pinion gear bearing holder, and tighten it.


Torque - Pinion Gear Bearing Holder: 137 N·m (14 kgf·m,

101 ft·lb)




When installing a new pinion gear bearing holder [A], install the holder so that the no coating area [B] (one pitch thread) faces gear case [C].

[D] Locking Agent Coating Area

•

Install:

Brake Camshaft [A]

Spring [B]

•

Install:

Steel Balls [A]

•

Install:

Brake Cam Plate [A]

○

Fit the cam plate and brake camshaft [B] as shown.

•

Install:

Steel Plate [A] (P/No. 41080-1483, two holes)

Set Pins [B] and Springs [C]




•

Install (alternately):

Friction Plates [A]

Steel Plates (P/No. 41080-1484, without holes)

•

Install:

Steel Plate [A] (P/No. 41080-1483, two holes)

○

Insert the pins [B] into the holes of steel plate.

•

Install:

Dowel Pins [A]

New Gasket [B]

•

Tighten:

Torque - Gasket Screws [C]: 1.3 N·m (0.13 kgf·m, 11 in·lb)

•

Install:

Rear Final Gear Case Front Cover [A]

•

Tighten:

Torque - Rear Final Gear Case Front Cover Bolts [B]: 24

N·m (2.4 kgf·m, 17 ft·lb)

•

Inspect:

Ball Bearing [A] (see Bearing and Oil Seal section)

Oil Seal [B] (see Bearing and Oil Seal section)

If they are damaged, replace them.

•

Apply grease to the oil seal lips and O-ring [C].

•

Install:

Shim [D]

Ring Gear [E]




•

Install:

Shim [A]

Rear Final Gear Case Right Cover [B]

•

Apply a non-permanent locking agent to the rear final gear case right cover bolts.

•

Tighten:

Torque - Rear Final Gear Case Right Cover Bolts (M12) [A]:

93 N·m (9.5 kgf·m, 69 ft·lb)

Rear Final Gear Case Right Cover Bolts (M10) [B]:

49 N·m (5.0 kgf·m, 36 ft·lb)

Rear Final Gear Case Right Cover Bolts (M8) [C]:

24 N·m (2.4 kgf·m, 17 ft·lb)

Rear Final Gear Case Oil Drain Plug [D]: 13 N·m

(1.3 kgf·m, 113 in·lb)

Rear Final Bevel Gear Adjustment

○

The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged.

•

After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears. First, adjust backlash, and then tooth contact by replacing shims.

○

The amount of backlash is influenced by the ring gear position more than by the pinion gear position.

○

Tooth contact locations is influenced by the pinion gear position more than by the ring gear position.



Rear Final Gear Case (Backlash-related Parts)


1. Pinion Gear

2. Pinion Gear Bearing Holder

3. Gear Case Right Cover

4. Ball Bearings

5. Ring Gear

6. Pinion Gear Shim(s)

7. Ring Gear Shim(s)

8. Ring Gear Shim(s)




6. Pinion Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1423

92180-1424

92180-1425

92180-1426

92180-1427

92180-1428

7. Ring Gear Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-1417

92180-1418

92180-1419

92180-1420

92180-1421

92180-1422

8. Ring Gear Shims for Tooth Contact Adjustment

Thickness

0.15 mm (0.006 in.)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

0.8 mm (0.031 in.)

1.0 mm (0.039 in.)

1.2 mm (0.047 in.)

Part Number

92180-0166

92180-0165

92180-0164

92180-0163

92180-0162

92180-0161

Backlash Adjustment

•


•

Install the pinion gear assembly with the primary shim 1.0

mm (0.039 in.) thickness.

•

Assemble the rear final gear case (see Rear Final Gear

Case Assembly).

○

Install the ring gear with the primary shims 1.0 mm (0.039

in.) thickness.

○

Check the backlash during tightening the cover bolts, and stop tightening them immediately if the backlash disappears. Then, change the ring gear shim to a thinner one.

•

Temporarily, install the rear axle in the gear case and hold it with a vise so that the ring gear is lower than the pinion gear.

•

Mount a dial gauge [A] so that the tip of the gauge is against the splined portion [B] of the pinion gear joint.

•

To measure the backlash, move the pinion gear shaft back and forth [C] while holding the rear axle steady.

The difference between the highest and the lowest gauge reading is the amount of backlash.

○

Measure backlash at three locations equally spaced on the splines.


Rear Final Bevel Gear Backlash

Standard: 0.04

∼

0.17 mm (0.002

∼

0.007 in.) at pinion gear spline



If the backlash is not within the standard, replace the pinion gear shim(s). To increase backlash, increase the thickness of the shim(s). To decrease backlash, decrease the thickness of the shim(s).


•



•


•

Apply checking compound to 4 or 5 teeth of the pinion gear.

NOTE

○


○

The checking compound must be smooth and firm, with the consistency of tooth paste.

○

Special compounds are available at automotive supply stores for the purpose of checking gear tooth patterns and contact. Use one of these for checking the bevel gears.

•

Assemble the rear final gear case (see Rear Final Gear

Case Assembly).

•

Turn the pinion gear for one revolution in the drive and reverse (coast) direction, while creating drag on the ring gear.

•

Remove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth.

○

The tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe.

If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown (see Correct

Tooth Contact Pattern in the Front Final Bevel Gear Adjustment section).

•

Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.

NOTE

○

If the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.




Pinion Gear Unit Disassembly

•

Remove:

Pinion Gear Unit [A] (see Rear Final Gear Case Disassembly)

•

Hold the pinion gear bearing holder nut [B] with the socket wrench [C] in a vise, and loosen the pinion gear shaft using the pinion gear holder [D].

Special Tools - Socket Wrench: 57001-1363

Pinion Gear Holder: 57001-1281

•

Remove the ball bearing [E] as necessary.

Special Tool - Bearing Puller: 57001-135

Pinion Gear Unit Assembly

○

The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set.

•

Visually inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a bearing, replace the bearing.

•

Be sure to check and adjust the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see Front Final Bevel Gear Adjustment).

•

Press the bearing [A] on the pinion gear until it is bottomed.

•

Install the pinion gear bearing holder nut [B] so that the projection [C] faces outward.

•

Apply a non-permanent locking agent to the pinion gear bearing holder nut [A], and tighten it.

Special Tools - Socket Wrench [B]: 57001-1363

Pinion Gear Holder [C]: 57001-1281

Torque - Pinion Gear Bearing Holder Nut: 157 N·m (16 kgf·m, 116 ft·lb)


Bearing and Oil Seal

Ball or Needle Bearing Inspection

Since the bearings are made to extremely close tolerances, the clearance cannot normally be measured.

CAUTION

Do not remove any bearings for inspection except the right rear axle bearing.

•

Turn each bearing in the case or hub back and forth [A] while checking for plays, roughness, or binding.

If bearing play, roughness, or binding is found, replace the bearing.


•

Check the needle bearings [A].

○

The rollers in the needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

If the bearing is damaged, replace the bearing.



Bearing and Oil Seal

Oil Seal Inspection

•

Inspect the oil seals [A].

Replace any if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.


BRAKES 13-1

Brakes


Exploded View...................................

Specifications ....................................

Special Tool .......................................

Brake Fluid ........................................

Brake Fluid Recommendation......

Brake Fluid Level Inspection........

Brake Fluid Change .....................

Brake Line Air Bleeding ...............

Master Cylinder .................................

13-10

Master Cylinder Removal.............

13-10

Master Cylinder Installation..........

13-10

Master Cylinder Disassembly ......

13-11

Master Cylinder Assembly ...........

13-11

Master Cylinder Inspection (Visual

Inspection).................................

13-12

Calipers .............................................

13-13

13-2

13-6

13-7

13-8

13-8

13-8

13-8

13-9

Caliper Removal ..........................

13-13

Caliper Installation .......................

13-13

Caliper Disassembly ....................

13-14

Caliper Assembly .........................

13-14

Fluid Seal Damage ......................

13-15

Dust Seal and Friction Boot

Damage.....................................

13-15

Piston and Cylinder Damage .......

13-16

Caliper Holder Shaft Wear

Inspection..................................

13-16

Brake Pads ........................................

13-17

Brake Pad Removal .....................

13-17

Brake Pad Installation ..................

13-17

Brake Pad Wear Inspection .........

13-17

Brake Discs .......................................

13-18

Disc Cleaning...............................

13-18

Disc Removal...............................

13-18

Disc Installation............................

13-18

Disc Wear ....................................

13-18

Disc Runout .................................

13-18

Brake Hoses ......................................

13-19

Brake Hose Inspection.................

13-19

Brake Hose Replacement ............

13-19

Rear Brake Lever, Pedal and Cables 13-20

Brake Pedal Position Inspection ..

13-20

Brake Pedal Position Adjustment.

13-20


Inspection..................................

13-20

Brake Pedal Free Play Inspection 13-20

Rear Brake Lever and Pedal Free

Play Adjustment ........................

13-20

Brake Pedal Removal ..................

13-20

Brake Pedal Installation ...............

13-21

Brake Cable Removal ..................

13-21

Brake Cable Installation ...............

13-22

Brake Cable Lubrication...............

13-22

Internal Wet Brake.............................

13-23

Internal Wet Brake Disassembly..

13-23

Internal Wet Brake Assembly.......

13-23

13


13-2 BRAKES

Exploded View


Exploded View

No.

Fastener

1 Reservoir Cap Screws

2 Brake Lever Pivot Bolt

3 Brake Lever Pivot Bolt Locknut

4 Master Cylinder Clamp Bolts

5 Brake Hose Banjo Bolts

6 Brake Caliper Mounting Bolts

7 Bleed Valves

8 Brake Disc Mounting Bolts

9 Caliper Holder Shaft

10 Pad Mounting Bolts

B: Apply brake fluid.




Si: Apply silicone grease.

BRAKES 13-3

N·m

1.5

6.0

6.0

9.0

25

25

5.4

37

17

17

Torque kgf·m

0.15

0.60

0.60

0.92

2.5

2.5

0.55

3.8

1.7

1.7

ft·lb

13 in·lb

52 in·lb

52 in·lb

80 in·lb

18

18

48 in·lb

27

13

13

Remarks

S

L


13-4 BRAKES

Exploded View


Exploded View

No.

Fastener

1 Variable Differential Control Lever Bolt

2 Gasket Screws

3. Bend both hooks after installing the spring.

G: Apply grease.


MF: Apply MOBIL FLUID 424 or equivalent oil.


BRAKES 13-5

N·m

–

–

Torque kgf·m

–

–

ft·lb

–

–

Remarks

L

L


13-6 BRAKES

Specifications

Brake Fluid

Type

Front Disc Brake

Item

Pad lining thickness

Disc thickness

Disc runout

Rear Brake Lever, Pedal and Cables

Rear brake pedal position

Rear brake lever free play

Rear brake pedal free play

Standard

DOT 3 or DOT 4 see text

1

∼

2 mm (0.04

∼

0.08 in.)

15

∼

25 mm (0.6

∼

1.0 in.)

Service Limit

– – –

4.0 mm (0.16 in.)

3.3

∼

3.7 mm (0.130

∼

0.146 in.)

1 mm (0.04 in.)

3 mm (0.12 in.)

TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.020 in.)

– – –

– – –

– – –


Special Tool


57001-143

BRAKES 13-7


13-8 BRAKES

Brake Fluid

WARNING

When working with the disc brake, observe the precautions listed below.

1. Never reuse old brake fluid.

2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.

3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.

4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.

5. Don’t change the fluid in the rain or when a strong wind is blowing.

6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine 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 disc brake.

7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.

8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.

9. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM

THE BRAKE LINE.

Brake Fluid Recommendation

Use extra heavy-duty brake fluid only from a container marked DOT3 or DOT4.

Recommended Disc Brake Fluid

Type: DOT 3 or DOT 4

Brake Fluid Level Inspection

•

Refer to the Brake Fluid Level Inspection in the Periodic


Brake Fluid Change

•

Refer to the Brake Fluid Change in the Periodic Maintenance chapter.


Brake Fluid

Brake Line Air Bleeding

•

Bleed the air whenever brake parts are replaced or reassembled.

•

Remove the reservoir cap and fill the reservoir with new brake fluid.

•

Slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir. This bleeds the air from the master cylinder and the brake line.

NOTE

○

Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir.

•

Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a con-

• tainer.

Bleed the brake line and the caliper as follows:

○

Hold the brake lever applied [A].

○

Quickly open and close the valve [B].

○

Release the brake lever [C].

•

The fluid level must be checked several times during the bleeding operation and replenished as necessary.

NOTE

○

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.

○

If the brake lever action still feels soft or "spongy", tap the brake hose from bottom to top and air will rise up to the top part of the hose. Slowly pump the brake lever in the same manner as above.

•

Tighten:


•

Apply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings.

BRAKES 13-9


13-10 BRAKES

Master Cylinder

Master Cylinder Removal

•

Remove:

Brake Hose Banjo Bolt [A]

Master Cylinder Clamp Bolts [B]

Master Cylinder [C]

CAUTION

Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately.

Master Cylinder Installation

•

Align the punch mark [A] on the handlebar with the mating surface end of the master cylinder clamp.

•

The master cylinder clamp must be installed with the "UP" mark [A] upwards.

•

Tighten 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 - Master Cylinder Clamp Bolts: 9.0 N·m (0.92 kgf·m,

80 in·lb)

•

Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt.

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Bleed the brake line after master cylinder installation (see

Brake Line Air Bleeding).

•

Check the brake for good braking power, no braking brag, and no fluid leakage.

WARNING

Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc. The brakes will not function on the first application of the lever if this is not done.


Master Cylinder

Master Cylinder Disassembly

•

Remove:

Master Cylinder (see Master Cylinder Removal)

Brake Lever Pivot Nut [A]

Brake Lever Pivot Bolt [B]

Brake Lever [C]

Dust Cover [D]

Circlip [E]

Piston [F]

Spring [G]


CAUTION

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

Master Cylinder Assembly

•

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

CAUTION

Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine 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 disc brake.

•

Take care not to scratch the piston or the inner wall of the cylinder.

•

Apply brake fluid to the removed parts and to the inner wall of the cylinder.

•

Tighten:

Torque - Brake Lever Pivot Bolt: 6.0 N·m (0.60 kgf·m, 53 in·lb)

Brake Lever Pivot Bolt Locknut: 6.0 N·m (0.60


BRAKES 13-11


13-12 BRAKES

Master Cylinder

Master Cylinder Inspection (Visual Inspection)

•

Disassemble the master cylinder (see Master Cylinder

Disassembly).

•

Check that there are no scratches, rust or pitting on the inner wall of the master cylinder [A] and on the outside of the piston [B].

If the master cylinder or piston shows any damage, replace them.

•

Inspect the primary [C] and secondary [D] cups.

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 brake lever, the piston assembly should be replaced to renew the cups.

•

Check the dust cover [E] for damage.

If it is damaged, replace it.

•

Check that the relief [F] and supply [G] ports are not plugged.

If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

•

Check the piston return spring [H] for any damage.

If the spring is damaged, replace it.


Calipers

Caliper Removal

•

Remove the front wheel (see Wheels/Tires chapter).

•

Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.

•

Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

•

Unscrew the banjo bolt and remove the brake hose [D] from the caliper.

CAUTION

Immediately wash away any brake fluid that spills.

NOTE

○

If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Disassembly).

•

Caliper Installation

Install the caliper and brake hose lower end.

○

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

•

Tighten:

Torque - Brake Caliper Mounting Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Check the fluid level in the brake reservoir.

•

Bleed the brake line (see Brake Line Air Bleeding).

•

Check the brake for good braking power, no brake drag, and no fluid leakage.

WARNING

Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc. The brakes will not function on the first application of the lever if this is not done.

BRAKES 13-13


13-14 BRAKES

Calipers

Caliper Disassembly

•

Remove:

Caliper (see Caliper Removal)

Pads (see Brake Pad Removal)

•

Anti-rattle Spring

Using compressed air, remove the piston.

○

Cover the caliper opening with a clean, heavy cloth [A].

○

Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper.

WARNING

To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

NOTE

○

If compressed air is not available, do as follows with the brake hose connected to the caliper.

○

Prepare a container for brake fluid.

○

Remove the pads (see Brake Pad Removal) and anti

-rattle spring.

○

Pump the brake lever to remove the caliper piston.

•

Remove:

Dust Seals [A]

Fluid Seals [B]

Bleed Valve [C] and Rubber Cap [D]

Boots [E] and Caliper Holder [F]

•

Caliper Assembly

Replace the fluid seal [A] with a new one.

○

Apply brake fluid to the fluid seal, and install it into the

• cylinder by hand.

Replace the dust seal [B] with a new one if it is damaged.

○

Apply brake fluid to the dust seal, and install it into the cylinder by hand.


BRAKES 13-15

Calipers

•

Apply brake fluid to the outside of the pistons [A], and push them into the cylinder by hand. Take care that neither the cylinder nor the piston skirt gets scratched.

•

Replace the rubber boots [B] if they are damaged.

•

Apply a thin coat of silicone grease to the caliper holder shafts [C] [D] (Silicone grease is a special high temperature, water-resistant grease).

•

Install:

Wave Washer [E]

•

Tighten:

Torque - Caliper Holder Shaft [D]: 17 N·m (1.7 kgf·m, 13 ft·lb)

•

Install:

Caliper Holder [F]

Bleed Valve [G] and Rubber Cap


•

Install the anti-rattle spring [A] in the caliper as shown.

•

Install the pads (see Brake Pad Installation).

Fluid Seal Damage

The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature.

•

Replace the fluid seals in accordance with the Periodic

Maintenance Chart or under any of the following conditions: (a) fluid leakage around the pad; (b) brakes overheat; (c) there is a large difference in inner and outer pad wear; (d) the seal is stuck to the piston.

If the fluid seal is replaced, replace the dust seal as well.

Also, replace all seals every other time the pads are changed.

Dust Seal and Friction Boot Damage

•

Replace the dust seals [A] in accordance with the Periodic Maintenance Chart or check that the dust seals and friction boots [B] are not cracked, worn swollen, or otherwise damaged.

If they show any damage, replace them.


13-16 BRAKES

Calipers

Piston and Cylinder Damage

•

Visually inspect the piston [A] and cylinder surfaces [B].

Replace the caliper if the cylinder and piston are badly scored or rusty.

Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.

•

Check to see that the caliper holder shafts are not badly worn or stepped, and that the rubber friction boots [B] are not damaged.

If the rubber friction boot is damaged, replace the rubber friction boot.

If caliper holder shaft is damaged, replace the caliper holder shaft and rubber friction boot as a unit.


Brake Pads

Brake Pad Removal

•

Detach the caliper from the disc (see Caliper Removal).

•

Remove:

Pad Mounting Bolts [A]

•

Remove:

Brake Pads [A]

Brake Pad Installation

•

Push the caliper piston in by hand as far as it will go.

•

Be sure that the anti-rattle spring is in place.

•

Install:

Brake Pads

Pad Mounting Bolts

•

Tighten:

Torque - Pad Mounting Bolts: 17 N·m (1.7 kgf·m, 13 ft·lb)

WARNING

Do not attempt to drive the vehicle until a firm brake lever can be obtained by pumping the brake lever until the pads are against each disc. The brake will not function on the first application if this is not done.

Brake Pad Wear Inspection

•

Refer to the Front Brake Pad Wear Inspection in the Periodic Maintenance chapter.

BRAKES 13-17


13-18 BRAKES

Brake Discs

Disc Cleaning

Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone.

WARNING

These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer’s warnings.

Disc Removal

•

Remove:

Front Hub (see Wheels/Tires chapter)

Brake Disc Mounting Bolts [A]

Brake Disc [B]

Disc Installation

•

The disc must be installed with the marked side [A] facing toward the steering knuckle.

•

Apply a non-permanent locking agent to the brake disc mounting bolts.

•

Tighten:

Torque - Brake Disc Mounting Bolts: 37 N·m (3.8 kgf·m, 27 ft·lb)

•

After installing the discs, check the disc runout. Completely clean off any grease that has gotten on either side of the disc with a high-flash point solvent. Do not use one which will leave an oily residue.

Disc Wear

•

Measure the thickness of each disc at the point [A] where it has worn the most.

Replace the disc if it has worn past the service limit.

Disc Thickness

Standard: 3.3

∼

3.7 mm (0.130

∼

0.146 in.)


Disc Runout

•

Jack up the vehicle so that the wheels are off the ground.

•

Remove the front wheels and turn the handlebar fully to one side.

•

Set up a dial gauge against the disc [A], and measure the disc runout.

If the runout exceeds the service limit, replace the disc.

Disc Runout

Standard: TIR 0.4 mm (0.016 in.) or less


Service Limit: TIR 0.5 mm (0.020 in.)

Brake Hoses

Brake Hose Inspection

•

Refer to the Front Brake Hose and Connections Inspection in the Periodic Maintenance chapter.

Brake Hose Replacement

•

Refer to the Front Brake Hose Replacement in the Periodic Maintenance chapter.

BRAKES 13-19


13-20 BRAKES


Brake Pedal Position Inspection

NOTE

○

The position of the brake pedal has been decided by the position of the adjusting bolt [A].

•

Check that the adjusting bolt is in the correct position as shown.

Adjusting Bolt Position [B]

Standard: 5

∼

6 mm (0.20

∼

0.24 in.) (between

Frame and Bolt Head)

If it is incorrect, adjust the adjusting bolt.

Brake Pedal Position Adjustment

•

Remove:

Right Footboard (see Frame chapter)

•

Loosen the locknut [A], and turn the adjusting bolt [B] until the brake pedal is correctly positioned.

•

Tighten the locknut.

•

Check the brake pedal free play (see Brake Pedal Free

Play Inspection).

Rear Brake Lever Free Play Inspection

•

Refer to the Rear Brake Lever Free Play Inspection in the


Brake Pedal Free Play Inspection

•

Refer to the Brake Pedal Free Play Inspection in the Periodic Maintenance chapter.

Rear Brake Lever and Pedal Free Play Adjustment

•

Refer to the Rear Brake Lever and Pedal Free Play Adjustment in the Periodic Maintenance chapter.

Brake Pedal Removal

•

Remove:

Right Footboard (see Frame chapter)

•

Loosen the locknut and the adjusting bolt [A].

•

Remove:

Brake Switch Spring [B]

Cotter Pin, Washer, Pin and Brake Cable Joint [C]

Cotter Pin and Washer [D]

O-ring and Brake Pedal [E]

Spring



Brake Pedal Installation

•

Apply grease:

Brake Pedal Pivot [A]

O-ring [B]

•

Install:

Spring [A]

Brake Pedal [B]

•

Apply grease:

O-rings [C]

•

Install:

Brake Cable Joint and Pin [D]

Brake Switch Spring [E]

Washers [F]

•

Replace the cotter pins [G] with new ones.

•

Bend both side hooks [H] of switch spring [E] after installing the spring.

•

Adjust the brake pedal position (see Brake Pedal Position).

Brake Cable Removal

•

Remove:

Right Rear Flap (see Frame chapter)

•

Unscrew the adjusters [A] at the rear ends of the cables, and pull the cables out of the joints [B] and cable mounts.

•

Loosen the knurled locknut [A] at the rear brake lever and screw in the adjuster [B].

•

Line up the slots [C] in the brake lever, knurled locknut, and adjuster, and then free the cable from the lever [D].

•

Remove the brake lever cable from the frame.

BRAKES 13-21


13-22 BRAKES


•

Remove:

Circlip [A]

Cotter Pin, Washer and Pin [B]

Brake Pedal Cable [C]

Brake Cable Installation

•

Grease the brake cable front ends.

•

Replace the cotter pin with a new one.

•

Route the brake cables according to the Cable, Wire, and

Hose Routing section in Appendix chapter.

•

Adjust the brake pedal and rear brake lever.

Brake Cable Lubrication

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

•

Lubricate the cable with a penetrating rust inhibitor.


Internal Wet Brake

Internal Wet Brake Disassembly

•

Refer to Rear Final Gear Case section in Final Drive chapter.

Internal Wet Brake Assembly

•

Refer to Rear Final Gear Case section in Final Drive chapter.

BRAKES 13-23



SUSPENSION 14-1

Suspension


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Shock Absorbers ....................................................................................................................

Front Shock Absorber Preload Adjustment.......................................................................

Front Shock Absorber Removal........................................................................................

Front Shock Absorber Installation.....................................................................................

Front Shock Absorber Inspection......................................................................................

Front Shock Absorber Scrapping......................................................................................

14-8

14-9

14-9

Rear Shock Absorber Preload Adjustment .......................................................................

Rear Shock Absorber Removal ........................................................................................

14-9

14-9

Rear Shock Absorber Installation .....................................................................................

14-10

Rear Shock Absorber Inspection ......................................................................................

14-10

14-2

14-6

14-7

14-8

14-8

14-8

Shock Absorber Spring Replacement...............................................................................

14-10

Rear Shock Absorber Scrapping ......................................................................................

14-11

Suspension Arms ...................................................................................................................

14-12

Front Suspension Arm Removal .......................................................................................

14-12

Front Suspension Arm Installation ....................................................................................

14-13

Front Suspension Arm Disassembly.................................................................................

14-13

Front Suspension Arm Assembly......................................................................................

14-14

Rear Suspension Arm Removal........................................................................................

14-15

Rear Suspension Arm Installation.....................................................................................

14-15

Rear Suspension Arm Disassembly .................................................................................

14-16

Rear Suspension Arm Assembly ......................................................................................

14-16

Stabilizer Removal ............................................................................................................

14-17

Stabilizer Installation .........................................................................................................

14-18

14


14-2 SUSPENSION

Exploded View


Exploded View

No.

Fastener

1 Front Shock Absorber Mounting Nuts

2 Front Suspension Arm Pivot Nuts

3 Front Knuckle Joint Nuts

G: Apply grease.


SUSPENSION 14-3

N·m

34

42

29

Torque kgf·m

3.5

4.3

3.0

ft·lb

25

31

22

Remarks


14-4 SUSPENSION

Exploded View


Exploded View

No.

Fastener

1 Rear Shock Absorber Mounting Nuts

2 Stabilizer Holder Bolts

3 Stabilizer Joint Nuts

4 Rear Suspension Arm Pivot Nuts

5 Rear Knuckle Mounting Nuts

G: Apply grease.


RL: Apply rubber lubricant.

SUSPENSION 14-5

N·m

34

23

48

48

48

Torque kgf·m

3.5

2.3

4.8

4.8

4.8

ft·lb

25

17

35

35

35

Remarks


14-6 SUSPENSION

Specifications

Item

Shock Absorbers

Spring Preload Setting Position (Front and Rear) No.2

Standard Service Limit

(Usable Range)

1

∼

5


Special Tools


57001-143


57001-144

Spring Compressor:

57001-1087

SUSPENSION 14-7

Steering Stem Nut Wrench:

57001-1100

Jack:

57001-1238


14-8 SUSPENSION

Shock Absorbers

Front Shock Absorber Preload Adjustment

The spring adjusting sleeve [A] on front shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions. If the spring action feels too soft or too stiff, adjust it in accordance with the following table.

Spring Action

Position

Spring

Force

Setting Load Terrain Speed

1

2 (STD)

3

4

Soft

↑

Light

↑

Smooth

↑

Low

↑

↓ ↓ ↓ ↓ ↓

5 Stronger Hard Heavy Rough High

•

Turn the adjusting sleeve on front shock absorber to the desired position with the wrench.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Front Shock Absorber Removal

•

Support the vehicle on a stand or a jack so that the front wheels are off the ground.


•

While holding the front wheels, remove the lower and upper shock absorber mounting bolts [A], nuts, and washers.

•

Remove the front shock absorber [B].

Front Shock Absorber Installation

•

Apply grease to the inside of bushing [A] and grease seal lips [B].

•

Install:

Collar [C]

•

Install:

Bushing [A] (press)

•

Tighten:

Torque - Front Shock Absorber Mounting Nuts [B]: 34 N·m

(3.5 kgf·m, 25 ft·lb)


Shock Absorbers

Front Shock Absorber Inspection

•

Check the bushings [A] in the upper and lower pivots.

If bushings are worn, cracked, hardened, or otherwise damaged, replace them.

SUSPENSION 14-9

Front Shock Absorber Scrapping

WARNING

Since the front shock absorber contains nitrogen gas, do not incinerate or disassemble the front shock absorber.

Before a front shock absorber is scrapped, drill a hole at a point about 15 mm (0.59 in.) [A] up from the bottom of the cylinder to release the nitrogen gas completely. Wear safety glasses when drilling the hole, as the gas may blow out bits of drilled metal when the hole opens.

Rear Shock Absorber Preload Adjustment

The spring adjusting sleeve [A] on rear shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions. If the spring action feels too soft or too stiff, adjust it in accordance with the following table.

Spring Action

Position

Spring

Force

Setting Load Terrain Speed

1

2 (STD)

3

Soft

↑

Light

↑

Smooth

↑

Low

↑

4

↓ ↓ ↓ ↓ ↓

5 Stronger Hard Heavy Rough High

•

Remove the axle guard.

•

Turn the adjusting sleeve on rear shock absorber to the desired position with the wrench.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Rear Shock Absorber Removal

•

Support the vehicle on a stand or a jack so that the rear wheels are off the ground.


•

While holding the rear wheels, remove the lower and upper shock absorber mounting bolts [A], nuts, and washers.

•

Remove the rear shock absorber [B].


14-10 SUSPENSION

Shock Absorbers

Rear Shock Absorber Installation

•

Apply grease to the inside of bushing [A] and grease seal lips [B].

•

Install:

Collar [C]

•

Install:

Bushing [A] (press)

•

Tighten:

Torque - Rear Shock Absorber Mounting Nuts [B]: 34 N·m

(3.5 kgf·m, 25 ft·lb)

Rear Shock Absorber Inspection

•

Check the bushings [A] in the upper and lower pivots.

If bushings are worn, cracked, hardened, or otherwise damaged, replace them.

Shock Absorber Spring Replacement

The spring replacements of front and rear shock absorbers are the same procedure.

The spring end of the rear shock absorber has a blue paint.

•

Remove:

Shock Absorber (see Front or Rear Shock Absorber Removal)

•

Use the spring compressor [A], and compress the spring of the shock absorber.

Special Tool - Spring Compressor: 57001-1087


Shock Absorbers

•

Remove:

Spring Seat Stopper [A]

•

Remove:

Spring Compressor

Spring Guide [A]

Spring [B]

Spring Adjusting Sleeve [C]

•

Install:

Spring Adjusting Sleeve [A]

•

Install the replaced spring [B] so that the small end faces downwards.

•

Install:

Spring Guide

•

Use the spring compressor, and install the spring seat stopper [A] so that recess side [B] faces upwards.

•

Remove the spring compressor.

Rear Shock Absorber Scrapping

WARNING

Since the rear shock absorber contains nitrogen gas, do not incinerate or disassemble the rear shock absorber.

Before a rear shock absorber is scrapped, drill a hole at a point about 15 mm (0.59 in.) [A] up from the bottom of the cylinder to release the nitrogen gas completely. Wear safety glasses when drilling the hole, as the gas may blow out bits of drilled metal

SUSPENSION 14-11


Suspension Arms

Front Suspension Arm Removal

•

Remove:


Wheel Hub [A]

Bolt [B] and Brake Hose [C] (from Suspension Arm)

Brake Caliper (from Brake Disk)

Knuckle Joint [D] (see Steering chapter)

Front Shock Absorber Mounting Bolt [E] (lower)

•

Remove:

Suspension Arm Pivot Bolt [A]

Front Upper Suspension Arm [B] and Knuckle

•

Remove:

Tie-rod End

Guard Bolts [A]

Suspension Arm Pivot Bolts [B]

Front Lower Suspension Arm [C] and Knuckle

•

Remove the knuckle joint [A] from the suspension arm [B] using a suitable nut [C] as shown.


Suspension Arms

Front Suspension Arm Installation

•

Clean the taper surface [A] of the suspension arm [B] and shank of the knuckle joint.

•

Install:

Front Upper Suspension Arm

Front Lower Suspension Arm

Suspension Arm Pivot Bolts and Nut (temporary)

Knuckle Joint (see Steering chapter)

Front Shock Absorber Mounting Bolt (lower)

•

Tighten:

Torque - Front Suspension Arm Pivot Nuts: 42 N·m (4.3


Front Knuckle Joint Nut: 29 N·m (3.0 kgf·m, 22 ft·lb)

Front Shock Absorber Mounting Bolt: 34 N·m (3.5


•

Install:

Brake Hose


Front Suspension Arm Disassembly

Front Upper Suspension Arm

•

Remove:

Collar [A] (rear side)

Sleeve [B] (front side)

Oil Seals [C]

Circlip [D]


•

Remove:

Ball Joint Bearing [E] (rear side)

Needle Bearing [F] (front side)

Front Lower Suspension Arm

•

Remove:

Bolts [A]

Collar [B]

Axle Guard [C]

Collars [D] (rear side)

Oil Seals [E]

Circlips [F]


•

Remove:

Ball Joint Bearing [G] (rear side)

Sleeve [H] (front side)

Needle Bearing [I] (front side)




Suspension Arms

Front Suspension Arm Assembly

•

Apply grease:

Ball Joint Bearing

Needle Bearing

•

Install the following parts as shown.

Front Upper Suspension Arm

Front [A]

•

Press the needle bearing [B] until it is stopped.

•

Press the ball joint bearing [C] until it is stopped.

•

Install:

New Circlip


•

Apply grease:

Oil Seal Lips

•

Install:

Sleeve (front side)

Collar (rear side)

•



Front Side [A]:

Needle Bearing [B]

7.5 ±0.1 mm (0.295 ±0.004 in.) [C]

Rear Side [A]:

Circlip [B] (front side)

Ball Joint Bearing [C]

Circlip [D] (rear side)


•

Apply grease:

Oil Seal Lips

•

Install:

Sleeve (front side)

Collars (rear side)


Suspension Arms

Rear Suspension Arm Removal

•

Remove:


Mounting Bolts and Nuts [A]

Rear Upper Suspension Arm [B]

•

Remove:

Stabilizer Joint [A]

○

Hold the joint bolt with an Allen wrench [B], and remove the nut [C].


•

Remove:

Mounting Bolts and Nuts [A]

Rear Lower Suspension Arm [B]

Rear Suspension Arm Installation

•

Install:

Rear Upper Suspension Arm

Rear Lower Suspension Arm

Suspension Arm Pivot Bolts and Nut (temporary)

Rear Shock Absorber Mounting Bolt (lower)

Stabilizer Joint

•

Tighten:

Torque - Rear Suspension Arm Pivot Nuts: 48 N·m (4.8


Rear Shock Absorber Mounting Nuts: 34 N·m (3.5


Stabilizer Joint Nut: 48 N·m (4.8 kgf·m, 35 ft·lb)

○

Hold the joint bolt with an Allen wrench, and tighten the nut.

•

Install:




Suspension Arms

Rear Suspension Arm Disassembly

Rear Upper Suspension Arm

•

Remove out the bushings [A]


•

Remove:

Screw [A]

Bolts [B]

Collars [C]

Axle Guard [D]

Collars [E] (rear side)

Oil Seals [F]

Circlips [G]


•

Remove:

Ball Joint Bearing [H] (rear side)

Sleeve [I] (front side)

Needle Bearing [J] (front side)

Rear Suspension Arm Assembly

•

Apply grease:

Ball Joint Bearing

Needle Bearing

Rear Upper Suspension Arm

•

Install the bushings [A] using a press.


Suspension Arms

Rear Lower Suspension Arm

•


Front Side [A]:

Needle Bearing [B]

7.5 ±0.1 mm (0.295 ±0.004 in.) [C]

Rear Side [A]:

Circlip [B] (front side)

Ball Joint Bearing [C]

Circlip [D] (rear side)


•

Apply grease:

Oil Seal Lips

•

Install:

Sleeve (front side)

Collars (rear side)

Stabilizer Removal

•

Remove:


Stabilizer Joint [A]

○

Hold the joint bolt with an Allen wrench [B], and remove the nut [C].

•

Remove:

Stabilizer Holder Bolts [A]

Stabilizer Holders [B]

Dampers and Stabilizer [C]




Suspension Arms

Stabilizer Installation

•

Install:

Dampers [A] and Stabilizer [B]

Stabilizer Holders [C] and Bolts

•

Tighten:

Torque - Stabilizer Holder Bolts [D]: 23 N·m (2.3 kgf·m, 17 ft·lb)

•

Install:

Stabilizer Joints [E]

○

Hold the joint bolt with an Allen wrench, and tighten the nut.

Torque - Stabilizer Joint Nuts [F]: 48 N·m (4.8 kgf·m, 35 ft·lb)

•

Install:



STEERING 15-1

Steering


Exploded View........................................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Steering ..................................................................................................................................

Steering Stem Removal ....................................................................................................

Steering Stem Installation .................................................................................................

Front Knuckle Removal.....................................................................................................

Front Knuckle Installation..................................................................................................

15-8

Front Knuckle Bearing Removal .......................................................................................

15-9

Front Knuckle Bearing Installation ....................................................................................

15-10

Tie-rod Removal ...............................................................................................................

15-10

Tie-rod Installation ............................................................................................................

15-10

Tie-rod End Removal ........................................................................................................

15-10

Tie-rod End Installation .....................................................................................................

15-10

Steering Maintenance.............................................................................................................

15-12

Steering Inspection ...........................................................................................................

15-12

Steering Stem Straightness ..............................................................................................

15-12

Steering Bearing Sleeve Lubrication.................................................................................

15-12

Steering Stem Clamp Inspection ......................................................................................

15-12

Steering Stem Bearing Inspection ....................................................................................

15-12

Steering Knuckle Bearing Inspection ................................................................................

15-13

Tie-rod End Inspection ......................................................................................................

15-13

Steering Knuckle Joint Inspection.....................................................................................

15-13

Handlebar ...............................................................................................................................

15-14

Handlebar Removal ..........................................................................................................

15-14

Handlebar Installation .......................................................................................................

15-14

15-2

15-4

15-5

15-6

15-6

15-6

15-7

15


15-2 STEERING

Exploded View


STEERING 15-3

Exploded View

No.

Fastener

1 Handlebar Holder Bolts

2 Steering Stem Clamp Bolts

3 Tie-rod End Nuts

4 Tie-rod Locknuts

5 Steering Stem Bearing Joint Bolts

6 Steering Stem Bottom End Nut

7 Front Knuckle Joint Nuts

8 Master Cylinder Clamp Bolts

9 Variable Differential Control Lever Bolt

N·m

29

25

42

37

23

62

29

9.0

–

AD: Apply adhesive agent.

AG: Apply grease (Amoco rykon premium grease No. 2 EP Green).

G: Apply grease.




Torque kgf·m

3.0

2.5

4.3

3.8

2.3

6.3

3.0

0.92

–

ft·lb

22

18

31

27

17

46

22

80 in·lb

–

Remarks

S

L

S

L


15-4 STEERING

Specifications

Item

Tie-rods

Tie-rod Length

Standard

393.3 mm (15.48 in.)

Service Limit

– – –


Special Tools


57001-143


57001-1129

STEERING 15-5


15-6 STEERING

Steering

Steering Stem Removal

•

Remove:


Handlebar (see Handlebar Removal)

Cotter Pins and Tie-rod End Nuts [A]

Steering Stem Bearing Joint Bolts [B] (right and left)

CAUTION

Do not loosen the locknuts [C] at the ends of the tie-rod adjusting sleeve, or the toe-in of the front wheels will be changed.

•

Flatten out the bended washer [A].

•

Remove:

Steering Clamp Bolts [B]

Steering Clamps [C]

Grease Seals

•

Cut the band [A] and pull the steering stem [B] out of the frame.

•

Remove:

Cotter Pin [A]

Steering Stem Bottom End Nut [B]

Collar [C]

Steering Stem Bearing [D]

Steering Stem Installation

•

Full grease up the seal grooves [A] in the steering stem bearing.

•

Install:

Collar

•

Tighten:

Torque - Steering Stem Bottom End Nut: 62 N·m (6.3 kgf·m,

46 ft·lb)

•

Bend both ends of the cotter pin.


STEERING 15-7

Steering

•


Steering Stem Bearing Joint Bolts [A]

•

Tighten:

Torque - Steering Stem Bearing Joint Bolts: 23 N·m (2.3


•

Apply Amoco Rykon Premium Grease No.2 EP (Green):

Inside of Steering Clamp [A]

Oil Seals [B]

•

Install:

Collars [A]

•

Apply above grease to the inside of steering clamp [B].

•

Tighten:

Torque - Steering Stem Clamp Bolts [A]: 25 N·m (2.5 kgf·m,

18 ft·lb)

Tie-rod End Nuts: 42 N·m (4.3 kgf·m, 31 ft·lb)

•

Bend the tabs of the washer [B] toward the bolt head.

•

Inspect the toe-in (see Wheels/Tires chapter).

Front Knuckle Removal

•

Remove:

Front Wheel and Hub (see Wheel/Tiers chapter)

Brake Caliper (see Brakes chapter)

Cotter Pin [A]

CAUTION

Do not loosen the locknuts [B] at the ends of the tie-rod, or the toe-in of the front wheels will be changed.


15-8 STEERING

Steering

•

Hold the flat surfaces [A] of the tie-rod end with a thin wrench [B], and remove the tie-rod end nut [C] and washers.

•

Tap the tie-rod end shaft lightly and remove the tie-rod end from the knuckle.

•

Remove:

Cotter Pins and Front Knuckle Joint Nuts [A]

•

Install a suitable nut [A] (M12) to the knuckle joint end temporary as shown.

•

Tap [B] the knuckle joint end and remove the joint from the front suspension arm [C].

•

Install a suitable nut [A] (M12) to the knuckle joint end temporary.

•

Tap the knuckle joint end and remove the knuckle [B].

Front Knuckle Installation

•

Inspect the spherical bearings in the knuckle joints [A].

If roughness, excessive play, or seizure is found, replace the knuckle joint.


Steering

•

Check the joint boot [A] is not torn, worn, deteriorated, or is leaking grease.

If it is found, replace the knuckle joint.

•

Clean the shanks [B] of the knuckle joint.

•

Clean the taper surface [A] in the front suspension arm

[B].

STEERING 15-9

•

Install:

Washers [A] and Knuckle Joint Nuts [B]

•

Tighten:

Torque - Front Knuckle Joint Nuts: 29 N·m (3.0 kgf·m, 22 ft·lb)

Tie-rod End Nuts: 42 Nm (4.3 kgfm, 31 ftlb)

•

Install the new cotter pins [C] and bend its both ends.

Front Knuckle Bearing Removal

•

Remove:

Front Knuckle (see Front Knuckle Removal)

Circlip [A]

Special Tool - Inside Circlip Pliers [B]: 57001-143

•

Drive the bearing [A] out using a suitable bearing driver from the bearing driver set.



15-10 STEERING

Steering

Front Knuckle Bearing Installation

•

The marked side of the bearing faces outward.

•

Press in the bearing until it is bottomed.

[A] V Block

Special Tool - Bearing Driver Set [B]: 57001-1129

•

Replace the circlip with a new one.


Tie-rod Removal

•

Remove:


Cotter Pin and Tie-rod End Nuts [A]

Tie-rod [B]

CAUTION

When removing the tie-rod, be careful not to bend it. Do not loosen the locknuts [C] at the end of the tie-rod adjusting sleeve, or the toe-in of the front wheels will be changed.

Tie-rod Installation

•

The right and left tie-rods are identical.

•

Tighten:

Torque - Tie-rod End Nuts: 42 N·m (4.3 kgf·m, 31 ft·lb)

•

Inspect the toe-in (see Wheels/Tires chapter).

Tie-rod End Removal

•

Remove the tie-rod (see Tie-rod Removal).

•

Holding the tie-rod flattened area [A], loosen the locknut

[B] and unscrew the tie-rod end [C].

NOTE

○

The locknut near the L mark on the tie-rod has left-hand threads. Turn the wrench clockwise for loosening.

CAUTION

Do not remove the grease seal. It is packed with grease.

Tie-rod End Installation

•

Check that the boot lip [A] is on the shank [B].


Steering

•

Install the tie-rod ends so that the tie-rod has the correct length [A], and both visible thread lengths [B] are equal.

Tie-rod Length

Standard: 393.3 mm (15.48 in.)

•

Tighten:

Torque - Tie-rod Locknuts: 37 N·m (3.8 kgf·m, 27 ft·lb)

STEERING 15-11


15-12 STEERING

Steering Maintenance

Steering Inspection

•

Refer to the Steering Inspection in the Periodic Maintenance chapter.

Steering Stem Straightness

•

Remove the steering stem (see Steering Stem Removal).

•

Check the steering stem for straightness.

○

Use a straightedge along the stem.

If the steering stem is bent, replace the steering stem.

•

Steering Bearing Sleeve Lubrication

Lubricate the steering stem bearings.

○

Remove the steering stem (see Steering Stem Removal).

○

Wipe all the old grease off the steering stem, bearing sleeves, and out of the grease seals.

○

Apply Amoco Rykon Premium Grease No. 2 EP (Green) to the steering stem [A] and the inside [B] of the both clamps.

•

Lubricate the steering stem bearing [A].

○

Remove the steering stem bearing.

○

Pack the grease seal lips with grease.

Steering Stem Clamp Inspection

•

Inspect the steering stem clamps [A].

If roughness, excessive play, or seizure is found, replace both clamps.

Steering Stem Bearing Inspection

•

Inspect the spherical bearing [A].

If roughness, excessive play, or seizure is found, replace the steering stem bearing.

•

Inspect the upper and lower grease seals [B].

If damage, wear or deterioration is found, replace the steering stem bearing.


Steering Maintenance

Steering Knuckle Bearing Inspection

CAUTION

Do not remove any bearings for inspection.

•

Remove the steering knuckle (see Steering Knuckle Removal).

•

Turn [A] the bearing back and forth while checking for roughness or binding.

If roughness or binding is found, replace the bearing.

•

Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

Tie-rod End Inspection

•

Inspect each spherical bearing [A].

If roughness, excessive play, or seizure is found, replace the tie-rod end.

•

Inspect each boot [B].

If damage, wear or deterioration is found, replace the tie

-rod end.

Steering Knuckle Joint Inspection

•

Inspect each spherical bearing [A].

If roughness, excessive play, or seizure is found, replace the steering knuckle joint.

•

Inspect each boot [B].

If damage, wear or deterioration is found, replace the steering knuckle joint.

STEERING 15-13


15-14 STEERING

Handlebar

Handlebar Removal

•

Remove:

Meter Unit (see Electrical System chapter)

Throttle Case

Front Brake Master Cylinder

Left-hand Switch Housing

Rear Brake Lever Assembly

Handlebar Holder Bolts [A] and Bracket [B]

Handlebar Holders [C]

Handlebar [D]

Handlebar Installation

•

Align the punch mark [A] on the handlebar with the mating surface end [B] of the steering stem.

•

Install the bracket [A].

•

Tighten the holder front bolts [B] first and then the rear bolts [C].

Torque - Handlebar Holder Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb)

○

If the holder is correctly installed, there will be no gap [D] at the front and an even gap [E] at the rear after tightening.

•

Install:

Right Switch Housing (Throttle Case) [A]

Front Brake Lever (Master Cylinder) [B]

Punch Mark [C]

[D] = 70 mm (2.76 in.)

•

Install the left switch housing [C] on the handlebar [B] so that the opening angle is 40° [A] or less.

NOTE

○

Do not open the housing more than 40°, the built-in parts in the housing may be damaged.


Handlebar

•

Install:

Left Switch Housing [A]

Rear Brake Lever Assembly [B]

Punch Mark [C]

[D] = 6 mm (0.24 in.)

STEERING 15-15



FRAME 16-1

Frame


Exploded View........................................................................................................................

Seat ........................................................................................................................................

Seat Removal ...................................................................................................................

Seat Installation ................................................................................................................

Carriers...................................................................................................................................

Front Carrier Removal ......................................................................................................

Front Carrier Installation ...................................................................................................

Front Carrier Bracket Installation ......................................................................................

Rear Carrier Removal .......................................................................................................

Rear Carrier Installation ....................................................................................................

16-9

16-9

Rear Carrier Bracket Installation.......................................................................................

16-10

Fenders ..................................................................................................................................

16-11

Front Fender Removal ......................................................................................................

16-11

Front Fender Installation ...................................................................................................

16-11

Rear Fender Removal.......................................................................................................

16-11

Rear Fender Installation....................................................................................................

16-12

16-2

16-8

16-8

16-8

16-9

16-9

16-9

16-9

Covers ....................................................................................................................................

16-13

Middle Cover Removal......................................................................................................

16-13

Middle Cover Installation...................................................................................................

16-13

Left Side Cover Removal ..................................................................................................

16-14

Left Side Cover Installation ...............................................................................................

16-14

Right Side Cover Removal................................................................................................

16-14

Right Side Cover Installation.............................................................................................

16-15

Electrical Parts Case Removal .........................................................................................

16-15

Electrical Parts Case Installation ......................................................................................

16-16

Radiator Cover Removal...................................................................................................

16-16

Radiator Cover Installation................................................................................................

16-16

Guards....................................................................................................................................

16-17

Front Guard Removal .......................................................................................................

16-17

Front Guard Installation ....................................................................................................

16-17

Front Bottom Guard Removal ...........................................................................................

16-17

Front Bottom Guard Installation ........................................................................................

16-18

Engine Bottom Guard Removal ........................................................................................

16-18

Engine Bottom Guard Installation .....................................................................................

16-18

Rear Bottom Guard Removal............................................................................................

16-18

Rear Bottom Guard Installation.........................................................................................

16-18

Flaps and Footboards.............................................................................................................

16-19

Left Footboard Removal ...................................................................................................

16-19

Left Footboard Installation ................................................................................................

16-19

Right Footboard Removal .................................................................................................

16-19

Right Footboard Installation ..............................................................................................

16-20

Footboard Bracket installation ..........................................................................................

16-20

16

Trailer Hitch Bracket ...............................................................................................................

16-21


Trailer Hitch Bracket Installation .......................................................................................

16-21

16-2 FRAME

Exploded View


Exploded View

No.

Fastener

1 Front Guard Bolts

2 Front Carrier Bolts, L = 50 mm (2.0 in.)

3 Front Bolts, L = 70 mm (2.8 in.)

4 Front Carrier Bracket Bolts

5 Rear Carrier Bolts, L = 14 mm (0.6 in.)

6 Rear Carrier Bolts, L = 41 mm (1.6 in.)

7 Rear Carrier Bracket Bolts

CN: Canada Model

FRAME 16-3

N·m

37

25

25

32

54

54

37

Torque kgf·m

3.8

2.5

2.5

3.3

5.5

5.5

3.8

ft·lb

27

18

18

24

40

40

27

Remarks


16-4 FRAME

Exploded View


Exploded View

No.

Fastener

1 Footboard Bracket Bolts

2 Hitch Bracket Bolts

3. Trailer Hitch Bracket

OP: Optional Parts

FRAME 16-5

N·m

42

82

Torque kgf·m

4.3

8.3

ft·lb

31

60

Remarks


16-6 FRAME

Exploded View


Exploded View

OP: Optional Parts

FRAME 16-7


16-8 FRAME

Seat

Seat Removal

•

Remove the seat [A] by lift the latch lever [B] and then pulling the seat up to the rear.

Seat Installation

•

Insert the front seat hooks [A] into the receivers [B] in the bracket.

•

Insert the rear seat hooks [A] into the dampers [B].

•

Push the rear part of the seat down to engage the latches

[C].


FRAME 16-9

Carriers

Front Carrier Removal

•

Remove:

Front Carrier Bolts [A]

Collars

Front Carrier [B]

Front Carrier Installation

•

Install:

Long Collars, L = 44.6 mm (1.8 in.) [A]

Short Collars, L = 21.6 mm (0.9 in.) [B]

Front Carrier [C]

•

Tighten:

Torque - Front Carrier Bolts [D], L = 70 mm (2.8 in.):25 N·m

(2.5 kgf·m, 18 ft·lb)

Front Carrier Bolts [E], L = 50 mm (2.0 in.):25 N·m

(2.5 kgf·m, 18 ft·lb)

Front Carrier Bracket Installation

•

Install:

Front Carrier Bracket [A]

•

Tighten:

Torque - Front Carrier Bracket Bolts [B]:32 N·m (3.3 kgf·m,

24 ft·lb)

Rear Carrier Removal

•

Remove:

Rear Carrier Bolts [A]

Collars [B]

Rear Carrier [C]

Rear Carrier Installation

•

Install:

Collar [A]

Carrier [B]

Carrier Bolts, L = 41 mm (1.61 in.) [C]

Carrier Bolts, L = 14 mm (0.55 in.) [D]

Carrier Bolts, L = 25 mm (0.98 in.) [E]


16-10 FRAME

Carriers

Rear Carrier Bracket Installation

•

Install:

Rear Carrier Bracket [A]

•

Tighten:

Torque - Rear Carrier Bracket Bolts [B]:37 N·m (3.8 kgf·m,

27 ft·lb)


Fenders

Front Fender Removal

•

Remove:

Seat (see Seat Removal)

Front Carrier (see Front Carrier Removal)

Left and Right Side Covers (see each Side Cover Removal)

Middle Cover

Quick Rivets [A] (both sides)

Bolts [B]

•

Remove:

Screws [A] and Collars

•

Remove:


Front Fender [B]

Front Fender Installation

•

Install:

Screws and Collars

Quick Rivets

•

Install:

Front Carrier (see Front Carrier Installation)

Rear Fender Removal

•

Disconnect:

Tail/Brake Light Lead Connector [A]

Bolts [A] and Collars

FRAME 16-11


16-12 FRAME

Fenders

•

Remove:


Rear Carrier (see Rear Carrier Removal)


•

Remove:


•

Remove:


Bolts [B] and Collars

Fuel Tank Cap [C]

Rear Fender [D]

•

Install the fuel tank cap after removing the rear fender.

Rear Fender Installation

•

Connect:

Tail/Brake Light Lead Connector

•

Install:

Rear Fender

Dampers [A] and Collars [B]

Rear Carrier (see Rear Carrier Installation)


FRAME 16-13

Covers

Middle Cover Removal

•

Remove:

Middle Cover Screws [A] and Collars

•

Remove:

Middle Cover Screw [A] and Collar

•

Disconnect:

Reverse Power Assist Switch Lead Connectors [A]

•

Remove the middle cover [A] as shown.

Middle Cover Installation

•

Connect:

Reverse Power Assist Switch Lead Connectors

•

Install:

Middle Cover [A]

Middle Cover Screws [B] and Collars [C]


16-14 FRAME

Covers

Left Side Cover Removal

•

Remove:


Middle Cover Screws

Storage Case Screws [A]

Storage Case [B]

•

Remove:


•

Remove:


Left Side Cover [B]

Left Side Cover Installation

•

Install:

Left Side Cover [A]

Insulator [B]

Screws [C] and Collars [D]

Washers [E]

Storage Case

Right Side Cover Removal

•

Remove:


Middle Cover Screws

Ignition Switch Nut [A]

Storage Case Screws [B]

Storage Case [C]


FRAME 16-15

Covers

•

Remove:

Shift Knob [A]

Screws [B] and Collars

•

Remove:


Left Side Cover [B]

Right Side Cover Installation

•

Install:

Right Side Cover [A]

Screws [B] and Collars [C]

Washer [D]

•

Install:

Storage Case

•

Fit the projection [A] on the ignition switch into the recess in the storage case.

•

Tighten the nut [B] securely.

Electrical Parts Case Removal

•

Remove:



Fuse Box [A]

Vehicle-down Sensor Lead Connector [B] (disconnect)

•

Remove the following parts from the case.

Starter Circuit Relays [C]

Radiator Fan Breaker [D]

Starter Relay [E]

Reset Connector [F]


Igniter [H]

16-16 FRAME

Covers

•

Remove:

Screw [A]

Bolts [B]

Electrical Parts Case [C]

Electrical Parts Case Installation

•

Install:

Removed Parts

•

Connect the vehicle-down sensor lead connector.

•

Route the electrical parts leads according to the Appendix chapter.

Radiator Cover Removal

•

Remove:

Front Fender (see Front Fender Removal)

Clamps [A] (both sides)

Radiator Cover Screws [B] and collars

•

Remove:


Radiator Cover [B]

Radiator Cover Installation

•

Set the corner line [A] and bottom line [B] of the radiator cover.

•

Install:

Radiator Cover Screws and Collars


FRAME 16-17

Guards

Front Guard Removal

•

Remove:



Front Guard Cover [C]

Bolts [D] and Collars

•

Remove:

Front Carrier Bracket Bolts [A]

Radiator Cover Screws [B] and Collars

Front Guard Bolts [C] (both sides)

•

Remove the front guard [D] from the radiator bottom stoppers [B].

Front Guard Installation

•

Insert the radiator bottom stoppers in the grommet in the front guard.

•

Install:

Front Guard [A]

Front Guard Bolts [B]

•

Tighten:

Torque - Front Guard Bolts: 37 N·m (3.8 kgf·m, 27 ft·lb)

Front Carrier Bracket Bolts: 32 N·m (3.3 kgf·m, 24 ft·lb)

•

Install:

Radiator Cover Screws

Front Guard Cover [A]

Screws [B] and Collars [C]

Bolts [D] and Collars [E]

Front Bottom Guard Removal

•

Remove:

Bolts [A] and Collars

Front Bottom Guard [B]


16-18 FRAME

Guards

Front Bottom Guard Installation

•

Install the front bottom guard [A] between the frame and engine bottom guard [B].

•

Install:

Bolts [C] and Collars [D]

Engine Bottom Guard Removal

•

Remove:

Bolts [A] and Collars [B]

Engine Bottom Guard [C]

Engine Bottom Guard Installation

•

Confirm:

Damper [D]

•

Install:

Engine Bottom Guard

Bolts and Collars

Rear Bottom Guard Removal

•

Remove:

Bolts (M6) [A] and Collars

Bolt (M8) [B] and Collar

Rear Bottom Guard [C]

Rear Bottom Guard Installation

•

Install:

Rear Bottom Guard [A]

Bolt (M8) [B] and Collar

Bolts (M6) [C] and Collars


FRAME 16-19

Flaps and Footboards

Left Footboard Removal

•

Remove:



•

Remove:



Left Footboard [C]

Left Footboard Installation

•

Install:

Left Footboard [A]

Bolts [B] and Collars [C]

Screws [D] and Collars [E]

Right Footboard Removal

•

Remove:



•

Remove:



Right Footboard [C]


16-20 FRAME

Flaps and Footboards

Right Footboard Installation

•

Install:

Right Footboard [A]

Bolts [B] and Collars [C]

Screws [D] and Collars [E]

Footboard Bracket installation

•

Install:

Footboard Bracket [A]

•

Tighten:

Torque - Footboard Bracket Bolts [B]: 42 N·m (4.3 kgf·m, 31 ft·lb)


Trailer Hitch Bracket

Trailer Hitch Bracket Removal

•

Remove:

Trailer Hitch Bracket Bolts [A]

Trailer Hitch Bracket [B]

Trailer Hitch Bracket Installation

•

Install the trailer hitch bracket [A] as shown.

•

Tighten:

Torque - Hitch Bracket Bolts: 82 N·m (8.3 kgf·m, 60 ft·lb)

FRAME 16-21



ELECTRICAL SYSTEM 17-1



Parts Location....................................

Exploded View...................................

17-3

17-6

Specifications ....................................

17-12

Wiring Diagram..................................

17-14

Special Tools .....................................

17-16

Precautions........................................

17-17

Electrical Wiring.................................

17-19

Wiring Inspection .........................

17-19

Battery ...............................................

17-20

Battery Removal ..........................

17-20

Battery Installation .......................

17-20

Battery Activation .........................

17-20

Precautions ..................................

17-22

Interchange ..................................

17-23

Charging Condition Inspection.....

17-24

Refreshing Charge ......................

17-24

Charging System ...............................

17-26

Alternator Cover Removal............

17-26

Alternator Cover Installation.........

17-27

Alternator Rotor Removal ...........

17-28

Alternator Rotor Installation .........

17-28

Alternator Stator Removal............

17-29

Alternator Stator Installation.........

17-29

Regulator/Rectifier Output

Voltage Inspection.....................

17-29

Alternator Inspection ....................

17-30

Regulator/Rectifier Inspection......

17-31

Ignition System ..................................

17-34

Spark Plug Removal ....................

17-34

Spark Plug Installation .................

17-34

Spark Plug Cleaning/Inspection...

17-35

Spark Plug Gap Inspection ..........

17-35

Ignition Coil Removal ...................

17-35

Ignition Coil Installation ................

17-35

Ignition Coil Inspection.................

17-36

Ignition Coil Primary Peak Voltage

Inspection..................................

17-37

Crankshaft Sensor Removal ........

17-37

Crankshaft Sensor Installation .....

17-38

Crankshaft Sensor Inspection......

17-38

Crankshaft Sensor Peak Voltage

Inspection..................................

17-39

Ignition Timing Test ......................

17-39

Vehicle-down Sensor Outline.......

17-40

Vehicle-down Sensor Removal ....

17-41

Vehicle-down Sensor Installation .

17-41

Vehicle-down Sensor Inspection..

17-41

Electric Starter System ......................

17-45

Starter Motor Removal.................

17-45

Starter Motor Installation..............

17-45

Starter Motor Disassembly...........

17-46

Starter Motor Assembly ...............

17-47

Commutator Cleaning/Inspection.

17-48

Armature Inspection.....................

17-48

Starter Motor Brush Length..........

17-49

Brush Assembly Inspection..........

17-49

Brush Plate and Terminal Bolt

Inspection..................................

17-49

Starter Relay Inspection...............

17-49

Starter Circuit Relay Inspection ...

17-50

Starter Motor Clutch Removal......

17-52

Starter Motor Clutch Installation...

17-52

Starter Motor Clutch Inspection ...

17-52

Torque Limiter Inspection.............

17-53

Lighting System .................................

17-54

Headlight Beam Vertical

Adjustment ................................

17-54

Headlight Bulb Replacement .......

17-54

Taillight Bulb Replacement...........

17-56

Radiator Fan System.........................

17-58

Radiator Fan Circuit Inspection....

17-58

Radiator Fan Motor Inspection.....

17-58

Radiator Fan Breaker Inspection .

17-58

Radiator Fan Breaker Installation 17-59

Fuel Level Sensor..............................

17-60

Fuel Level Sensor Removal.........

17-60

Fuel Level Sensor Installation......

17-60

Fuel Level Sensor Inspection.......

17-60

Meter .................................................

17-62

Multifunction Meter Unit Removal 17-62

Multifunction Meter Unit

Inspection..................................

17-63

Drive Belt Failure Mode Memory

Clearing Procedure ...................

17-68

Actuator Control System....................

17-72

2WD/4WD Actuator Removal ......

17-72

2WD/4WD Actuator Installation ...

17-72

Engine Brake Actuator Removal..

17-72

Engine Brake Actuator

Installation .................................

17-73

Actuator Control System Outline..

17-73

17

17-2 ELECTRICAL SYSTEM

Actuator Control System

Troubleshooting ........................

17-74

Drive Belt Failure Detection System..

17-83


System Inspection.....................

17-83

Carburetor Heater System.................

17-84

Air Temperature Sensor

Inspection..................................

17-84

Carburetor Heater Inspection.......

17-85

Switches ............................................

17-86

Brake Light Switch Adjustment ....

17-86

Radiator Fan Switch Inspection ...

17-86

Coolant Temperature Warning

Light Switch Inspection .............

17-87

Switch Inspection .........................

17-87


Switch........................................

17-88

Fuses ................................................

17-89

Fuse Removal..............................

17-89

Fuse Installation...........................

17-89

Fuse Inspection............................

17-89


Parts Location

Light/Dimmer Switch [A]

Starter Button [B]

Engine Stop Switch [C]

Reverse Power Assist Switch (Override) [D]

Rear Brake Light Switch [E]

Power Outlet Connector [F] (120 W)

2WD/4WD Shift Switch [A]

Front Brake Light Switch [B]

Ignition Switch [C]


Battery [A]

Igniter [B]

Actuator Controller [C]

Reset Connectors [D]

Starter Circuit Relay (Neutral) [E]

Fuse Box [F]

Starter Relay [G]

Radiator Fan Breaker [H]

Vehicle Down Sensor [I]

Starter Circuit Relay (Brake) [J]

Radiator Fan Switch [A]

Radiator Fan [B]

Frame Ground Lead [C]

Ignition Coil [D]

Air Temperature Sensor [E]

Spark Plug Cap [A]

Spark Plug [B]

Crankshaft Sensor [C]

Reverse Position Switch [D]

Neutral Position Switch [E]

Starter Motor [F]

Oil Pressure Warning Light Switch [G]

Alternator [H]

Forward/Reverse Detecting Sensor [I]



Parts Location

Frame Ground Lead [A]

Water Temperature Switch [B]

2WD/4WD Actuator [C]

Engine Brake Actuator [D]

Spark Plug [A]

Engine Ground Lead [B]

Ignition Coil [C]

Frame Ground Lead [D]

Rear Brake Light Switch [E]

Speed Sensor [F]

Drive Belt Failure Detection Switch [G]

Engine Brake Actuator [H]

Regulator/Rectifier [A]


Parts Location

Multifunction Meter [A]

“SET/RESET” Button [B]

Belt Check Indicator Light [C]

Neutral Indicator Light [D]

Reverse Indicator Light [E]

Oil Pressure Warning Indicator Light [F]

“4WD” Indicator Light [G]

“2WD” Indicator Light [H]

Coolant Temperature Warning Symbol [I]

Fuel Level Gauge [J]

“TIME SET” Button [K]

Clock [L]

Speedometer [M]

Trip Meter/Odometer/Hour Meter [N]

“MODE” Button [O]




Exploded View


Exploded View

No.

Fastener

1 Starter Motor Mounting Bolts

2 Starter Motor Terminal Nut

3 Starter Motor Terminal Locknut

4 Starter Motor Bolts

5 Starter Motor Clutch Bolts

6 Alternator Stator Bolts

7 Crankshaft Sensor Mounting Bolts

8 Alternator Cover Plugs

9 Alternator Rotor Bolt

10 Alternator Cover Bolts

G: Apply grease for oil seal and O-ring.






N·m

8.8

4.9

6.9

4.9

34

13

5.9

18

127

8.8

Torque kgf·m

0.90

0.50

0.70

0.50

3.5

1.3

0.60

1.8

13

0.90

ft·lb

78 in·lb

43 in·lb

61 in·lb

43 in·lb

25

113 in·lb

52 in·lb

13

94

78 in·lb

Remarks

L



Exploded View



Exploded View

No.

Fastener

1 Spark Plugs

2 2WD/4WD Actuator Mounting Bolts

3 Engine Brake Actuator Mounting Bolts

4 Forward/Reverse Detecting Sensor Mounting Bolt

5 Speed Sensor Mounting Bolt

6 Neutral Position Switch

7 Reverse Position Switch

8 Ignition Coil Mounting Bolts

9. Igniter

10. Actuator Controller

11. Vehicle Down Sensor

12. Power Outlet Connector (120 W)


14. Carburetor Heaters

15. Ground Terminal

G: Apply grease.



Torque

N·m kgf·m

13

9.8

1.3

1.0

ft·lb

113 in·lb

87 in·lb

8.8

15

8.8

15

15

8.8

0.90

1.5

78 in·lb

11

0.90

78 in·lb

1.5

1.5

0.90

11

11

78 in·lb

Remarks

L, S



Exploded View



Exploded View

No.

Fastener

1 Radiator Fan Switch

2 Coolant Temperature Warning Light Switch

3 Oil Pressure Switch

4 Oil Pressure Switch Terminal Bolt

5 Regulator/Rectifier Mounting Bolts

6 Fuel Level Sensor Mounting Bolts

7. Radiator Fan Breaker

OP: Optional Parts for U.S.A. and Canada models

R: Replacement Part (Fuel Pump Gasket)


N·m

18

6.9

15

1.5

8.8

2.0

Torque kgf·m

1.8

0.70

1.5

0.15

0.90

0.20

ft·lb

13

61 in·lb

11

13 in·lb

78 in·lb

18 in·lb

Remarks

SS

SS



Specifications

Item

Battery

Type

Capacity

Charging System

Alternator Type

Charging Voltage

(Regulator/Rectifier Output

Voltage)

Alternator Output Voltage

Stator Coil Resistance

Ignition System

Sealed Battery

12 V 12 Ah

Three-phase AC

14

38

∼

∼

0.29

15 V

58 V @3 000 r/min (rpm)

∼

0.43

Ω

Standard

Spark Plug:

Spark Plug Gap

Spark Plug Cap Resistance

0.7

∼

0.8 mm (0.028

∼

0.031 in.)

3.75

∼

6.25 k

Ω

Ignition Coil:

3 Needle Arcing Distance 7 mm (0.28 in.) or more

Primary Winding Resistance 0.09

∼

0.13

Ω

Secondary Winding Resistance 3.8

∼

5.8 k

Ω

Primary Peak Voltage

Crankshaft Sensor Resistance

Crankshaft Sensor Peak Voltage

Vehicle-Down Sensor

120 V or more

423

∼

517

Ω

2 V or more

Detection Method

Detection Angle

Detection Time

Magnetic flux detection method

More than 65° ±5° for each bank

Within 0.5

∼

1.0 second in the text Output Voltage

Electric Starter System

Starter Motor:

Commutator Diameter 28 mm (1.10 in.)

12.5 mm (0.49 in.) Brush Length

Fuel Level Sensor

Fuel Level Sensor Resistance:

Full Level Position 120

3

Ω

Ω

Empty Level Position

Actuator Control System

Actuator Resistance

Forward/Reverse Detecting Sensor

Resistance

Carburetor Heater System

Carburetor Heater Resistance

Switches

in the text

1.2

11

∼

∼

1.6 k

20

Ω

Ω

Service Limit

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

27 mm (1.06 in.)

5 mm (0.20 in.)

– – –

– – –

– – –

– – –

– – –

Brake Light Switch Timing ON after 10 mm (0.4 in.) of pedal – – –



Specifications

Item

Radiator Fan Switch Resistance:

Rising Temperature

Falling Temperature

Standard

From OFF to ON at 96

∼

100°C

(205

∼

212°F)

From ON to OFF at 91

∼

95°C

(196

∼

203°F)

ON: Less than 0.5

Ω

OFF: More than 1 M

Ω

Coolant Temperature Warning Light

Switch Resistance:

Rising Temperature

Falling Temperature

From OFF to ON at 112

∼

118°C

(234

∼

244°F)

From ON to OFF at 108

∼

111°C

(226

∼

232°F)

ON: less than 0.5

Ω

OFF: More than 1 M

Ω

Service Limit

– – –

– – –

– – –

– – –



Wiring Diagram


Wiring Diagram




Special Tools

Timing Light:

57001-1241

Peak Volt Adapter:

57001-1415

Flywheel Holder:

57001-1313

Hand Tester:

57001-1394

Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5:

57001-1405

Needle Adapter Set:

57001-1457

Drive Pulley Holder:

57001-1520


Precautions

There are a number of important precautions that should be taken when servicing electrical systems. Learn and observe all the rules below.

○

Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts.

○

Always check battery condition before condemning other parts of an electrical system. A fully charged battery is required for conducting accurate electrical system tests.

○

The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.

○

To prevent damaging electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.

○

Because of the high current, never keep the starter button depressed when the starter motor will not turn over, or the current may burn out the starter motor windings.

○

Only use an illumination bulb rated for the voltage or wattage specified in the wiring diagram, or the handle cover could be warped by excessive heat radiated from the bulb.

○

Take care not to short the leads that are directly connected to the battery positive (+) terminal to chassis ground.

○

Troubles may involve one or in some cases all items.

Never replace a defective part without determining what

CAUSED the failure. If the failure was caused by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail again.

○

Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Defective wires and bad connections will affect electrical system operation.

○

Measure coil and winding resistance when the part is cold

(at room temperature).

○

Color Codes:

BK Black

BL Blue

G Green

GY Gray

P Pink

PU Purple

BR Brown LB Light blue R

CH Chocolate LG Light green W

DG Dark green O Orange Y

Red

White

Yellow




Precautions

○

Electrical Connectors:

Female Connectors [A]

Male Connectors [B]


Electrical Wiring

Wiring Inspection

•

Visually inspect the wiring for signs of burning, fraying, etc.

If any wiring is defective, replace the damaged wiring.

•

Pull each connector [A] apart and inspect for corrosion, dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it

• is damaged, replace it.

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○

Set the tester to the ×1

Ω range.

If the tester does not read 0

Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.




Battery

Battery Removal

•

Turn off the ignition switch.

•

Remove:


Battery Holder Bolts [A] and Collars

Battery Holder [B]

•

Disconnect the battery negative (–) cable [C] first, and then the positive (+) cable [D].

•

Take out the battery [E].

Battery Installation

•


•

Install:

Rubber Dampers [A]

Clamp Nut [B]

•

Connect the positive cable first and then the negative.

•

Put a light coat of grease on the terminals to prevent corrosion.

•

Install:

Battery Holder [C]

Collars [D]

Battery Holder Bolts [E]

Battery Activation

Electrolyte Filling

•

Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These names must be the same.

Battery Model Name for KVF750-A1: KMX 14-BS

CAUTION

Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type. This is to prevent overfilling of the electrolyte, shorting the battery life, and deterioration of the battery performance.


Battery

CAUTION

Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume.

•

Place the battery on a level surface.

•

Check to see that the sealing sheet has no peeling, tears, or holes in it.

•

Remove the sealing sheet.

NOTE

○

The battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge.

•

Remove the electrolyte container from the vinyl bag.

•

Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery.

NOTE

○

Do not pierce or otherwise open the sealed cells [B] of the electrolyte container. Do not attempt to separate individual cells.


•

Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.

NOTE

○

Do not tilt the electrolyte container

•

Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times.

•

Keep the container in place for 20 minutes or more. Don’t remove the container from the battery until it’s empty, the battery requires all the electrolyte from the container for proper operation.

CAUTION

Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the electrolyte container until it is completely empty and 20 minutes have elapsed.



Battery

•

Gently remove the container from the battery.

•

Let the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance.

NOTE

○

Charging the battery immediately after filling can shorten service life. Let the battery sit for at least 60 minutes after filling.

Initial Charge

•

Place the strip [A] of caps loosely over the filler ports.

•

Newly activated sealed batteries require an initial charge.

Standard Charge 1.2 A × 5

∼

10 hours

If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers:

Optimate III

Yuasa 1.5 Amp Automatic Charger

Battery Mate 150–9

If the above chargers are not available, use equivalent one.

NOTE

○

Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. If it is not at least 12.8 volts, repeat charging cycle.

•

After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery.

CAUTION

Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery.

NOTE

○

To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds.

Re-check voltage and if less than 12.8 volts repeat the charging cycle and load test. If still below 12.8 volts the battery is defective.

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 sealing plug to add water is very dangerous. Never do that.

2) Refreshing charge



Battery

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification

(see Refreshing Charge).

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

CAUTION

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 caps 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 once a month 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.)

WARNING

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.

Interchange

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

Be careful, if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.



Battery

Charging Condition Inspection

Battery charging condition can be checked by measuring battery terminal voltage.

•

Remove the battery (see Battery Removal).

CAUTION

Be sure to disconnect the negative (

−) lead first.

•

Measure the battery terminal voltage.

NOTE

○

Measure with a digital voltmeter [A] which can be read to one decimal place voltage.

If the reading is below the specified, refreshing charge is required.

Battery Terminal Voltage

Standard: 12.8 V or more

Refreshing Charge

•

Remove the battery [A] (see Battery Removal).

•

Refresh-charge by following method according to the battery terminal voltage.

WARNING

This battery is sealed type.

Never remove seal sheet [B] even at charging.

Never add water.

Charge with current and time as stated below.

Terminal Voltage: 11.5

∼

less than 12.5 V

Standard Charge

1.2 A × 5

∼

10 h (see following chart)

Quick Charge

6.0 A × 1.0 h

CAUTION

If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do the standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method: 1.2 A × 20 h


Battery

NOTE

○

Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current [D], decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

•

Determine battery condition after refreshing charge.

○

Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal voltage according to the table below.

Criteria

12.8 V or higher

12.0

∼

12.5 V or lower

12.0 V or lower

Judgement

Good

Charge insufficient

→ Recharge

Unserviceable

→ Replace




Charging System

Alternator Cover Removal

•

Drain:

Coolant (see Cooling System chapter)

Oil (see Periodic Maintenance chapter)

•

Remove:


Water Pump Impeller (see Cooling System chapter)

Torque Converter Cover (see Converter System chapter)

•

Remove the three bolts of the drive pulley cover [A].

•

Install the drive pulley holder [B], tightening the remove three bolts [C].


•

Holding the drive pulley with the drive pulley holder, loosen the alternator rotor bolt [A].

•

Remove:

Alternator Rotor Bolt

Pulley [B]

•

Remove:

Collar [A]

○

Install the M6 bolts [B] to the collar, and remove it.

•

Remove:

Alternator and Crankshaft Sensor Lead Connectors (disconnect)

Alternator Cover Bolts [A]

Alternator Cover [B]


Charging System

Alternator Cover Installation

•

Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces.

•

Check that the dowel pins [A] are in place, and fit a new gasket on the crankcase.

•

Check that the bearing [B] is in place.


•

Fit the grommets [A] into the notch in the cover.

•

Grease the alternator cover oil seal.

•

Tighten:

Torque - Alternator Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•

Check that the O-ring [A] in the collar [B] is in good condition.

•


•

Install the collar on the alternator cover.

•

Hold the drive pulley with the drive pulley holder [A].


•

Install the pulley [A] so that the holes of the pulley fit on the pins [B] of the collar.

•

Tighten:

Torque - Alternator Rotor Bolt [C]: 127 N·m (13 kgf·m, 94 ft·lb)

•

Install the removed parts (see appropriate chapter).

•

Pour:

Coolant (see Coolant Change section in the Periodic

Maintenance chapter)

Engine Oil (see Engine Oil Change section in the Periodic Maintenance chapter)



Charging System

Alternator Rotor Removal

•

Remove:

Alternator Cover (see Alternator Cover Removal)

Ball Bearing [A]

•

Thread the flywheel puller [A] onto the alternator rotor.

Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×

1.5: 57001-1405

•

Holding the flywheel puller, turn the rotor puller until the alternator rotor is forced off the end of the crankshaft.

CAUTION

If the rotor is difficult to remove, turn the puller while tapping the end of the puller. Do not strike the alternator rotor. Striking the rotor can cause the magnets to lose magnetism.

Alternator Rotor Installation

•

Clean [A] the inside of the rotor and the end of the crankshaft.

•

Fit the rotor onto the crankshaft so that woodruff key [B] fits in the groove [C] in the hub of the rotor.

•

Install the alternator rotor [A] while turning the starter clutch gear [B].

•

Apply molybdenum disulfide grease to the shaft of the torque limiter [C].

•

Install the torque limiter.


Charging System

Alternator Stator Removal

•

Remove:


Crankshaft Sensor [A] (see Crankshaft Sensor Removal)

Bolts [B] and Alternator Stator [C]


Alternator Stator Installation

•

Tighten:

Torque - Alternator Stator Bolts: 13 N·m (1.3 kgf·m, 113 in·lb)

•

Install:

Crankshaft Sensor (see Crankshaft Sensor Installation)

•

Fit the lead grommets into the notch on the alternator cover.

Grommets [A] for Alternator Leads

Grommets [B] for Crankshaft Sensor Leads

Regulator/Rectifier Output Voltage Inspection

•

Remove the seat (see Frame chapter).

•

Check the battery condition (see Battery section).

•

Warm up the engine to obtain actual alternator operating conditions.

•

Check that the ignition switch is turned off, and connect a hand tester to the battery terminals.


•

Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off.

The readings should show nearly battery voltage when the engine speed is low, and as the engine speed increases, the readings should also increase.

Regulator/Rectifier Output Voltage

Connections

Tester Range Reading

Tester (+) to Tester (–) to

25 V DC Battery (+) Battery (–) 14

∼

15 V

•

Turn off the ignition switch, and disconnect the hand tester.

If the regulator/rectifier output voltage is between the values given in the table, the charging system is working normally.

If the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open.

If the battery voltage does not increase as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.



Charging System

Alternator Inspection

There are three types of alternator failures: short, open, or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output.

•

To check the alternator output voltage, perform the following procedures.

○

Disconnect the alternator connector [A].

○

Connect a hand tester [B] as shown in the table.

○

Start the engine.

○

Run it at the rpm given in the table.

○

Note the voltage readings (total 3 measurements).

Alternator Output Voltage

Tester Range

250 V AC

Connections Reading

Tester (+) to Tester (–) to @3 000 rpm

One black lead

Another black lead

38

∼

58 V

If the output voltage is within the values in the table, the alternator is operating correctly, and the regulator/rectifier is damaged. A much lower reading indicates that the alternator is defective.

•

Check the stator coil resistance as follows:

○

Stop the engine.

○

Disconnect the alternator connector.

○

Connect a hand tester as shown in the table.

○

Note the readings (total 3 measurement).

Stator Coil Resistance @20°C (68°F)

Tester Range

× 1

Ω

Connections

Tester (+) to Tester (–) to

One black lead

Another black lead

Reading

0.29

∼

0.43

Ω

If there is more resistance than shown in the table, or no reading (infinity) for any two leads, the stator has an open and must be replaced. Much less resistance means the stator is shorted and must be replaced.

•

Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground.

Any reading less than infinity (

∞) indicates a short, necessitating stator replacement.

If the stator coils have normal resistance, but the voltage check shows the alternator to be defective; then the rotor magnetism has probably weakened, and the rotor must be replaced.



Charging System

Regulator/Rectifier Inspection

•

Remove:

Connectors [A] (disconnect)

Bolts [B] and Regulator/Rectifier [C]

Rectifier Circuit Check

•

Check conductivity of the following pair of terminals.

Rectifier Circuit Inspection

Tester connection

W-BK1,

BK/Y-BK1,

W-BK2,

BK/Y-BK2,

W-BK3,

BK/Y-BK3,

The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and must be replaced.

NOTE

○

The actual meter reading varies with the meter and the individual rectifier. Generally speaking the lower reading should be from zero to one half of the scale.

Regulator Circuit Check

To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3

∼

6 W bulb in a socket with leads).

CAUTION

The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of a test light.

•

Check to be sure the rectifier circuit is correct before continuing.

Regulator Circuit Test-1st Step

•

Connect the test light [A] and the 12 V battery [B] to the regulator/rectifier [C] as shown.

•

Check Y1, Y2, and Y3 terminal respectively.

If the test light turns on, the regulator/rectifier is defective.

If the test light does not turn on, continue the test.




Charging System

Regulator Circuit Test-2nd Step

•

Connect the test light and a 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step".

•

Apply 12 V to the BR terminal.

•

Check Y1, Y2, and Y3 terminals.

If the test light turns on, the regulator/rectifier is defective.

If the test light does not turn on, continue the test.

Regulator Circuit Test-3rd Step

•

Connect the test light and a 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step".

•

Momentarily apply 24 V to the BR terminal by adding a 12

V battery.

•

Check Y1, Y2, and Y3 terminals.

CAUTION

Do not apply more than 24 V to the regulator/rectifier. Do not leave the 24 V applied for more than a few seconds, or the unit will be damaged.

If the test light did not light when the 24 V was applied momentarily to the BR terminal, the regulator/rectifier is defective.

If the regulator/rectifier passes all of the tests described, it may still be defective. If the charging system still does not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.


Charging System

Charging System Circuit


1. Ignition Switch

2. Fuse Box

3. Main Fuse 30 A

4. Load

5. Alternator

6. Regulator/rectifire

7. Starter Relay

8. Battery 12 V12 Ah

9. Engine Ground Terminal



Ignition System

WARNING

The ignition system produces extremely high voltage.

Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock.

CAUTION

Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent igniter damage.

Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the diodes and igniter.

Use the standard regulator/rectifier, or the igniter will be damaged.

Spark Plug Removal

Front Side

•

Remove:

Spark Plug Cap [A]

•

Using a spark plug wrench, remove the spark plug [B].

Rear Side

•

Remove:


Clamp Screws [A] and Clamps

Rubber Air Duct [B]

•

Remove:

Spark Plug Cap [A]

•

Using a spark plug wrench [A], remove the spark plug.

Spark Plug Installation

•

Tighten:


•

Fit the spark plug caps securely.

•

Pull up the spark pug caps lightly to make sure of the installation of the spark plug caps.

Ignition System

Spark Plug Cleaning/Inspection

•

Refer to the Spark Plug Cleaning/Inspection in the Periodic Maintenance chapter.

Spark Plug Gap Inspection

•

Refer to the Spark Plug Gap Inspection in the Periodic


Ignition Coil Removal

Front Side

•

Remove:

Spark Plug Cap [A]

Primary Lead Connectors [B]

Bolt [C]

Ignition Coil [D]


Rear Side

•

Remove:


Rubber Air Duct (see Spark Plug Removal)

Spark Plug Cap [A]

•

Remove:

Primary Lead Connectors [A]

Bolt [B]

Ignition Coil [C]

Ignition Coil Installation

•

Connect the primary leads to the ignition coil terminals as shown.

Front Side

G/W Lead

→ (+) Mark [A]

BK/Y Lead

→ (–) Mark

Rear Side

BL/W Lead

→ (+) Mark [A]

BK/Y Lead

→ (–) Mark



Ignition System

Ignition Coil Inspection

•

Remove the ignition coil.

•

Measure the arcing distance with a coil tester [A] to check the condition of the ignition coil [B].

•

Connect the ignition coil (with the spark plug cap left attached at the end of the spark plug lead) to the tester in the manner prescribed by the manufacturer and measure the arcing distance.

Ignition Coil Arcing Distance

7 mm (0.28 in.) or more

WARNING

To avoid extremely high voltage shocks, do not touch the ignition coil body or leads.

If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.

•

To determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil. Remove the cap by turning it counterclockwise.

If the arcing distance is as before, the trouble is with the ignition coil. If the arcing distance is normal, the trouble is with the spark plug cap.

If a coil tester is not available, the coil can be checked for a broken or badly shorted winding with a hand tester.


NOTE

○

The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.

•

Measure the primary winding resistance [A] as follows:

○

Connect the tester between the coil terminals.

○

Set the tester to the × 1

Ω range.

•

Measure the secondary winding resistance [B] as follows:

○

Remove the plug cap by turning it counterclockwise.

○

Connect the tester between the spark plug lead and terminal.

○

Set the tester to the × 1 k

Ω range.

Ignition Coil Winding Resistance

Primary Windings: 0.09

∼

0.13

Ω

Secondary Windings: 3.8

∼

5.8 k

Ω

If the hand tester does not read as specified, replace the coil.

○

To install the plug cap, turn it clockwise.


Ignition System

Ignition Coil Primary Peak Voltage Inspection

NOTE

○

Be sure the battery is fully charged.

•

Remove the spark plug cap (see Spark Plug Removal), but do not remove the spark plug.

•

Measure the primary peak voltage as follows.

○

Connect a commercially peak voltage adapter [A] to the hand tester [B] (250 V DC range).

Install the needle adapter [C] on the peak voltage adapter leads.

Special Tools - Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Brand: KOWA SEIKI

○

Insert the needle adapter into the terminal of the G/W

(front) or BL/W (rear) primary lead [D].

○

Install a new spark plug [E] into the spark plug cap, and ground it to the engine.

[F] Ignition Coil

WARNING

To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections.

•

Turn the ignition switch ON, rotate the engine for 4

∼

5 seconds with the transmission in neutral to measure the primary peak voltage.

•

Repeat the measurements 5 times for one ignition coil.

Ignition Coil Primary Peak Voltage

Standard: 120 V or more

•

Repeat the test for the other ignition coil.

If the reading is less than the specified value, check the following.

Ignition Coils (see Ignition Coil Inspection)

Crankshaft Sensor (see Crankshaft Sensor Inspection)

If the ignition coils and crankshaft sensor are normal, see the Ignition System Troubleshooting chart on page 17-43.

Crankshaft Sensor Removal

•

Remove:


Crankshaft Sensor Mounting Bolts [A]

Plate [B]





Ignition System

Crankshaft Sensor Installation

•

Install:

Stator Coil Leads [A]

Plate [B]


•

Tighten:

Torque - Crankshaft Sensor Mounting Bolts: 5.9 N·m (0.60


•

Fit the lead grommets into the notch on the alternator cover.

Grommets [A] for Alternator Leads

Grommets [B] for Crankshaft Sensor Leads

Crankshaft Sensor Inspection

•


•

•

Disconnect the crankshaft sensor lead connector [A].

Measure the crankshaft sensor resistance.

○

Connect a hand tester between the BK/W lead and the

BL lead.

○

Set the tester to the × 100

Ω range.

Crankshaft Sensor Resistance

423

∼

517

Ω

If the tester does not read as specified, replace the crankshaft sensor.


Ignition System

Crankshaft Sensor Peak Voltage Inspection

NOTE

○


•

Remove the spark plug caps, but do not remove the spark plugs.

•

Disconnect:

Crankshaft Sensor Lead Connector [A]

•

Set the hand tester [B] to the 10 V DC range.

•

Connect the peak voltage adapter [C] to the hand tester and crankshaft sensor leads in the connector.


Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Brand: KOWA SEIKI

Connections:

Crankshaft Sensor

Lead

Adapter Hand Tester

Black/White

←

Red

→

(+)

Blue

←

Black

→

(–)

•

Turn the ignition switch on, and rotate the engine for 4

∼

5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage.

•

Repeat the measurement 5 or more times.

Crankshaft Sensor Peak Voltage

Standard: 2 V or more

If the peak voltage is lower than the standard, inspect the crankshaft sensor.

Alternator Rotor Inspection

•

Check the timing projection [A] for damage such as chipping or grooving.

If the timing projection on the rotor is visibly damaged, replace the alternator rotor.


Ignition Timing Test

•

Remove the ignition timing inspection plug.

•

Attach a timing light [A] and a tachometer in the manner prescribed by the manufacturer.

Special Tool - Timing Light: 57001-1241

•

Start the engine and aim the timing light at the timing mark on the alternator rotor.

•

Run the engine at the speeds specified and note the alignment of the timing marks.



Ignition System

[A] F or R mark

Ignition Timing

Engine speed r/min (rpm)

1 100 and below

5 000 and above

Slot [B] aligned with:

Advanced mark [C] on alternator rotor

Advanced mark [D] on alternator rotor

NOTE

○

Do not mix up the timing marks with mark [A].

If the ignition timing is incorrect, replace the igniter and the crankshaft sensor.

Vehicle-down Sensor Outline

This sensor has a weight [A] with two magnets inside, and sends a signal to the igniter. But when the vehicle banks 60

∼

70° or more to either side (in fact falls down), the weight turns and shuts off the signal in the vehicle-down sensor circuit. The igniter senses this change, and stops the fuel pump and the ignition system.

Hall IC [B]

Vehicle-down Sensor [A]

Ground Terminal [B] BK/Y

Output Terminal [C] Y/G

Power Source Terminal [D] BR

Constant Voltage Circuit [E]

Hall IC (Integrated Circuit) [F]

Vehicle-down Sensor Circuit [G]

Front [H]


Ignition System

Vehicle-down Sensor Removal

CAUTION

Never drop the vehicle-down sensor, especially on a hard surface. Shock to the sensor can damage it.

•

Remove:


Vehicle-down Sensor Lead Connector [A]

Screws [B]

Vehicle-down Sensor [C]

Vehicle-down Sensor Installation

•

Install the vehicle-down sensor [A] so that the sensor lead base faces forward [B], and the arrow mark [C] on the sensor points upward.

•

Tighten the screws securely.

WARNING

Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power.

The rider could lose balance during certain riding situations, like leaning over in a turn, with the potential for an accident resulting in injury or death. Ensure that the down sensor is held in place by the sensor brackets.

Vehicle-down Sensor Inspection

NOTE

○


Vehicle-down Sensor Power Source Voltage

•

Remove:


Vehicle-down Sensor Lead Connector

•

Connect:

Vehicle-down Sensor Lead Connector [A] (harness side)

Digital Volt Meter [B]

I. Connections to Connector (12 V circuit)

Meter (+)

→ Connector BR Lead [C]

Meter (–)

→ Connector BK/Y Lead [D]

•

Turn the ignition switch ON, and measure the power source voltage.


Standard: Battery Voltage

•

Turn the ignition switch OFF.

If there is no battery voltage, check the following:

Main Fuse 30 A

Ignition Switch

Wiring for Vehicle-down Sensor Power Source




Ignition System

II. Connections to Connector (5 V circuit)

Vehicle-down Sensor Lead Connector [A] (harness side)

Digital Volt Meter [B]

Meter (+)

→ Connector Y/G Lead [E]

Meter (–)

→ Connector BK/Y Lead [D]

•

Turn the ignition switch ON, and measure the power source voltage.


Standard: about 5 V

•

Turn the ignition switch OFF.

If there is no standard voltage, check the following:

Igniter

Wiring for Vehicle-down Sensor Power Source

Vehicle-down Sensor Output Voltage

•

Remove the vehicle-down sensor (see Vehicle-down

Sensor Removal).

•

Connect the vehicle-down sensor [A] to the connector of the harness.

•

Hold the sensor almost vertical [B] with the arrow mark pointed up.

•

Connect:

Vehicle-down Sensor Lead Connector [C]

Digital Volt Meter [D]

Needle Adapters [E]

Special Tool - Needle Adapter Set: 57001-1457

Connection to Connector (5 V circuit)

Meter (+)

→ Connector Y/G Lead [F]

Meter (–)

→ Connector BK/Y Lead [G]

•

Turn the ignition switch ON, and measure the output voltage with the connector joined.

Vehicle-down Sensor Power Output Voltage

Standard: 0.4

∼

1.4 V (with sensor arrow mark pointed up)

•

Tilt the sensor 60

∼

70° or more [H] right or left, and measure the output voltage.

○

The time lag is from 0.5 to 1 second.

Vehicle-down Sensor Power Output Voltage

Standard: 3.7

∼

4.4 V (with sensor tilted 60

∼

70° or more, right or left)

If the output voltage is out of the specified, replace the vehicle-down sensor.


Ignition System

Ignition System Troubleshooting




Ignition System

Ignition System Circuit

1. Ignition Switch

2. Reverse Switch

3. Speed Sensor

4. Fuse Box (Main Fuse 30 A)

5. Multifunction Meter

6. Belt Failure Detection Switch

7. Engine Stop Switch

8. Reverse Power Assist Switch (Override)

9. Reset Connector

10. Crankshaft Sensor

11. Ignition Coils

12. Spark Plugs

13. Battery


15. Igniter

16. Vehicle-down Sensor




Starter Motor Removal

•

Remove:

Air Intake Rubber Duct [A]

•

Remove:

Joint Duct [A] and Collars

•

Remove:

Starter Motor Cable [A]

Starter Motor Mounting Bolts [B]

Clamp [C]

Starter Motor [D]

CAUTION

Do not tap the end of the starter motor shaft or the motor may be damaged.

Starter Motor Installation

•

When installing the starter motor, clean the starter motor lugs [A] and crankcase [B] where the starter motor is grounded.

If the O-ring [A] shows wear or damage, or if it is hardened, replace it with a new one.

•

Apply a small amount of engine oil to the O-ring.




•

Install:

Starter Motor [A]

Clamp [B] (as shown)

Starter Motor Cable [C]

•

Tighten:

Torque - Starter Motor Mounting Bolts: 8.8 N·m (0.90 kgf·m,

78 in·lb)

Starter Motor Terminal Nut: 4.9 N·m (0.50 kgf·m,

43 in·lb)

•

Apply grease to the O-ring [D] in the joint duct [E].

•

Install:

Joint Duct and Collars [F]

Clamp [G] (as shown)

•

Tighten:

Torque - Joint Duct Bolts [H]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

Starter Motor Disassembly

•

Remove:

Starter Motor Bolts [A], Washers and O-rings

Left End Cover [B]

Right End Cover [C]

Yoke [D]

•

To remove the brush plate assembly [A], remove the terminal nut [B].

•

Hold the brush spring [A] with needle nose pliers, and pull the brush [B] off the holder.



Starter Motor Assembly

•

Replace the O-rings.

•

Install the brush plate assembly to the right end cover so that the projection [A] on the brush plate fits into the groove on the right end cover.

•

Install the O-ring, insulators [B], and washer [C] in that order on the terminal bolt.

•

Tighten:

Torque - Starter Motor Terminal Locknut: 6.9 N·m (0.70


•

Install the washers [A].

•

Install the armature [B] between the brushes.


•

Install the yoke [A] onto the right end cover [B] aligning the marks [C] on the yoke and right end cover.

•

Install the washers [A].

•

Install the plate [A] on the left end cover [B].




•

Align the mark [A] on the left end cover with the mark [B] on the yoke.

•

Tighten:

Torque - Starter Motor Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)

Commutator Cleaning/Inspection

•

Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.

•

Measure the diameter [A] of the commutator.

Replace the starter motor with a new one if the commutator diameter is less than the service limit.

Commutator Diameter

Standard:

Service Limit:

28 mm (1.10 in.)

27 mm (1.06 in.)

Armature Inspection

•

Using the × 1

Ω range, measure the resistance between any two commutator segments [A].

If there is a high resistance or no reading (

∞) between any two segments, a winding is open. Replace the starter motor.

•

Using the highest range, measure the resistance between the segments and the shaft [B].

•

If there is any reading at all, the armature has a short.

Replace the starter motor.

NOTE

○

Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.



Starter Motor Brush Length

•

Measure the overall length [A] of each brush.

Starter Motor Brush Length

Standard: 12.5 mm (0.49 in.)


If any is worn down to the service limit, replace the brush plate assembly.


Brush Assembly Inspection

•

Using the × 1

Ω range, measure the resistance as shown.

[A] Terminal Bolt and Positive Brush

[B] Brush Plate and Negative Brush

If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assembly.

Brush Plate and Terminal Bolt Inspection

•

Using the highest range, measure the resistance as follows:

[A] Terminal Bolt and Right - Hand End Cover

[B] Terminal Bolt and Brush Plate

If there is any reading, the brush holder assembly has a short. Replace the brush plate assembly.

Starter Relay Inspection

•

Remove:


Starter Relay [A]

•

Connect the hand tester [A] and a 12 V battery [B] to the starter relay as shown.

If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay

Hand Tester Range: × 1

Ω range

Criteria: When battery is connected

⇒ 0 Ω

When battery is disconnected

⇒

∞

Ω




Starter Circuit Relay Inspection

•

Remove:

Seat (see Frame chapter).

Starter Circuit Relay [A] (Brake Switch Circuit)

Starter Circuit Relay [B] (Neutral Switch Circuit)

○

The starter circuit relays for the brake and neutral switch circuits are identical.

•

Connect the hand tester [A] and a 12 V battery [B] to the starter circuit relay [C] as shown.

If the relay does not work as specified, the relay is defective. Replace the relay.

Testing Relay

Hand Tester Range: × 1

Ω

Criteria: When battery is connected

⇒ 0 Ω

When battery is disconnected

⇒

∞

Ω

Relay Coil Terminals [1] and [2]

Relay Switch Terminals [3] and [4]



Electric Starter Circuit


1. Starter Button

2. Engine Stop Switch

3. Parking Brake Light Switch

4. Front Brake Light Switch

5. Rear Brake Light Switch

6. Main Fuse 30 A

7. Starter Circuit Relay (Brake)

8. Reset Connector

9. Ignition Switch

10. Starter Motor

11. Starter Relay

12. Battery


14. Starter Circuit Relay (Neutral)

15. Neutral Switch




Starter Motor Clutch Removal

•

Remove the alternator rotor (see Alternator Rotor Removal).

•

Hold the rotor with the flywheel holder and take out the starter motor clutch bolts [A].

Special Tool - Flywheel Holder: 57001-1313

•

Take out the one-way clutch [A].

Starter Motor Clutch Installation

•

Install the one-way clutch so that the flange [A] fits on the recess [B] of the race.

•


Starter Motor Clutch Bolts

•

Tighten:

Torque - Starter Motor Clutch Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

Starter Motor Clutch Inspection

•

Remove:

Alternator Rotor (see Alternator Rotor Removal)

•

Fit the starter clutch gear into the starter motor clutch.

If the alternator rotor turns counterclockwise [A] freely from the starter clutch gear, but not clockwise [B], the clutch is operating correctly.

If the clutch does not operate correctly, or if it makes noise, disassemble it and examine each part visually. Replace any worn or damaged parts.

NOTE

○

Examine the starter clutch gear [A]. Replace it if it is worn or damaged.



Torque Limiter Inspection

•

Remove:

Alternator Rotor (see Electrical System chapter)

•

Remove the torque limiter [A] and visually inspect it.

If the limiter has wear, discoloration, or other damage, replace it as a unit.




Lighting System

Headlight Beam Vertical Adjustment

•

Turn the adjusting screw [A] on each headlight rim in or out to adjust the headlight vertically.

NOTE

○

On high beam, the brightest point should be slightly below horizontal with the vehicle on its wheels and the rider seated. Adjust both headlights to the same angle.

Headlight Bulb Replacement

•

Remove:

Connector [A]

Calmp [B]

Screw [C]

•

Remove:

Headlight Bolts [A] and Collasrs

Headlight Body [B]

•

Remove:

Bolts [A]

Vertical Adjustment Screw [B], Spring, and Nut

Headlight Cover [C]

•

Disconnect:

Connector [A]


Lighting System

•

Turn the bulb socket [A] counterclockwise [B], and remove the bulb.


•

Align the mark [A] of a new bulb socket with the mark [B] of the headlight body.

•

Turn the bulb socket clockwise until it is stopped.

•

Disconnect the position light lead connector.

•

Turn the bulb socket [A] counterclockwise [B], and remove the bulb.

•

Align the mark [A] of a new bulb socket with the mark [B] of the headlight body.

•

Turn the bulb socket clockwise until it is stopped.

•


[A] Bolt and Collar [L = 6 mm (0.24 in.)]

[B] Bolt and Collar [L = 4 mm (0.16 in.)]

[C] Bolt (only)



Lighting System

Taillight Bulb Replacement

•

Remove:

Taillight Lens Mounting Screws [A]

Taillight Lens [B]

•

Push the bulb [A] in, turn it counterclockwise, and pull it out.

•

Be sure the socket is clean.

•

Insert the new bulb by aligning the pins [A] with the grooves in the walls of the socket.

•

Push the bulb in, turn it clockwise, and release it. It should lock in position.


Lighting System

Lighting System Circuit



2. Reverse Switch

3. Reverse Light (EUR and GB models)

4. Main Fuse 30 A

5. Front Brake Light Switch

6. Parking Brake Light Switch

7. Rear Brake Light Switch

8. Position Light (Right)

9. Headlight (Right)

10. Headlight (Left)

11. Position Light (Left)

12. Light/Dimmer Switch

13. Reset Connector

14. Ignition Switch

15. Starter Relay

16. Battery


18. Tail/Brake Lights



Radiator Fan System

Radiator Fan Circuit Inspection

•

Remove:

Screw [A]

Left Lower End of Radiator Cover [B]

•

Disconnect the leads from the radiator fan switch [A].

•

Using an auxiliary wire [B], connect the radiator fan switch leads.

If the fan rotates, inspect the fan switch.

If the fan does not rotate, inspect the following.

Leads and Connectors

Main Fuse and Fan Fuse

Fan Motor

Radiator Fan Motor Inspection

•

Disconnect the connector [A] in the fan lead.

•

Using two auxiliary wires, supply battery [B] voltage to the fan motor.

If the fan does not rotate, the fan motor is defective and must be replaced.

Radiator Fan Motor Leads

BL: Battery (+)

BK: Battery (–)

Radiator Fan Breaker Inspection

•

Remove:


Radiator Fan Breaker [A]

•

Inspect the breaker for operation.

•

Connect:

12 V Battery [A]

0.6

Ω Resistance [B]

Radiator Fan Breaker [C]

Switch [D]

If the circuit in the breaker will not open within 60 seconds, replace the breaker.


Radiator Fan System

Radiator Fan Breaker Installation

•

Install:

Radiator Fan Breaker [A]

Holder [B]

•

Connect:

White Lead [C]

Blue/White Lead [D]

[E] Electrical Parts Case

[F] Right Side

Radiator Fan Circuit


1. Radiator Fan Breaker

2. Radiator Fan Switch

3. Main Fuse 30 A

4. Radiator Fan

5. Starter Relay

6. Battery 12 V12 Ah





Fuel Level Sensor Removal

•

Remove:


Electrical Parts Case (see frame chapter)

Fuel Level Sensor Lead Connector [A]

Fuel Level Sensor Mounting Bolts [B]

Fuel Level Sensor [C]

Fuel Level Sensor Installation

•

Install:

New Gasket

Fuel Level Sensor

•

Tighten:

Torque - Fuel Level Sensor Mounting Bolts: 2.0 N·m (0.20


Fuel Level Sensor Inspection

•

Remove:

Fuel Level Sensor (see Fuel Level Sensor Removal)

•

Check that the float moves up and down smoothly without binding. It should go down under its own weight.

If the float does not move smoothly, replace the fuel pump assembly.

•

Using a hand tester [A], measure the resistance across the terminals in the fuel pump lead connector [B].


NOTE

○

In contrast to the normal measuring method, the current that flows through the gauge when measuring it with a tester is very low, thus making the measurement easily affected by the oxidized film of the resistance plate, and resulting in excessive resistance. Therefore, make sure to wipe the resistance plate with alcohol before taking a measurement.

If the readings are not as specified, replace the fuel pump assembly.

Fuel Level Sensor Resistance

Standard: Full Level Position [C]: 120

Ω

Empty Level Position [D]: 3

Ω



Fuel Level Sensor Circuit



2. Fuel Level Sensor

3. Ignition Switch

4. Main Fuse 30 A

5. Starter Relay

6. Battery




Meter

Multifunction Meter Unit Removal

•

Remove:

Handle Cover Screws [A]

•

Remove:

Handle Cover Screws [A]

Handle Cover Front [B]

•

Remove:

Meter Lead Connectors [A]

Handle Cover Screws [B]

•

Remove:

Handle Cover Screw [A]

Handle Cover Rear [B]

•

Remove:

Bracket Mounting Screws [A]

Meter and Bracket [B]

Upper Damper


Meter

•

Remove:

Multifunction Meter Mounting Nuts [A] and Washers

Bracket [B]

Multifunction Meter Unit [C]

CAUTION

Do not drop the meter unit.


Multifunction Meter Unit Inspection

•

Remove:

Multifunction Meter Unit (see Multifunction Meter Unit

Removal)

CAUTION

Do not drop the meter unit.

[A] Meter Unit Lead Connector

[1] Speed Sensor Pulse

[2] Belt Indicator Light (LED) (–)

[3] Water Temperature Sensor (–)

[4] 2WD/4WD LCD Indicator (–)

[5] Fuel Gauge (Fuel Indicator LCD Segments)

[6] Meter Illumination (+)

[7] Reverse Indicator Light (LED) (–)

[8] Neutral Indicator Light (LED) (–)

[9] Ignition (+)

[10] Battery (+)

[11] Oil Pressure Warning Indicator Light (LED)

[12] Battery (–)

LED: Light Emitting Diode

LCD: Liquid Crystal Display

Check 1: LCD Segments Check

•

Using auxiliary wires, connect a 12 V battery to the meter unit connector as follows.

•

Connect the battery positive (+) terminal to terminal [10].

•

•

Connect the battery negative (–) terminal to terminal [12].

Connect terminal [9] to the battery (+) terminal.

○

When the terminal [9] is connected, all the LCD segments appear for one second.

○

When the terminal [9] is disconnected, all the LCD segments disappear.

If this display function does not work, replace the meter unit.



Meter

Check 2: MODE and TIME SET Buttons Operation

Check

•

Connect the wires in the same manner as Check 1.

•

Check that when the MODE button [A] is pushed and held continuously, the display [B] cycles through the four modes.

ODO

→ TRIP A → TRIP B → Hour → ODO


•

Cycle the meter to TRIP A or TRIP B mode.

•

Check that when the SET/RESET button [A] is pushed, the display turns to 0.0.

If this display function does not indicate 0.0 [B], replace the meter unit.

•

Check that when the TIME SET [A] and SET/RESET [B] buttons are pushed, the time [C] will reset.

If the meter function does not work, replace the meter unit.

Check 3: Speedometer Check

•


•

The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal

[1].

○

Indicates approximately 40 mph if the input frequency is approximately 789 Hz.

○

Indicates approximately 40 km/h if the input frequency is approximately 526 Hz.

If the meter function does not work, replace the meter unit.


Meter

Check 4: Odometer Check

•


•

Pushing the MODE button [A], cycles the odometer [B].

•

Raise the input frequency of the oscillator to see the result of this inspection.

If the value indicated by the odometer does not work, replace the meter unit.


Check 5: Trip Meter A/B Check

•


•

Pushing the MODE button [A], cycles the trip meter A or

B [B].

•

Raise the input frequency of the oscillator to see the result of this inspection.

If the value indicated by the trip meter A or B does not increase, replace the meter unit.

•

Check 6: Fuel Meter Check


○

The first segment (LCD) [A] should flash.

It the segment (LCD) does not flash, replace the meter unit.

•

Connect terminal [5] to the battery (–) terminal.

○

When terminal [5] is connected, one segment in the fuel gauge should appear every 15 seconds.

CAUTION

When all segments appeared, disconnect the terminal [5].


•

Check 7: 2WD/4WD Indicator Lights Check


○

The 2WD indicator light (LCD) [A] should appear.



Meter

•


○

The 4WD indicator light (LCD) [A] should appear.


Check 8: Coolant Temperature Warning Symbol Check

•


•


○

The coolant temperature warning symbol (LCD) [A] should appear.


Check 9: Oil Pressure Warning Light Check

•


•



Meter

○

The oil pressure warning light (LED) [A] should flash.

If the LED light does not flash, replace the meter unit.


Check 10: Neutral Indicator Light Check

•


•


○

The neutral indicator light (LED) [A] should go on.

If the LED light does not go on, replace the meter unit.

Check 11: Reverse Indicator Light Check

•


•


○

The reverse indicator light (LED) [A] should go on.

If the LED light does not go on, replace the meter unit.



Meter

Check 12: Meter Illumination Check

•


•

Connect terminal [6] to battery (+) terminal.

○

The meter illumination [A] should go on.

If the illumination does not go on, replace the meter unit.

Check 13: Belt Check Indicator Light check

•


•


○

The belt check indicator light (LED) [A] should go on.

It the LED does not go on, replace the meter unit.

Drive Belt Failure Mode Memory Clearing Procedure

A flashing BELT check indicator LED (Light Emitting

Diode) light means that the drive belt failure detection system has activated. The belt check indicator light will illuminate and stay on when activated by the 100 hour belt check system.

NOTE

○

Follow the instruction on page 2-25 of this Service Manual to complete the necessary inspections.

○

After completing the inspections, follow these instructions to clear the system memory and turn off the light.


Meter

•


•


•

Disconnect both sets of 4 pin connectors [A] in the electrical parts case.


•

Reconnect these 4 pin connectors to their opposite gray to black and black to gray as shown.

•

•


Observe the belt check indicator light [A].

○

It should be flashing quickly.

•

Disconnect the belt switch at the 2 pin connectors [A] above the torque converter cover.

•

Observe the belt check indicator light.

○

It should be flashing slowly.

○

Let it flash for at least five seconds.

NOTE

○

More than five seconds is OK.

•

While observing the belt check indicator light, turn off the ignition switch.

•

Disconnect the mismatched 4 pin connector sets and reconnect them normally. (Black to black, gray to gray) [A]



Meter

•

Connect the belt switch 2 pin connector [A].

•


•

Confirm that no belt check indicator light is flashing.

•

Put the connectors back and bend the clamps.


Meter

Meter Circuit



2. Neutral Switch

3. Reverse Switch

4. Coolant Temperature Switch


6. 2WD/4WD Switch

7. Speed Sensor

8. Main Fuse 30 A

9. Fuel Level Sensor

10. Igniter


12. Oil Pressure Switch

13. Frame Ground Terminal (Meter)

14. Light/Dimmer Switch

15. Reset Connector

16. Ignition Switch

17. Starter Relay

18. Battery 12 V 12 Ah





2WD/4WD Actuator Removal

•

Drain the front final gear case oil (see Front Final Gear

Case Oil Change in Periodic Maintenance chapter).

•

Remove:

Actuator Lead Connector [A]

Clamp [B]

•

Remove:

Actuator Mounting Bolts [A]

Actuator [B]

2WD/4WD Actuator Installation

•

When installing the pin [A], apply engine oil to the rod of the actuator and install the collar [B] on the actuator and then press the pin.

•

Apply grease to the O-ring [C].

•

Apply molybdenum disulfide grease to the collar.

•

Insert the collar into the groove [D] of the shifter so that the long side [E] faces downward.

•

Apply a non-permanent locking agent to the actuator mounting bolts, and tighten them following the tightening sequence [1

∼

3].

Torque - 2WD/4WD Actuator Mounting Bolts: 9.8 N·m (1.0


Engine Brake Actuator Removal

•

Confirm that the ignition switch is in OFF position.

•

Remove:


Actuator Mounting Bolts [A]

Actuator [B]



Engine Brake Actuator Installation

•

Apply grease and Install:

O-ring [A]

•

Apply molybdenum disulfide grease to the pin [B].


•

Apply grease to the trim seal [A] and install the cover [B].

•

Insert the pin into the collar [A] of the engine brake lever assembly [B].

•

Wipe off any protruding grease.

•

Tighten the actuator mounting bolts following the tightening sequence [1

∼

3].

Torque - Engine Brake Actuator Mounting Bolts: 8.8 N·m

(0.90 kgf·m, 78 in·lb)

Actuator Control System Outline

The actuator controller has a microprocessor that detects vehicle speed, state of the selectable 2WD/4WD shift switch, ignition switch, and the forward/reverse movement of the vehicle in order to control the engine brake actuator and selectable 2WD/4WD actuator.





Actuator Control System Troubleshooting

When the actuator fails, the controller enters failure mode and the indicator light illuminates 2WD and 4WD alternately.

[A] 2WD Indicator Light (LCD)

[B] 4WD Indicator Light (LCD)



Failure Indication Pattern and Failure Part

No.

Failure Indication Pattern

1


Failure Part

Selectable 2WD/4WD actuator

2 Engine brake actuator

3

Both the selectable 2WD/4WD actuator and the engine brake actuator

Malfunction Mode

No.

1

2

3

Malfunction Mode

The 2WD/4WD actuator does not operate correctly.

The engine brake actuator does not operate correctly.

The 2WD/4WD indicator light does not switch.

Probable Faulty Part/Location Check Number

2WD/4WD actuator 1

Controller power supply

Speed sensor

2WD/4WD shift switch

3

4

5

6

Controller

Engine brake actuator

Controller power supply

2

3

Speed sensor

F/R detecting sensor

Controller

Indicator light (LCD)

Controller

6

8

4

7

6




Check 1. 2WD/4WD Actuator Inspection

•

Remove:


Clamp [B]

•

Measure the resistance between the following terminals in the actuator lead connector [A].


Actuator Internal Resistance

4 (Red) - 6 (Black):

1 (Orange) - 3 (Blue):

2 (Yellow) - 3 (Blue):

3

∼

15

Ω

3.5

∼

6.5 k

Ω

630

∼

3,720

Ω

If any reading is not within the specified range, replace the 2WD/4WD actuator.

Check 2. Engine Brake Actuator Inspection

•

Remove:


•

Measure the resistance between the following terminals in the actuator lead connector [A].


Actuator Internal Resistance

4 (Red) - 6 (Black):

1 (Orange) - 3 (Blue):

2 (Yellow) - 3 (Blue):

3

∼

15

Ω

3.5

∼

6.5 k

Ω

630

∼

5,330

Ω

If any reading is not within the specified range, replace the engine brake actuator.



Check 3. Controller Power Supply Inspection

NOTE

○


•

Remove:


•

Connect:

Controller Connector [A]

Hand Tester [B] (range: DC 25 V)

Tester (+)

→ Connector (BR) Terminal [9]

Tester (–)

→ Connector (BK/Y) Terminal [10]

○

Install the needle adapters on the tester leads.



•

Turn ON the ignition switch.

Controller Power Supply Voltage

Standard: near Battery Voltage

If the reading is not battery voltage, check the wiring harness, 30 A fuse, or ignition switch.

Check 4. Speed Sensor Inspection

NOTE

○


•


•

Remove:


•

Connect:



Tester (+)

→ Connector (P) Terminal [5]

Tester (–)


○




•


•

Spin a rear wheel, measure the voltage.

Speed Sensor Output Voltage

Standard: repeat from 0 to 5 V

If the reading is not standard, replace the speed sensor.

When installing a new O-ring on the speed sensor, apply grease all around the O-ring. Insert the speed sensor to the fully seated position before tightening the mounting bolt for the sensor.

NOTE

○

If the sensor is not fully seated before tightening the bolt, the O-ring can be damaged and oil may leak.





Check 5. 2WD/4WD Shift Switch Inspection

NOTE

○


•

Remove:


•

Connect:



Tester (+)

→ Connector (G) Terminal [7]

Tester (–)


○




•


•

Push the switch to the 4WD position.

Controller Output Voltage (at 2WD/4WD Shift Switch OFF,

4WD)

Standard: about 5 V

If the reading is not standard, check the 2WD/4WD shift switch or actuator controller unit.

•

Push the switch to the 2WD position.

Controller Output Voltage (at 2WD/4WD Shift Switch ON,

2WD)

Standard: 0 V

If the reading is not standard, check the 2WD/4WD shift switch or actuator controller unit.

Check 6. Controller Unit Inspection

NOTE

○


•

Remove:


•

Connect:



Tester (+)

→ Connector (O) Terminal [2]

Tester (–)


○




•


•

Measure the controller output voltage for the actuators.

Controller Output Voltage (to Actuators)

Standard: 4.8 ±0.2 V

If the reading is not standard, replace the actuator controller unit.



•

Disconnect the speed sensor lead connector.

•

Connect:



Tester (+)

→ Connector (P) Terminal [5]

Tester (–)


○




•


•

Measure the controller output voltage for the speed sensor.

Controller Output Voltage (to speed sensor)

Standard: 5 ±0.25 V


•

Disconnect the 2WD/4WD shift switch lead connector.

•

Connect:



Tester (+)

→ Connector (G) Terminal [7]

Tester (–)


○




•


•

Measure the controller output voltage for the 2WD/4WD shift switch.

Controller Output Voltage (to 2WD/4WD shift switch)

Standard: 5 ±0.25 V






•


•

Connect:



Tester (+)

→ Connector (W/R) Terminal [15]

Tester (–)


○




•


•

Spin a rear wheel as forward rotation.

•

After the wheels stop and one second elapses, turn OFF the ignition switch.

•

After two seconds elapses, measure the controller output voltage for the engine brake actuator until the actuator stops.

Controller Output Voltage (to engine brake actuator)

Standard:

5

∼

12 V

If the reading is not standard, check the forward/reverse detecting sensor.

If the forward/reverse detecting sensor is normal, replace the actuator controller unit.

•


•

Run the engine and shift to the 4WD position.

•

Stop the engine and turn OFF the ignition switch.

•

Connect:



Tester (+)

→ Connector (W/Y) Terminal [13]

Tester (–)


○




•


•

Shift to the 2WD position.

•

Measure the controller output voltage for the 2WD/4WD actuator until the actuator stops.

Controller Output Voltage (to 2WD/4WD actuator)

Standard: 5

∼

12 V

If the reading is not standard, check the 2WD/4WD shift switch.

If the 2WD/4WD shift switch is normal, replace the actuator controller unit.



Check 7.

Forward/Reverse Detecting Sensor

Inspection

•

Disconnect forward/reverse detecting sensor lead connector [A].

•

Measure the forward/reverse detecting sensor resistance.

○

Connect the hand tester between the BK lead and the W lead.

○

Set the tester to the × k

Ω range.


Forward/Reverse Detecting Sensor Resistance

Standard: 1.2

∼

1.6 k

Ω

If the reading is not within the specified range, replace the forward/reverse detecting sensor.

•

Using the highest resistance, measure the resistance between forward/reverse detecting sensor leads and chassis ground.

If the tester reading is less than infinity (

∞) indicates a short, replace the forward/reverse detecting sensor.

Check 8. Indicator Light (LCD) Inspection

•

Refer to Check 7: 2WD/4WD Indicator Lights Check in

Multifunction Meter Unit Inspection.





Actuator Control System Circuit

1. Speed Sensor

2. Forward/Reverse Detecting Sensor

3. 2WD/4WD Actuator

4. Engine Brake Actuator


6. Ignition Switch

7. Controller Fuse 10 A

8. Main Fuse 30 A


10. 2WD/4WD Shift Switch

11. Igniter


13. Starter Relay

14. Battery



Drive Belt Failure Detection System

If the drive belt failure detection system activated by abnormal belt, the drive belt failure detection switch is damaged. Make sure replace the torque converter cover (see

Converter System chapter).

Drive Belt Failure Detection System Inspection

•

Refer to the Drive Belt Failure Detection System Inspection in the Periodic Maintenance chapter.

Drive Belt Failure Detection System Circuit




3. 2WD/4WD Shift Switch

4. Main Fuse 30 A

5. Igniter

6. Drive Belt Failure Detecting Switch

7. Ignition Switch

8. Starter Relay

9. Battery





Air Temperature Sensor Inspection

•

Remove:

Air Cleaner Housing (see Fuel System chapter)

Air Temperature Sensor [A]

•

Connect the battery [A] and hand tester [B] to the sensor lead connector [C].


Battery

(+)

→ Red and Yellow Leads

(

−) → Black Lead

Hand Tester

(+)

→ White Lead

(

−) → Black Lead

CAUTION

Use the sensor within

− 30

∼

80°C (

− 22

∼

176°F). If it is used without the specified range, the sensor will be damaged.

•

Suspend the sensor [A] in a container of cold water of less than 8°C (46.4°F) so that the temperature sensing part [B] is submerged as shown.

[C] Ice

•

Suspend an accurate thermometer [D] in the water.

•

Measure the output voltage between W/Y terminal and battery (–) terminal (tester range: DC 25 V).

Air Temperature Sensor: less than 8°C (46.4°F)

Output Voltage: 8

∼

16 V (near battery voltage)

If the voltage is less than DC 0.1 V, replace the sensor.

•

Warm up the sensor [A] more than 22°C (71.6°F) with a hand.

•

Measure the output voltage between W/Y terminal and battery (–) terminal (tester range: DC 2.5 V).

Air Temperature Sensor: more than 22°C (71.6°F)

Output Voltage: less than 0.1 V

If the voltage is 8

∼

16 V, replace the sensor.



Carburetor Heater Inspection

•

Disconnect:

Carburetor Heater Lead Connectors [A]

Ground Lead Connector [B]

•

Using the hand tester, measure the resistance of the heater.

•

Connect the tester between the heater terminal and the ground terminal.

If the tester does not read as specified, replace the heater.

Carburetor Heater Resistance

11

∼

20

Ω

Carburetor Heater System Circuit


1. Carburetor Heaters 12 V 23 W


3. Ignition Switch

4. Main Fuse 30 A

5. Alternator

6. Starter Relay

7. Battery




Switches

Brake Light Switch Adjustment

•

Refer to the Brake Light Switch Inspection and Adjustment in the Periodic Maintenance chapter.

Radiator Fan Switch Inspection

•

Remove:

Radiator Fan Switch (see Cooling System chapter)

•

Suspend the fan switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.

•

Suspend an accurate thermometer [B] in the coolant.

NOTE

○

The switch and thermometer must not touch the container sides or bottom.

•

Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently.

•

Using the hand tester, measure the internal resistance of the switch across the terminals at the temperatures shown in the table.

If the hand tester does not show the specified values, replace the switch.

Radiator Fan Switch Resistance

Rising Temperature:

From OFF to ON at 96

∼

100°C (205

∼

212°F)

Falling Temperature:

From ON to OFF at 91

∼

95°C (196

∼

203°F)

ON: Less than 0.5

Ω

OFF: More than 1 M

Ω


Switches

Coolant Temperature Warning Light Switch Inspection

•

Remove:

Coolant Temperature Warning Light Switch (see Cooling

System chapter)

•

Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.

•

Suspend an accurate thermometer [B] in the coolant.

NOTE

○

The switch and thermometer must not touch the container sides or bottom.

•

Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently.

•

Using the hand tester, measure the internal resistance of the switch across the connector and the body at the temperatures shown in the table.

If the hand tester does not show the specified values, replace the switch.

Coolant Temperature Warning Light Switch Resistance

Rising Temperature:

From OFF to ON at 112

∼

118°C (234

∼

244°F)

Falling Temperature:

From ON to OFF at 108

∼

111°C (226

∼

232°F)

ON: Less than 0.5

Ω

OFF: More than 1 M

Ω

Switch Inspection

•

Using the hand tester, check to see that only the connections shown in the table have continuity (about zero ohms).

○

For the handlebar switches, ignition switch, refer to tables in the Wiring Diagram.

If the switch has an open or short, repair or replace it with a new one.




Switches

Neutral Switch Connection

[A] Neutral Switch

Reverse Switch Connections

[B] Reverse Switch

2WD/4WD Shift Switch

Oil Pressure Switch Connections*

*: Engine Iubrication system is in good condition

Drive Belt Failure Detection Switch

If the drive belt failure detection system is activated by abnormal belt, the drive belt failure detection switch is damaged. Make sure to replace the torque converter cover (see

Converter System chapter).

•

Remove:


[A] Drive Belt Failure Detection Switch


Fuses

Fuse Removal

•

Remove:


Lid [A]

•

Pull the fuses [A] straight out of the fuse box with needle nose pliers.


Fuse Installation

If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.

•

Install the fuses on the original position as specified on the lid [A].

Fuse Inspection

•

Inspect the fuse element.

If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.

Housing [A]

Fuse Element [B]

Terminals [C]

Blown Element [D]

CAUTION

When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause damage to wiring and components.



APPENDIX 18-1

Appendix


Troubleshooting Guide ...........................................................................................................

Cable, Wire, and Hose Routing ..............................................................................................

18-2

18-7

18


18-2 APPENDIX

Troubleshooting Guide

NOTE

○

This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist

Spark plug cap not in good contact

Spark plug incorrect

Crankshaft sensor trouble

Igniter trouble

the troubleshooting for some of the more common difficulties.

Ignition coil trouble

Battery voltage low

Ignition or engine stop switch shorted

Engine Doesn’t Start, Starting Difficulty:

Wiring shorted or open

Starter motor not rotating:

Fuse blown

Neutral switch trouble

Compression Low:

Starter motor trouble

Spark plug loose

Battery voltage low

Cylinder head not sufficiently tightened

Relays not contacting or operating down

Starter button not contacting

No valve clearance

Wiring open or shorted

Cylinder, piston worn

Ignition switch trouble

Piston ring bad (worn, weak, broken, or

Engine stop switch trouble sticking)

Fuse blown

Piston ring/groove clearance excessive

Starter motor rotating but engine doesn’t

Cylinder head gasket damaged

turn over:

Cylinder head warped

Starter motor clutch trouble

Valve spring broken or weak

Recoil starter not operating

Valve not seating properly (valve bent,

Recoil starter spring broken worn, or carbon accumulation on the

Recoil starter pawl not engaging seating surface)

Engine won’t turn over:

Compression release cam (K.A.C.R.) sticks

Valve seizure open (Engine stalls when moving off)

Rocker arm seizure

Poor Running at Low Speed:

Cylinder, piston seizure

Spark weak:

Crankshaft seizure

Spark plug dirty, broken, or maladjusted

Connecting rod small end seizure

Spark plug cap or spark plug lead trouble

Connecting rod big end seizure

Spark plug cap shorted or not in good con-

Transmission gear or bearing seizure tact

Camshaft seizure


No fuel flow:

Igniter trouble

Fuel tank air vent obstructed


Fuel tap clogged


Fuel line clogged

Battery voltage low

Float valve clogged

Fuel/air mixture incorrect:

Fuel pump damaged or circuit open/short

Pilot screw and/or idle adjusting screw mal-

Engine flooded:

adjusted

Fuel level too high

Pilot jet or air passage clogged

Float valve worn or stuck open

Starter plunger stuck open

Starting technique faulty

Air cleaner clogged, poorly sealed, or miss-

(When flooded, crank the engine with the ing throttle

Fuel level too high or too low fully opened to allow more air to reach the

Fuel tank air vent obstructed engine.)

Carburetor holder loose


Air cleaner duct loose

Pilot screw and/or idle adjusting screw mal-

Compression low:

adjusted

Spark plug loose

Pilot jet or air passage clogged

Cylinder head not sufficiently tightened

Air cleaner clogged, poorly sealed, or missing

Starter jet clogged



No valve clearance


Piston ring bad (worn, weak, broken, or sticking)

Spark plug cap or spark plug lead trouble down


APPENDIX 18-3



Cylinder head warped


Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)

Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off)

Other:

Carburetor vacuum piston doesn’t slide smoothly

Engine oil viscosity too high

Brake dragging

Igniter trouble

Front or rear final gear case oil viscosity too high

Poor Running or No Power at High Speed:

Firing incorrect:


Spark plug cap or spark plug lead trouble

Spark plug cap shorted or not in good contact



Igniter trouble


Drive belt failure detection switch activated


Main jet clogged or wrong size

Jet needle or needle jet worn

Main air jet clogged

Bleed holes of air bleed pipe or needle jet clogged

Fuel level too high or too low

Air cleaner clogged, poorly sealed, or missing


Water or foreign matter in fuel



Fuel tank air vent obstructed

Fuel tap clogged

Fuel line clogged

Compression low:

Spark plug loose

Cylinder head not sufficiently tightened down

No valve clearance


Piston rings bad (worn, weak, broken, or sticking)




Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface.)

Compression release cam (K.A.C.R.) sticks open (Engine stalls when moving off)

Knocking:

Carbon built up in combustion chamber

Fuel poor quality or incorrect


Igniter trouble

Miscellaneous:

Throttle valve won’t fully open

Carburetor vacuum piston doesn’t slide smoothly

Brake dragging

Overheating

Engine oil level too high


Front or rear final gear case oil viscosity too high

Overheating:

Firing incorrect:



Igniter trouble


Main jet clogged

Fuel level too low


Air cleaner poorly sealed, or missing


Air cleaner clogged

Compression high:


Engine load faulty:



Drive train trouble

Brake dragging

Lubrication inadequate:

Engine oil level too low

Engine oil poor quality or incorrect

Front or rear final gear case overheating:

Insufficient oil

Bevel gears maladjusted

LSD clutches in front final gear case maladjustment

Coolant incorrect:

Coolant level too low

Coolant deteriorated

Thick coolant

Cooling system component incorrect:

Radiator clogged

Thermostat trouble

Radiator cap trouble

Radiator fan switch trouble

Fan motor broken

18-4 APPENDIX


Fan blade damaged

Water pump not turning

Water pump impeller damaged

Over Cooling:

Cooling system component incorrect:

Radiator fan switch trouble

Thermostat trouble

Converter Operation Faulty:

Belt slipping:

Belt dirty, worn, or wetted

Drive or driven pulley sheave dirty or worn

Drive pulley spring broken or weak

Converter engagement speed too low:

Drive pulley spring broken or weak

Converter engagement speed too high:

Belt dirty or worn


Drive pulley weight doesn’t move smoothly

Drive pulley movable sheave doesn’t move smoothly

Drive or driven pulley movable sheave bush worn

Drive pulley weight or roller worn

Shifting too quickly:

Drive pulley spring weak

Driven pulley spring weak or incorrectly installed (too loose)

Shifting too slowly:

Belt dirty or worn


Drive pulley weight doesn’t move smoothly

Drive pulley movable sheave doesn’t move smoothly

Drive pulley spring incorrect installed (too tight)

Driven pulley movable sheave doesn’t move smoothly

Gear Shifting Faulty:

Doesn’t go into gear:

Shift arm bent or seized

Gear stuck on the shaft

Shift tie-rod maladjusted

Shift tie-rod damaged

Jumps out of gear:

Shifter groove worn

Gear dogs worn

Shift block worn

Shift arm positioning bolt spring weak or broken


Drive shaft, output shaft, and/or gear splines worn

Overshifts:

broken


Abnormal Engine Noise:

Knocking:

Igniter trouble


Fuel poor quality or incorrect


Overheating

Piston Slap:

Cylinder/piston clearance excessive


Connecting rod bent

Piston pin, piston holes worn

Valve noise:

Valve clearance incorrect


Camshaft bearing worn

Rocker arm worn

Other noise:

Connecting rod small end clearance excessive

Connecting rod big end clearance excessive

Piston ring worn, broken, or stuck

Piston seizure, damage

Cylinder head gasket leaking

Exhaust pipe leaking at cylinder head connection

Crankshaft runout excessive

Engine mounts loose

Crankshaft bearing worn

Camshaft chain tensioner trouble

Camshaft chain, sprocket, guides worn

Loose alternator rotor

Abnormal Drive Train Noise:

Converter noise:

Belt worn

Drive or driven pulley sheave worn

Drive or driven pulley movable sheave bush worn

Drive or driven pulley mount loose

Driven pulley shoe worn

Drive pulley weight or roller side washer worn

Drive pulley weight or roller worn

Wear guides worn

Transmission noise:

Bearing worn

Transmission gears worn or chipped

Metal chips jammed in gear teeth

Engine oil insufficient or too thin

Front or rear final gear case noise:

Insufficient lubricant

Incorrect oil (Front final gear case)

Bevel gear bearings worn

Bevel gears worn or chipped

Bevel gears maladjusted

APPENDIX 18-5


Worn LSD clutch friction plate (Front final gear case)

Thrust plug maladjusted (Rear final gear case)

Damaged side gears or pinions (Front final gear case)

Abnormal Frame Noise:

Shock absorber noise:

Shock absorber damaged

Disc brake noise:

Pad installed incorrectly

Pad surface glazed

Disc warped

Caliper trouble

Rear brake noise:

Foreign matter in hub

Brake not properly adjusted

Other noise:

Bracket, nut bolt, etc. not properly mounted or tightened

Exhaust Smokes Excessively:

White smoke:

Piston oil ring worn

Cylinder worn

Valve oil seal damaged

Valve guide worn



Black Smoke:

Air cleaner clogged

Main jet too large or fallen off


Fuel level too high

Brown smoke:

Main jet too small

Fuel level too low


Air cleaner poorly sealed or missing

Handling and/or Stability Unsatisfactory

Handlebar hard to turn:

Tire air pressure too low

Steering stem bearing damaged

Steering stem bearing lubrication inadequate

Steering stem bent

Damaged steering knuckle joint

Damage tie-rod end

LSD clutch maladjusted (front final gear case)

Noise when turning:

Damaged side gear or pinion (front final gear case)

Worn LSD clutch friction plates (Front final

Handlebar shakes or excessively vibrates:

Tire worn

Wheel rim warped

Rear axle runout excessive

Wheel bearing worn

Handlebar clamp loose

Steering stem clamp bolt loose

Handlebar pulls to one side:

Frame bent

Wheel maladjustment

Suspension arm bent or twisted

Steering stem bent

Front or rear tire air pressure unbalanced

Front shock absorber unbalanced

Shock absorption unsatisfactory:

Too hard:

Tire air pressure too high

Shock absorber maladjusted

Too soft:

Shock absorber oil leaking

Shock absorber spring weak

Tire air pressure too low

Shock absorber maladjusted

Brake Doesn’t Hold

Front brake:

Air in the brake line

Brake fluid leakage

Brake fluid deteriorated

Primary or secondary cup trouble

Master cylinder scratched inside

Pad overworn or worn unevenly

Oil, grease on pads and disc

Disc worn or warped

Brake overheated

Rear Brake:

Brake not properly adjusted

Plates worn

Brake parts worn or damaged

Kawasaki Engine Brake Control and

Selectable 2WD/4WD System Malfunction:

Actuators failed

Speed sensor short or open

Forward/Reverse detecting sensor short or open

Actuator controller failed

Controller 10A fuse blown

Battery disconnected

18-6 APPENDIX


Battery Discharged:

Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte level too low)

Battery leads making poor contact

Load excessive (e.g., bulb of excessive wattage)

Ignition switch trouble

Regulator/rectifier trouble

Alternator trouble

Wiring faulty

Battery Overcharged:

Regulator/rectifier trouble

Battery trouble


Cable, Wire, and Hose Routing

APPENDIX 18-7

1. Tube

2. Clamps

3. Align the white paint mark on the tube with the adjustment mark on the crankcase.

4. Starter Motor

5. Install the oil pressure switch lead not to interfere with starter motor.


18-8 APPENDIX


1. Starter Motor Lead

2. Engine Ground Lead (Install the lead so that the flat side of the lower terminal faces toward the engine.)

3. Install the clamp on the engine ground lead.

4. Drive Belt Failure Detecting Switch Lead Connector

5. Engine Brake Actuator Lead Connector

6. Clamps



APPENDIX 18-9

1. Clamp

2. Vacuum Hose

3. Clamps

4. Boot

5. Clamps

6. Choke Cable Plunger

7. Water Hose

8. White Paint

9. Mark

10. Water Pipe

11. Coolant Catch Tank


13. Ignition Coil Lead

18-10 APPENDIX


1. Air Cleaner Cover

2. Breather Tank

3. Breather Hoses

4. Breather Hose

5. Check Valve

6. Duct Screw

7. Air Intake Duct

8. Drain Tube

9. Drain Tube

10. Engine Breather Hose



APPENDIX 18-11

1. Main Harness

2. Bands

3. Vacuum Hose (Blue Line)

4. Ignition Coil Lead

5. Torque Converter Air Duct

6. Fuel Hose (Red Line)

7. Vacuum Hose

8. Clamps

9. Drain Hose

10. Crankshaft Sensor Lead

12. Alternator Lead

13. 2WD/4WD Actuator Lead

14. Plug

15. Frame Pipe

16. Rear Final Gear Case Breather Hose

17. Starter Motor Cable

18. Engine Ground Leads

19. No Interference

20. Engine Side

21. Install the clamp so it does not interfere

11. Oil Pressure Switch Lead with the harness.

Position the clamp


22. 60°

18-12 APPENDIX


1. Rear Final Gear Case Breather Tube

2. Front Final Gear Case Breather Tube

3. Fuel Breather Tube

4. Radiator Fan Motor Breather Tube

5. Bands

6. Main Harness

7. Outside

8. Fix breather tube to right frame pipe.

9. Water Hose

10. Water Hose

11. Radiator Mounting Bracket

12. Damper

13. Collar

14. Radiator Screen

15. Nut

16. Frame Pipe

17. about 5 mm (0.20 in.)



APPENDIX 18-13

1. Not crush fan motor breather tube to pull it.

2. Clamps

3. Fan Motor Breather Tube

4. Fan Motor Lead Connector

5. To Thermostat

6. To Water Pump

7. Water Hose

8. Band

9. Reserve Tank


18-14 APPENDIX


1. Water Hose

2. Water Pipe

3. Coolant Temperature Warning Light Switch

4. Water Hose

5. Thermostat

6. Clamp

7. Reserve Tank

8. Reverse Switch Lead

9. Neutral Switch Lead

10. Clamp

11. Forward/Reverse Detecting Sensor Lead Connector



APPENDIX 18-15

1. Clamp

2. 2WD/4WD Actuator Lead

3. Air Intake Duct

4. Band

5. Front Final Gear Case

6. Carburetor Air Vent Tube

7. No Interference


18-16 APPENDIX


1. Maine Harness

2. Drive Belt Failure Detecting Switch Lead

3. Engine Brake Actuator Lead

4. Starter Motor Cable

5. Clamp

6. Drive Belt Failure Detecting Switch

7. Engine Brake Actuator



APPENDIX 18-17

1. Vacuum Hose (to rear cylinder head with blue line)

2. Connect the thick side of hose to the fuel pump.

3. Fuel Hose (to carburetor with red line)

4. Clamps

5. Vacuum Hose (to front cylinder head)

6. Fuel Pump

7. Rubber Cover



18-18 APPENDIX


1. Rear Brake Lever

2. Parking Brake Lock Lever

3. Variable Differential Control Cable

4. Cable Adjuster

5. Variable Differential Control Lever

6. Handle Holder Clamp

7. Variable Differential Operating Lever

8. Fit the dust cap.

9. 27

∼

35 mm (1.1

∼

1.4 in.)



APPENDIX 18-19

1. Clamp

2. Bands

3. Radiator Fan Motor Breather Tube

4. Fuel Breather Tube

5. Final Gear Case Breather Tubes

6. Joint

7. Tube

8. Dampers

9. Bands

10. 220 mm (8.66 in.)

11. 60 mm (2.36 in.)


18-20 APPENDIX


1. Right Headlight Lead

2. Radiator Cover

3. Frame Ground Lead

4. Horn Switch Lead (Australia and Europe Models)

5. Alternator, Crankshaft Sensor and Oil Pressure Switch Leads

6. Rear Brake Light Switch Lead

7. 2WD/4WD Shift Switch Lead

8. Left Handlebar Switch Lead

9. Meter Lead

10. Front Brake Light Switch Lead

11. Bands

13. Radiator Fan Switch Lead

14. Ignition Coil Primary Lead

15. Radiator Fan Motor Lead


APPENDIX 18-21

1. Right Handlebar Switch Lead

2. Throttle Cable

3. Meter Lead

4. Variable Differential Control Cable

5. Parking Brake Cable

6. Choke Cable

7. Left Handlebar Switch Lead

8. Bands

9. Front Brake Light Switch Lead

10. Brake Hose

11. Tubes

13. Leads

14. Rear Brake Light Switch Lead

18-22 APPENDIX


1. Air Intake Duct

2. Bands

3. Parking Brake Cable

4. Foot Brake Cable

5. Bracket

6. Clamp

7. Foot Brake Light Switch

8. Speed Sensor Lead Connector

9. Run the lead front side of frame pipe.

10. Clamps

11. Reverse Switch Lead Connector

13. Forward/Reverse Detecting Sensor Lead Connector

14. Apply grease (Amoco Rykon Premium Grease No.2 EP Green)


APPENDIX 18-23

1. Fuse Box

2. Igniter

3. Main Harness

4. Clamp


6. Reset Connectors

7. Starter Circuit Relay (Neutral)

8. Electric Parts Case

9. Vehicle Down Sensor

10. Starter Circuit Relay (Brake)

11. Clamp

13. Starter Relay

14. Battery (+) Cable

15. Run the cable under the case.

18-24 APPENDIX


1. Main Harness

2. Battery (

−) Cable

3. Bands

4. To Brake Switch

5. Clamps

6. Fuse Box Lead

7. To Igniter

8. To Actuator Controller

9. To Starter Relay

10. Battery (+) Cable

11. Reset Connector

12. To Starter Circuit Relay (Neutral)

13. To Vehicle Down Sensor

14. To Starter Circuit Relay (Brake)

15. Accessory Connector

16. To Tail/Brake Light

17. To Reverse Light (Europe Model)

18. Regulator/Rectifier

19. Run the lead inside of frame pipe.

20. White Tape

21. Run the lead under side of frame pipe.

22. Insert the clamp into hole of frame.

23. To Speed Sensor

24. Insert the band into hole of frame.

25. To Engine Brake Actuator

26. To Drive Belt Failure Detection Switch

27. Engine Ground Lead Terminal

28. Frame Ground Lead



APPENDIX 18-25

1. To Left Headlight

2. Run the radiator fan switch inside of frame pipe.

3. Clamps

4. To Power Outlet Connector

5. Front Ignition Coil

6. To Air Temperature Sensor

7. Clamps

8. Main Harness

9. Rear Ignition Coil

10. Frame Ground Terminal

11. To Carburetor Heater

12. To Water Temperature Switch

13. To Radiator Fan Motor

14. To 2WD/4WD Actuator

15. To Ignition Switch

16. To Right Headlight

17. Radiator Cover

18. Band


18-26 APPENDIX


1. Battery

2. Red Cap

3. From Starter Motor

4. Run the battery cable under the frame pipe.

5. Insert the clamp info the hole of bottom side.



APPENDIX 18-27

1. Belt Converter Intake Duct

2. Bands

3. Rear Final Gear Case Breather Tube

4. Rear Final Gear Case


Year

2005

2005

MODEL APPLICATION

Model

KVF750-A1

KVF750-B1

Beginning Frame No.

JKAVFDA1

□

5B500001 or

JKAVF750AAB600001

JKAVFDB1

□

5B500001

□

:This digit in the frame number changes from one machine to another.


Part No.99924-1334-02

Printed in Japan

Kawasaki Brute Force 750 Service manual

BRUTE FORCE 750 4×4i

KVF 750 4×4

All Terrain Vehicle

Service Manual

Quick Reference Guide

BRUTE FORCE 750 4×4i

KVF 750 4×4

All Terrain Vehicle

Service Manual

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

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 removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded.

b.Use of replacement parts or accessories which adversely affect the performance or durability of the vehicle.

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.

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

(US MODEL only)

Foreword

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

How to Use This Manual

GENERAL INFORMATION 1-1

General Information

1-2 GENERAL INFORMATION

Battery Ground

Edges of Parts

Solvent

Cleaning vehicle before disassembly

Arrangement and Cleaning of Removed Parts

GENERAL INFORMATION 1-3

Storage of Removed Parts

Inspection

Replacement Parts

Assembly Order

1-4 GENERAL INFORMATION

Tightening Sequence

Tightening Torque

Force

Gasket, O-ring

Liquid Gasket, Locking Agent

Press

GENERAL INFORMATION 1-5

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

1-6 GENERAL INFORMATION

Lubrication

Direction of Engine Rotation

Electrical Wires

GENERAL INFORMATION 1-7

1-8 GENERAL INFORMATION

GENERAL INFORMATION 1-9

1-10 GENERAL INFORMATION

GENERAL INFORMATION 1-11

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

2-4 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-7

2-8 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-9

2-10 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-11

2-12 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-13

2-14 PERIODIC MAINTENANCE

Throttle Lever Free Play Inspection

Throttle Lever Free Play Adjustment

Choke Lever Free Play Inspection

Choke Lever Free Play Adjustment

PERIODIC MAINTENANCE 2-15

Idle Speed Inspection

2-16 PERIODIC MAINTENANCE

Idle Speed Adjustment

Fuel System Cleanliness Inspection