Kawasaki Voyager XII Service Manual

Kawasaki
··J/·XH
Motorcycle
Ser-vice Manual
Quick Reference Guide
Fuel System
1
2
Cooling System
3
Engine Top End
4
Clutch
Engine Lubrication System
5
6
Engine Removal/Installation
7
Crankshaft/Transmission
8
9
General Information
, Wheels/Tires
Brakes
10
11
Suspension
12
Steering
13
Frame
14
Electrical System
15
Appendix
16
Final Drive
Th is quick refe rence guide will assist you in
locating a desired topic or procedure .
• Send the pages back to match the black
tab of the des ired chapter number with
the black tab on the edge at each table
of contents page.
eRefer to the sec tional table of contents for
the exact pages to loca te the specific topic
required.
xu
KaVlasaki
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products
Group/ Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every
possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an
obligation to make such changes to products manufactured previously. See your Motorcycle dealer
for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at
the time of publication. Illustrations and photographs in this publication are intended for reference
use only and may not depict actual model component parts.
@Kawasakl Heavy Industries. Ltd .. 1986
First Edition (9): June 25. 1997 (K)
LIST OF ABBREVIATIONS
A
ampere(s)
ABOC
after bottom dead center
AC
alternating current
ATOC
after top dead center
BBOC
before bottom dead center
BOC
bottom dead center
BTOC
before top dead center
°c
degree(s) Celsius
DC
direct current
F
farad(s)
of
degree( s) F ah renheit
ft
foot, feet
g
gram(s)
h
houris)
L
liter(s)
Ib
pound(s)
m
meter(s)
min
minute(s)
N
newton(s)
Pa
pascal(s)
PS
horsepower
psi
pound(s) per square inch
r
revolution
rpm
revolution(s) per minute
TOG
top dead center
TIR
total indicator reading
V
W
volt(s)
n
ohm(s)
watt(s)
Read OWNER'S MANUAL befqre operating
I
~
ti
~
i•
I
•I
•
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase
emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control
system (3) in compliance with applicable regulations of the California Air Resources Board
on vehicles sold in California only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors i nto the atmosphere. Instead,
the vapors are routed through an oil separator to the intake side of the engine. While
the engine is operating, the vapors are drawn into combustion chamber, where they are
burned along with the fuel and air supplied by the carburetion system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the
exhaust of this motorcycle. The fuel and ignition systems of this motorcycle have
been carefully designed and constructed to ensure an efficient engine with low exhaust
pollutant levels.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are ·not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored
in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and
returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains
what is commonly referred to as the Act's "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited ...
(3)(A) for any person to remove or render inoperative any device or element of design
i nstalled on or in a motor vehicle or motor vehicle engine in compliance with
regulations under this title prior to its sale and delivery to the ultimate purchaser,
or for any manufacturer or dealer knowingly to remove or render inoperative any
such device or element of design after such sale and delivery to the ultimate
purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or
trading motor vehicles or motor vehicle engines, or who operates a fleet of motor
vehicles knowingly to remove or render inoperative any device or element of
design installed on or in a motor vehicle or motor vehicle engine in compliance
with regulations under this title following its sale and delivery to the ultimate
purchaser ... "
(Continued on next page)
NOTE
:m
~~
~
~v..
~
._.
~m
~~
••
~
~
~~
~
m
0 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 motorcycle.
c. Addition of components or accessories that result in the vehicle exceeding the
standards.
d. Permanently removing. disconnecting. or rendering inoperative any component
or element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS DF FEDERAL
LAW. THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT
EXCEEDING $10.000 PER VIOLATION .
~
~
~
~
~
,
tr.i
~I!
~~
~
~
:fl!
In~
~
~
~d
~:f':
pn
~
ou
WI
:fl!
or
rn
~
~
~
:fl!
~
~
~~*******~*~**~~*~~~~*~~~~*~
OJ
te
tl
P
tt
s
l
r
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: ! 1) The removal or
rendering inoperative by any person other than for purposes of maintenance, repair, or
replacement, of any device or element 01 design incorporated into any new vehicle for
the purpose of noise control prior to its sale or delivery to the ultimate purchaser or
while it is in use, or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperat ive by any person.
Among those acts presumed to constitute tampering are the acts listed below :
eReplacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.
eRemoval of the muffler!s) or any internal portion of the muffler!s).
eRemoval of the air box or air box cover.
eModifications to the muffler(s) or air intake system by cutting. qrilling, or other means if
such modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic
information to make it useful to the owner who
desires to perform his own basic maintenance
and repair work. A basic knowledge of mechan ics, 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 repai r shou Id be carried
out only by qualified mechanics_
I n 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 your warranty period,
especially, we recommend that all repairs and
scheduled maintenance be performed in accord ance with this service manual.
Any owner
maintenance or repair procedure not performed
in accordance with th is manual may void the
warranty.
To get the longest life out of your Motorcycle:
_ Follow the Periodic Maintenance Chart in the
Service Manual.
-Be alert for problems and non ·scheduled
maintenance.
_Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
motorcycles are introduced by the Special Tool
Manual.
Genuine parts provided as spare
parts are Iisted in the Parts Catalog.
_Follow the procedures in this manual carefully .
Don 't take shortcuts.
_Remember to keep complete records of main tenance and repair w ith dates and any new
parts installed .
....................................... .....................................
How to Use this Manual
.......................... ...................... ........................... .
In preparing this manual, we divided the
product into its major systems. These systems
became the manual 's chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a single
chapter.
The Quick Reference Guide shows you all of
the product's systems and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
the General Information chapter . The chart
gives a time schedule for required maintenance
operations.
I f you want spark plug information , for
example, go to the Periodic Maintenance Chart
first. The chart tells you how frequently to
clean and gap the plug. Next, use the Quick
Reference Guide to locate the Electrical System
chapter. Then, use the Table of Contents On the
first page of the chapter to find the Spark Plug
section.
Whenever you see these WA R N I NG and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
I WARNING'
o This warning symbol identifies special instructions or procedures which, if not correctly
followed, could result in personal injury, or
loss of life.
o 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 five more symbols (in
addition to WARNING and CAUTION) which
will help you distinguish different types of
information .
NOTE
c This note symbol indicates points of particular
interest for more efficient and convenient
operation.
I
elndicates a procedural step or work to be done.
0 1ndicates a procedural sub·step or how to do
the work of the procedural step it follows .
It also precedes the text of a WARNING ,
CAUTION , or NOTE .
*Indicates a conditional step or what action to
take based on the results of the test or inspec·
tion in the procedural step or sub·step it
follows.
"'Indicates a conditional sub·step or what action
to take based upon the results of the condi·
tional step it follows.
In most chapters an exploded view il lustration
of the system components follows the Table of
Contents. In these illustrations you will find
the instructions indicating which parts require
specified tightening torque, oil , grease or a
locking agent during assembly.
- .,..
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
'-2
Model Identification .......................... . .... _ . . . . . . . .
'-4
General Specifications ......................................
'-5
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
'-7
Torque and Locking Agent .. ..... .. _ ... . ... . ......... . _ . . . . . .
'-8
Cable. Wire, and Hose Routing..... . ....... .. ................ .
'-'2
1-2 GENERAL INFORMATION
( 121
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations,
a certain amount of basic knowledge is also required for successful work .
Especially note the fOllowing:
(1) Dirt
Before removal and disassembly, clean the motorcycle . Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Remove the ground (-) lead from the battery before performing any disassembly operations
on the motorcycle_ This prevents :
(a) the possibility of accidentally turning the engine over while partially disassembled.
(b) sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tightening Sequence
Generally, when installing a part w ith several bolts, nuts, or screws, they should all be started
in their holes and tightened to a snug fit. Then tighten them evenly in a cross pattern. This is to
avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the
bo lts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or
screws must be tightened in the order and method indicated.
(4) Torque
The torque values given in this Service Manual should always be adhered to. Either too little
or too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly . If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary , tap lightly using a wooden or plastic faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in
order to avoid damaging the screw heads ..
(6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(7) High Flash-point Solvent
A high flash -point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). A lways follow manufac·
turer and container directions regarding the use of any solvent.
(B) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service.
The mating
surfaces around the gasket should be free of foreign matter and perfectly smooth to
avoid oil or compression leaks.
(9) Liquid Gasket, Non-permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly . Excess ive amounts may block engine oil passages and cause
serious damage. An example of a non·permanent locking agent commonly available in North
America is Loctite Lock'n Seal (Blue) .
(10) Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly.
( 11) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed
by a su itable driver. Th is prevents severe stress on the balls and races, and prevents races and
balls from being dented. Press a ball bearing until it stops at the stop in the hole Or on the shaft.
(1
Pi
GENERAL INFORMATION 1-3
(12) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages
seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
Seals should be pressed into place using a suitable driver, which contacts evenly with the side of
seal, until the face of the seal is even with the end of the hole.
(13) Seal Guide
A seal guide is required for certain oil or grease seals during installation to avoid damage to the
seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature
grease on the lips to reduce rubber to metal friction.
(14) Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens
and deforms them. When installing circlips and retaining rings, take care to compress or expand
them only enough to install them and no more.
(15) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is
more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
may contain abrasive foreign particles.
Don't use iust any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain
engine and chassis parts. Always check manufacturer recommendations before using such special
lubricants.
(16) Electrical Wires
All the electrical wires are either single-color or two-color and, with only a few exceptions,
must be connected to wires of the same color. On any of the two-color wires there is a greater
amount of one color and a lesser amount of a second color, so a two-color wire is identified by
first the primary color and then the secondary color. For example, a yellow wire with thin red
stripes is referred to as a "yellow/red" wire; it would be a "red/yellow" wire if the colors were
reversed to make red the main color.
Wire
(cross-section)
-~
f',
~
-
t1'
Red
Wire
strands
7' +--Yellow
___
~Red
Name of
Wire Color
f
Picture in
Wiring Diagram
- - Yellow
Yellow/red
'I'
I
if
t
Red
(17) Replacement Parts
..
When there is a replacement instruction, replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their origin~1 function cnce removed.
(18) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or
other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion
Crack
Hardening
Warp
Dent
Scratch
Wear
Bent
Color change
Deterioration
Seizure
(19) Service Data
Numbers of service data in this text have following meanings:
"Standards": Show dimensions or performances which brand-new parts or systems have_
"Service limits": Indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
I
1-4 GENERAL INFORMATION
.........
Model Identification
Gener
ZG1200-Al Left Side View:
-
........ ,
ItlfRl
OliN
~
()
0'
W
R
S
C
(
-
I
Pel
-
Er
ZGl200·A1 Right Side View :
GENERAL INFORMATION 1-5
General Specifications
~ : California Model
ZG1200-A1
Items
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry weight
Curb weight:
Front
Rear
Fuel tank capacity
Performance:
Braking distance
Minimum turning radius
2,815mm
965 mm
1,485 mm
1,620 mm
140mm
755 mm
317 kg ~ 317.5 kg
155 kg
191.5kg ~ 192kg
23.2 L
12.5 m from 50 kml h
2.9 m
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Carburetion system
Starting system
Ignition system
Timing advance
Ignition timing
Spark plug
Cylinder numbering method
Firing order
Valve timing:
Inlet
Open
Close
Duration
Exhaust
Open
Close
Duration
Lubrication system
Engine oil:
Grade
Viscosity
Capacity
SE Or SF class
SAE10W40, 10W50, 20W40, or 20W50
4.0 L
Drive Train:
Primary reduction system:
Type
Reduction ratio
Clutch type
Gear
1.706 (99/ 58)
Wet multi disc
4·stroke, DOHC, 4·cylinder
Liquid-cooled
78.0 x 62.6 mm
1,196 mL
10.0
Carburetors, Keihin CVK30 x 4
Electric starter
Battery and coil (transistorized)
Electronically advanced
10" BTDC @800 rl min (rpm)
NGK DPR8EA -9 or ND X24EPR·U9
Left to right, 1-2·3-4
1-2-4·3
20" BTDC
48" ABDC
2480
54" BBDC
14" ATDC
0
248
Forced lubrication (wet sump)
1-6 GENERAL INFORMATION
Items
Transmiss ion :
Type
Gear ratios: 1st
2nd
3rd
4th
5th
Final drive system :
Type
Reduction ratio
Overall drive ratio
Final gear case oil:
Type
Capacity
Frame:
Type
Caster (rake angle)
Tra il
Front tire:
Type
Size
Rear tire:
Type
Size
Front suspension :
Type
Wh eel t ravel
Rear suspension :
Type
Wheel travel
8rak e type :
Front
Rear
Electrical Equipment:
Battery
Headl ight:
Type
Bulb
T ail / brake light
Alternator:
Type
Rated output
Vo ltage regulator:
Type
ZG1200-Al
5-speed , constant mesh, return shift
2.733 (41 / 15)
1_800 (36/ 20)
1.333 (32/ 24)
1.035 (29/ 28)
0 .838 (26/ 31)
Shaft
2.424 (15/22 x 32/ 9)
3.4 70 @Top gear
API GL-5 Hypoid gear oil
SAE 80
210 mL
Tubular, double cradle
30°
121 mm
Tubeless
130/ 90-1667 H
Tubeless
150/ 90-15 74 H
T elescopic fork (pneumatic)
140 mm
Swing arm
100 mm
Dua l disc
Single disc
12 V 20 Ah
Semi -sealed beam
12 V 60/ 55 W (quartz-halogen)
12V8127Wx4
Three-phase AC
35 A @7,500 r/ min (rpm), 13_5 V
Short-circuit
Specifications subject to change w ithout not ice, and may not apply to every country .
GENERAL INFORMATION 1·7
Periodic Maintenance Chart
The scheduled ma intenance must be done in accordance with this chart to keep the motorcycle in
good runn ing condition. The initial maintenance is vitally important and must not be neglected .
FREQUENCY
OPERATION
Spark plug .. clean
Spark plug .. ch eck'
Air suction valve .. check (US)'
Air cleaner element .. clean
Throttle grip play .. check"
Idle speed .. check'
Engine vacuum synchronization .. check'
Fuel system -- check"
Cylinder head bolt tightness .. check'
Evaporative emission control system
··check (Ca l)'
,E"gine oil .- change
Oil filter -- replace
Radiator hoses, connections _. check'
Coolant .. change
Final gear case oil level -- chec k'
Final gear case oil ·· change
Propeller shaft joint .- lubricate
Fuel hose _. rep Ieee
Clutch flu id level·· check'
Clutch fluid .- chan!lf1
Clutch fluid hose and pipe -- replace
Clutch master cylinder cup and dust seal
.. replac~
Clutch slave cy linder piston seal ·· replace
Brake lining or pad wear -. check'
Bra ~ e fluid level·· check'
Brake flu id _. change
Brake hose .. replace
Brake master cylinder cup and dust seal
.' replace
Caliper piston seal and dust seal .- replace
Brake light switch .- check'
Steering -- check'
Steering stem bearing '- lubricate
Front fork oil -- change
Tire wear .- check '
Swing arm pivot _. lubricate
General ~ubrication _. perform
Nut, bolt, and fast ener tightness .. check'
~;;:.~~
t
'*"~ "'.~s><;)'*"~.s><;)'*"~.s><;)'*"~~'*"~.s><;)'*"~S
s;)
Every
<0<;)<;)
•
•
•
•
•
•
year
year
2 years
•
•
•
•
4 years
month
2 years
4 years
•
<¢~<;j
,<;).
~. tf>.
• • • • • •
• • • • • •
• • • • • •
•
•
•
•
•
•
• • • • • •
• • • • • •
•
•
•
•
•
•
• • • • • •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
.
•
•
• • • • • •
•
,..,<;).
Pa~:
15·20
15·20
4-7
2·15
2·6
2·8
2·9
2·10
--2-20
6-5
6·5
3 -12
3·4
10: 5
10-5
10-9
- -5-5
5·5
- - -
2 yea rs
5-7
2 years
5-8
11 · 13
11 -5
11-6
11·14
month
2 years
4 years
•
• • • • • •
• • ,• • • •
•
2 years
11 -8
2 years
11·11
15-39
13-4
13-8
12-5
9-10
12·13
16-8
16·8
2 years
•
•
• • • • • •
• • • • • •
•
•
• • • • • •
•
•
• • • • • •
•
•
•
•
For hi gher odom eter readings, repeat at the frequency interval establi shed here .
• : Replace, add, adjust, clean, or torque if necessary .
(Cal) : California vehicle only
(US ) : US only
T :
'),<¢<i5
,.
1·8 GENERAL INFORMATION
I
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of
a non·permenent locking agent or liquid gasket.
Letters used in the " Remarks" column mean :
L : Apply a non·permanent locking agent to the threads.
LG : Apply liquid gasket to the th reads.
M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads and seated surface, or
washer.
S : T ighten the fasteners fol/owing the specified sequence.
SS : Apply silicone sealant to the threads.
St : Stake the fasteners to prevent loosening.
Torque
Fastener
Cooling System :
Radiator Fan Switch
Water Temperature Sensor
Engine Top End :
Cylinder Head Cover Bolts
Camshaft Cap Bolts
Oil Filter Reta iners
Cylinder Head Bolts : 11 mm (New)
11 mm
8mm
Oil Pipe Banjo Bolts (8 mm)
Camshaft Sprocket Bolts
Chain Guide (Rear) Bo lt
Chain Tensioner Bolts
Clutch :
Clutch Lever Pivot Nut
Master Cyl inder Clamp Bolts
Clutch Hose Banjo Bolts
Cl utch Hose Connecting Nut
Clutch Slave Cylinder Bolts
81eed Valve
Clutch Cover Damper Bolts
Clutch Hub Nut
Clutch Spring Bolts
Engine Lubrication System:
Crankcase ( Lower) Oil Passage Plug
Crankcase ( Lower) Cap
Oil Pump Gear Holder Screws
Oi l Pump Mounting Bolts
Oil Pump Bracket Bolts
O il Pressure Relief Valve
Oil Pressure Switch
Engine Dra in Plugs
Oil Filter Mounting Bolt
Oil Pipe Banjo Bol t s (12 mm)
Oil Pan Bo lts
kg·m
ft·lb
7.8
15
0.80
1.5
69 in·lb
11.0
9.8
12
1.0
1.2
B7 In·lb
104 in·lb
-
51
48
25
25
15
5.2
4.9
2.5
2.5
1.5
-
-
9.8
1.0
Er)
Er
Ri
Cra~
C
Remarks
N·m
-
E~r
38
35
18.0
18.0
11.0
-
(
SS
St
M,S
M,S
L
L
87 in·lb
,
5 .9
11
25
18
-
0.60
1.1
2.5
1.8
-
52 in·lb
95 in·lb
18.0
13.0
-
7.8
9.8
130
11
0.80
1.0
13.5
1.1
69 in·lb
87 in·lb
98
95 in·lb
18
18
1.8
1.8
13.0
13.0
-
-
12
12
15
15
29
20
25
1.2
1.2
1.5
1.5
3.0
2.0
2.5
-
-
104 in·lb
104 in·lb
11 .0
11.0
22
14.5
18.0
-
L
L
L
L
L
SS
L (2)
p
GENERAL INFORMATION 1-9
Torque
Fastener
Engine Removal/Installation:
Engine Mounting Bolts
Engine Mounting Bracket Bo lts
Right Down Tube Mounting Bolts
Crankshaft/Transmission:
10 mm (New)
Crankcase Bolts:
10 mm
8 mm (New)
8mm
6mm
8mm
Oil Pipe Banjo Bolts:
6mm
Alternator Shaft Chain Guide
Mou nting Bolts
External Shift Mechanism
Return Spring Pin
Connect ing Rod Big End Cap Nuts
Crankshaft Flywheel Bolt
Ignition Timing Rotor Bolt
Alternator Shaft Coupling Bolt
Starter Clutch Holder Bolts
Alternator Shaft Bearing Holder Bolts
Idle Gear Shaft Holder Bolt
Balancer Shaft Guide Pin Plate Bolt
Shift Drum Pin Plate Bolt
Shift Drum Bearing Holder Bolts
Wheels/Tires:
Front Axle Nut
Rear Axle Nut
Air Valve Nuts
Air Valve Locknuts
Final Drive:
Front Gear Case Bolts
Damper Cam Nut
Drive Gear Nut Cap Bolts
Drive Gear Nut
Neutra l and Overdrive Sw itch
Switch Collar
Oi l Pipe Ban jo Bo lts (8 mm l
Oi l Pipe Clamp Bo lts
Driven Gear A ssembly Mounting Bo lt s
Driven Gear Bo It
Final Gear Case Mounting Nuts
Pinion Nut
Final Gear Case Cover 80lts
Remarks
kg-m
ft-Ib
34
25
57
3.5
2.6
5.8
25
19.0
42
49
39
29
27
12
12
7.8
5.0
4.0
3.0
2.8
1.2
1.2
1.0
36
29
22
20
104 in-Ib
104 in-Ib
87 in-Ib
-
-
-
L
-
-
-
L
M
N-m
,
28
145
25
25
12
2.9
15.0
2.5
2.5
1.2
-
-
88
110
1.5
5.9
12
225
12
265
9.8
4.9
12
12
120
29
120
24
-
-
87 in-Ib
1.0
9.8
-
21
110
18.0
18.0
104 in-Ib
I
I
-
-
-
1.2
12.0
3.0
12.0
2.4
L
L
L
L
L
L
65
80
13 in-Ib
52 in-Ib
9.0
11 .0
0.15
0.60
1.2
23
1.2
27
1.0
0.50
1.2
S
S
•
104 in- Ib
165
104 in-Ib
195
87 in-Ib
43 in-Ib
104 in-I b
104 in-Ib
87
22
87
17.5
L( 1)
M
L
St
L
SS
L
St
St
L
"
1-10 GENERAL INFORMATION
The
Fastener
Final Gear Case Studs
(For reference)
Pinion Bearing Retainer
Reta iner Stop Screw
Brakes:
Brake Lever Pivot Nut
Front Master Cylinder Clamp Bolts
Brake Hose Banjo Bolts
Caliper Mounting Bolts
Bleed Valves
Disc Mounting Bolts
Rear Master Cylinder Mounting Bolts
Rear Caliper Holder Bolt
Suspension:
Front Fork Clamp Bolts
Front Axle Clamp Nut
Front Fork Drain Screws
Front Fork Bottom Allen Bolts
Swing Arm Pivot Shaft Retainer Bolts
Swing Arm Pivot Shaft Adjuster
Adjuster Locknut
Rear Shock Absorber Mounting
Bolt and Nuts
Rear Shock Absorber Air Hose Fittings
Steering:
Handlebar Clamp Bolts
Handle Grip Bar Mounting Allen Bolts
Weight Mounting Screws
Steering Stem Nut
Steering Stem Locknut
Frame:
Trunk Guide Mounting Screws
Right Down Tube Mounting Bolts
Rear Frame Mounting Bolts
Electrical System:
Alternator Mounting Bolts
Alternator Coupling Bolt
Starter Relay Terminal Nuts
Spark Plugs
Ign ition Timing Rotor Bolt
Torque
N-m
kg-m
Tt-Ib
-
-
-
540
16
55
1.6
400
11.5
5.9
11
25
32
7.B
23
23
98
0.60
1. 1
2.5
3.3
0.80
2.3
2.3
10.0
52 in-Ib
95 in-Ib
18.0
24
69 in-Ib
16.5
16.5
20
14
2.0
1.4
14.5
10.0
-
-
-
20
11
18
53
2.0
1. 1
1.8
5.4
14.5
95 in-Ib
13.0
39
30
12
3. 1
1.2
22
104 in-Ib
27
44
2.8
4.5
20
33
-
-
-
42
11
4.3
1. 1
-
-
-
57
57
5.8
5.B
42
42
-
-
9 .8
4.9
14
25
1.0
0.50
1.4
2.5
Remarks
L
72
L
L
L
31
95 in-Ib
87 in-Ib
43 in-Ib
10.0
18.0
L
L
and
All 0"
GENERAL INFORMATION 1-11
The table below, relating tightening torque to thread diameter, lists the basic' torque for the bolts
and nuts. Use this table for only the bolts and nuts which do not require a specific torque value.
All of the values are for use with dry solvent-cleaned threads.
General Fasteners:
Torque
Threads dia. Imml
N-m
kg-m
ft-Ib
5
3.4 - 4.9
0.35 - 0.50
30 - 43 in-Ib
6
'5 .9 - 7.8
0.60 - 0.80
52 - 69 in-Ib
8
14 - 19
1.4 - 1.9
10.0 - 13.5
10
25 - 34
2.6 - 3.5
19.0 - 25
12
44 -61
4.5 - 6.2
33 -45
14
73 -98
7.4 - 10.0
54 -72
16
115 - 155
11.5 - 16.0
83 - 115
18
165 - 225
17.0 - 23
125 - 165
20
225 - 325
23 -33
165 - 240
..( I
.- ,.',
1·12 GENERAL INFORMATION
Cable, Wire, and Hose Routing
Control Cables
Viewed from Front
Viewed from T op
1. Right Han dlebar Switch Leads
2.
F rant Brak e H ose
3.
4.
5.
6.
Throttle Cables
Clutch Fluid Hose
Left Handlebar Switch Leads
Choke Cable
7. Connecting Pipe
8. Strap (holding (ro n I fork air hose
and right handlebar switch leads)
9. Strap (holding fu se case leads and
left haodletw switch leads)
10 . Ignition Coil (#1 & 4)
GENERAL INFORMATION 1-13
Electrical Wires
1. Main Harness
Viewed from Left
2. Connectors
3. Surge Tank
4. Side Stand
~.
Rear Frame
6.
7.
8.
9.
Wiring Holder
FuelTank
Harness Position Mark
Clamps (both left and '
.
10. Strap (both If
' right
Sides)
e t and right
sides)
Vi twed from Front
1
o
'I 5
"
"J '"
j~
11 . Connecting P'
12. pLeft H.ndlebar
'peSwitch Leads
13
.
assenger Switch Leads
14 . Passenger Switches
15. Travel Trunk
16. Antenna Lea d
1-14 GENERAL INFORMATION
Ellctri
Electrical Wires
IMeter Assembly)
IEngine Left Side)
Viewed from Bottom
144 mm
IEngine Right Side)
40mm
Viewed from Bottom
1. Clamp
2. Strap
1. Allernator Lead,
4. SUrter Motor Lead
j. Overdrive Switch lead
6. Neutral Switch Lead
7. Oil Pressure Switch Lead
8. Pickup Coil l eads
9. B<tttery Vent Hose
GENERAL INFORMATION 1-15
Electrical Wires
I. R.l d iator Fan Switch Lead
2. Ground Lead
3. Travel Trunk
5. Sad dleba g
6. Rear Fender Rear
7. Tail / Brake Ligh! Leads
4. Trunk Room Light Leads
8. License Light Leads
1-16 GENERAL INFORMATION
I.
2.
3.
4.
5.
6.
7.
Front Brake Hoses
8.
9.
10.
11 .
12.
13.
14.
Front Brake Master Cylinder
Brake Hose
2·way Joint
Front Caliper
Rea r Caliper
Rear Shock Absorber l<1ount
Reservo ir
Rear Brake Master Cylinder
Clamp
Strap
Clamp
Clutch Fluid Hose
Clutch Master Cylinder
Clutch Slave Cylinder
Radilt,
Viewed from Front
Rear Brake Hoses
Air
(
,
,,"
••,
,
••
,
Clutch Fluid Hose,
9
(J--'
(9
H23
I
'T'
~~
t - - -@
?--- .-~W--:1
GENERAL INFORMATION 1·17
Rad iator Hmes
Viewed from Top
Front
'f
,," :
D'
'H
45 _ 50°
Front
V iewed from To p
(3
=' ",
-0-
/~
Viewed from Fro nt
Air Hoses and Vacuum Hoses (US Mode l)
California Model
,
r-- ----- -- - - - -- --- -------~
Vie wed fro m To p
<Lt
1~)
l. Clam p
2.
3.
4.
5.
Thermostat Housing
Bypass Hose
To wa ter pu mp
Radiator
6. Clamp
7. Reservoir Tank
8. Reservoir Tank Hose
9. Ra dia tor Cap
10. To canister
Viewed from Right
II.
12.
13 .
14.
15.
,.\ ir Cleaner Housing
Air Suctio n Val ve Cover
Si lenc.er
Vacuum Swi tch Valw
Tu carburetors
1-18 GENERAL INFORMATION
Fuel Hoses
Bruth,
Viewed from F ron t
(I"'
Viewed from Left
6'-'
C§:;,--~.~rJ\
Cali
(fQ; <>
,
(
/~.'
+-t-t
(QY/"--t-.'
V,
Vacuum Hoses and Breather Hoses (US Model) '
'.
l. Fuel Tank
Rear Brake Light Switch Leads
Fuel Pump Leads
Fuel Pump
Fuel Filter
6. Drain Hose
7. Frame Tube
8. From Fuel Tank
9. Inlet Filling
10. To carburetors
Il. Swing Arm
12. Frame Tube
13. Choke Cable
14. To Vacuum Switch Valve
15. Cyl inder Head Cover
16. Carburetors
17. Surge Tank
, IS. To Vacuum Valve
'19. To Liquid jVagpr Separator
2.
3.
4.
5.
0
Viewed from Left
'20. To Canister
'California Model
Viewed from Top
GENERAL INFORMATION 1-19
(~~l
Breather Hoses
,
'i::
,,
,
r
U
-1--- --- ~
·ii'."-"'~"'"
Viewed from Top
California Model
California Model
Vacuum Hoses and Breather Hoses (California Modell
Viewed from Front
_
";,21 'J
(0/
lijP'ff
o
I. Fuel Tank Cap
2. Check Valve
3.
4.
5.
16.
17.
18.
To Liquid/Vapor Separator
Plug
19.
20.
Surge Tank
Reservoir Tank Overflow Hose 21.
6.
7. Catch Tank Drain Hose
8. Catch Tank
9. Hase (Red)
Hose (Bluc. Lon g)
To Fuel Tank
10 .
1112.
13.
14.
15.
0
To Air Clcaner
Hose (t reen)
Hose (Yellow)
Cani ster
Liqu id!Vapor Separator
Hose (White)
Hose (Blue, Short)
To Vacuum Val ve
To Carburetors
Vacuum Va lve
1·20 GENERAL INFORMATION
Rear Shock Absorber Air Hoses
--- ---
J;©
,,,
,
-
Battery Vent Hose
'I. Rear Shock Absorber
2. Fuel Tank
3. Oil Separator
4. Ignition Coil (#2 & 3;
5. Air Valve
6. Batter y
7 . Battery Venl Hose
p
FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded View
Specifications
2·2
. . . . . , ..
. . . . . . . . . . . . . . . . . , . .. . .
Special Tools ..... . . . .
2·5
2·5
High Altitude Performance Adjustment
High Altitude Carburetor Adjustment . ...
Throttle Grip and Cable . .. . . . . . .
Throttle Gri p Pla y Inspection . . . . . . . . .
Throt1le Cable Adjustment . . ... . .. .. .
Throt1 le Cable Lubricat ion . ... . . _ .. . .
Thrott le Cable Inspection . . . . . . .
Choke Cable " " " " " " '," ' " . ,
Choke Cable Free Play Inspection , .. '"
Choke Cable Adjustment
Choke Cable Lubrication
Choke Cable Inspection
Carburetors . .. .. . , , . . . . . . . . • . . . •....
, , . .. ... ,
2,6
2-6
. . . . ... . . . . . . . . . •..
Fuel Tank Inspectio n . , , ' , " , . , " " 2·19
Check Valve Inspection , . ' . ' . , , , , , , , 2·19
2·7
2,8
2,8
Carburetor Cleaning .. ... .
Vacuum Valve Inspection .
2-20
2-9
2 -10
2·10
2,11
2·12
2,12
2·14
Air Cleaner Element Cleaning . .. .. . ... 2 , 15
Air Cleaner Element Inspection
2· 15
Air Clean er Housing Removal
2,1 5
Fuel Pump Removal
..
Fuel Pump Installation Notes
2·19
Cani ster Inspection . , ...
Air Cleaner Element Installation Notes . .. 2·14
Fuel Pump " " " " " " , . ' , . , . .
2,19
Parts Removal/Installation Notes . .
2-8
, . . . . . . . . .. .. 2·14
' , . , , , '
(US Californ ia Veh icle Only) , " " " " "
2·20
2·20
2-20
Carbureto r Inspection . . . . . . . . . . ... . 2 ·13
Air Cl eaner El eme nt Removal . .
Evaporative Em iss ion Control System
2·20
Carburetor Separation!
Assembly Notes .. ... . . . . , .. ... '
In stallation Notes . . . . . . . . . . . . . . . 2-18
Hose Inspection . .. ... . . . . . . .. .. . .
Carburetor D isassemb ly !
Assembly Notes . . . . . . . . . , . . . . . .
2·18
Separator Inspect ion .. .. . .. , ... ... ,
Carburetor Removal l
In sta llation Notes . . . . . . . . . . . .
Fuel Tank Installation Notes , ' , • ,
2·8
2 ·8
2,8
2·10
....
Fu el System Cleanl iness Inspection
2·17
Fuel Tank Removal , . , . , , . , . •. , . . , , 2·17
2·7
2·7
2·9
. .. . , ..
Fuel Tank and fuel Level Sensor . ...• .
2-17
Fuel Tank Cleaning, , , , • , , , ' . , ' , ' , , 2-19
2 ·9
Catch Tank "
" , .. ,""
Catch Tank Draining , , ,
. . . . .. ... 2-17
2·7
2,7
Fuel Level Inspectio n ..
A ir Cleaner .. .. ...
Fuel Fi l ter Installation Notes
Fuel Leve l Sensor Removal /
Carburetor Synchronization . . . . . . . . ..
Fuel Leve l Adjustment
.. . . . . . . . . . . . . . 2 · 17
2·6
2·6
Carbu re tor Synchronization
Inspection
Fuel Filter Removal
Fuel Filte r Inspection ,. ,.
IUS Model) " , , , , , '
Idle Speed Inspection "
Idle Speed Adjustment
2·17
Fuel Filter . ...
2·16
2,16
2·16
2·16
2·1 6
Separator Operation Test
2-2 FUEL SYSTEM
Exploded View
v
I
.
California Model
CD-f
p
FUEL SYSTEM 2-3
1 1
US Model
~. .
California Model
I
Q>
<9
1. Jet Needle
2. Pilot Screw
11. Pilot Jet
4 Needle Jet
Needle Jet Holder
6 Main Jet
7 : Catch Tank
8 Check Valve
9 : Fuel Level Sensor
10. Fuel Filter
11. Fuel Pump
5:
2-4 FUEL SYSTEM
California Model
r- -
-
- - -
- - -
- - - - - - - - - - -
- -
- - -
- - - - - - - - - - - - -
- -
I
1
I
I
I
I
Blue
Yellow
Blue
\
Green
~~
I
I
I
I
I
I
I
I.
I
I
I
I
ite
I
I
@
I
•
L_ __ ___________ _ __ ___ - - - - - - - - - - - - - - - - - - - - - - - - -12. filter
13. V ••uum Valve
14. Canister
15. Liquid/Vapor Separator
SplCi
.......
-
p
FUEL SYSTEM 2-5
- -
T
r
I
r
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Specifications
-
Standard
Item
High Altitude Performance Adjustment (US model only):
Carburetor Adjustment :
Main Jet
Pilot Jet
105
35
Throttle Grip:
Throttle Grip Free Play
2-3mm
Choke Cable:
Choke Cable Free Play
2-3mm
Carburetors:
Idle Speed
Synchronization Vacuum
Standard Specifications:
•
MakefType
Main Jet
Main Air Jet
Needle Jet
Jet Needle
Pilot Jet
Pilot Air Jet
Pilot Screw
Starter Jet
Service Fuel Level
Float Height
I
I
I
I
I
I
Special Tools
-
800 ±50 rlmin (rpm)
Less than 2.7 kPa (2 cmHg)
Keihin/CVK30
108
100
6
N36G, California: N36H
38
150
2 turns out, US : - 48
-0.5 ±1 mm
17.0 mm
•
,,'
Vacuum Gauge: 57001·1198
-'
Alorlll with co mmon hand LOol,. the following more
specialize<fJ tools arc re quired for complete fuel system
ser vic ing .
.--:c.=..:.
Pre.. ur. Cable luber : K56019.(J21
NOTE
OThe vacuum gauge & lachom~~r (PIN 57001·1291)
can be ust1d instead of ,t he Y/lCuum gauge (PI N 57001·
1198).
Fuel level Gauge: 57001·1017
2-6 FUEL SYSTEM
High Altitude Performance Adjustment
(US Modell
Throttle Grip Free Play
2 -3mm
Thro
.Loo
.dju
so •
• Witl
deci
bee
To improve the Emission Contfol Performance of
vehicles operated above 4,000 feet (1,219 meters),
Kawasaki recommends the following Environmental
protection Agency (EPA) approved modification.
.Tur
thn
NOTE
CWhen properly performed, these specified adjustments
are nor considered to be emission control system
"tampering" and vehicle performance is generally
unchanged as a result.
A. Throttle Grip Free Play
High Altitude Carburetor Adjustments
eHigh altitude carburetor adjustments require replacement of certain carburetor jets.
-With the throttle grip closed, check that [he decelerator
inner cable is tight by touching it at the lower end with
a thin-bladed screwdriver.
A.
High Altitude Carburetor Specifications
B.
Main Jet: 105
Pilot Jet: 35
eAfter high altitude carburetor adjustments are per-
formed,
provide
the customer
with
the Vehicle
Emission Control Information Update Label and label
installation instructions (PIN 99969-0614i.
-Advise the customer that by law, the Vehicle Emission
Control Information Update Label must be affixed to
any vehicle modified with the high altitude carburetor
adjustments.
NOTE
a vehicle wirh rhe high a/rirude adjusrmenrs is used
below 4,000 fee, (T ,219 me,ers), 'he upda,e label must
be removed and rhe original carburetor pans musr be
reinsralled.
A. Decelerator Cable
C If
Throttle Grip and Cables
Throttle Grip Play Inspection
-Check throttle grip free play by lightly turning the
throttle grip back and forth.
*Ir free play is not correct, adjust the throttle c(tbles.
*If the lhrottle grip free play is incorrect or the decelerator inner cable is loose with the throttle closed,
adjust the throttle cables.
*If the free play is correct, make the following tcst:
-Start the engine.
_Turn the handlebar from side· to side while idling the
engine.
*If idle speed varies, the ttlrottle c a ble ~ may be poorly
routed or they may be damaged.
_Correct any problem befo re operating the motorcycle.
I WARNING.
COperation with an improperly adjusted. incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
FUEL SYSTEM 2-7
Throttle Cable Inspection
Throttle Cable Adjustment
.Loosen lhe locknuts and
~crew
both throttle cable
adjusters in fully at the upper end of the throttle cables
eWith the throttle cable disconnected at both ends, the
cable should move freely within the cable housing.
so as to give the thronle grip plenty of play ,
eWjth the throttle grip completely closed, turn out the
decelerator cable adjuster until the inner cable just
Throttle Cable Inspection
becomes light. Tighten the locknut.
.Turn the accele ra tor cable adjuster until the correct
throttle grip free pla y is obtained. Tighten the locknut.
1. Throttle wbl.
*If cable movement is not free after lubricating (see
Throllie Cable Lubricatio n), if th e cable is frayed, or if
the housing is kinked, replace the cable.
A. Ac celerator Cable
B. Decelerator Cable
C. Adjusters
D. Locknuts
NOTE
Off the throttle cables can not be adjusted by using the
cable adjusters at the upper end of the throttle cables,
use the cable adjusters at the lower ends of the throttle
cables. Do not forget to securely tighten the locknuts
after adjustment.
_Start the engine.
eTurn the handll:bar from side to ~idc whik: idling the
engine.
*if idle speed varies, the throttle cables ma y be poorly
routed or they may be damaged .
-COrrect any problem before operating the motorcycle.
Choke Cable
Choke Cable Free Play Inspection
eChec k t.hat the cl10ke le ver return s properly and that
the inner cable slides smoothly.
*If there is any irregularity, ch ec k the choke cable. as
follows:
eOetermine the amount of choke cable play at the
choke leve.r. Pull the choke lever until the starter
plunger lever at the carburetor contacts with the st.arter
plunger; the amount of choke lever travel is the amount
of choke cable play.
I WARNING.
COperation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
Throttle Cable Lubrication
Whenever t he throttle cables are removed and in
accord ance with the Periodic Maintenance Chart
lu bricate lhe throltle cables (see App endi x chapter).
'
A . Starter Plunger Lever
B. Starter Plunger
2-8 FUEL SYSTEM
* 1f cable movement is not free after lubricating, if th e
cable is frayed, or jf th e housing is kinked, replace the
cable.
(I
Carbu retors
Idle Speed Inspection
A. Choke Lever
B. Free Play
C. Adjuster
D. Lo cknut
*If free play b not correct, adjust the choke cable.
-Start th e engine and warm it up thoroughly,
-With the cngine idling, turn the handlebar to both
sides.
*If handlebar movement changes the idle speed; the
throttle cables may be improperly adjusted or incorrectly routed, o r they may be damaged. Be sure to
correct any of these co nditions before riding.
I WARNING I
Choke Cable Fr •• Ploy
GOperation with improperly adjusted, incorrectly
routed, or a damaged cable could result in an unsafe
riding condition.
2-3mm
Choke Cable Adjustment
eLoosen the locknut at the adjuster of the choke
cable, and turn the adj uster until the cable has the
proper amount of play.
_Tighten the locknut after adjustment.
-Check idle speed.
*If the idle speed is out. of the specified range, adjust it.
Idle Speed
800 ±50 rlmin (rpml
Choke Cable Lubrication
Whenever the choke cable is removed, and in
accordance with the Periodic Maintenance Chart,
lubricate the choke cable (se() Appendix chapter).
Idle Speed Adiustment
eTurn the idle adjusting screw until idle speed is correct.
Choke Cable Inspection
.With the choke cable disconnected a t the both ends,
the cable should move freely within the cable housing.
Choke Cable Inspection
A. Idle Adjusting Screw
CD
1. Choke Cabl c
eOpen and close· the ,t hrottle a few limes to make Sure
that the idle speed is within the specified range. Re·
adjust if neCessary.
•
FUEL SYSTEM 2·9
Carburetor Synchronization Inspection
.Warm up the engine.
-Check idle speed an d adjust if necessary.
-Remove the air delmer housing.
OAttach the vacu um gauge sct (speciallOol: P/,'l 570011198) to the vacuum hose fittings on the carburetors.
(Viewed from front)
A. Vacuum Hose Fitting
B_ Adjusting Screw
-Install the air cleaner housing. Be sure to install the
air cleaner ele ment.
-Start the engine and let it idle to measure the engine
intake vacuum.
*If the intake vacuum differenc e between any two
cylinders exceeds the Iimit ,synchroni7.e the carburetors.
Carburetor Synchronization Vacuum
Fuel Level Inspection
I WARNING
I
CGasoline 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.
eRemove the carburetors, and hold them in upright on a
stand.
-Connect <1 fucl tank to the carburetors wit h a suita ble
hose.
ePrepare a fuel hose (6 mm in diameter and about 300
mm long),
'Connect the fuel level gauge (s peci,1 tool) to the
carburetor float bowl with the fuel hose.
eHold the gauge vertically against the side of the carburetor body so that the "zero" line is several millimeters higher than the bottom edge of the carburetor
body,
.Hold the fuel tank to feed fuel to the carburetor, then
turn out the carburetor drain plug a few turns.
.Wait until the fuel level in the gauge settles.
eKeeping the gauge vertical, slowly lower the gauge until
the "zero" line is even with the. bottom edge of the car·
buretor body_
NOTE
ODD not lower the "zero" line below tIle bottom edge of
the carburetor body. If the gauge is lowered and then
raised again, the fuel level measure shows somewhat
If the gauge ;s
higher than the actual fuel level.
lowered too far, dump the fuel out of it into suitable
container and stan the procedure over again.
Le" than 2.7 kPa (2 cmHg) difference between
any two cylinden
_Remove th e vacuum gauge set, and install the removed
parts ,
eRead the fuel level in the gauge and compare it to the
specification. Screw in the carburetor drain plug.
eRemove th e fuel lev.el ::rauge.
.Inspect the fucl I~vejin the other carburetors in the
same manner.
*If any fuel level is ihcorrect, .dju~t it,
Carburetor Synchronization
_Turn th e adjusting sc rews to synchroni ze the car·
buretor<;,
NOTE
OFirst synchronize the left two and then the right two
cylinders by means of the adiusting screw between No.
T and No, 2 cylinders, and between No.3 and No.4
cylinders.
o Then synchronize the left two cylinders and the right
two cylinders using the center adjusting screw.
IChec k idle speed and adjust jf neccssarr.
A_Fuel Leyel Gauge : 57001-1017
B, Carburetor Body Boltom Edge
I
~
2-10 FUEL SYSTEM
Fuel level
OS ±1
Fuel System Cleanliness Inspection
mm above the bottom edge of carburetor
I WARNING I
body
Fuel Level Adjustment
-Read the WARNING in the Fuel Level Inspection.
eDrain the fuel out of the carburetors into a suitable
container.
-Remove th e fioat bowl by taking out the screws with
lockwashers.
-Sl ide out the pivot pin and re move the float.
-Bend the tang on the float arm very slightl y to change
the float height. Increasing the float height lowers the
fuel level and decreasing the fioat height raises the fuel
level.
cGasoline it 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.
-Connect a suitable hose to the fitting at the bottom of
each carburetor float bowl.
eRun the lower ends of the hoses into a suitable container.
eTurn out each drain plug a few turns and drain the
fioat bowls.
OIf
bl
CIt
011
"
Float Height
17.0 mm
c
A. Drain Plug
A. Tang
e Assemble the carburetor, and recheck the fuel level.
*If
fuel level cannot be adjulted by this method, the
float or the float valve is damaged.
the
eCheck to sec if waler or dirt comes out.
-Tighten the drain plugs.
*If any water or dirt appeared during the above inspection, clean the fuel system (see Carb uretor Cleaning
and Fuel Tank Cleaning).
Float Height Measurement-Keihin Carburetor
Carburetor Removal/Installation Notes
I WARNING I
C: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.
1. Float Bowl Mating Surface
2. Float Valve Needle Rod (con tacted but unloadedj
3. Float
eTa remove the carbu retors, remove the air cleaner
housing,
eAfter removing the carburetors, stoff pieces of lint-free,
clean clOlh inlo the carburetor holders and the intake
ducts to keep dirt out of the engine and air cleaner.
p
FUEL SYSTEM 2-11
I WA.RNING.
QI' dirt' or ,d ust d.nowed to pass' through into the carbur,tors. the t!vQttl, may beoome stuck. possibly
cousin, on Iccidont.
COo not apply too much bonding agent to the plug or the
pilot screw itself may be fixed.
Plug Installation (US model onlyl
01' dirt gets through into the engine, excessive engine
wear and possibly engine damage will occur.
-Install the carburetor holder clamps so thal the screws
are positioned downward to prevent them from
contacting anything.
eAfter installing the Qrburetors, perform the following.
cCheck fuel leakage from the carburetors.
I WARNING I
OFuel spilled from the carburetors is hazardous.
OAdj ust the following items if necessary.
Idle Speed
Carb uretor Synchronization
Throttle Cables
Choke Cable
1. Apply bonding agent .
2. Plug
3. Pilot Screw
4. Carburetor Body
_Turn th e carb uretor body upside-down r and drop the
needle jet into place so that the smaller diameter end of
the jet goes in first.
Carburetor Disassembly/Assembly Notes
ORead the WAR NINGS in the Carburetor Removal !
Installation Notes .
• For the US model, remo ve the pilot screw plug as
follows:
o Punch a hole in the plug and pry it at with an awl or
other suitable [001.
_Turn in the pilot screw and count the number of turn ~
until it seats funy but not tightl y, and thell rem o\le th e
screw. This is to, set the screw to its original position
when assembling.
eAfte r insta!llng the upper chamber co ver, check that
the vacuum piston slides up and down smooth ly without binding in the carburetor bore.
CDuring carburetor disassembly. be careful not to
damage the diaphragm. Never use a sharp edge to
remove the diaphragm.
eTurn in the pilot screw fully but not tightly, and then
back it oul the same number of turns counted during
disassembly.
eFor the US model, install the pilot screw plug as
fo llow:
Olnstall a new plug in the pilot screw hole, and appl y a
sma ll amount of a bonding age nt to the circum ference
of the plug to fix the pltlg.
A. Small End
OCarcfully screw in the air. bleed pipe. It will seat
against the needle jet, pushing the end of the jet into
the carburetor bore.
GOo not force the air bleed pips or overtighten it . The
needle jet or the carburetor body could be damaged
requiring replacement.
2-12 FUEL SYSTEM
.[
.S lip th e nee dl e th ro ugh the h ole in th e center of the
vac u um pis ton, and put the spri ng seat on t he to p o f
th e needl e. Turn [he sea t so that it does no t block the
ho le a t th e bo tto m of the vac uum piston _
.1
5
.1
e\
eI
.,
c
A, Bala nce Adju sti ng Screw
8 , Cleara nce
(
NOTE
A. Spring Sea t
B. Hole
Carburetor Separation/Assembly Notes
.Rea d th e WA RNIN GS in th e Carburetor Re mova l!
In stalla tion Notes,
- The center li n es of the carburt! tor bores must be
paral lel both horizo n tall y an d ver ticall y. If th ey are
no t , loosen th e mo untin g sc rews and align th e carbure to rs o n a fla t surface. Re tighten the mounting
screws.
e Aft e r asse mbli ng th e choke mechan ism, c hec k to see
tha t th e c hoke sha ft sl id es righ t to left smoo thl y
without abnormal fric tion.
OFirst synchronize the left two and then the right two
carburetors by means of the adjusting screw between
No . 1 and No. 2 carburetors. and between No , 3 and
No , 4 carburetors.
OThe syn chronize the left two carburetors and the right
t wo carburetors using the center adjusting screw.
Carburetor Cleaning
I WARNING
I
CClean the carburetors in a well·ventilated area , and take
care that there is no spark or flame anywhere near the
working area; this includes any appliance with a pilot
light . Because of the dang .. of highly flammable
liquids, do not use gasoline or fow flash·po int solvents
to clean the carburetors.
{ CAUTlO~]
OFuel mixture trouble could result if the starter does
not seat properly in its rest position aher the choke
knob it returned .
- Visually sy nchronize the thro ttle (butterfly) va lves.
CChec k to see that all thro ttl e va lves o pen and close
smoothl y without bindi ng when turn ing th e pulley .
oVisua lly chec k th e clearance between tht: th ro tt le va lve
and t he carb uretor bore in each ca rbu reto r.
~ If th ere is a difference be tween a ny two carburetors,
turn tht: balance adjusting screw (s) to ob ta in the same
clearan ce.
0 00 not use compressed air on an assembled carburetor,
the floats may be aushed by the pressure, and the
vacuum piston diaphragms may be damaged.
ORemave as many rubber or plastiC parts from the car·
buretor as possible before cleaning the carburetor with
a cleaning solution. This will prevent damage or
deterioration of the parts.
o The carburetor body has plastic parts that cannot be
removed. 00 NOT use a strong carburetor cleaning
solution which could attack these parts; instead , use a
mild high ffash-point cleaning solution safe for plastic
parts.
c Oo not use wire or any other hard instrument to clean
carburetor parts , especially jets, as they may be
damaged.
•
FUEL SYSTEM 2-13
'Disassemble the carburetors.
'lmmcr~e all the metal pans in a carburetor cleaning
sofution.
eRinse the: plrts in water .
• When the parts are clean, dry them with compressed air.
eBiow thro ugh the air and fuel passages with compressed
*If any of the O-rins> o r diaphragms are not in good
con dition, replace them.
eCheck the plastic tip of the float valve needle. It
should be smo'o th, without any grooves, scratches, or
tears.
~r.
eAssemble the carburetors.
Float Valve Wear
Carburetor Inspection
-I---{2
I WARNING'
OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. Do not smoke. Make sure the area is weH
ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.
eRemove the carburetors .
'Before disassembling the carburetors, check the fuel
level.
*If the fuel I.vel is Incorrect, inspect the rest of the
carburetor before correcting it.
'Move the choke shaft left and release it to check that
the starter plungers move smoothly and return by
spring tension.
*\f the starter plungers do not work properly, replace
the carburetors.
eTurn the throttle Cdble pulley to check that the
throttle valves move smoothly and return by spring
tension,
*If the throttle valves do not move smoothly, replace
the carburetors .
Push and release
1. Rod
2. Valve Needle
3. Valve Needle Wear
*1 f the plastic ti p is damaged , re place the needle.
-Push i,n the rod in the other end of the float valve
needle and then replace it.
*I f it does not :"pring out, replace the needle.
eCheck the tapered portion of the pilot screw for wear
or damage,
Pilot Screw
•
1. Pilot Screw
A. Thro ttle Valves
B. Starter Plungers
-Oi sasse mble the carb uretors.
IClean the carburetors.
_Check that the O-rings on the carburetors and the
diaphragm on the vacuum piston are in good condition.
2. Tapered Portion
*1 f the pilot screw is '''forn or damaged on the tapered
portion, it will prevent the engine from idling
smoothly, Replace it.
-Check that til e vacuum piston moves smoothly in the
carburetor body. The surface of the pislOn mu st not
be excessively worn.
*If the vac uum piston does not move smooth1v, or if it
is very lo ose in carburetor body, replace the carburelOr.
2-14 FUEL SYSTEM
A. Vacuum Pisto n
A. IC Igniter
B. Housing Bolts
.Pu ll out air cleaner element holders, and take off the
element.
A.
eE
A
c
............................................................................
•
•
Air Cleaner
............................................................................
Air Cleaner Element Removal
eRemove the dummy t ank cover .
A. Element
B. Hol ders
-Stuff pieces of lint-free , clean cloth into the air in take
dU ClS to keep d in .GU[ of engi ne.
I WARNING I
e lf dirt of dust is allowed to pall through into the
carburetors, the. butterfly .alve. mlY become stuck,
possibly causing In ,a ccident.
Clf dirt gets through into the Ingine, excessive engine
wear and possibly engine damage will occur .
A . Dummy Tank Cover
C. Retaining Knob
B. Screw
e()pen the air cleaner housing upper half by taking out
the housing bolts. It is not required t o remove the Ie
igniter.
Air Cleaner Element Installation Notes
eMeet the element sponge gas~et' with th e body opening
in the air cleaner housing low t r half.
FUEL SYSTEM 2-15
.,8
A, Sponge Gasket
A. Element
eSe sure! to install the element holders in their place.
*'
Air Cleaner Element Cleaning
B. Gasket
f the clement or gasket have any tears or breaks,
replace the element.
*If the clement frame is damaged or distorted, replace
the clement.
*If the sponge gasket comes loose, stick it back on with
an adhesi ve sealant.
NOTE
Oln dusty areas, the element should be cleaned more
frequently than the recommended interval.
OAfter riding through rain or on muddy roads, the
element should be cleaned immediately.
Air Cleaner Housing Removal
-Remove the air cleaner element.
-Ory the element by directing a stream of compressed
air from the clean side to thl.:! dirt)' side.
eRe move the following.
Dummy Tank Cover
Battery and Tray
IC Igniter
.Pull the air hose connecting the housing to the silencer
off the housing,
A, Compresicd Air
B, Clean Side (Sponge Gasket Side)
elnspect the element before installing it.
A. Air HO:iC
C. Housing Mounting Bolt
B, Air Intake Duct Clamps
Air Cleaner Element Inspection
eLoosen the air intake duct clamp screws.
eRemove the remaining housing mounting bolt.
-Visually check the element for lears of breaks , Check
epull the air cleaner housing upward and take it off the
the sponge gasket also. and the plastic frame .
surge tank .
2·16 FUEL SYSTEM
............................................................................
Catch Tank
A catch tank is provided beneath the surge tank, and
catches the water or oil from the bottom of the surge
tank. Usually water or oil do not collect at the bottom
of the surge tank. In the event that rain water is drawn
in through the air cleaner, or if engine oil is blown
back, drain the tank.
A. Fuel Pump
Catch Tank Draining
-Visually check the catch tank if the water or oil
accumulates in the tank .
*tf any water or oil accumulates in the tank, drain it by
taking off the drain plug at the lower end of the drain
B. Pump Bracket Mounting Bolts
A.
8.
eTake out [he bolts and remove th e fuel pump with its
bracket.
_Djsconnect the pump lead connector.
.Pull the fucl hoses off the fuel pump. Be prepared for
fuel spillage.
hose .
eBe sure to install the plug firmly, or the air is drawn
WARNING'
in through it .
OGasoline 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.
,
A. Catch Tank
B. Drain Plug
A. Fuel Pump
B. Fuel Filter
Fuel Pump
Fuel Pump Installation Notes
Fuel Pump Removal
eRemove the fuel tank for extra clearance.
-Connect the fuel hose from the filter to the fitting
marked INLET, and the hose to tMC c.arburetors to the
another fitting.
FUEL SYSTEM 2-17
A. Fuel Hose from Filter
A. Fuel Hose from Tank
B. Fuel Hose to Pump
B. Fuel Hose to Carburt:'tors
• Be sure to ro ute the hoses so they wilt not be kink ed or
eBe sure to route the hoses so they will not be kinked
or stretched .
stretched.
Fuel Filter Inspection
-Visually inspect the fuel filtec.
*If the filter is c1e.r with no signs of dirt or other
co ntamination , it is OK and need nor be replaced.
*If the filt .. is dark or looks dirlY, repl". it. Also,
check the res t of the fuel syste m for contamination.
Fuel Filter
Fuel Filter Removal
-R emove the fuel tank for e-xtra clearance.
.Pul l the filter off the hose.
spillage.
Be pre pared fo r fuel
Fuel Tank and Fuel Level Sensor
Fuel Tank Removal
WARNING
I
cGasoline 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 5parks;
this includes any appliance with a pilot light .
Fuel Filter Installation Notes
-Install the fuel filt er so that the arrow on it shows the
fuel flow from the fuel tank to the fuel pump .
I WARNING I
CGasoline 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 applilnce with a pilot light.
Olf gasoline, solvent, water or any other liquid enters
the canister, the canister's vapor absorbing capacity
is greatly reduced .
If the canister does become
contaminated replace it with a new one.
2·18 FUEL SYSTEM
eBefore removing the fuel tank, remove the fuel in the
tank as possible using a suitable pump.
eRemove the rear shock absorbers. It is not required to
remove the air hoses from the shock absorbers.
-oisconnect the fuel level sensor lead connector.
eFree the overflow hose lower end from the clamp~n the
frame lower pipe .
oFar California vehicles. the breather and fuel return
hoses must be disconn ected from the tank fittings .
• Holding the fuel tank on its position , remove the rear
frame.
-Clamp the fuel hose conn ec ting the fuel tank with the
filter shut using the locking pliers.
A. Dampers
.,f
the check valve at the breather hose was removed ,
install it so that the arrow on it shows the fuel vapor
flow from the tank to the tank filler tray or e-anister.
A. Clamp this hose .
• Pull the fu el hose off the filter. Be prepared for fuel
spillage .
-Tilt the tank out the rear of th~ frame .
eDrain the fuel tank.
oArrange a suitable container under the fucl t.ank .
ORemove the locking pliers from the fuel hose to flow
the remaining fuel in the tank.
A. Check Valve
eBe sure to rou te the hoses so th ey will not be kinked or
stret ched.
Fuel Tank Installation Notes
eBc sure to install the rubber dampers in place.
Fuel Level Sensor Removal/Installation Notes
I WARNING I
CGasoline 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 o,r sparks;
this includes any appliance with a pilot light.
A. Dampers
eSefore removipg the fuel level sensor. che ck the fuel
level in the fue l tank is low enough to remove the
se nsor. The fuel level shou ld be below the opening for
the sensor mounting .
-Be sure to install the gasket in its place.
FUEL SYSTEM 2-19
Fuel level Sensor Gasket
Check Valve Inspection
-Inspect th e ch eck val ve by bl o wi ng air inr o each hose
fitt ing of th e valve , Air flo ws in the directio n o f the
arrow o n the valve, an d does not fl ow in the re verse
di rec tio n .
*I f it docs no t , re p la ce the ch eck va lve.
Check Valve
I. Sle pped Bo h
2. Sensor Bracket
3. Gaske t
4 . Fuel Ta nk Bracke t
Air flows .
¢~C(~:~~J<:;
Fuel Tank Cleaning
Air does no t flo w.
-Remove the fuel tank and drai n it.
_Remove th e fuel level sen so r ,
.pour so me high flash-poin t solvent into the fue l tank
and shake the tank to remove din and fuel d e posits,
[ WARNING
I
CClean the tank 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 to clean the tank .
-Po ur the so lvent out of the tank ,
- Ory the tank with co mpressed air.
-Instal/ th e f uel leve l sensor,
Oinslalll hc f uel lan k.
Fuel Tank Inspection
. Visu all y inspec t the gask ets on the se nsor and ca p for
any damage ,
*Replace the gask ets if th ey are damaged.
_Check to sec jf the o ri fic e at th e:: bo tto m of th e
brca ther hose fi tti ng is no t cl ogged .
*I r it is cl ogged, bl o w through th e fi tting to frce the
orifi ce fr o m cloggi ng.
not use compressed air during the valve check, or
the check valve may be damaged .
0 00
Evaporative Emission Control System
(US California Vehicle only)
The Eva pora tive Em issio n Co ntrol System ro ules fuel
va pors from the fue l sys tem into t he run nin g en gine or
stores th e vapo rs in a ca nister whe n th e engine is sto p·
ped. Although no ad jus tments are req uired , a th o rough
ViS UCi!' insp ec ti on must be mad e a t the int erval s sp ec ified
by th e Periodi c Mai ntenance Char t.
Parts Remo val/ Installation Notes
Breather Hose Fitting Orifice
I WARNING I
/1-'
'- --'
o Gasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignit ion 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.
1. Breather Hose Fitting
2 . Orifice
3. Fuel Ta nk
Olf gasoline, solvent, water or any other liquid enters
the canister. the canister's vapor absorbing capacity
is greatly reduced .
If the canister does become
contaminated replace it with a new one .
2·20 FUEL SYSTEM
-To prevent the gasoline from flowing into the canister
or from flowing out of the canister, hold the se parator
perpendicular to the ground.
-Connect the host'S according to the diagram of the
system . Make sure they do not get pinched or kinked.
Canister Inspection
-Visually inspect the canister for cracks and other
damage.
-If the ca ni ster has any crack or bad damage, replace it
with a new one.
NOTE
Hose Inspection
-Ch ec k th at the hoses (lfe securely connec ted.
-Replace any kinked, deteriorated or damaged hoses.
OThe canister is designed to work well through the
motorcycle's life without any maintenance if it is used
under normal conditions.
Separator Inspection
- Visuall y inspect the separator for cracks and other
damage.
-If the separator has any cracks or is bad ly damaged,
replace it with a new one.
Separator Operation Test
I WARNING I
c Gasoline is extremely flammable and can be explosive
under certain conditions. Do not smoke. Make sure
the area is well ventilated and free from any source of
flame or sparks.
-Connect the hoses to the separator, and install the
separator on the motorcycle.
-Disconnect the breather hose from the se parator, and
inject about 20 mL of gasoline into the separator
through the ho,e fitting.
-Disco nn ect the fuel return hose from the fue l tank.
-Run the open end of the return hose into the container
level with th~ tank top.
-Start the engine, and let it idle.
-If th e gasoline in the separator comes o ut of the hose,
the sep arator works well. If it does not, replace. the
separator with a new one.
Vacuum Valve Inspection
-Ch eck the vacuum valve by blowing air into the hose
fitting of the valve.
oll'h en applying vacuum (2 cmHg) to the vacuum
se nsing fitting, th~ valve is opened and air flows from
the filter fitting to the carburetor float cha mber fitting,
a.nd vice \'ersa.
c Whcn stopping to apply vacuum. the valve is clost:!d and
air does not flow.
*If the vacuum va lve does not operate as described.
replace the va lve.
COo not use compressed air during the valve check, or
the vacuum valve may be damaged .
NOTE
0 The vacuum valve is opened to apply atmospheric
pressure to the carburetor floBt chambers when the
engine is running, and closed to store the vapors from
the float chambers in the can;srer when the engine is
stopped.
Vacuum Valve Operation
_;J~i~:;}--:-
~~~r;;;;~
Vacuum
No vacuum
Air does not flow.
•
I
I
Valve c losed
COOLING SYSTEM 3-1
Cooling System
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
Coolant Flow Chart .................... _. . . . . • . . . . . . . . . . . . .
3-3
Coolant ........................ _. . . . . . . . . . . . . . . . . . . . . . . .
3-4
Coolant Level Inspection ........ . ..... . ....... _. . . . . . . . .
3-4
Coolant Inspection. . . . . . . . . .• . . . . . . . . . . . . . . . . . . • . . . . . . .
3-4
Coolant Change ................ . •....... . .•.... __ . . • . .
3-4
Cooling System Air Bleeding . .................... . •.. . ...
3-5
Mechanical Seal Inspection (Visual Leak Inspection) . . . . • . . . .. .
3-6
Cooling System Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
Cooling System Flushing ......... . ... . ...... . .... .. .....
3-6
Radiator Cap ................. , . .... . •... , . ........ . ......
3-7
Radiator Cap Inspection ..... , .......... , . . . . . . . . . . . . . . . .
3-7
Radiator, Fan, and Fan Switch .......... . ......... . .... . ... , , .
3-7
Radiator Removal Notes .......................... • .....
3-7
Radiator Installation Notes ....••....•... . .....•...•... . .
3-8
Radiator Inspection. . . . . . . . . . . • . . . . • . . . . . . . . . . . . . • . . . . .
3-B
Radiator Cleaning. . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
Water Pump. . . . . . . . . . . . . . . .. . . . . • . . . .. . . . . . . . . . . . . . . . . . . .
3-8
Water Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .
3-8
Water Pump I nstallation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
Pump I mpeller Inspection ........... .. ..................
3·9
Thermostat and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
Thermostat Removal Note ................... , . . . . . . . . . . .
3-9
Thermostat I nstallation Notes ............ _. . . . . . . . . . . . . . .
3-9
Thermostat Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10
Hoses and Pipes ... . .. . .... . .... . .... . .. . ... . .... . .. . .. . , ..
3-10
Hose and Pipe Removal Note ...... , . . . . . . . . . . . . . . . . . . . . . .
3-10
Hose and Pipe Installation Notes ......... .. .......... , . . ..
3-10
Hose Inspection ..... .. ......... _.......... . ..... . , .. , .
3·12
•
3·2 COOLING
SYST
........ ........................... .. ....... .
EM
..........
..........View
........ .
'E"x"p"loded
.................. ... ................ ..
............. .. ........... .. ....... .........
1. Radiator Fan Switch
2 Radiator Fan
e Sensor
3 . Water Temperatur
SS
. · SoI,eone
..
Sealant
69 .on.1 b)
.
(080 kg·m,
Tl : 7 .8 N.." .
11.0 ft.lb)
T2: 15 N-m (1.5 kg·m,
COOLING SYSTEM 3·3
SplI!;ifications
Item
Standard
Mixed Ratio (Provided coolant when shipping)
Freezing Point (Provided coolant when shipping)
Total Amount
Permanent type of antifreeze (soft water and
ethylene glycol plus corrosion and rust inhib·
itor chemicals for aluminum engines and
radiators)
Soft water 57%, coolant 43%
- 30°C (- 22°F)
3.8 L
Coolant:
Type (recommended)
Radiator Cap:
Relief Pressure
73.5 - 103 kPa
(0.75 - 1.05 kg/cm 2 , 11 - 15 psi)
Thermostat:
Valve Opening Temperature
Valve Full Opening Lift
80 - 84° C (176 -183°F)
More than 8 mm @95°C (203 F)
0
Coolant Flow Chart
Thermostat Operation
(Cold Engine)
~@
~ .~ ~
Cold Coolant
Hot Coolant
~
~~
®
~~W'
~-,~~-~:j(fa)
___,
~
~
1. ihdia'lor Cap
2. To Reservoir Tank
3. Radiator
4. W.ter P"mp
5. To, Cylinde< lacket
6. From Cylinder Head (cold Engine)
7. From Cylinder Head (Hot Engine)
8. Thermostat
9. To Bypass PalS.ge
10. To Radiator
.......... /
ltI. ...
@~t
,~
'-
"
m
(Hot Engine)
c
:f''-O)
3-4 COOLING SYSTEM
*If the coo lant gives off an abnormal smell when
changing , check for a coo ling sl'stem leak. It may be
cause d by exhaust gas leakiog ioto the cooling system .
Coolant
Coolant Level Inspection
NOTE
-Set th e motorcycle up on its center sta nd.
-Rt'move the rese rvoi r tan k cover.
ec:heck the coolant level in the reservoir tank. The
coolant level should be between the " F" and rhe "L"
marks.
c Be sure to inspect the coolant at the reservo ir tank. If
the coolant is checked by removing the radiator cap.
the air must be bleed from the COOling system.
NOTE
cCheck (he level when the engine is cold (room or
ambient temperature),
ODD not check the level by removing the radiator cap. If
the cap is removed, air may get into the coo/ant, and
lower cooling efficiency.
'Coolan t Change
CUte coolant containing corrosion inhibitors made
specifically for aluminum engines and radiators in
accordance with the instructions of the manufactures,
WARNING
A. "F" Mark
B. " L " Mark
C. Tank Cap
*If the coolant level is low, add coolant thro ugh
filler opening to the "F" mark.
th~
OFor refilling, add the specified mixture of coolant and
soh water . Adding water alone dilutes the cooJant and
degrades its anticorrosion properties. The diluted
coolant can attack the aluminum engine parts. In an
emergency soft water can be added. But the diluted
coolant must be returned to the correct mixture ratio
within a few days.
0 1f coolant must be added often, or the reservoir tank
has run completely dry; there is probably leakage in the
cooling system, Check the system for leaks.
a 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.
c Coolant on tires will make them slippery and can cause
an accident and injury . Immediataly wipe up or wash
away any coolant that spills on the frame. engine, or
other painted parts.
GSince coolant is harmful to the human body. do not
use for drinking.
- Set the motorq'c!c up on its center stand.
-Remove the dummy tank cover.
eR emove the radiator cap in two steps. Firs t turn the
cap cou ntercl ockwise to the first stop and wait t here
for J few seconds. Then push down and remove the
cap.
I
Coolant Inspection
-V isually in spect the coolant in the reservoi r tank.
*If whitish coLlon-like wafts arc observed, a.luminum
parts in the cool ing system are corroded. If the coolant
is brown, iron or steel pans are rus ting, In either case,
flush the cooling system .
I
A. Radiator Cap
COOLING SYSTEM 3-5
-Place a container under the drain plug at the boltom of
the coolant pipe .
eDrain the coolant from the radiator and engine by
removing the drain plug.
Radiator Filler Neck
1. Radiator Filler Neck
2. Coolant Level
eFill the reservoir tank up to the "F" mark wilh
coola nt, and install the ca p .
-Bl eed the air from the system.
A. Coolan t Pi pe
8. Drain Plug
[CAUTION
-Remove the rese rvoir tank cover.
-Unscrew the bolt and remove the reservoir tank with
hoses attached .
-Unscrew the cap and pour the coolant into a container .
I
USoft or distilled weter must be used with the antifreeze
(see below for antifreeze) in the cooling system.
Olf hard water is used in the syuem, it causes scales
accumulation in the water passages, and considerably
reduces the efficiency of the cooling system.
NOTE
CChoose a suitable mixture ratio by referring to the
coolant manufacturer's directions.
Original Coolant
Type
A. Bolt
B. Reservoir Tank
Color
Mixed Ratio
Freezing Point
Total Amount
Permanent type antifreeze for
aluminum engina and radiator
green
soft wate, 57%, coolant 43%
-looe (_22°F)
3.8 L (up to "F" mark)
-Inspec t the coolant de teriora tion .
-I nstall the drain plug. Always replace the gasket with
new one , if it is damaged.
- Fill the radiator up to th e top of th e filler neck with
coolant.
NOTE
OPour in the coolant slowly so that it can expel the air
from the engine and radiator.
c The radiator cap must be installed in two steps. First
turn the cap clockwise to the first stOp. Then push
down on it and the rest of the way.
Cooling System Air Bleeding
-Loose n the air bleeder bolt on the top of the water
pump cover, and the coolant begins to flow ou t the air
bleeder bolt hol e (t hat is, when alilhe remain ing air has
been forced out).
3-6 COOLING SYSTEM
Cooling System Pressure Test
CDuring pressure testing, do not exceed the pressure for
which the system is designed. The maximum pressure
is 103 kP. (1.05 kglem', 15 psi) .
• Remove the radiator cap, and in5tall a cooling system
pressure tester on the radiator filler neck .
• Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks .
A. Air Bleeder Bolt
B. IVater Pump Cover
eBuild up pressure in the system carefully until the
pressure reaches 103 kPa (1.05 kg/em', 15 psi).
-Watch the gauge for at least 6 seconds.
*If the pressure holds steady, the system is all right.
-Tighten the air bleeder bolt.
- Fill the radiator up to th e radiator filler neck with
coolant.
-Check the cooling system for leaks.
-In stall the radiator cap turning it clockwise about Vo,
turn .
_Start the engine, warm it up thoroughly, and then stop
it.
-Check th e coolant level in the reservoir tank after the
engine cools down.
*If th e coolant level is low, add coolant up to the "F"
mark thro ugh the reservoir tank opening.
Mechanical Seal Inspection
(Visual Leak Inspection )
Any time th e sys tem slowly loses water. inspect for
leaks.
-Check the water pump bod y drainage outlet passage for
coolant lea ks .
*If the mechanical seal is damaged, the coolant leaks
through the seal and drains through the passage .
Replace the water pump unit.
*If there are no apparent leaks, pressure test the system .
A. Pressure Tester
B. Adapter
eR emove the pressure tester, re pleni sh th e. coolant, and
install the radiator cap.
_If the pressure drops and no external so urce is found,
check for internal leaks. Droplets in the engine oil in-
dicate internal lea kage.
Check the cylinder head
gasket and the cylinder liner O-ring leak .
Cooling System Flushing
Over a period of time, the !;ooling system accumu -
A. Drainage Outlet Passage
:at the bottom of the pump body
lates rust, scale , and lime in the water jacket and radiator. When this accumulation is suspected or observed,
flush the cooling system. If this accumutation is not
removed, it will clog up th~ waler passage and considerably reduce the efficiency of the cooling system .
-Drain th e coo ling ~y stem.
eFill the cooling system with fresh water mixed with a
flu shing com pou nd .
COOLING SYSTEM 3·7
Radiator Cap TIHt
OAvotd the use of a flushing compound which harmful
to the aluminum engine and radiator. Carefully follow
the instructions supplied by the manufacturer of the
cIeoning product.
-Warm up the engine, and run it at normal operating
temperature for about ten minutes.
estop the engine, and drain the cooling system.
-Fill the system with fresh water.
-Warm up the engine and drain the system.
eR.epeat the previous two steps once more.
-FiU the system with a permanent type coolant·, and
bleed the air from the system.
1. Pressure Tester
2. Radiator Cap
Radiator Cap
Radiator Cap Inspection
ec:heck the condition of the valve spring, and the top
and bottom valve seals of the radiator cap.
ICheck the condition of the top and bottom sealing
seats in the filler neck. They must be smooth and clean
for the radiator cap to function properly ,
*If anyone of them shows visible damage, replace the
cap or cap assembly.
Radiator, Fan, and Fan Switch
Radiator Removal Notes
I WARNING.
CThe radiator fan and fan switch are connected directly
to the battery. The radiator fan may start even if the
ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE ENGINE COMPLETELY
COOLS OFF. TOUCHING THE FAN BEFORE THE
ENGINE COOLS COULD CAUSE INJURY FROM
THE FAN BLADES .
• Wait until the coolant cools down , and then drain the
coolant (see Coolant Change) .
• Do not touch the radiator core directl y, or the radiator
fins are deformed.
Radiator Installation Notes
A. Valve Spring
B. Seals
C. Sealing Seats
.,f the radiator fan was removed, install it onto the
radiator . Be sure to ground the lead by tightening it
with the fan mountin, bolt.
.Wet the cap sealing surfaces with water Of <:oo1ant to
prevent pressure leaks,
.'nstall the cap on a cooling system pressure tester,
.Watching the pressure gauge, pump the ,pressure tester
to build up the pressure. The cap. must retain the
pressure at least 6 seconds. Alw the cap must open at
the specjfied relief pressure.
Radiator Cap Relief Pressure
73.5 -103kPa
(0.75 - 1.05 kglem' , 11 - 1S psi)
*If the cap C4nnot hold the specified pressure, or if it
holds too much pressure, replace it with a new one.
A. Ground Lead
B. Radiator Fan
•
3·8 COOLING SYSTEM
elf the radiator fan switch was removed, tighten it to the
specified torque (see Exploded View) . Be sure to
®-1-----r-
instJlIlhe O-ring onto the switch.
A. Steam Gun
A. Radiator Fan Switch
B. More than 0.5 m
-Run the gun horizontally following the core fin
direction holding it perpendicular to the core surface.
-Fill th e cooling s)'stem with the coolant and bleed the
air from the system .
Radiator Inspection
e<::heck the radiator core .
*Jf there are obstructions to air flow, remove them,
*If the corrugated fins arc deformed, carefully straighten
them with the blade of a thin screw driver.
A. Thin Screwd river
.,r
the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparabl y
deformed fins, replace the radiator with a new one.
Water Pump
Water Pump Removal
eWail until the coolant cools down, and then drain the
coolant (see Coolant Change) .
eRemove the following .
Shift Pedal Linkage
Front Gt!ar
Radiator Cleaning
When cleaning the radiator with a steam cleaner, be
careful of the following to prevents radiator damage.
-Keep Ihe steam gun J.wa~' more than 0.5 m from lhe
radiator core .
Ca~e
Cover
Clutch Slave Cylinder
Radi ator
1\1ufncrs and Exhaus;t Pipe')
eRemove the water pipe holding bolts and pull the pipes
off the pump .
•
COOLING SYSTEM 3-9
-Fill the cooling system with the coolant and bleed the
air from the system.
.awas
Pump Impeller Inspection
-Visually check the impeller.
*If the surface is corroded, or if the blades are damaged,
replace the water pump unit .
•
A. Pipe Holding Bolts
B. Pump Mounting Bolts
,
'Pull the pump out of the crankcase.
•
W,ter Pump Installation Notes
IWhen installing the water pump, note the position of
the oil pump shaft projection and turn the water pump
s~aft so that the projection fits into the slot.
A. Impeller
Thermostat and Temperature Sensor
Thermostat Removal Note
.Wait until the coolant cools down, and then drain the
coolant (see C.oolant Change).
A. Oil Pump Shaft Projection
B. Water Pump Shaft Slot
IBe sure to inslall the O-ring on each water
A. O-ring
Thermostat Installation Notes
p ip~
fitting.
.Slow the air bleeder hole in the thermostat hou si ng
with compressed air.
A. Air Bleeder Hole
B. Air Bleeder Valve
3-10 COOLING SYSTEM
elnstall the thermostat in its housing so that the air
bleeder valve is on lOp.
elf the coolanr temperature sensor was removed, apply a
silicone sealant to the threads, and ti ghten it to the
specified torque (see Exploded View) .
-Watch the valve. As soon as the valve starls to open,
note the temperature.
*If it is out
the speCified range, replace the ther mostat.
of
Thermortat Valve Opening Temperature
80 - 84'C (176 - '83'F)
e(ontinue heating until the water temperature is 95°C
(203'F), and hold the water at the temperature for five
minutes.
-Then measure the bypass valve height. The difference
between the two bypass valve heights, measured at
room temperature and at 9S'C (203'F), is the full
valve lift.
*Ir it is less than the standard range, replace the thermostat.
Valve Lift Measurement
A. Temperature Sensor
-Fill the cooling system with the coolant and bleed the
air from the system.
Thermostat Inspection
-Remove the thermostat, and inspect the thermostat
valve at room temperature,
*If the valve is open, replace the valve with a new one,
eTa check valve opening temperature, suspend the
thermostat and an accurate thermometer in a container
of water .
• Place the container dYer a source of heat and gradually
raise the temperature of the water while stirring the
water gently .
Bypass Valve Height
>!<The bypass valve height difference is the valve lift.
Valve Opening Temperature Measurement
Thermometer
----J
Thermostat ' : must be
completely
submerged
Thermostat Valve Full Opening Lift
Mor. than 8 mm @9S'C 1203'F)
Hoses and Pipes
Hose and Pipe Removal Note
-Wait until the coolant cools down, and then drain the
coolant (see Coolant Change) .
/
They must not touch the container
sides or bottom.
Hose and Pipe Installation Notes
-Be sure to install the O-ring on tach pipe fitting which
is mounted onto the ty'llnder, cylinder head , thermostat housins , or water pump _
COOLING SYSTEM 3-11
O-ring on Pipe Fitting
-lnsta.11 the clamps as near as possible to the hose e nd to
clear the raised rib on the fitting, This will prevent the
hoses from working loose.
oThe clamp screws should be posi ti o ned correctly to
prevent the clamps from contacting anything.
Hose and Clamp Installation
1. G-ring
2. Raised Rib on Pipe
-Install the hoses and pipes being careful to follow
bending direction or installat io n marks. Avoid sharp
bending, kinking, flattening , or twisting,
1. Fitting
2. Rai sed Rib
3. Hose End
4. Hose Clamp
5. Hose
Iistallation Marks on Hoses and Pipes
li\i-t- - @
g
1. Line Mark
2. Arrow Mark
3. Paint ,\lark (White)
4. Pa int Mark (Yello w)
3-12 COOLING SYSTEM
-Fill the cooling system with the coolant and bleed the
air from the system.
Hose Inspection
-Visually inSp!!Cl the hoses for signs of deterioration.
Squeeze the hoses. A hose should be not hard and
brittle, nor should not be soft or swollen.
-R eplace any damaged hoses .
..
I
ENGINE TOP END 4-1
Engine Top End
Table of Contents
Exploded View
4·2
Cylinder Head .. . .. ... , . .. , . . . . . . , ..
4·18
.. . . , ... . . ...• , .. , • •..
44
Cylinder Head Removal Note .. " . , . ,
4-18
Si>t<:ial Tools . ... . . . . . . . . . . . .. .. • ••.
4·6
Cylinder Head Installation Notes . . . . . .
4·18
Cltan Air System (US model)
4·7
5pe(ifications
Air Suction Valve
Installation Note
. .. . . . .. ..•••.
Air Suction Valve Inspection
... .•...
Vacuum Switch Valve Test ... . .. . • . .
Cylinder Head Covers . ....
4·18
4-19
Cylinder Head Cleaning
4 -20
4·7
4·7
4-7
Carburetor Holders ... . . . . . . . . . . . . . . . .
4-20
Carburetor Holder Installation Notes ,_,
4·20
4 ·8
Valves
Cylinder Head Cover
Removal Notes . .... .. ... . .. •. .
Cylinder Compression Measurement
Cylinder Head Warp ........ ....•.
4·8
Cylinder Head Cover
........ .
4 ·20
Valve Mechanism Removal Notes .. , . ..
4 -20
Valve Mechanism Installation Notes ... .
4·20
Valve Head Thickness
4·21
4·2 1
.. " . . . . , . . . . . . . "
Installation Notes
4·8
Valve St em Bend ., _ . , . , . . . . . . ,
Camshaft Chain Tens ioner
4·9
Valve/ Valve Guide Clearance
Measurement (Wobble Method) . . . ..
4·21
4·9
Valve Seat Inspection ........ .....
4 ·22
Valve Seat Repair ... , . . . . . . • ... .
4·22
Camshaft Chain Tensioner
Removal Notes .
Camshaft Chain Tensioner
4·9
Installation Notes
Replacement Cha in
Cylinders and Pistons
. . . . . . . , . . . . . , .. .
4 ·25
Piston Removal Notes .. .. , . . .. ... ,
4-25
4·9
Piston Installat ion Notes . . . . . . . ....
4 -26
4·10
Cylinder Installation Notes . . . . • .. .. '
4 ·27
4·10
Cylinder Inside Diamete( . . . ' . • . _ . .
4·27
Piston Diameter . . . . . , .. , . . . . . . ' .
4 ·28
4-10
Piston /Cyli nder Cleara nce
., .. • ... ,.
4·28
Camshaft Sprocket Installa tion Notes. . .
4-12
Cylinder Bor ing and Honing ... .. .. , .
4·28
Cam He ight Measurement .. . . . . . . .. .
4·12
Piston / Cylinder Seizure . . . . . . •.. , ..
4 ·28
Camshah Run o ut . . . . . . . . .. _ .
4·12
Piston Cleaning
4·29
Tensioner Installat ion Notes . . . . . . .
Camshafts and Sprockets
Camshaft Removal Notes . . . . . . . .
Camshaft Installation Notes
(Including Chain Timing Procedure) . .
Camshaft Bearing Oil Clearance
.. , ... . .. .
Piston Ring and Ring Groove Wear ...
4·29
Piston Ring End Gap . ..
4·29
Inspection . . . . . . . . . . . . . .
4·12
Camshah Chain and Guides . . . . _ .. .
4·13
Exhaust Pipes and Mufflers , . . . . . ' , . . . . . .
4·30
4 ·13
Muffler Removal Notes . . . . . . . . . . . .
4·30
Camshaft Chain Removal Note . . . . " .
Camshaft Chain Guide
Exhaust Pipe and Muffler
Removal No tes . _ . . . . . . . .. . . . . .
Camshaft Chain Wear
,........ . . .
4·13
4 -13
Camshaft Chain Guide Wear . . . . . .
4-13
Hydraulic Lash Adjuster (HLA) ... . .. .... ,
4·13
H LA Removal Notes
4·13
HLA Installation Notes. . . . • . •• . . ..
4-14
H LA Air Bleeding . ... ... . .. . . . .
4·14
HLA Leak-down Measurement . ,
4-14
HLA Troubleshooting Guide. . . . . . . ..
4·16
Installat ion Notes .. , .. .. .
4 ·30
4-2 ENGINE TOP END
Exploded View
1 . Vacuum Switch Valve
L : Non-permanent Locking Agent
M : Molybdenum Di5ulfide Grease
S : Follow the specified tightening sequence .
Canada Model
1- -
- -.,
Ii:
I
'"
SS: Silicone Sealant
I
I
)/"W] I
I~I
St : Stake the fastener.
L __ _
T1 : 9.8 N-m (1.0 kg-m. 87 in-Ib'
T2: 12 N-m (12 kg-m. 104 in-Ib'
T3: 15 N·m (1.5 kg-m. ll.o ft-Ib'
T4 : 25 N-m (2.5 kg-m. 18.0 It-Ib'
T5 : 48 N-m (4.9 kg·m. 35 ft-Ib)
T6: 51 N-m (52 kg -m. 38 ft~b)
St
~'I
~
/ -
0
,0.-
~ . _ .l'~.,o
~v
0
i
ENGINE TOP END 4-3
/
/
/
)
~
~
{
.U
'~! \
,
;
,f,
/
I
r
4-4 ENGINE TOP END
Specifications
Standard
Item
Service Limit
Clean Air System (US model only):
Vacuum Switch Valves Switch Pressure:
Open .... Close
57 - 65 kPa
---
(430 - 490 mmHg)
Camshafts:
Cam Height
37.021 - 37.163 mm
36.92 mm
Camshaft Runout
0.03 mm TIR
0. 1 mm TlR
Journal A
0.030 - 0.072 mm
0.16 mm
Journal B
0.070 - 0.112 mm
0.20mm
Journal A
24.949 - 24.970 mm
24.92 mm
Journal B
24.909 - 24.930 mm
24.88 mm
25.000 - 25.021 mm
25.08 mm
158.8 - 159.0 mm
161 .2mm
0- 0.2 mm
0.2mm
Camshaft Bearing Oil Clearance :
Camshaft Journal Diameter:
Camshaft Bearing I nside Diameter
Camshaft Chain:
Camshaft Chain 20·link Length
Hydraulic Lash Adjuster (HLA):
Hydraulic Lash Adjuster Leak Down Distance
Cylinder Head:
(usable range)
Cylinder Compression
960 kPa - 1,470 kPa
---
(9.8 - 15.0 kg/ em' ,
139 - 213 psi)
Cylinder Head Warp
- - -
0.05 mm
Inlet
0.8mm
0.4 mm
Exhaust
1.0mm
0.5mm
0.02 mm TIR
0.05 mm TIR
5.4 75 - 5.490 mm
5.46 mm
Valves :
Valve Head Thickness :
Valve Stem Bend
Va lve Stem Diameter:
Inlet
Ex haust
5.455 - 5.470 mm
5.44 mm
5.500 - 5.512 mm
5.58 mm
Inlet
0.02 - 0.09 mm
0.29 mm
Exhaust
0.07 - 0.14 mm
0.34 mm
41.3 mm
39.5 mm
Valve Guide I nside Diameter
Valve/Valve Guide Clearance
(wobble method):
Valve Spring Free Length
ENGINE TOP END 4-5
Standard
Item
Valve Seating Surface:
Width
Outside Diameter:
Inlet
Exhaust
Valve Seat Cutting Angle
Cylinders and Pistons:
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Oversize Piston and Rings
Piston Ring/Groove Clearance:
Top
Second
Piston Ring Thickness:
Top & Second
Piston Ring Groove Width: Top
Second
Oil
Piston Ring End Gap:
Top
Second
I
I
0.5 - 1.0 mm
28.9 - 29.1 mm
24.9 - 25.1 mm
32". 45". 60"
Service Limit
---------
77.994 -78.006 mm
77.935 -77.950 mm
0.044 - 0.071 mm
+ 0.50 mm
78.10 mm
77.80 mm
0.03
0.02
0.97
1.02
1.01
2.01
0.17 mm
0.16 mm
0.90 mm
1.12 mm
1.11 mm
2.11 mm
0.7mm
0.7mm
- 0.07 mm
- 0.06 mm
- 0.99 mm
- 1.04 mm
-1.03 mm
- 2.03 mm
0.20 - 0.35 mm
0.20 - 0.40 mm
-----
4-6 ENGINE TOP END
Valve Guide Reamer: 57001-1079
Special Tools
Along with common hand tools, the following more
special ized tools are required for complete engine top
end servicing.
Piston Ba,e: 57001-149
Piston Ring Compressor Assembly (4): 57001-1094
Compression Gauge : 57001-221
Adapter: 57001-1183
Valve
Valve
Valve
Valve
Valve
Seat_Cutter
Seat CUller
Seat Cutter
Seat Culler
Seat Culler
45° - <1>27.5
32° - <1>28.0
32° - <1>30.0
60° - ¢ 3O_0
45° - \\30.0
Valve Spring Compr~ssor Assembly: 57001-241
Adapter: 57001-1019
Cutter Holder ¢5.5: 57001-1125
.~
Piston Pin Puller Assembly: 57001-910
Bar: 57001-1128
..o.
Valve Guide Arbor: 57001-1021
Tappet Bloeder: 57001-1200
)
57001 -1114
57001 -1119
57001-1120
57001-1123
57001-1187
ENGINE TOP END 4-7
[~AUTION :I
Clean Air System (US model)
Air Suction Valve Installation Note
elnstall the air suction valve Jlssembly into its h9using so
000 not scrape off the deposits with a scraper 8S this
could damage the rubber. requiring replacement of the
suction valve assembly.
that the rear edge of it contacts with the rear
projection on th e housing.
Vacuum Switch Valve Test
-Check the vacuum switch va lve by blowing air into the
air hose fitting .
oWhen the vacuum applied to the vacuum hose fitting of
the valve is low, the vacuum switch valve is opened
and air flows through th~ air hos~ f ittings.
oWhcn the vacuum rises gradually and reach a certain
level, the valve is closed and air does not flow .
• If the vacuum switch valve does not operate as
described, replace the valve.
Vacuum Switch Valve Operation
During Cruising (Open Throttle)
A. Air Suction Valve Assembly
B. No gap.
Air Suction Valve Inspection
-Visuall y inspect the reeds for cracks, folds, warps, heat
damage, or other damage,
*If there is any doubt as to the condition of the reed,
replace the air suct io n valve as an assembly.
No Vacuum
During Engine Braking (Closed Throttle)
'--iYI Air does not flow .
A. Valve Holder
B. Reeds
echeck the reed contact areas o f the valve ho lder for
grooves, scratches, any signs of separation from the
holder, or heat damage.
*If there is an y doubt as to the condition of th e reed
Vacuum
contact areas. replace the air suction valve as an
assemb ly.
elf any carbon or other fo re ign particles have accumulated between the reed and the reed contaCt area, wash
the valve' aS5tmbl y clean with a high flash-point solvent.
Vacuum Switch Valve Closing Pressure
Open .... Close: 57 - 65 kPa (430 - 490 mmHg)
4-8 ENGINE TOP END
Cylinder Head Covers
Cylinder Head Cover Removal Notes
-Remove the cylinder head covers by taking out the
cover moun tin g bolts..
o Removc the air suction valves and head cover assembl y
Allen bolts and separate the left and right covers if the
cngine is on the frame.
A. Appl y si licone scalant.
A. Cylinder Head Cover Mounting Bolts
B. Clamp
eBe care ful not to fall the rubber dampers on each
fitting of the oil pipe inlo the chain tun nel.
A. Apply sil icone sea lant.
eSe sure to in stall the rubber damper onto each fitting
of the oil pipe with the correct side of it facing up.
A. Rubber Dampers
Oil Pipe Damper Installation
Cylinder Head Cover Installation Notes
elf the left and right covers were s.ep~r:\lcd, asse mble
th t;:m with bolts. and knoc k pins. One of the bolt
should be tightened with the cable clamp.
- Aprly a silicone sea lant to Ih e ma ting surfacc5 of the
cylinder head and (overs a:. shown .
1. Rubber Damper
2. Oil Pipe Fitting
3. O·r ing
ENGINE TOP END 4·9
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal Notes
This is a non-return type cam chain tensioner. The
push rod does not return to its original position once it
moves out to tllke up cam chain slack. Observe all the
rules listed below:
CWhen removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner
and the camshaft chain. Once the bolts are loosened,
the tansioner must be removed and reset as described in
"Chain Tensioner Installation,"
COo not turn over the crankshaft while the tensioner is
removed. This could upset the cam chain timing, and
damage the va,yes.
. Loosen th e ca p bolt before tensioner re moval for later
disasse mbl y convenience .
A. Compress th e rod .
B. About 10 mm
C. Screwdriver
D. Cloc kwise
.While ho lding th e rod in. posi l ion with [he screwdr iver
im,ta li t he tens ioner on th e cylinder block .
• Whil e pushing th e tensione r agai nst th e cy linder block
as show n , rem ove the scre wdriver .
• Unscrc w th e mounting bolts and rem ove the camshaft
chain ten sio n cr.
A. Push the tensioner.
A. Mounting Bolts
B. Screwdrivcr
B. Ca p Bolt
-Holding the tcnsioner. tiiht f!n the mo unting bolts
to
the specified (org,ue (see Explo ded View) .
• Insull the O-ring and tighten the ca p bol t.
Camshaft Chain Tensioner Installation Notes
.R emovc the: ca p bol t and O-ring .
• Whi lc co mpressi ng th c push rod , l urn it clockwise with
a sui tab le screwdri ver to put it imo unt il the ro d
protr usion Comes to a bout 10 mm fr om the tensioncr
bod y as sh o wn .
COo not turn the rod counterclockwise at installation.
Tliis could detach the rod and the tensioner cannot be
reinstalled.
Replacement Chain Tensioner Installation Notes
. A re placement cha in tensioner (spare partS) has a push
rod holder plate .
not pull the rod holder plate while the tensioner hi
removed . This could detach the rod and the tensioner
cannot be installed easily .
0 00
4-10 ENGINE TOP END
-Remove the plate to release the push rod after installing the tensioner .
A. Rocker Arms
!~~UTlO~]
>\. Rod Holder Plate
OThe crankshaft may be turned, while the camshafts are
removed, but always pull the chain taut while turning
the crankshaft. This avoids kinking the chain on the
lower (crankshaft) sprocket. A kinked chain could
damage both the chain and the sprocket.
Camshafts and Sprockets
Camshaft Removal Notes
eRemove the camshaft chain tensioner before removing
the camshaft caps.
.Pull the oil pipes with the rubber dampers and O-rings.
Camshaft Installation Notes
(Including Chain Timing Procedure)
eThe camshaft caps are machined with the cylinder
head, so if a new cylinder head is installed, use the
caps that arc supplied with the new head,
-If the oil filter(s) for the lash adjuster oil passage will
be replaced, install the spring, new filter, and retainer.
oThe top end of the retainer should be level with the
bottom of the oil reservoir. Stake the retainer to
secure it in place.
lash Adjuster Oil Filter
.........
Il,
(3;--------l;~.JIH__Jjl: ::,::· ·
......
- --.--»'
r.-,
''....
-,:-::,,:-:-:-:
'-4/>-----~f':
A. Oil Pipes
B. Chain Guide
C. Camshaft Caps
-Remove the camshaft cap bolts and take off the camshaft caps.
_Remove tht: camshafts. At this time, t.he rocker arms
can be removed easily. Be careful not to fall them into
the chain runnel.
1.
2.
3.
4.
Cylinder Head
Retainer
Oil Filter
Spring
:...-:::.,: :....":':,:-: :.....>:::.. ..:\-.,.-+-,.,
'.':-. ' .'.
-Fill the oil reservoirs on the cylinder head with engine
oil before installing (he camsh afts_
ENGINE TOP END 4·"
Camshaft Chain Timing (Chain Tensioner In..alled)
28th
2nd
A. Oil Reservoir
elf the camshaft{s) andicr cylinder head arc replaced
with new ones, apply a thin coat of a moly bdenum
di sulfide grea')e on the new cam part surfaces.
eThe exhau')l camshaft has an EX mark and [he inl~t
camshaft has an IN mark. Be careful not to mix up
th ese shafts.
Viewed from Right
I. Cylinder Head Upper Edge
2. Punch Mark
3. Inlet Camshaft Sprocket
4. Exhaust Camshaft Sprocket
5. Timing Mark
6. Timing Rotor
eln acco rding to the camshaft cap location numbers,
inslall the ca ps in the correct pos ition.
A. EX Mark ·
B. IN Mark
eEngage th e camshaft chain with the camshafl sprockets
so that th e chain timing is correct.
OPositi on the crankshaft at 1,4 piston TOe
CPull the tension side (exha ust side) of the chain taut to
ins tall the chain on th e exh aust camshaft sprocket.
oEngag~ the chain and sprockets, The timina marks
must be positi oned ;lS shown, after th e camshaft chain
slac k is taken up by the tensione r.
A. Camshaft Cap Locat ion Numbers
4-12 ENGINE TOP END
Camshaft Runout
Camshaft Runout Measurement
o Tha camshaft caps are machined with the cylinder
head. So, if a cap is installed in the wrong location, the
camshaft may seize because of improper oil clearance
in the bearings.
OFirst tig hten down all cams ha ft cap bolts evenl )' to scat
th e camshafts in place, then torque a ll bolts to tht:
specified torque (see Exploded View). from th e chai n
tunnel side to th e outside.
c-Be sure to install the top chain guide with t he camshaft
cap bo lts .
eAfter installing the camshaft ca ps, install the chain
tensioner and then check the cams ha ft chain timing
again.
-Fill the oil passage in each camshaft cap with engine oil
before ins tallin g the oil pipes.
Camshaft Runout
Standard:
Service Limit:
0.03 mm TlR
0.1 mm TIR
Camshaft Bearing Oil Clearance Inspection
Camshaft Sprocket Installation Notes
-The inlet and exhaust sprockeL~ arc identical.
e Bo th sprockets should be installed with the marked
side of the sprocket facing th e opposi te side of the
sprocket mount.
eAppl y a non-permanent locking agent to tht: camshaft
sp rocket boils an d tighten them to th e specified torq ue
(see Exploded View ).
The journal wear is measured using plastigage (press
gauge), which is Inserted into the clearance to be
measured. The pi astigagc in dicates lh c dearanc e by the
amount il is compressed Jnd widened when the pa rts are
ass embled.
eWipe each jo urn al surface on the cranks hafts an d caps
clean o f oil.
-Cut strips of plastigage to journal width. Place a strip
on each jo urn al parallel to the camshaft with the camshaft installed in the co rrec t position and so that th e
plastigagc will be compressed between th e journal and
camshaft cap.
Cam Height Measurement
Cam Height Measurement
Cam Height
-t---+--t-+-
;\ . Plastigage Strip
Cam Height
Standard:
Service Limit:
37.021 - 37.163 mm
36.92mm
elnslall the cam sha ft caps, tightening the bolts in th e
correct sequen ce to the ~pecincd torq ue (see Ex ploded
View) .
ENGINE TOP END 4-13
NOTE
Camshaft Chain Guide Removal Notes
ODo not turn the camshaft when the plastigage is
between the journal and camshah cap.
-Remove the camshaft caps again, and measure the
pl as tigage width to determine the clearance between
each journal and the camshaft cap. Measure the widest
portion of the plastigage.
*1(
eThe top chain guide is removed during camshaft
removal .
-The front chain guides (upper and lower) can be
remo\'ed after removing the cylinder head,
eThe rear chain guide can be removed after splitting the
crankcase.
any clearance exceeds th e service limi[, measure the
diameter of each camshaft journal.
Camshaft Chain Wear
Camshaft Bearing Oil Clearance
Journal A
Journal B
Standard
0.030 - 0.072 mm
0.070 - 0.112 mm
Service Limit
0.16 mm
0.20mm
-Hold the chain taut with a force of about 5 kg in some
manner, and measure a 20·link length , Since the chain
may wear unevenly, take measurements at several
places.
*If any measurement exceeds the s.ervice limit, replace
the chain.
Chain Length Measurement
Camshaft Journal Ide.ntification
20·l ink Length
A. Journal A
B. Journal B
Camshaft Chain 20·link Length
Standard:
*If th e camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
158.8 - 159.0 mm
Service Limit: 161.2 mm
Camshaft Chain Guide Wear
Camshaft Journal Diameter
Journal A
Journal B
Standard
Service Limit
24.949 - 24.970 mm
24.909 - 24.930 mm
24.92 mm
24.88 mm
eVisually inspect the rubber on th e guides.
*If the rubber is damaged, cut, or is missing pieces,
replace the guides.
_If the clearance sti ll remains out of the limit, replace
th e cylinder head unit.
Hydraulic Lash Adjuster (HLA)
HLA Removal Notes
eTake off the rocker arms,
_Pull o ut the hydraulic lash adjuster.
Camshaft Chain and Guides
Camshaft Chain Removal Note
e<:amshaft chai n removal requires the crankcase splittin g
and crankshaft removJI.
c ee careful not to damage or deform a lash adjuster by
tapping it during removal or installation.
0 00 not drop the lash adjuster or hit it sharply. If it
is deformed, the plunger will not operate smoothly.
4-14 ENGINE TOP END
Lash Adjuster Air Bleeding
..
A. Rocker Arms
B. Hydraulic Lash Adjuster
1. Tappet Bleeder: 57001-1200
2. Hydraulic Lash Adjuster
HLA Installation Notes
oPrior to installation, measure the lash adjuster feakdown. If it is greater than specified, replace the ad·
juster. Also, be sure to air-bleed it.
e Ta clean the adjuster, rinse it in clean kerosene and
then blow it dry with compressed air. Do not dry it
with 8 cloth to prevent dust or lint contamination. Be
careffJl not to get any adhesives or liquid gasket on the
adjuster during servicing.
eBefore installing the adjusters in the cylinder head,
fill the holes for adjuster with clean engine oil.
.Put the adjusters in their holes, being careful not to
get any air or dust in the holes and not to allow the
ker osene to leak out of the adjusters.
elnstall the rocker arms.
eWhen air bubbles stop coming out of the adjuster, lift
the bleeder off the adjuster and take the adjuster out of
the container with the adjuster kept upright.
HLA Leak.<fown Measurement
ePut the lash adjuster vertically on a measuring stand
and set the dial gauge on the adjuster.
.Push down the head of the adjuster quickly with your
fingers and measure the distance it sinks.
Measuring Leak-down Distance of the Lash Adjuster
Dial Gauge
HLA Air Bleeding
.Provide a container filled with kerosene.
elnsert the lash adiuster into [he tappet bleeder (special
too! ) and move it up and down in the kerosene.
-Check that the lash adjuster plunger moves up and
down smoothl~'.
"If the plunger do~s not move smoothly, rep!act! the lash
adjuster.
Lash Adjuster
NOTE
Leak-down Distance
OKeep the lash adjuster always upright and immersed in
kerosene for easy air bleeding.
Standard:
Service Limit:
O-O.2mm
O.2mm
ENGINE TOP END 4-15
*If the leak -down distan ce exceeds the service limit,
re peat the air bleeding opera.t ion and t.hen measure the
leak-down agai n. If leak-down is still out of the service
limit, replace th e adj uster .
NOTE
C8e careful not to tip the lash adjuster and nO( to allow
the kerosene
(0
leak out of the adjuster.
Hydraulic Lash Adjuster
(Fr •• Ball Type)
1. Pi vot Plunger
2. Bod\,
3.
4.
5.
6.
7.
8.
9.
10.
Oil Feed Passage
Ball ·check Valve
Plunger Spring
Ret ai ner Cap
Reservoir
Ball Seat
Ball Cage
High Pr essure Chamber
4-16 ENGINE TOP END
HLA Troubleshooting Guide
Aeration of Oil
Insufficient engine oil will cause air to enter the lash adjuster resulting in tappet noise or poor engine running at both
low Jnd high ,peeds.
Pump-Up
Excessive oil pressure will cause the lash adjuster to hold the valve open . Also, operation in red zone can cause valve
float. This allows the rockers to momentarily lift. off the end of the HLA, which t.hen draws in oil to move the plunger
up, preventing th e valve from scating completely.
Hydraulic la,h Adjuster (HlAI
Trouble,hooting Guide (11
(NOiSY Valve Train
I
Is engi ne warmed up
thoroughly?
No
,
Wait 2 to 3 minutes
with the engine idling
1
Ye,
Adv ise the user not to
U
Open and close throttle valves
about 10 times, and then run
the engine for 2 minutes at
about 3,000 r/ min (rpm) with
no load.
run the engine beyond
usable range
Is
valve still noisy
1/ Yes
,
/
Did engine
operate in red zone?
No
Ye,
Good
\
No
Is
valve still noisy
?
Since valve noise may
return, check oil level
and contam ination
No
1,
Check oil line
I
~OOd
Yes
\
Check oil level and contamination
Bad
I
~~
;;0
Good
Clean oil screen, replace oil
filter, and add or change oiL
Noise test from beginning
~
,
in
to
Air
HLA
inSUffiCIent
andlor
contammated ad
Bad
~
Check oil preS5ure
Go ad or
hi~
1 Too low pressure
pressure
Aeration of oil
J,
Remove cylinder head cover and
Bad
outside oil pipe to inspect oil line
~-
-IGOOd
Inspect HLA wear, stick,
break , excessive leakdown
Bad
\
I,
Replace HLA
Repair oil line and noise
test from beginning
spring
Good
Inspect and repair camshaft,
rocker arm, and valve. Noise
test from beginning,
f-
Check and repair the
following parts and noise
test from beginning .
Oil Pump
~
Oil Screen
Oil Filler
Crankcase Oil Passage
ENGINE TOP END 4·1 7
I
Hydraulic Lash Adjuster (HLA)
Trouble Shooting Guide (2)
Poor runn ing or no power
at low and/ or high speed
L
\It'
....
Ves
"
Does
engine s1art
easily?
-J;
No
_Run the engine for 2 to 3 minutes
at about 3,000 r/min (rpm) with
no load, or raise the engine speed
for a moment within usable range,
.Check startabi lity and idling
stabil ity .
Good
f
AdYise the user not to
run the engine beyond
uw~ e
range.
p<§""""'
operate in red
zone?
\
Sad
\l,t
~'M"
compreS;ion low
~
\
oil line in the crank ·
change oil.
Oil pump
Oil relief valve
Oil filter
\/NO
/
Check oil level and
contam ination
Check an d repa ir the
case.
No
Clean oil screen,
replace oil filter, / Sad
add
or
>nd
,
Trouble may be caused by engine
parts other than HLA. See trouble shooting gu ide in appendix and
repai r the related parts.
r)
Che(:k oil pr essure
Sad ~
-
Crankcase oil
passage
I
+I
I
I
)
Good
\if
Trouble may be caused by pump-up
due to excessively high oil pressure.
If pump-up occurs too often , check
oil pressure.
I
I
II Good
Check and repair the oil line
from crankcase to cylinder head.
Oil pipes
Cylinder head oil passages
a nd filters
Oil passages in the camshaft
caps
SId
Good
II
I
Remove HLA to check it.
Good
,
II
\
Sad
HLA damaged or worn .
Replace HLA.
I
Trouble may be caused
by other parts of tht
valve train . See Trou'
bleshooting guide in
appendix and repa ir the
related parts
:-
4·18 ENGINE TOP END
elnstall the new cylinder head gasket with the side
marked UP fac ing up.
Cylinder Head
.~.
Cylinder Head Removal Note
eBe sure to remove the bolts at the front and rear of the
cyHnder head chain tunnel.
eTighten the cylinder head bolts.
CApply a molybdenum disulfide lubricant (grease or oil
type, either will do) to both upper and lower si des of
the 11 mm cylinder head bolt washers.
OTorque the 11 mm cylinder head bolts following the
tightening sequence. Torque them first to about o ne
A. Cylinder Head Bolts
half of the specified torque and then torque them to
the specified torque (see Exploded View ).
Cylinder Head Installation Notes
eBefore installing the cylinder hea d, be sure the front
camsh<:tft chain guides are in place.
Cvlinder Head Bolt Tightening Sequence
Exhaust
Front Camshaft Chain Guides
Inlet
oT orque the 8 mm cylinder head bo ilS to the spec ified
torque (sec Exploded View).
elnst.all new washers on each side of the oil pipe
finings,
and tighten the banio bolts to the specified torque (see
Exploded View).
1.
2.
).
4.
Front Chain Guide (Upper)
Front Chain Guide (Lower)
Cylinder Head
Cylinder
5. Crankcase
Cylinder Compression Measurement
eBefore: measuring compression, do th e
OBe sure the battery is fully charged.
oWarm up the engine (if the engine will run).
fo llowing:
ENGINE TOP END 4-19
CDur ing warm-up, check fo r leaks around the cylinder
head gas ket o
-Sto p the engine, remo ve th e spark plugs, and attach
compression gauge and adapter (special tool s) fi rm ly
into the spark plug ho le.
A. Compression Gauge : 57001·221
8. Adapter: 5 7001·1183
-Using the jumper cables, connect th e rl! mo ved battery
to the di sconnected battery cables.
cConnect the jumper cable from the positive (+)
terminal of the battery to the positi ve (+) batlery
cable.
cConncct another jumper cab le from the nega ti ve ( --)
terminal of th e batter y to the negative (-) battery
cable .
I WARNING'
OTake care thal you do not louch lhe positive and
negative cables together, and do not touch the cables to
the frame.
c Oo not reverse polarity by connecting positive (+) to
negative (-) or a serious damage to lhe electrical
system may occur.
c Carbon build·up on the piston head and cylinder head.
- clean off an y carbon on the piston head and cylinder
head.
CCylinder head gasket, cy linder base gask et -- use
onl y the proper gask ets for the cylinder head and
basc o The use of gasket s o f the incorrect thickness
will change the compression.
oValve stem oil sea ls a.nd piston rings -- rapid carbo n
accumulation in the combustion chambers may be
ca used by damaged valve stem oil seals and /or damaged piston oil rings. Th is may be indicated by white
exhaust smoke.
*If the comprcssion is below the specified range, squirt a
litt le oil into the spark plug ho le and repeat the compression mea surement.
~r lf thc compression does no t changl: Vl:ry much, the
piston rings are probably OK, check the following :
C-G as lea kage around the cylinder head - replace the
damaged gasket and check the cylinder head for
warp.
OC:ondition o f the valve sea ting.
OHydraulic lash adjuster (operation, seizure, spring
breakage) - repla ce the dama ged lash adjuster.
COil pressure - if the pressure is high, chec k the oil
lin e for clogs.
~~If the compression increases , the pi ston rings are not
sealing properly, check th e following:
iJPiston/cylinder clearance, pi ston seizure.
OPislon ring, piston ring groove .
Cvlinder Head Warp
-Lay a straightedge across th e lower surface of the head
at several d iffe rent points, and measur e warp by
in5erting a thi ckness gauge between the straighledge
an d the h""d.
*Jf warp exceeds th e servi ce limit, repair the mating
surfac e.
Replace the cylinder head if the mating
surface is badly damaged .
-HoJd the throttle wide open and crank the engine with
th e starter.
-When the gauge sto ps rising, stop eran king and read th e
gauge.
-Repea t the measurem ent for the other cyl inder.
Cylinder Compression
U,able Range:
960 - 1,470 kPa
(9.8 -15.0 kglem', 139 - 213 psi!
*If th e compr ess ion is within the specified range, the
piston rin gs, cylinder and valves arc probabl y in go od
co nd itio n.
*I f cylinder compress ion is high er than the specified
ra ng0, check the followi ng:
A. Straightedge
Cylinder Head Warp
Service limit: 0.05 mm
8. Thickness Gauge
4-20 ENGINE TOP END
Cylinder Head Cleaning
eRemove the cylinder head.
eRemove the valves .
• Wash the head with a high flash-point solvent.
-Scrape the carbon out of the combustion chamber and
exhaust port with a suitable tool.
.................... ••••••••••••••••••••••••••••••••••••••••••• •••••••• ••••• •
Valves
Valve Mechanism Removal Notes
-Use the valve spring compressor assembly and adapter
(special tools) to press down the valve spring retainer,
and remove the split keepers .
00
Carburetor Holders
Carburetor Holder Installation Notes
.Install the carburetor holders so that the projections of
them face upwards and aljgn with the cylinder head
ribs.
A. Valve Spring Compressor Assembly: 57001-241
B. Adapter: 57001-1019
eHeat the area around the valve guide to about 120 -150°C (248 - 302°F), and hamm er lightly on the valve
guide arbor (special tool) to remove the guide from the
top of the head.
B_ Rib
A. Holder Projection
-Install the holder clamps as shown being careful of the
screw position and the screw head direction.
II WARNING I
Olnstall the clamps in the correct poSition. 0" the
clamps could come in contact with the carburetor
control parts. resulting in an unsa.fe riding condition.
A. Valve Guide Arbor: 57001-1021
Holder Clamp Installation
Top
Holder Clamp
Valve Mechanism Instal/ation Notes
.'nstall the valve guide.
OApply oil to the valve guide outcr surface before
installation .
('; Heat the area around the val ve guide hole to about 120
- 150°C 1248 - 302°F).
c Drive the valve guide in from th e top of the head using
Screw Head S
Bottom
crew
the valve guide arbor. Be sure to instal! the O-ring
under the valve guide flange.
ORea m the valve guide with the valve guide rcamer
(special tool) even if rhe old guide is ro-u se d .
ENGINE TOP END 4-21
Valve Head Thickness
Valve Head Shape
Valve Head
Thickn.ss
45°
A. Valve Guide Reamer: 57001 · 1079
Valve Head Thickness
-Install the valve.
CChcck to sec that the valve moves smoothly up and
down in the guide.
CC.heck to see that the valve seats properly in the
valv~
Inlet
Exhaust
Standard
0.8 mm
1.0mm
Service Limit
0.4 mm
OS mm
seat. If it does not, repair the \lalve seat.
OApply a thin ooat of molybdenum disulfide grease to
the valve stem before valve installation.,
OBc sure to install the spring seat under the spring.
8-1nsrall the spring so that the closed coil end is fac in::;
Valve Stem Bend
Valve Stem Bend Measurement
toward the valve sca t (downwards).
Valve and Spring
fit&- Split Keepers
Valve Spring
Retainer
--@
Valve Stem Bend
Standard:
Service Limit:
0.02 mm TIR
0.05 mm TIR
Spring --A~~,;{
Spring Seat
OilSeal~
Valve
Valve/Valve Guide Clearance Measurement
(Wobble Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the. valve to valve guide
clearance with the wobble method, .IS indicated below.
-Insert a new valve into the guide and set a dial gauge
.Igainst the stem perpendicular to it as close as possible
to the cylinder head mating surface.
-wl o ve the stem back and forth to measure valve/valve
guide clearance.
_Repeat the measurement in a direction at J right angle
to the first.
*If the reading exceeds the service limit, repJact: the
guide.
4-22 ENGINE TOP END
NOTE
Valve Seating Area Dimensions
OThe reading is not actual IIBlve/llalve guide clearance
because the measuring point is above the guide.
ValveNalve Guide Clearance (Wobble Method)
Standard
Senice limit
Inlet
0.02 - 0 .09 mm
029mm
Exhaust
0.07 - 0.14 mm
0.34 mm
:3)
1. Valve
2. Valve Seat
3. Seating Area Outs ide
Diameter
4. Seating Area Width
Wobble Method
Close as possible.
Valva Seating Pattern
Valve Guide
about
30mm
Valve Seat Inspection
Good
Too Wid e
Too Narrow
Uneven
e Coat valve seat with machinist 's dye .
• Push the valve into the guide.
eRo tate the valve against the seat with a lapping too l.
.Pull the valve out, and check th e sealing pattern on the
valve head. It must be the correct width and even all
the way around.
-Measure the outside diameter of the seating pattern on
the valve seat.
*1 f the outside diameter of lhe valve sealing pattern is
too large o r too small , repair the seat (see Valve Seat
Repair).
Valve Seating Surface Width
Inlet
Exhaust
0.5 - 1.0 mm
0.5 -1.0 mm
Valve Seating Surface Outside Diameter
Inlet
Exhaust
28.9 - 29.1 mm
24.9 - 25 .1 mm
NOTE
C The
valve stem and guide must be in good condition or
this check will not be valid.
Valve Seat Repair
*If the valve seating pattern is not correct, repair the
seat (see Valve Scat Repair).
-Use the following procedures and lools to repair the
valve seat.
ENGINE TOP END 4·23
S, After use, wash it with washing oil and apply thin
layer of engine oil before storing,
Valve Seat Cutters
Inlet Valves
45° -";30.0
32° - ¢30.0
60' -~O.O
57001·1187
57001·1120
57001·1123
Exhaust Valves
45° - ";27.5
32° - '1128.0
60° - ";30.0
57001·1114
57001·1119
57001·1123
Cutter
Holder and Bar
Holder - ¢5.5
Bar
Marks Stamped on the Cutter:
The mark s stamped on the back of the cutler
represent th e following.
60° .
Cutter angle
Outer diameter of cutter
37.54>
57001-1125
57001·1128
Outer Diameter of Cutter
Seat Cutter Operating Care:
I. This valve seat cutter is dc vt! lopcd to grind the valve
seat for repair. Therefore the cutter musr not be used
for other purposes than scal repair.
2, Do not drop or shock the val ve seat cu tter , or the diamo nd particles may falloff:
3. Do not fail to apply engine o il to the val ve seat cutter
before grinding the seat surface. Also wash o ff
ground particles sticking to the cutter with washing
o il.
NOTE
000 not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the va lve sca t cutter holder in position,
operate the cutter in o ne hand . Do not apply too
much for ce to th e diamond port ion.
Angle of Cu ner
_ ¥ -..i-
Operating Procedures:
-Clean the seat area ca refull y.
-Coat th e seat with machinist 's dye ,
-Fit a 45° cutter to the holde r and slide it into the valve
gu ide.
-Press down lightl y on the handle and turn it right or
left. Grind th e sealing surface only until it is smooth ,
NOTE
cPrior to grinding, apply engine oil to the cutter and
during the operation, wash off any ground particles
sticking to the cutter with washing oil,
Valve Seat Cutter
1. Cutter
2. Cutter Hold er
3. Bar
COo not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the "falve sinks too far into the head, it will be
impossible to adjust the clearance, and the cylinder
head must be replaced,
-;v1easu re the outside diameter of the seating surface
with a vern ier cali per,
*If the o utsi de d iame ter of the seating surface is too
small, repeat the 45° grind until the diameter is within
th e specified range.
*If the o utsid~'diam e ter of the seating surface is too
0
la rge , make the 32 grind described below,
*If the outside di amet er of the seating surface is within
the speci fied range, measu re the seat width as described
belo w.
0
-Grind the seat at a 32 angle until the seat 0 ,0. is
within the specified range.
8To make the 32' grind, fit. 32' ev tter to th e holder,
and slide it into th e \'JI ve guide.
a Turn the ho lder o ne turn at a time while pressing down
very li ghtly. Check theseat after each turn,
,
4-24 ENGINE TOP END
Valve Seat Repair
(
START
Machinis.t 's
I
dyt: on -;eJ!
+
45° Gr ind
,
45° Cutler
make seati ng area
Tool :
Purpose-:
smooth and round
Mea sure St'<tting Area 0.0.
Tool
Vernier Caliper
Purpose:
chec k seat 0.0.
against spec.
,
I
Rl:IU'IS
t
,
I Too l small I
I
OK
I
I
45° Grind
Tool:
Purpose:
I
Machinist 's
dvc on seat
45'Cutter
increase 0.0. of s~at
ar~a
,
t
Too big
t
to spec.
32' Grind
Tool :
32' Cutter
reduce 0 .0. of seat area
to spec.
Purpose:
Measure Seat Width
Tool :
Purpose :
Vernier Caliper
check seat width
against spec.
,
I
Rcs,lb
I Too
,
t
narrow
I
I
OK
I
I
t
Too wide
I
t
45° Grind
Machinist's
Tool:
45' Cutter
dye on sea t
Purpose:
increase width of seat
t
area beyond spec. to
increase O. D.
60' Grind
Tool:
Purpose:
60' Cutter
reduce seat width
to spec.
Lap Va lve
Too ls:
Va lve lapper, grinding
compound
Purpose :
perfectl y match valve
and sea t area; check
va lve head for damage
L
( FINISHED )
ENGINE TOP END 4·25
OThe 32° cutter removes material very quickly. Check
the seat outside diameter frequently to prevent overgrinding.
*If the seat area is not in the right place on the va lve,
check to be sure the valve is the correct part. If it is, it
may have been refaced too much; replace it.
eBc su re to remo ve all grinding compound befo re
assembly.
Valve Lapping
Valve Seat Repair
Wid ened width of
engagement by machining
with 45° cutter
/
Ground vo lume
by 32° cu lter
t
Ground volume
by 60° cu ttcr
1. Lapp er
2. Valve Seat
CAfter making the 32° grind, return to (h e seat 0.0.
measurement step above.
eTa measure the seat width , use a vernier caliper to
measure the width of th e 45° angle portion of the seat
at several places around the seat,
*If the sear width is too narrow, repeat the 45° grind
until the ~eat is. slightly too wide, a nd then return to
the seat 0.0. mea~urement step above.
* If the scat width is too wide, make the 60° grind
described below.
*If th e seat width i ~ within the specified range, lap the
val ve to the seat as described below.
eGrind the sca t at a 60° angle until the seat width is
withi n the specified range.
Q
J To make th e 60 grind, fit a 60° cutter to the holder,
and slide it into the valve guide.
oTurn the ho lder, while pressing down lightly.
OAftcr making the 60° grind, return to the seat width
measurement step above.
eLap the valve to the seat, once the seat width and 0.0.
are within th e ranges specified above,
CP ut a little coarse grinding compound on th e face of
the valve in a number of places around the valve head.
c Spin the valve against the: seat until the grinding compound produces a smooth, matct1ed ~urrface on both
the seat and the valve.
ORepeat the prUess with a, fine grinding· compound.
eTh e sea ting area should be mark~d about in the middle
of th e valve face.
3. Val ve
Cylinders and Pistons
Piston Removal Notes
eRemove t.he piston pin snap rings from the outside of
each pisto n.
OBe sure to place a clean cloth under the piston to
preve nt the snap ring from falling into the crankcase.
A. Snap Ring
4-26 ENGINE TOP END
eRe move the piston by pushing its piston pin out the
side that the snap ring ~as removed. Use the piston pin
puller assembly (special tool), if the pin is tight.
A. Expander ends butt together.
Cl nstall the upper and lower st eel rails. There is no UP
or DOWN to the ralls. They can be installed either
way.
-Install the top and second rings in that order.
COo not mix up the top and second rings. The top and
second rings are not symmetrical and must be installed
with the correct side facing up.
A. Piston Pin Puller Assembly: 57001-910
eRemove the top and second piston rings.
cSpread the ring opening with your thumbs 'and then
push up on the opposite side of the ring to remove
Piston Rings
it.
.Remove the 3-piece oil ring with yo ur thumbs in the
R Mark
same manner.
Top
Ring
•
2nd
Ring
A. Spre.ld .
B_ Push up.
Piston Installation Notes
elf a new piston is installed, be sure to check piston/
cylinder clearance before starting (see Piston/Cylinder
Clearance) .
• Install the 3-piece oil ring.
CFirst install the expander in the bottom ring groove
so that the expander ends butt together, never overlap.
-The arrow on the tep of the piston must poim toward
the front of the engine,
-When installing a piston pin snap ring, compress it only
enough to install it and no more .
!~AUTIII~J
COo not reuse snap rings, as removal weakens and
deforms them. They could fan out and score the
cylinder wall.
ENGINE TOP END 4-27
Cylinder Installation Notes
-Install the cylinder block on th e pist ons .
elf a new cylinder is installed, be sure to check piston!
cylinder clearance before starting (see Piston/Cylinder
cSlip the piston blSes (special tools) und er 'he base
Clearance).
-Turn the piston rings so that the openings are in the
specified positions.
gasket and pistons to hold them level.
c Compress th e piston rings using the piston ring com-
pressor assemblie;:s (special tools).
Piston Ring Opening Positions
Top Ring :
Second Ring:
Oil Expander:
Top Oil Rail:
Bottom Oil Rail:
Forward
Rear
Forward
30° Left of Forward
30 0 Right of Forward
Piston Ring Openings: Viewed from Front
:f._~
-
~#--Rmark
R~~
(2;
A. Piston Ring Compressor Assembly : 57001-1094
B. Piston Base: 57001-149
~
U
Front
Arrow
Cylinder Inside Diameter
eMeasure the cyli nd er inside diameter.
:JUse a dial bore gauge to measure front-to-back and
side-to-side at the points shown below.
I. Top Ring
2. Second Ring
3. Steel R,il, Oil Ring
4. Expander, Oil Ring
-Install a new cylinder base gasket with the side marked
UP facing up.
Cylinder Inside Diameter
I."
77.994 - 78.006 mm, and
than
0.01 mm difference between any two
measurements
Service Limit : 78.10 mm, or more than 0.05 mm
difference between any two measurements
Standard:
*If any of the cylinder inside diameter measuremt:nts is
grealer than the service limit, the cylinder must be
bored oversize and th en honed (see Cylinder Boring
and Honing).
However, jf the amount of boring
necessary would make the cylinder imide diameter
greater than the bore limit, [he cylinder must be
replaced.
NOTE
O/f the cylinder has been bored oversize, see the Oversize
Cvlinder Inside Diameter table.
4-28 ENGINE TOP END
Oversize Cylinder Inside Diameter
Oversize Piston Diameter
Standard:
Measure at bottom of cylinder for
baseline standard diameter
Service Limit: Standard plus 0.' mm, or more than
0.05 mm difference between any two
measurements
78.50 mm
Bore Limit:
Cylinder Inside Diameter Measurement
Standard:
77.935 - 77.950 mm plus 0050 mm as
stamped in piston head.
Service Limit: Standard size minus 0.15 mm
Piston/Cylinder Clearance
eMeasure the piston diameter,
eMeasure the cylinder inside diameter with a dial bore
gauge at the bottom of the cylinder.
10 mm-?l---J<-
;>H-*20mm
_SubtrJct the piston diameter from the cylinder inside
diameter to get the piston/cylinder clearance.
*If the piston/cylinder clearance is less than the specified range. use a small piston or increase the cylinder
inside diameter by honing (sec Cylinder Boring and
Honing).
*If the piston/cylinder clearance is greater than the
specified range, usc a large piston or bore to the next
larg~r oversize (see Cylinder Boring and Honing) .
60mm
Piston/Cylinder Clearance
Standard:
0.044 - 0.071 mm
Piston Diameter
Piston Diameter Measurement
Cylinder Boring and Honing
.\Vhen boring and honing a cylinder, follow the boring
and honing tool manufacturer's instructions. Note the
following:
.Before boring a cylinder, measure the diameter of the
piston to be used . Bore and hone the cylinder to
obtain the standard piston /cylinder clearance specified .
• Cylinder inside diameter must not vary by more than
0.01 mm at any point.
.Do not measure the cylinder inside diameter immediately after boring or honing, because the boring and
honing operations heat the cylinder. Heat affects
cylinder size.
Piston Diameter
Standard:
77 .935 - 77 .950 mm
Service Limit 77.80 mm
Piston/Cylinder Seizure
.Visually inspect the cylinder and piston damage.
*1 f there is only light dlm;age, ,5mooth the piston with
NOTE
elf rhe oversize piston has been used, see Oversize Piston
Diameter table,
#400 emery cloth. Remove small aluminum deposits
from the cylinder with #400 emery cloth or light
honing.
*If the damage is severe, the cylinder must be bored
oversize and an oversized piston installed.
ENGINE TOP END 4-29
Piston Ring Thickness (Top &. Second)
Piston Cleaning
-Remo ve the pis ton and piston rin gs .
Standard:
Service Limit:
(CAUTlO~ I
c Never clean the pinon head with the engine assernbled.
Carbon particles will fall between the piston and
cylinder, and damage the crankshaft bearings.
- Scrape th e ca rbo n o ff the p is ton head.
o Use the scra ping tool care fu lly. Do not gouge th e
piston head .
.clean th e piston ri ng groove with a broken piston ring
o r o ther suitable tool.
c ae careful not to widen the ring grooves or the piston
must be replaced.
0 .97 - 0.99 mm
0.90 mm
Piston Ring Grooye Width
Standard
Top
1.02 -1.04 mm
Second
1.01-1.03mm
Oil
2.01 - 2.03 mm
Service Limit
1 .12 mm
1.11 mm
2.11 mm
NOTE
C:When using new rings in a used piston , check for
uneven groove wear. The rings should fit perfectly
parallel to the groove sides. If not, replace the piston .
Piston Ring End Gap (top and second only)
Piston Ring and Ring Groove Wear
• Visually ins pect the piston rings and ring grooves.
-If the piston ri ngs are v.'orn une venly or damage d ,
re place them.
-If the ring groo ves .a re worn unevenly o r damaged,
re pla ce bot h the piston and piston rings.
eMeasu re (h e clearan ce between the to p and second
rings and their gr ooves.
Piston Ring/Groove Clearance
Top
Second
Standard
0.03 - 0.07 mm
0 .02-0.06mm
Service Limit
0.17 mm
0 .16 mm
ePu sh each ring (one at a time) into th e bottom end of
the c ylinder .
':"'Use th e piston [0 push it in to be ~ure it is square.
e Meas ure the ga p between the en d of the ring with "'
thickness ga uge.
Piston Ring End Gap
Standard
0.20 - 0.35 mm
0 .20 - 0.40 mm
Top
Second
Piston Ring End Gap Measurement
Pi sto n
Ring
~ap
A. Th iL:k ness Ga uge
*/f the pi sto n ring groove clearance is grea ter than the
servic e limit, m easure [h e ring thicknes,) and groo ve
wid th a') fo ll ows to decide whclher to replace t he rings,
the piston or bo th .
Service Limit
0.7mm
0.7mm
4-30 ENGINE TOP END
Exhaust Pipe and Muffler Installation Notes
Exhaust Pipes and Mufflers
elnstall th e clamps so that the openings are in the
specified positions to obtain the specified road
clearance of th e veh icl e.
Muffler Removal Notes
eTighten th e exhaust pipe and muffler mounting bolts,
-Remove the mufflers as following.
o Remove the left and right muffler covers,
A. Muffier Cover
nuts, and da mp bolts in th e order and method indicated below.
CFirsl, tighten all the bolts and nut s to a snug fit.
cScco ndl y, tighten the exhaust pipe holder nuts evenly
to avoid exhaust leaks.
B. Muffler Mounting Bolt
A. Exhaust Pipe Holder Nuts
OLoosen
the cla mp s connecting the left and right
mufflers a.nd exhaust pi pes.
ORe move the left and right muffler mounting bo lts .
oPul1 the mufflers out rear en ds of the exhaust pipes .
CLastly, tighten the rest of rhe mounting bolts and
clamp bolts securely.
-Thorough ly warm up the engine, wait until the engine
cools down, and ret ighten all the clamp bolts .
Clamp Positions
Viewed from Left
t
Level of Road Clearance
.
(
about 16 mm
Vi ewed from front
More than 45°
•p
•
Level of Road Clearance
CLUTCH 5·'
Clutch
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5·4
Clutch Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5
Clutch Fluid Recommendation .......... . .. .. .... .... ....
5-5
Clutch Fluid Level Inspection . .... .. .. . ...•. . ... . .. . . . .. .
5-5
Clutch Fluid Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .
5-5
Clutch Line Air Bleeding ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
Clutch Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
Clutch Master Cylinder Removal ............•....•....•...
5-7
Clutch Master Cylinder Installation Notes. . . . .•. . . . . •. . . .•. .
5-7
Clutch Master Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . .
5·7
Clutch Master Cylinder Assembly Notes. . . • . . . . • . . . . . . . . . . . .
5-7
Clutch Master Cylinder Inspection. . . . . . . • . . . . . . . . . . • . . . . . .
5·7
Clutch Slave Cylinder . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . .
5-8
Clutch Slave Cylinder Removal Notes ........... . .. .•. .... .
Clutch Slave Cylinder I nstallation Notes. . . . . . . . . . . . . . . . . . . . .
5·8
5·8
Clutch Slave Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . .
5·8
Clutch Slave Cylinder Assembly Notes. . . . . . . . . . . • . . . . • . . . . .
5-8
Clutch Slave Cylinder Inspection .............. .•.... . .. ...
5-9
Clutch . ............ .............. . ..... . ..... • ....•.....
5·9
Clutch Removal ......... ........•...... .... • .... .. .. ..
5·9
Clutch Install ation Notes. . . . . . • . . . .• . . . . • . . . . • . . . . . . . . . .
5·10
Clutch Hub Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5·11
Friction Plate Wear, Damage Inspection . . . . . . . . . . . . . . . . . . . . .
5· 11
Friction or Steel Plate Warp Inspection . ..... . ...... . . . .....
5-11
Clutch Spring Free Length Measurement. . . . ... .. .. . .. . . . .. .
5·11
Clutch Housing Finger Inspection .. ........ . . .. ..... . . . . . .
5-12
Clutch Hub Spline Inspection ..... . ..... .... .. .. . ...... . ..
5-12
Cam Damper Inspection.......... . . . .. . .. . .. . .... . ... ...
5-12
5-2 CLUTCH
___________ _
.......................................................................
~~:._I~~~_~_i_~~ __________ .__ .. _
.____ .. __ .____.. _.... _._ ...................
T5
T4
i
CLUTCH 5-3
Viewed from Righ t
1. Starter Lockout Switch
G :
L :
M ;
SS:
Grease
Non -permanent Locking Agent
Molvbdenum Disulfide Grease
Silicone Sealant
T1 ; 5.9 N-m (0 .60 kg-m. 52 in·lbl
T2; 7 .8 N ill (0 .80 kg·m. 69 in·lb)
T3; 9.8 N 'm (1 .0 kg·m. 87 in-Ib)
T4; 11 N -m (1.1 kg 'm, 95 in·lb)
T5; 18 N-m (1 .8 kg ·m, 13.0 ft·lbl
T6; 25 N-m (2.5 kg·m, 18.0 ft·lb)
T7 ; 130 lI!·m (13.5 kg·m, 98 ft·lbl
5-4 CLUTCH
Specifications
Standard
Item
Clutch Fluid:
Service Limit
Grade
D.O.TA Heavy Duty Brake Fluid
Brand (recommended)
Castro I Girling·Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid
Check Shoc k Premium Heavy Duty
Clutch :
Friction Plate Thickness
2.9 -3. 1 mm
2.8mm
Friction and Steel Plate Warp
Less than 0.2 mm
0.3mm
Clu t ch Spring Free Length
33.2mm
Special Tool
.............................................................................
A lo ng wi th co mmon hand tools, the followi ng more
speciali zed tool is requi red for com p let e clutch servicing .
Clutch Holder: 57001·305
NOTE
CThe clu tch h older (PI N 5100 1· 1243) can be used
instead of the clu tch holder (PI N 5100 1·305).
32. 1 mm
CLUTCH 5·5
Clutch Fluid
Clutch Fluid Recommendation
OAfter changing the fluid, use only the same type and
brand of flutd thereafter. Mixing different types and
brands of fluid lowers the fluid boiling point and could
cause the clutch to be ineffective. It may also cause
the rubber clutch parts to deteriorate.
Recommended fluids are given in the table below. If
nonc of the recommended fluids are avai lable, use extra
heavy-duty brake fluid only from il container marked
D.O.T.4.
Recommended Clutch Fluid
Grade:
Brand:
D.O.T.4 Heavy Duty Brake Fluid
Castrol Girling-Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid
Check Shock Premium Heavy Duty
NOTE
OSince the clutch fluid is the same as the brake fluid,
refer to Brake Fluid Section in Brakes for further
details.
A. Upper Level Line
eQperate tile clutch, and check for fluid leakage around
the fittings.
Clutch Fluid Level Inspection
-Posi ti o n the reservoir hori zon tal , and check that the
fluid level in [he reservoir is high er than the lo wer level.
I WARNING'
Olf the clutch lever has a soft or "Spongy feeling" when
it is appli~d, there might be air in the clutch lines or the
clutch m8Y be defective. Since it is dangerous to
operate the motorcycle under such conditions, bleed
the air from the clutch line immediately.
Clutch Fluid Changing
A. Lower Level
*If the fluid level is lower than the lower level, check for
the fiuid leakage of the clutch line , and add the fluid as
follows.
ORemove the reservoir c.ap, and fill the reservoir to the
upper level line in th~ reservoir with the same type and
brand of the fiuid that already is in the reservoir. And
then install the reservoir cap.
eRemove the reservoir cap.
eAttach a clear plastic hose to the bleed va lve on th e
clutch slave cylinder, and run (he other cnd of the
hose into a container.
-Open the bleed valve (counterclockwise to open), and
rump the clutch lever until all the fluid is drained from
the line.
e<:lose the bleed valve.
-Remove the diaphragm.
eFil1 the res€fvoir with fresh fluid.
e()pen the bleed val,e, ~queele the dutch lever, clo'Se
the valve with the clutch tlcld applied, and then quickly
release th e lever. RepeOit th is. operation until the d utch
line is filled and fluid starts coming out into th~ plastic
hme.
NOTE
I WARNING'
the fluid in the clutch line compl~tely if the
fluid must be refilled but the type and brand of the
flu id that already is in the reservoir are unidentified.
OReplenish the fluid in the reservoir as often as necessary to keep ;r from running completely out.
~ Change
eTighten the bleed valve to
Exploded View).
the specified
torque
5-6 CLUTCH
Filling up Clutch Line
.When air bleeding is finished, check th"t the fluid is
filled to the upper level line- marked in the reservoir.
A. Upper Level Line
-Install the reservoir cap.
-Tighten the bleed valve to the specified torque (see
Exploded View),
-Apply the clutch lever forcefully for a few seconds, and
check for fluid leakage around the fittings.
Bleeding Clutch Line
1. Open the bl«d valve.
2. Appll' the clutch lever and hold it.
3. Close the bleed valve.
4. Then rei casu the clutch lever suddenl y,
Clutch Line Air Bleeding
-Remove the reservoir cap, and check th,,[ there is
plenty of fluid in the reservoir.
NOTE
o The fluid lellel must be checked severill times during
the b/~ing operation and replenished as necessary. /I
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.
-Connect a clear plastic hose to the bleed \'alve at the
clutch slave cylinder, running the other end of the hose
into a container.
-With the reservoir cap off, slowly pump the clutch
le\'t~r
several times until no air bubbles can be seen rising up
through th e fluid from the holes at the bottom of the
reservoir. This bleeds the air from the master cylinder
t'nd of the lin~ .
• Pump the clutch lever a few times until it becomt"s hard
and then, holding the lever squt'czcd, quickly open
(tlR'n counterclockwise) .lnd close the bleed valve.
Then relcase the lever. Repeat this opcldtion until no
morc air can be seen coming out into the plastic hose.
1. Hold the clutch lever applied.
2. Quickly open and c/OSI.! tht: valve.
3. Rc ! c~se the clutch lever.
CLUTCH 5-7
.............................................................................
Clutch Master Cylinder
000 not remove the secondary cup from the piston since
removal will damage it.
Clutch Master Cylinder Removal
-Disconnect the slaner lockout switch wires.
-Remove the clamp bolts and clamp, and t.ake the clutch
master cylinder off the handlebar.
Clutch Master Cylinder Assembly Notes
Clu tch Master Cylinder Installation Notes
-The master cylinder clamp must be installed wilh the
UP mtlrk faced upwards.
-Tighten the upper clamp boll first, and then t.he lower
clamp bolt to the specified torque (see Exploded View).
There will be a gap at the lower part of the clamp after
tightening.
-Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
oUse only disc brake fluid, isopropyl alcohol, or ethyl
alcohol, for cleaning parts. Do not use any other fluid
for cleaning these parts. Gasoline, motor oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be
difficult to wash off completely, and will eventually
deteriorate the rubber used in the cylinder.
_Apply brake fluid to the parts removed and to the
inner wall of the cylinder. Take care not to scratch the
piston or the inner wall of cylinder.
_Check to see thai the piston return spring pushes back
the piston to its rest position when the spring is
compressed.
-Install the push rod with the dust seal fitted into the
groove.
cThe push rod round end must be faced inwards.
-Use a new fl.lt washer on each side of the hose fitting.
-Tighten the banjo bolt to the specified torque (see
Exploded View).
_Fill the clutch fluid into the clutch line dnd bleed the
clutch Itne (see Clutch Fluid Changing and Clutch Line
Air Bleeding).
A. Tighten upper clamp bo lt first.
B. UP Mark
Clutch Master Cylinder Disassembly
-Orian the clutch fluid.
-Pull b£lCk the dust cover, and remove the banjo bolt to
disconnect [he clutch hose from the masler cylinder.
There i-. a flat washer on each side of the hose fitting.
_Remove the clutch lever Jnd the master cylinder.
-Remove the push rod, the dust seal and the circlip.
Master Cylinder Inside Parts
~
,r 3.
6
4.
~ 5.
~
6.
7.
8.
Push Rod
Rod Round End
Dust Seal
Circiip
Primary Cup
Piston Assembly
Secondary Cup
Spring
Clutch Master Cylinder Inspection
IVislJallnspection)
-Check tha.I there are no scratches, rust or pitting on
the inside of the master cylinder and on 'he outside
of the pi'non.
*If the master cylinder or piston s.hows any dam age',
replace them.
_I nspect the primary cu p Jnd secondary cup.
*If a cup is worn, dam aged, softened (rotted), or swollen,
replace it.
*If fluid leakage is noted at the clutch lever, the piston
assembly should be replaced to renew the cup.
-Check the dust cover for damage.
*If it is damaged, replace It.
_Check that the relief and supply por ts are not plugged.
*If the small rel ief port becomes plugged, the clutch will
slip. Blow the ports clean with compressed air.
-Check the piston return spring for any damage.
*If the spring is damaged, replJce it.
I
5·8 CLUTCH
Clutch Slave Cylinder Disassembly
Clutch Slave Cylinder
eReomove the banjo bolt and pour the fluid into a
container.
Clutch Slave Cylinder Removal Notes
"Using compressed air, remove the piston.
eRemove the mounting bolts.
eRemove the slave cylinder unit and spacer.
cCover the cylinder opening with a clean, heavy cloth.
cFace the opening downwards.
oRemove the piston by lightly applying compressed air
to where the clutch line fits into the slave cylinder.
A. Slave Cylinder Unit
B. Mounting Bolts
A. Apply compressed air.
C. Spacer
cOo not spill clutch fluid onto any painted surface.
not squeeze the clutch lever during the slave
cylinder removal, or the slave cylinder will be moved
B. Cloth
Olf the fluid seal is removed from the piston, replace the
seal with a new one. Removal would damage the seal.
000
out of their proper position.
I WARNING.
eTo avoid serious injury, never place your fingers or
palm in front of the cylinder opening. If you apply
high compressed air to the cylinder, the piston may
injure your hand or fingers.
Clutch Slave Cylinder Installation Notes
eReplace the spacer with new one.
elf the clutch push rod was pulled out, apply a
molybdenum disulfide grease to the flat end of [he rod,
and insert it with the round end of it facing outward
(towards the engine left side).
Clutch Slave Cylinder Assembly Notes
eBefore assmebly! clean all parts including the cylinder
with brake fluid or alcohol.
{CAUTj~~]
QUse only disc brake flUid, isopropyl alcohol, or ethyl
alcohol, for cleaning parts. Do not use any other fluid
for cleaning these parts. Gasoline, motor oil, or any
other petroleum distillat. will cause deterioration of
the rubber parts. Oil Ipilled on any part will be
difficult to wash off completely,_nd will eventually
deteriorate the rubber USedl in the cylinder.
A. Round End
eApply clutch fiuid to the Qutsid~ ' of the piston and the
fluid seal, and push the piston into the cylinder by
hand. Take care that neither the cylinder nor the
piston get scratched.
CLUTCH 5·9
Clutch SI ••• Cylinder
1. Cylinder
A. Clutch Spring Bolt
B. lVasher
C. Spring Plate
D. Spring Plate Pusher
2. Piston
3. Fluid Seal
4. Spring
- Use J new flat washer on each side of the hose fitting.
e Tighten th e banjo bolt to the specified torque (see Ex ·
ploded View).
e Fili tile clutch fluid into tile clutch line and bleed the
clutch line (sec Clutch Fluid Changing and Clutch Line
Air Bleeding).
eRemove the friction plates and steel plates.
eW hen loosening the clutch hub self·locki ng nut, use the
holder (special tool) to keep the ' clutch hub from
turning as shown in the fia,ure below.
OReinstali the right footpeg to set the holder.
0 1nseft a thick cloth or • baird between the holder and
the frame tube to avoid damag,ing the painted surface
of the tube.
-
Clutch Slave Cylinder Inspection
!Visually Inspection)
- Visually inspect the piston and cylinder surfaces.
*Replace the cylinder and pi;ton if the y arc badly
scored or rust)'.
*Replace the fluid ,.al under any of the following
cond itions: flu id leakage around the piston or the sCJI
is stuck to the cylinder.
-Check the piston spring for any damage.
*If the spring is damaged, replace it.
A. Hub Nut
B. Holder: 57001·305
Clutch
ePu l1 out the clutch hub, splined collar, thrust washer,
Clutch Removal
-Remove the clutch cover.
o Remove the brake pedal and right footpeg.
eRemove the clutch spring Allen bolts, washers, and
sprin~.
eRemove the spring plate with the spring plate pusher
and circlip.
clutch housing bearing collar, needl'e bearin&, Clutch
housing, oil pump dri'te gear, and t.paca".
c The ,Iutch housing ,bear ins collar can easily b. removed
by in'lAlling clutch cover bol .. into the collar lapping
holes and pulJjng them.
oThe ,IUICh housing can be removed after removing the
bearing collar.
5-10 CLUTCH
elnstall the friction plates and steel plates, starting wit h
a friction plalc and alternating them.
oThe grooves on the friction plate surfaces are cut
tangentiall y and radially, install the friction plat.es so
that the grooves run toward the center in the direction
of the clutch housing rotation (cou ntercl ockwise
viewed from the engine right side).
Friction Plate Installation
A. Collar
B. Clutch Cover Bolts
C. Clutch Hous ing
Clutch Instal/ation Notes
elnstall the spac er with the chamfer side facing in.
1. Oil Groove
2. Direction of Rotati on
o The first steel plate and the last steel plate must be a
thinn er one (2.6 mm thick). The other plates from the
second to the seventh must be a thicker one (2.9 mm
thick ).
A. Spacer
B. Chamfer
-Install the clutch housing bearing collar with tapping
hale side facing ou t.
.Discard the used clutch hub self-locking
a new nut.
nUL,
and install
_Install the cl utch holder to keep the clutch hub from
turning and tighten the clutch hub nut to the specified
torque (see Exploded View).
CPUl a wooden bar behind the cylinder block to set the
holder.
A. Holder: 57001-305
Olf new dry steel plates and friction plates are installed,
apply engine oil to the surfaces of each plate to avoid
clutch plate seiZUre.
NOTE
oFirst, Install the seven friction plates fitting the tangs
of plates in the grooves @ in the clutch housing. And
then, install the last one fitting the tangs in the grooves
® in the housing.
CLUTCH 5-11
eApplya si licone sealant to the crankcase halves matin g
surface on the front and rear sides of the cover mount,
Friction Plate Thickness Measurement
A. Friction Plate
1.\, Apply silicone sealant.
Friction or Steel Plate Warp Inspection
Clutch Hub Disassembly
-Push in the damper spring plate, ar,d remove the circ!ip,
-Place each fric tion plate o r steel plate on a surface
platl:':, and measure the gap between the surface plate
d.nd each fricti o n plate or steel plate. The gap is the
amount of or steel plate warp.
*If any plale is warped o~er th e service limit, replace it
with J new one.
Friction and Steel !>tate Warp
Standard:
Service limit:
less than 0.2 mm
O.3mm
F ric1ion and Steel Plate Warp Measurement
C. RetJiner
A. Press
B. Damper Spri ng PI.te
- Take the damper ,pring plate, damper springs, damper
spring scat , seat stop, and damper cam foll ower out of
the clutch hub.
A. Friction Plate
B. Steel Plate
Friction Plate Wear, Damage Inspection
-Visuall y inspect the fricti on plates to see if th ey show
<my signs o f seizure, overheating, or unev en wear.
*If any plates show signs of dam,18,e, replace the friction
pla tes and steel pla tes JS a set.
Friction Plate Thickness
Standard :
2.9-3.1mm
Service Limit:
2.8 mm
Clutch Spring Free Length Measurement
Clutch Spring Free Length
Standard:
Service Limit:
33.2mm
32.1 mm
5-12 CLUTCH
Clutch Housing Finger Inspection
.Visually inspect the fingers of the clutch housing where
the tangs of the friction pl.tes hit them.
*If they are badly worn or if there arc grooves cut where
the tangs hit, replace the housing,
Also, replace the
friction plates if their tangs are damaged.
A. Damper Cam
B. Damper Spring
A. Clutch Housing Finger
B. Friction PI.te Tang
Clutch Hub Spline Inspection
.Visualry inspect where the teeth on the steel plates
wear against the spline,of the clutch hub.
*If there are hatches worn into the splines, replace the
clutch nub. Also, replace the steel plates if their teeth
are d.maged.
A. Clutch Hub Spline
Cam Damper Inspection
eVisually inspect the damper cam, damper spring, and
cam foll ower.
*Replace any pan that appears damJged.
C. Cam Follower
ENGINE LUBRICATION SYSTEM 6-1
Engine Lubrication System
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . • . . . . . . . . . . • . . . • . . . . . . . . . . .
6-2
Engine Oil Flow Chart ................ . .... _ . . . . . • . . . . . . . . . .
6-3
Specifications. . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4
Special Tools .............•..........................•..•.
6-4
Engine Oil and Filter ....... ... .. . ...... . . .. . ... . ...........
6-5
Engine Oil Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5
Engine Oil and/or Filter Change. . . . . . . . . . . . • . . . . . . . . . . . . . .
6-5
Oil Filter and Bypass Valve Removal .... ........ ...... .• . ..
6-6
Oil Filter and Bypass Valve Installation Notes. . . . . . . . . . . . . . . .
6-6
Bypass Valve Disassembly ................ . . .. ........ .. .
6-6
Bypass Valve Assembly . ............. . • . ... . ... . •.......
6-6
Bypass Valve Cleaning and Inspection . .. . .....•.. .. ........
6-6
Oil Pan and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .
6-6
Oil Pan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . .
6·6
Oil Pan Installation Notes ... . .. .. _. . . . . . . . . . . . . .. . .. . . . . .
6-7
Oil Pump and Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7
Oil Pump and Relief Valve Removal. . . . . . . . . . . . .. . . . . . . . .. .
6-7
Oil Pump and Relief Valve I nstallation Notes. . . . . . • . . . . • . . . . .
6-8
Oil Pump Disassembly ....... ..... ......... _ . . _. . . • . . . . .
6·8
Oil Pump Assembly Notes ......... . ......... . ... . .. . ..• .
6·8
Oil Pump Drive Gear Removal ............ . • . ... . . . ... .. . .
6·8
Oil Pump Drive Gear Installation. . . . . • . . . . . . . . . . • . . . . . . . . .
6-8
Oi l Pump Gear Removal. . . . . . . . . . . . . . . • . . . . . . . . . . . . . . • . .
6·8
Oil Pump Gear I nstallation Notes. . . . . . . . . . . . . • . . . . . . . . . . . .
6·9
Oil Pressure Measurement. . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .
6-9
Oil Pump Inspection. . . . . . . . . . . . .. . . .. • . . . . . . . . . . . . .. . . .
6-10
Relief Valve Inspection .. . • ...... . ... .• ... . .. ... .....•..
6-10
Oil Screens . . . . . . . . . . . . . . .. .. .. . . . . •. . .. .. . . . . . . . . . . . . . . . .
6-10
Oil Screen Removal ........ . .... . ....... ... •....... . ...
6·10
Oil Screen Installation Note ... .. ......... " .. . . . . . . • . ... .
6·10
Oil Screen Cleaning and Inspection ........•........ . •.. . ..
6·10
6-2 ENGINE LUBRICATION SYSTEM
..................................................................................
,
Exploded View
...................................................................................
1. Oil Pressure Switch
l : Non-permanent Locking Agent
M : Molybdenum Disulfide Grease
SS : Silicone Sealant
Tl :
T2 :
T3 :
T4 :
12
15
18
20
15: 25
©~
N-m (12 kg-m, 104 in-Ib)
N-m (1 .5 kg-m , 11.0 ft -Ib)
N-m (1 .8 kg-m , 13.0 ft·lb)
N-m (2 .0 kg·m, 14.51t·lb)
N·m (2 .5 kg-m, 18.0 It·lb)
T6 : 29 N·m (3.0 kg-m , 22 ft~b)
~f~
@
T5
o
I
1
I
!
~
ENGINE LUBRICATION SYSTEM 6-3
Engine Oil Flow Chart
1.
2.
3.
4.
Camshaft
Hyd ra ulic Las h Ad juster
Co nn ec ting Rod
Crank'h aft
S. Balancers
6.
7.
8.
9.
10.
11.
12.
13.
14 .
To Primary Cha in
Alt erna to r Sha ft
Drive Shaft
Output Shaft
To Fro nt Bevel Gears
To Driven Gear Bearings
From Tran smisson Chamber
Fro m Balancer Chambe r
To Transmissio n Chamber
6-4 ENGINE LUBRICATION SYSTEM
Specifications
Standard
Item
Engine Oil :
Grade
SE or SF class
Viscosity
SAE 10W40, 10W50, 20W40, or 20W50
Capacity
i
3.2 L (when filter is not removed)
3.5 L (when filter is removed)
4.0 L (when engine is completely dry)
Oil level
Between upper and lower levels
Oil Pump and Relief Valve:
Oil Pressure @4 ,000 r/min (rpm),
Oi l Temp. BO" C ( 176" F)
Special Tools
Alo ng w it h common h.and too ls, th e fo ll owing
more speci ali zed tool s arc requ ired for compl et e engin e
lubrica tion system servici ng.
Oil Pressure Gauge : 57001·164
A bout 370 kPa (3.B kg/em' , 54 psi)
Oil Pressure Gauge Adapter: 57001 ·1188
ENGINE LUBRICATION SYSTEM 6-5
Engine Oil and Filter
.,
............ , ...................................................... ,.. ,...
I WARNING
I
CMotorcycie operation with insufficient. deteriorated, or
contaminated engine oil will cause accelerated wear and
may result in engine or transmission seizure. accident,
and injury.
Olnsufficient, deteriorated. or contaminated engine oil
will cause the hydraulic lash adjusters to malfunction,
and develop tappet noise or poor engine running.
A. Upper Level
C. Oil Filler Opening Cap
B. Lower Level
Engine Oil Level Inspection
elf the oi l has just been cha nged, start the engine and
run it for several minutes at- idle speed. This fills
the oil filter with oil. Stop the engi ne, th en wait
several minutes un til the oil scttl(;:s.
Engine Oil and/or Filter Change
-Warm up the engine so thac the oil will pick up any
sediment and drain easily. Then sto p the engine.
_With the motorcycle up on its center sta nd, place an oil
pan beneath the engi ne.
-Remo ve two engi ne drain plugs, and let the oil drain
co mpletely.
ORacing the engine before the oil reaches every part can
cause engine seizure.
-If the motorcycle has just been used, wait several
minutes for all the oil to drain down.
_Situate th e motorcycle sa (hat it is perpend icu lar to the
ground, and check the engine oi l level thr ough the oil
level gauge.
*The oil level ihould come up between the upper and
lower level lin es.
*If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
*If the oi ll t!vel is too low, add che correct amount of oil
throu gh the oil filler opening. Use the :;arne type and
make of oil that is already in the engine.
NOTE
olf the engine oil type and make iJre unknown. use any
brand of the specified oil to top up the level in preference to running the engine with the oil level low.
Then at your earliest convenience, change the oil
completely.
~"J lf
lhe engine oil gets exuemely low or if lhe oil pump
or oil passages clog up or otherwise do not function
properly. lhe oil pressure warning light will lighl. If
lhis light stays on when the engine is running above idle
speed, stop the engine immediately and find the cause.
A. Drain Plug
B. Oil Filter Mounting Bolt
-If the oil fi ltc( is ( 0 be changed, replace it with a new
one (see Oil Filter and Bypass Valve Removal and
Installatio n Notes).
-Check the gasket< at the drain plug< for damage.
*Replace the gaskets with new ones i:t they are damaged.
-Aftcr the oil has completely droined out, inst all the
drain plugs with the gaskets, and tighten them to the
specified torque (see Exploded Viewl.
-F ill the engine with a good quality motor o il specified
in th e table.
eCheck the oil level.
6-6 ENGINE LUBRICATION SYSTEM
Engine Oil
Grade:
Viscosity:
SE or SF cia ..
SAE 10W40. 10W50.
20W40. or 20WsO
Required Amount
When filter is not removed: 3.2 L
When filter is removed: 3.5 L
elnstall the oil filter and tighten the mounting bolt to
the 'pecined torque (see Exploded View).
eAdd engine oil (,ee Oil Level Inspection).
Bypass Valve Disassembly
eRemove the oil filter. Oil draining is not necessary.
eDrive the retaining pin out of the filter mounting bolt.
eDrop out the spring and the bypass valve steel ball.
Oil Filter and Bypass Valve Removal
-With the motorcycle up on its center stand, place an oil
pan beneath the engine.
-Unscrew the oil filter mounting bolt and drop out the
fII ter.
eRe move the oil fence.
eHolding the filter steady, turn the mounting bolt to
work the filter free.
eRemove the flat washer and spring, and pull the filter
cover off the bolt.
eThe oil filter bypass valve is assembled in the mounting
bolt.
Oil Filter and Bypass Valve Installation Notes
echeck that the O-rings are in good condition.
*If they are damaged, replace them with new ones,
Bypass Valve Assembly
eDrop the bypass valve ~teel ball into the filter mounting
bolt.
ePut the spring into the mounting bolt and compress it
beyond the small hole.
eDrive the retaining pin into the small hole to hold the
spring.
eln't~11 the oil filter.
Bypass Valve Cleaning and Inspection
eRemove the oil filter.
eDisassemble the bypass valve.
e(lean the bypass valve parts in a high flash·point
solvent..
I WARNING I
celean the parts 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
solvent.
00
A. ().ring'
eVbually inspect the bypass valve parts.
*If there is any damaged part, replace it.
B. Bypa" Valve
eApply oil to the mounting bolt, turn the filter or the
mounting bolt to work the filter into place. Be careful
that the filter grommets do not slip out of place.
Oil Pan and Oil Pressure Switch
Oil Pan Removal
A. Turn {he filter.
B. Grommet
eDrain the engine oil (see Engine Oil and/or Filter
Change).
eRemove the mufflers and exhaust pipes.
eRemove the oil niter (,ee Oil Filter and Bypa" Valve
Removal and I",tallation Notes).
eRemove the banjo bolts at both ends of the oil pipe
connecting the oil pan and the crankcase lower half.
eRemove the banjo bolt at the lower end of the oil pipe
connecting the oil pan and the cylinder head.
eRemove the oil pan bolts, and oil pipe and pull the oil
pan off the crankcase.
eThe oil pipes in the crankcase and one of the oil screens
come off with the oil pan.
ENGINE LUBRICATION SYSTEM 6-7
Oil Pan Installation Notes
-Check that the O-rings are in good condition.
cThe outlet side O-ring between the oil pan and oil
pump bracket must be installed so that flat side faces
the bracket.
-If the oil pressure switch was removed, apply a silicone
sealant to the threads and tighten it to the specified
torque (see Exploded Viewl.
_Tighten the oil
pipe banjo bolts to the specified
torque (see Exploded View).
_Install the oil filter and fill the engine with tl1e
specified oil (sec Engine Oil and/or Filter Changel_
Oil Pump and Relief Valve
A. O-rings
Oil Pump and Relief Valve Removal
_Remove the oil pan .
• Pull out the oil screen, oil pipe, collar, and O-rings.
-Unscrew the oil pump bracket bolts, and pull out the
bracket and pump as an assembly.
oRemovc the pickup coil cover, and turn the crankshaft
until the catches of the pump shaft ends are vertical.
Th is procedure allows the pump and bracket assembly
to be removed easily, if the pump drive gear and/or
water pump are installed.
A. O-ring
-Apply a small amount of oil to the O-rings.
-Apply a non-permanent locking agent to the threads of
the two oil pan bolts which are indicated by the
triangular marks.
A. Catches
-Remove the oil pump mounting bolts, and separate the
pump from the brackcL
B. Relief Valve
A. Bolts requiring locking agent.
B. Triangular 1\1ark
A. Oil Pump
C. Oil Pressure Switch
_Unscrew the relief valve.
1
6-8 ENGINE LUBRICATION SYSTEM
Oil Pump and Relief Valve Installation Notes
eApply a non -perm anen t lo cking agent to the threads of
the relief valve, and torque it to the specified (sec
elf the oil pump drive gear and/or water pump are
installed, check that the oil pump shaft catches of
both components arc vertical.
eTighten the oil pump bracket bolts to the specified
torque (see Exploded View).
Exploded View).
COo not over-apply a non-pennanent locking agent to
the threads. This may block the oil passage.
-F ill the pump with engine oil before installation.
-Ch eck that the collars and O-rings are between the oil
pump and th e bracket. The o utlet side O-rings must be
installed so that the flat sid!: faces th e bracket.
Oil Pump Disassembly
eRemove the oil pump.
eTake out the oil pump cover screws.
eTake out the oil pump cover.
eDrop the rotors out of the oil pump body.
ePu l1 the pin out of the pump shaft.
eRemo ve the rotors from the other side of the pump in
the same manner.
ePull the oil pump shaft out of th e body.
Oil Pump Assembly Notes
eSe sure the dowel pins are in place in the pump body.
A. Collars
B. Q·rings
eAppl y a non-permanent locking agent to the threads of
the oil pump mounting bolts,
eT ighte n the oil pump mounting bolts to th e specified
torque (see Explodod View).
-Check that the knock pin, nozzle, and Q·ring are
between the crankcase lower half and the oil pump
bracket. Tht! sma ll hol e of th e nozzle must face the
br.)ckct.
A . Dowel Pin
eBefore installing the oil pump, be sure th e shaft and
rotors turn freely .
Oil Pump Drive Gear Removal
eThe oil
pump drive gear is removed during clutch
assembly removal (see Clutch chapter) .
Oil Pump Drive Gear Installation
eThe oil pump drive gear is installed during clutch
assembly installation (see Clutch chapter).
Oil Pump Gear Removal
eRemove the clutch assembly (see Clutch chapter).
A. Knock Pin
B. Nozzle
C. Q-ring
eTurn the oil pump gear until th e gcar holder screws arc
visible through the hol es in the oil pump gear.
ENGINE LUBRICATION SYSTEM 6-9
Oil Pressure Measurement
eMc.a::,urc th e o il pressure al normal operating
temperatur e.
OWarm up the engine, and then stop the engine.
0Removt' t he oi l Pdssage plug.
c lmlall th ~ oil pressure gauge and adapter (special
to ols) .
A. Oil Pump Drive Gear
B. Oil Pump Gear
eTake o ut th e screws and r~m o v e th~ oil pump gedr with
the Il older.
-Remove the circlip and separ.ate the gear fro m the
holder.
Oil Pump Gear Installation Notes
-Wh en installing the o il pump gear, nOle the po siti o n o f
the oi l pump shaft projectio n and
!Ufn
the projection fits into th e slot o f the
th e gL'Jf so that
A. Oil Pressure Gauge: 57001-164
B. Adapter: 57001·1188
C. Plug
~h.1ft.
WARNING
I
GIf the oil passage plug is removed while the engine is
warm, hot engine oil will drain through the oil passage;
take care against burns.
OStart the engine a gain.
ORull th e engin e at the specified speed, and read t he o il
pressur e gauge.
0 Stop the;' engine.
ORemo ve the oil prcssu rt! ga uge and adapt er.
Gln st.]!! the oil passage plu g.
A. Slot
B. Projection
. App ly a non-permanent lock ing agent to the t h reads of
the ho lder screws.
*If the oil pre ss ure is significantly belo w th e specificatio n, insp ec t the oil pump and reli ef valve.
Oil Pressure
About 370 kPa (3.B kglem' , 54 psi)
@4,OOO rlmill (rpm), BOoe (176° F)
>'!If th e o il pump and reli ef val ve a re not at fault , inspect
th e re st of the lubrication sv ste m .
6-10 ENGINE LUBRICATION SYSTEM
Oil Pump Inspection
.Disassemble the oil pump.
_Visually inspect the oil pump body , outer and inner
rotors, and Covers.
*If there is any damage or uneven wear, replace the
rotors or the oil pump assembly.
Relief Valve Inspection
-RellK>vc the relief valve.
-Check to sec if the steel ball inside the valve slides
smoothly when pushing it in with a wooden or other
soft rOd, and see if it comes back to its sea t by valve
spring pressure.
A. Oil Scree n>
NOTE
olnspect the valve in its assembled state.
Disassembly
and assembly may change the valve performance.
*If any rough spots are found during above inspection,
wash the valve clean with a high 'flash-point solvent
and blowout ;any foreign particles that may be. in the
valve with compressed air.
I WARNING.
CClean the parts 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 flashpoint solvents.
*If cleaning does not solve the problem, replace the
relief valve as ,1 n assembl y. The relief valve is precisio n
made with no allowance (or replacemen t of individual
parts.
eUnscrew the screws and lake off the oil screen which is
located on the oi l pan.
Oil Screen Installation Note
e(l ean the oi l screens thoroughly whenever they are
removed for any reason.
Oil Screen Cleaning and Inspection
-Clean the oil screen with high flash-point solvent and
remove any particles stuck to i·t.
I WARNING
I
Celean 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
oWhile cleaning th.lCreen, check for any metal particles
that might indic.til internal enginl! damage.
e(heck the screen carefully for ilny damage: hol es and
broken wires.
*If the screen i,s da.rnag~Q. replace it.
Oil Screens
Oil Screen Removal
eRemove lhc oil ran .
ePul1 the oil sc reen which is loca led on the oil pump
bracket , and take it off the bracket.
ENGINE REMOVAl/INSTALLATION 7-1
Engine Removal/Installation
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . • . . . .
7-2
Engine Removal / I nstallation .... . •....•.. .•. .. .. . ..• .. .. ... . .
7-3
Engine Removal . . . . . . . . . . . . . . . . • . . . . . . . . . . . . • . . . . . . . . .
7-3
Engine Installation Notes. . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . .
7-3
7-2 ENGINE REMOVAL/INSTALLATION
Exploded View
T2
T1: 25 N-m 12.6 kg·m. 19.0 ft·lb)
T2: 34 N-m 13.5 kg·m. 25 ft·lb)
T3: 57 N-m 15.8 kg·m . 42 ft~b)
=-----...<Tl
ENGINE REMOVAL/INSTALLATION 7-3
Engine Removal/Installation
............................................................... ........... .
~
Engine Removal
-Drain the engine oil (see Engine O il Cha nge in the
Engine Lubrication System cha pter) .
eOrain the coolant (see Coolanl Change in the Cooling
Systcm chapter).
eFor later inslallation (;onvenicncc, nol e and record how
and where cables, wiri ngs, and hoses are rouled. They
should not be bent sharply, k inked, or twisted.
eRemove the following:
Battery
Air Cleaner Housing
Ca rburetor ::.
Fa iring
A. Mounting Bolts
B. Bracket Bo lts
Radiator
Thermostat Hou sing
Ignit ion Coils
Mufflers and ExhauSt Pipe>
Rcar Wheel
Fina.l Gear Case
eDisconnec t wirings fr om the engine compone nts, Jnd
free them from th e clamps if there are.
Start er Motor Lead
Alternator Leads
Neutral Switch Wire
Overdrive Switch Wire
Oil Pressure Switch Wire
Pickup Coil Leads
Battery Ground Le.ld
eRemove thl;! engine mounting bolts. Support the
engine before sliding out the engine mounting bolts.
eRemO't'e the engine mounting brackt!t bolts and tcike
off (he brackets.
eRemove the right down tube and (he rear brakl;! peda l.
eRemove the engine.
Engine Installation Notes
eBe sure to install the rubber dampt.::rs on th e engine
mounting bracke~s,.
• Ti ghten the engine mounting bolts and bracket bolts to
the specified torque (see Exploded View ).
eRemove the swing arm to engage the propeller shaft
with the front driven gear joint, if necessa ry.
eFill th e engine with engine oil (see Engine Oil Change
in the Engine Lubricati on Syst~m chap ter ).
eF111 the engine with coolant (see Coolant Change in the
Cooli ng System chapter).
eAdjust (he fo llowing.
Throttle Cables
Choke Cable
I
t
A. Mounting Bolts
B. Bracket Bolt s
C. Right Down Tube
D. Tube Mounting Bolts
CRANKSHAFTITRANSMISSION
8·'
Crankshaft/Transmission
Table of Contents
Exploded View
.....••. . . .•• ...•• . ..
8·2
Damper Inspection . . . . . . . . . . . . . . .
8·20
Specifications . . . . . . . • . . . . . . . . . . • . . .
8·5
Starter Motor Clutch Inspection
..... .
8·20
Special Tools ... . . . . . . . . . . . . ... • ....
8·7
eall and Needle eearing Wear . . . . . . . .
8·20
Crankcase Splitting . .. . . . . . . . . .. . .. • . .
8 ·8
Transmission ... . . . . . . . . . . . . . . , ... _ .
8·21
Crankcase Splitting . . . . . . . . . . . . . . .
8·8
Transmission External Shift Mechanism ...
8·21
Crankcase Assembly Notes •...• .• . ..
8·8
Crankshaft/Connecting Rods ........•••.
8·10
Crankshaft , Connecting Rods
External Shift Mechanism Removal
External Shift Mechanism
Installation Notes . . . . . . _ .. ,
Removal / Installation . . . . . . . . . . . .. .
8·10
Flywheel Removallln.tallation
Notes .... _ ... . .... . . . . . . .. .
8·21
External Shift Mechanism
Inspection . . . . . . . , ... . ... .
8·10
8·21
Transmission Shafts , Shift Drum, Forks
Transmission Shaft Removal . .
8·21
8·22
8·22
" ' , . . . . . . . .. ,
8·10
Crank.haft In.tallation Notes ... ..•..
8-11
Transmission Shaft Installation Notes . .
8·22
Connecting Rod Removal , ... __ .. , .,
8-1 1
Transmiss ion Shaft Disassembly
8·22
Connecting Rod Installation Notes, . . _.
B-l1
Crankshaft Removal
Crankshaft, Connecting Rods
Inspection/Maintenance , .. , , .. , . .. _
8-11
Crankshaft/ Connecting Rod Cleaning. ..
8·11
Connecting Rod 8endITwist . . . . . . . ..
8·12
Connecting Rod 8ig End
Side Clearanoe .. . .. .. . .. . .. .
8·12
.. , ...
Transmission Shaft Assembly Notes . , . ,
8·23
Shift Drum and Fork Removal ...... .
8·23
Shift Drum and Fork
Installation Notes . . . . . , , . . . . . . .
8·24
Gear Backlash . . . . . . . . . . . . • .....
8·25
Shift Fork Bending ..... ... . ... .. .
8·25
Shift Fork / Gear Groove Wear
8·25
Shift Fork Guide Pin/ Shift
Connecting Rod Big End Bearing
8·26
.......... .
8·12
Crankshaft Runout . . . . . . . . . • . . . ..
8·14
Gear Dog , Dog Hole , and
Recess Damage . . . . . . . . . . . . .
8·26
8·14
Ball and Needle Bearing Wear ....•...
8·26
Insert/Crank pin Wear
Crankshaft Main Bearing
Insert/Journal Wear. . . . . . . . . . . ..
Crankshaft Side Clearanoe .... .•..
8·16
8·16
Balancers
Balancer Removal . ... _ . . . . . . . . _ ..
8-16
Balancer Installation Notes. . . . . . . . . .
8- 16
Balancer Gear Inspection . . . . . . , ... .
8·17
Damper Inspection .. , , . . . . . . . . . ..
B-17
Needle eearing Wear . . . . . . . . . . . • ..
8·18
Alternator Shaft/Starter Motor Clutch . . . •..
8·18
Alternator Shaft and
Starter Clutch Removal ..
8-18
Alternator Shaft and Starter
Clutch Installation Notes ... _ . . . ..
8-19
Starter Clutch Disassembly. . . . . . . • ..
8·19
Starter Clutch As.embly Notes
8·19
Alternator Shaft Chain Wear , .
8·19
Cha~n
8·20
Guide Wear . .
Drum Groove Wear . . . , , .
CR
8-2
RANSMISSION
ANKSHAFT/T
............. ...................................
...............
············ed····V·
'9W
............. .............
Explod
..... ......................... ........... . ...............
New : @T5
'1t~~Fr!!!
o
T7
@
@
New: @
...
CRANKSHAFTITRANSMISSION 8-3
®
T6
SS
G : Grease
l : Non-permanent locking Agent
LG : Liquid Gasket
M : Molybdenum Disulfide Gr....
S : Follow the specified tightening sequence.
SS : Silicone Seolant
n : 7.8 N-m
L
(0.80 kg-m, 69 in-Ib)
T2: 9.8 N-m (1 J) kg..", 87 in~b)
T3: 12 N-m (1.2 kg..", 104 in-Ib)
T4 : 25 N-m (2.5 kg·m, 18.0 ft·lb)
T5 : 27 N'm (2.8 kg·m, 20 ft·lb)
T6: 28 N·m 12.9 kg·m, 21 ft·lb)
T7: 39 N-m 14.0 kg·m, 29 ft~b)
Ta: 145 N-m 115.0 kg..." 110 ft·lb)
T9: 49 N-m (5.0 kg·m, 36 ft·lb)
no: 29 N-m (3.0 kg-m. 22 ft·lb)
f
8-4 CRANKSHAFT/TRANSMISSION
L : Non·parmanent locking Agem
T2 : 9.8 N-m (1 .0 kg..", 87 in-Ib)
CRANKSHAFT/TRANSMISSION 8-5
Specifications
Item
Standard
Service Limit
Crankshaft/Connecting Rods:
Connecting Rod Twist
- ----
0.2/100 mm
Connecting Rod Big End Side Clearance
0.13 - 0.38 mm
O.SOmm
Connecting Rod Bend
0.2/100 mm
Connecting Rod Big End Bearing
Insert/Crankpin Clearance
0.040 - 0.064 mm
Crankpin Diameter:
0.10 mm
,
,
37.984 - 38.000 mm
Marking
None
37.984 - 37.992 mm
0
37.993 - 38.000 mm
Connecting Rod Big End Bore Diameter :
Marking
37.97 mm
I
- - -
41.000 -41 .016 mm
None
41 .000 - 41.008 mm
0
41.009 - 41.016 mm
Connecting Rod Big End Bearing
Insert Thickness:
Brown
1.476 - 1.480 mm
- - -
Black
1.480 - 1.484 mm
Blue
1.484 - 1.488 mm
-- - --
Connecting Rod Big End Bearing Insert Selection :
Con ·rod Big End
Bearing Im ert
Crank pi n Diameter
Bore Diameter
Mark ing
Ma rking
Size Co lor
Part Number
Black
92028·1395
0
0
None
Non e
0
None
Blue
92028-1394
Non e
0
Brow n
92028-1396
Crankshaft Runout
-- -
0.05 mm TIR
0.022 - 0.046 mm
0.08 mm
37.984 - 38.000 mm
37.96 mm
Crankshaft Main Bearing Insert/
Journal Clearance
Crankshaft Main Journal Diameter :
Marking
None
37.984 - 37.992 mm
1
37 .993 - 38.000 mm
Crankcase Main Bear ing Bore Diameter:
Marking
41 .000 -41 .016 mm
0
41 .000 - 41_008 mm
None
41.009 - 41 .016 mm
---
I
8-6 CRANKSHAFTrrRANSMISSION
Standard
Item
Service Limit
Crankshaft Main Bearing Insert Thickness:
Brown
1.490 - 1.494 mm
---
Black
1.494 - 1.498 mm
---
Blue
1.498 - 1.502 mm
- --
Crankshaft Main Bearing Insert Selection:
Crankcase Main
Crankshaft Main
Bearing Bore
Journal Diameter
Diameter Marking
Marking
0
1
Brown
None
None
Blue
0
None
None
1
Bearing Insert-
Size Color
Black
Part Number
Journal Nos.
92028-1460
2,4
92028-1457
1,3,5
92028-1458
2,4
92028-1455
1,3,5
92028-1459
2,4
92028-1456
1,3,5
-The bearing inserts for Nos. 2 and 4 journals have oil grooves,
Crankshaft Side Clearance
0.05 - 0.20 mm
0.40 mm
158.8 - 159.0 mm
161.2 mm
Gear Backlash
0.02 - 0.19 mm
0.25 mm
Shift Fork Ear Thickness
5.9 -6.0mm
5.8mm
Gear Shift Fork Groove Width
6.05 - 6.15 mm
6.3 mm
Shift Fork Guide Pin Diameter
7.9 - 8.0 mm
7.8mm
Shift Drum Groove Width
8.05 - 8.20 mm
8.3mm
0.03 - 0.11 mm
0.15 mm
Alternator Shaft:
Alternator Shaft Chain 20-link Length
Transmission:
Primary Reduction:
Primary Gear/Clutch Housing Gear Backlash
CRANKSHAFT{TRANSMISSION 8·7
Special Tools
Bearing Driver Set: 57001-1129
Along with common hand tools, the following more
specialized tool s are required for complete crankshaft!
transmission servicing.
Dr1ver: 57001-137
Clutch Holdor: 57001-1156
Circlip Pliers: 57001·144
Rotor Puller: 57001-1216
Boaring Puller: 57001-158
Adapter: 57001 -317
Magneto Puller: 57001 -259
8-8 CRANKSHAFT/TRANSMISSION
Crankcase Bolts
Crankcase Splitting
Crankcase Splitting
-Remove the engine (see Engine Removal/Installati on
chapter).
-Set the engine on a clean surface and hold the engine
jtcady while parts are being removed .
-Remove the following parts from the engine.
I
®--
External Shift Mechanism
Starter Motor
Alternator
Pickup Coils
Clutch Cover
Left Engine Cover
eRemove the following parts only if the cra nkshaft is to
be removed,
Pistons
Flywheel
eRemove the following part onl y if the tr.lnsmission
drive shaft assembly is to be di sassemb led .
Clutch
-Remove the following part onl y if the tra.nsmission
outpul shaft assembly is to be disasse mbled.
Damper Cam
-Remove the 6 mm upper crankcase-half bolts first, and
then the 8 mm bolts .
A. 6 mm Bolts
B. 10 mm Bolli
C. Removal is not ne cessary for cr,lOkcase split.
D. Clamp
ePry the points indicated in the figure to split th e crank case halves itpart, and remove the lower crankcase half.
There arc two knock pins on the left and right of the
mating surface_
Crankca5e Pry Points
Crankcase Bolts
,
®
A. 6 mm Bolts
A. Pry Point
B. 8 mm Bolts
Crankcase Assemblv Notes
eTurn the engine upside down and remove the fo llowing
parts .
Oil Pump and Brac ket
eRemove the 6 mm lower crankc.l)e-h,:tlf bolts fir)t, and
then the 10 mm bolls. B~ careful not to lake out th e
.;:;rankshaft main bearing cap 001 t:i .
OThe clamp is in) talled with one of the 6 mm bo lts.
NOTE
~: The
upper crankcase half, the lower crankcase half, and
the crankshaft main bearing cap are machined at tlu!
factory in the assembled state, $0 the crankcase halves
and the main bearing cap must be replaced together as
a set.
CRANKSHAFT/TRANSMISSION 8-9
eBefore fitting the lower case on the upper case, check
the following.
CChcck to see that the following parts are in place on
th e upper crankcase half.
A. Do nOI ap pl y a liquid gasket here.
A. Knock Pins
CCheck to see that the shift drum is in the neutral
position, that is, the neutral positioning lever fits into
the detent on the shih drum bearing holder.
A. Neutral Positioning Lever
e Appl y a si licone sealant to the circumference of the o il
se.!J.l s at both ends of th e crankshaft .
• Fit the lo wer crank case half on the upper crankcase
half obser ving 'he following .
USet the shift forks so that the fingers of each fork
fit into the.! groov~s of the gears .
DHoid the balancers so that the mark on the rear
balancer weight aligns with the center of the oil passage
hole. At th is time, the mark on the front balancer
weight is a little closer to the rt:ar side.
8 . Neutral Det.ent
CCheck that the crankshaft is positioned so the #1 and 4
pistons are at TDC.
CChcck that the oil iea ls are in both ends of thu crank ·
shaft if the cranks haft have been rcmo ved . Be careful
not to mix up the seals (see CrankihJ.ft Installation) .
• With a high flash-po in t solvent, clean of( the mating
surfaces of the crank cases halves and wipe dry .
. Apply a liquid gasket to the mating sur face of the
lower cran kcase half and the circumference of each sClil.
[~AUTION
I
COo not apply a liquid gasket around the crankshaft
main bearing inserts.
A. Align mark with hole center .
eTi ghten the lower cra nkcase half bolts using the following 3 steps:
OLightly tighten all lower crankcase half bolts to a snug
fit. The three 10 mm bo lts (sequence numbered 1
through 3) ha ve J flat washer.
e>rollowing th e sequenc e num bers on the lower crank·
case half, torque the 10 mm bolts nrst to about one
half of th e specifica tion {see Exploded ViewL and
finally to the specification in the same seq uence.
8-10 CRANKSHAFT/TRANSMISSION
10 mm Boh Tightening Sequence
A. Clutch Holder: 57001·1156
Torque Value for 10 mm Bolts
First:
20 N·m (2.0
Final:
39 N·m (4.0
(when using new boilS)
First:
25 N' m (2.5
Final:
49 N·m (5.0
kg·m, 14.5 It·lb)
kg·m, 29 fl-lb)
eUsing the magneto puller (special tool) to hold the
flywheel steady, remove the flywheel with the rotor
puller (special tool) .
kg·m, 18.0 ft·lb)
kg·m, 36 It·lb)
OTorque the 6 mm bolts to the specification (see
Exploded View).
eAfter tightening all crankcase bolts, check the follow·
ing items :
cDrive shaft and output shaft turn freely_
c While spinning (he output shaft, gears shift smoothly
from the 1st to 5th gear, and 5th to 1st.
;: When th e output shait stays still, th e gea r can nol be
s-hifted 10 2nd gear or other higher gear positions.
A. Magneto Puller: 57001 ·259
B. Rotor Puller: 5700 1· 1216
Crankshaft/Connecting Rods
-When installing the flywheel, clea n the inside of the
flywheel hub and the end of the crankshaft thoroughly
or the taper will not fit ,nugly.
eTighten the flywheel bolt to the specified torque (sec
Exp lode d View).
o Repla ce the flywheel bolt with new o ne. This bolt is a
specia l finishi ng bolr.
Crankshaft , Connecting Rod
Removal!1 nstallation:
Flywheel Removal/ Installation Notes
Crankshaft Removal
euse the cl utch holder (special tool ) to loos en and
tighten the crankshaft flywheel bolt.
OPrepare three 8 mm bolts (20 mm or more length , 1.25
mm pitch ) and three or six 10 mm nuts (8 mm or more
hight) .
Oln sta ll the clutch hold er using the 8 mm boll,. The 10
mm nuts are set to the both sides or inside of the
holder ... collar.
eTil!f1ten the 8 mm bo lts securely.
-Remove the engi ne .
_Remove the pistons.
- Sp lit the crankcasC'.
-Remo ve the alternator shaft and sta rt er clutch .
-Remove the main bearing cap boits with flat washers,
and take o ff the cap .
eLift up th e crankshaft with the camshaft chain and
alternator shaft chai n. There is the oil seal on both
ends of the crankshaft.
CRANKSHAFT/TRANSMISSION 8-11
Crankshaft Installation Notes
elf the crankshaft or bearing inserts are replaced with
new ones, check clearance with plastigage before
assembli ng engine to be sure the correct bearing inserts
are in sLllled .
eAppl y a high temperature grease to th e lips of the right
side oil sea l (timing roLOr side), and fit the oil seals
onto both ends of the cra nkshaft with the arrow mdrk
on th e seal facing out. Th e arrow mark should show
the same direction of the cranksha ft rOLa tion
(c lockwise, watching from th e ignition timing rotor
,ide).
ICAU~jO~]
OTo prevent damage to the crankpin surfaces, do not
allow the big end cap bolts to bump against them.
Connecting Rod Installation Notes
eTa minimize vibration, J pair of connecting rod (left
two rods or right two) should have the same weight
mark. Th e left two rods arc a pair Jnd the right two
rods are a pair. The weight mark is indicated by a
capit.a.1 letter, and is stamped on the connecting rod big
end.
Weight Mark Location
I
•
eApply a si licone sealant to the circumference of the oil
seals.
elnstall the crankshaft main bearing cap with the arrow
on it pointing forward. TIghten bolts to the specified
torque (see E. ploded View) .
NGfF------(l
1. Big End Ca p
2_ Connecting Rod
3. Weight Mark , Alphabet
_Before installin g the connecting rods, blow the crankshaft oil passages with co mpressed air to remove any
foreign particl es or residue tha t ma y have accumulated
in the passages.
-If the connecting rod s or bearing inserts are replaced
wjth new ones, check clearance with plastigage before
assembling engine to be sure the correct bearing inserts
are installed.
_Tighten the cap nuts to the specified torque (see
Exploded Vi.wj.
A. Arrow point forward .
Connecting Rod Removal
eRemove the crankshaft.
-Mark Jnd record lo cati ons of the connecting rods Jnd
their big end caps so that th ey can be re-assembled in
their original positions.
eRemove the connecting rod big end cap nuts! and t..lke
off the rod and cap with the bearing inserts.
Crankshaft, Connecting Rod
Inspection/Maintenance:
Crankshaft/Connecting Rod Cleaning
_After remo ving lhe connecting rods from the crankshaft with a high flash-pOint solvent.
-Blow the crankshaft oil passages with compressed air to
remove any forejgn particles or re sidue that may have
accumulated in the passages.
8·12 CRANKSHAFTITRANSMISSION
Connecting Rod Bend/Twist
Connecting Rod Twist Measurement
eMeasure connecting rod bend.
ORemove the connecting rod big end bearing inserts, and
reinstall the connecting rod hig end cap.
oSelect an arbor of the same diameter as the connecting
rod big end, and insert the arbor through the Con necting rod big end.
o Select an arbor of the same diameter as the piston pin
and at least 100 mm long, and insert the arbor through
the connecting rod small end .
o()n a surface plate, set the big-end arbor on V block .
oWith 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 length to
determine the amount of connecting rod bend .
*If connecting rod bend exceeds the service limit, the
connecting rod must be replaced .
100mm
Connecting Rod Big End Side Clearance
_Measu re connecting rod big end side clearance.
o lnsert a thickness gauge between the big end and either
crank web to determine clearance.
Connecting Rod Bend
Seryice limit:
0.2/100 mm
Connecting Rod Big End Side Clearance
Standard:
Service limit:
0.13 - 0.38 mm
0.50 mm
Connecting Rod Bend Measurement
/
100mm
A. Connecting Rod
.Measure connecting rod twist.
" With th e big·end arbor still o n V block. hold the
connecting rod horizontally and measure the a mo unt
that the arbor varies form being parallel with the
surface plate over a 100 mm 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
k,rvice Limit:
0.2/100 mm
B. Thickness Gauge
*If Glearance exceeds the service limit, replace the
connecting rod with new one and then check clearance
again. If clearance is too large after connecting rod
replaccment ~ also the crankshaft must be replaced .
Connecting Rod Big End Bearing
Insert/Crankpin Wear
Bearing insert/crankpin wear is measured using a
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.
CRANKSHAFT/TRANSMISSION 8-13
eMtasure the beari ng insert/crankpin clearance .
c Rcmove the co nnecting rod big end caps and wipe each
bearing insert and cra n kpi n surface clea n of oil.
CCUI strips of plasLigage [0 beari ng insert width, and
place a s\rip on the crank pin for each connecting rod
paraliel to the cran kshaft so that the plastigage will be
compressed between the crankpin Jnd [he bearing
insert.
Olnstall the connec ting rod big end caps and ti ghten the
big end cap nuts to the specified torque (see Exploded
*I f clearance is within the standard , no bearing replacement is required .
*I f clearance is between 0.064 mm and the se rvice limit
(0. 10 mOl ). replace the bea ri ng inserts wi th inserts
painted blue. Check insert /crankpin cleara nce with
plastigage. The clearance may exceed the standard
slightly, bUl it must not be less than the minimum in
order to avoid bearing seizure.
*If clearance exceeds the service limit, measure the
diameter of th e cran kpins.
View).
NOTE
Crankpin Diameter
00 0 not turn the crankshaft during clearance measurement.
Service limit :
o Remove the co nnecting rod big end caps, and measure
the plastigage width to dcter mine the bearing insen/
crankpin clearance.
SllIndard:
37 .984 - 38 .000 mm
37.97 mm
*If any cra nkpin has worn past the service limit, replace
th e crankshaft with a new one.
*I f the measured crankpin diameter are no t Jess than the
service lim it, but do no t coincide wi th the original
dia meter mark ings on (he cra nkshaft, write new marks
on it. .
Crankpin Diameter Marks
37.984 - 37.992 mm
37.993 - 38.000 mm
None :
0:
ePut th ~ co nn ecti ng rod big end ca ps on the rods and
tighten th e nuts to th e specified torq ue (see Ex ploded
Vi ew).
eMeasure the inside diameter and mark each connecting
rod big end in accordance with the inside diameter.
I
NOTE
A. Cr. n kpin
B. Plastig.ge
o The mark already on rhe big end should almos( coincide wirh the measuremenr.
Connecting Rod Big End
Bearing Insert/Crankpin Clearance
Standard :
Service Limit :
Connecting Rod Big End Inside Diameter Marks
None:
0.040 - 0.064 mm
0.10 mm
41 .000 - 41.008 mm
41.009 - 41 .016 mm
0:
Crankshah Mark location
#3
#1
-
-
C~~ ..;::..
-~
r-
r-
T
~\
.,\
f--.-
:-]
I'-
'l:.
~r--
t-
F
r-
,:"~r-D
G t--
f!:.
;.....-
\
Left
:::-
-
#s
#4
' j~
V
-''L-
-
"-
-
~
'-
bd~'-U
Ri ght
8-14 CRANKSHAFT/TRANSMISSION
*If the measurement exceeds. the service limit, replace
the crankshaft.
Connecting Rod Mark Location
Crankshaft Runout
Service Limit:
0.05 mm TIR
Crankshaft Runout
I. Big End Cap
2. Connecting Rod
3. Diameter Mark
Cmark or no mark, around
weight mark alphabet
-Select the proper bearing insert in accordance with the
combination of the connecting rod and crankshaft
coding,
-Install the new insert in the connecting rod and check
insert/crankpin clearance with plastigage.
Bearing Insert Selection
CDn-rod Big
End Bore Diameter 1\-1ark
Crankpin
Diameter
Mark
0
0
None
None
0
None
Bearing Insert
Size
Part Number
Color
Black
92028-1395
None
Blue
0
Brown
92028-1394
92028-1396
Crankshaft Main Bearing Insert/Journal Wear
Bearing insert/journal wear is measured using a
plastigage (press gauge), which is inserted into the
clearance to be measured. The pJastigage indicates
the clearance by the amount it is compressed and
widened when the parts are assembled.
-Measure the bearing insert/journal clearance.
uSplit the crankcase and wipe each bearing insert and
journal surface clean of oil.
CCut strips of plastigage to bearing insert width, and
place a strip on each journal parallel to the crankshaft
so that the plastigage will be compressed between the
journal and the bearing insert.
olnstall the lower crankcase half, and tighten the case
bolts to the specified torque (see Exploded View).
NOTE
Bearing Insert Size Mark Location
ODD not turn the crankshaft during clearance measure·
menlo
CRemove the lower crankcase half and measure the
plastigage width to determine the bearing insert/journal
clearance.
1-----<(1)
1. Bearing Insert
2. Color Size Mark
Crankshaft Runout
eMeasure the crankshaft runout.
CSet the crankshaft in a flywheel alignment jig or on V
blocks.
OSet a dial gauge against the center journal.
OTurn the eran kshaft slowly to measure the runout, The
difference between the highest and lowest dial gauge
readings (TI R) is the amount of runout.
A. Journal
B. Plastigage
CRANKSHAFT/TRANSMISSION 8-15
Crankshaft Main Bearing Insert/Journal Clearance
Standard:
0.022 - 0.046 mm
Service Limit:
0.08 mm
NOTE
o The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Bore Diameter Marks
.If clearance is within the standard, no bearing
replacement is required.
.If clearance is between 0.046 mm and the service limit
(0.08 mm). replace the bearing inserts with inserts
painted blue.
Check insert/ journal 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 clearance exceeds the service limit, mea sure the
diameter of the crankshaft main jo urnal.
o
41.000 - 41.008 mm
41.009 - 41.016 mm
None:
Crankcase Mark Location
#5
#4
#3
#2
#1
Crankshaft Main Journal Diameter
Standard:
Service Limit:
37.984 - 38.000 mm
37.96mm
"If an y journal has worn past th e service limit, replace
the crankshaft with a new one .
• If the measured journal diameter are not les~ than the
service limit, but do not coincide with the original
diameter markings on the crankshaft, write new marks
on it.
-Select the proper bea ring insert in accordance with the
combination of the crankcase and crankshaft coding.
-Install the new insert in the crankcase and cap and
check insert/ journal clearance with plastigage.
Crankshaft Main Journal Diameter Marks
None:
1 :
Bearing Insert Size Mark Location
37.984 - 37.992 mm
37.993 - 38.000 mm
-Put the lower crankCdSC half and bearing cap on the
upper crankcase half without bearing inserts, and
tighten the case and cap bolts to the specified torque
and sequence (see Crankcase Assembly).
-Measure the main bearing bore diameter, and mark the
upper crankcase half in accordance with the bore
diameter.
1---0
1. Bearing Insert
2. Color Size Mark
Crankshaft Mar\( Location
#3
#1
,-
Cr-.~
..
... r--
.. :---
r--
1-'-
,c-
#5
F
U,
~,
L.-
'--
-
-6=0
r-'--
~'J
-'-
V
t:;
'--
r-
!\ ::;.
t--
\
1\.
1-''---
Left
·r\ _..
U·
:
V
\
r~:
I-
-r......
.--
r-
#4
LI
Right
8-16 CRANKSHAFTITRANSMISSION
Bearing Insert Selection
Crankcase Main
Bearing Bore
Diameter Mark
Bearing Insert'"
Crankshaft Main
Journal Diameter
Mark
Size
Color
0
1
Brown
None
None
Blue
0
None
None
1
*The bearing inserts for Nos.
~
Black
Part Number
Journal Nos .
92028·1460
92028·1 457
92028·1458
92028·1455
92028·1459
92028·1456
2,4
1,3,5
2,4
1,3,5
2,4
1,3,5
and 4 journals have oil groove .
Crankshaft Side Clearance
-Measure cfilnkshaft side clearance.
olnsert a thickness gauge between the crankcase main
bearing and the crank web at the No.2 journal to
determin e clearance.
*If the clearance exceeds the service limit, replace [he
crankcase halves ,md main bear ing cap as a sec
NOTE
OThe upper crankcase half, lower crankcase half, and
main bearing cap are machined at the facrory in the
Balancers
Balancer Removal
-Split the crankcase.
-Unscrew the balancer shaft clamp bolts, and pull
the clamp lever .
-Unscrew the bolt holding the balancer shaft gu ide
plate , and take off the plate and guide pins.
-Pull the balancer shafts with the oil seals toward
right out of the crankcase. At the:: same time,
balancer weight and gear assemblies come off.
off
pin
the
the
assembled state, so they must be replaced as a set.
Balancer Installation Notes
Crankshaft Side Clearance
Standard:
Service Limit:
A. Measure here .
0.05 -020mm
0.40 mm
-When coupling the balancer weight and the damper
housing, observe the following.
CCheck that the damper rubbers are in place.
OFit the balancer weight into the balancer housing so
that the weight is opposite the mark on the balancer
housing.
A. Weight Center
B. Mark
CRANKSHAFT/TRANSMISSION 8-17
_If the balancer gears were removed, install the balancer
gears onto the damper housing with the punch mark on
th e main gear aligning with the mark on the end of the
damper housing. The oil grooved side of the sub gear
must be faced to the main gear .
A. Align marks.
B. Oil Groove
- Fi t the copper washers on both sides of the weight and
gear assembly.
assembly .
The projected side Faces toward the
eTurn the balancer shafts until the punch mark o n the
end of each shaft points to the correct side. The mark
on the Front shaft po(nts to the rear. And then, install
the clamp lever on the shafts and ti ghten the damp
bolts temporarily.
A. Punch Mark
B. Balancer ShaFt
C. Clamp lever
eAdjust the balancer gear backlash during the preparation of the motorcycle.
The amount of backlash
can be changed by turning th e balancer shafts .
OStart th e engi ne and let it at idle.
o loose n the bala ncer shaFt clamp bolts.
oTurn the front balancer shaft clockwise until the
balan cer gear makes a noi se .
o Turn back Ihe shaft cou nlerclockwise untIl jusl [he sear
spots making a nojse.
OAdjust the rear balancer shaft in the same manner.
OTighten the balancer shaFt damp bolts securely.
Balancer Gear Inspection
eVis uall y
inspect th e balancer gears For chipping,
abrasion, color change, or other damage.
*If they appear damaged or deteriorated. replace them.
A. Pro jected Side
eMesh the Front and rear balancer gears aligning the
punch marks on the gears.
A. Align marks.
Damper Inspection
eVisuall y inspect the rubb er dampers.
*IF they appear damaged or deteriorated, replace them.
A. Rubber Dampers
8-18 CRAN KSHAFT /TRANSMISSION
®
allenc.r Timing
Viewed from Right
Front
©
@ Viewed from Right
Viewed from Bottom
4'
®
Viewed from Right
1. Balancer Gear
2, Align the punch marks,
3, Lower Crankcase Bauam Edge
4. Punch Mark
5. Oil Passage Hole
Needle Bearing Wear
-Visually check the ncedle bearings.
oThe roll ers in
little, and
d
needle bearing normally wear very
wear is difficult to measure . Instead of
-Remove the transmission output and drive shaft
assemblies .
eKeeping
the crankshaft from turning , remove --the
coupling bolt at the alternator shaft left end,
measuring, inspect the bearing for abrasion, col or
change, or oth er damage .
*If there is any doubt as to the condition of a needle
bearing, replace it.
Alternator Shaft/Starter Motor Clutch
Alternator Shaft and Starter Clutch Removal
eRemove th e engine.
-Split the crank case.
A, Coupling Bolt
CRANKSHAFT/TRANSMISSION 8·19
ePu11 the coupling from the shaft with the damper
rubbers and flat washer.
eRemove the bearing holder bolts and take off the
holder.
eHolding the chain tensioner bracket, remove the
tensioner bra.cket bolts a.nd take off the tensioner
assembly.
A. In sert a wire into the hole.
Starter Clu tch Disassembly
A. Tensioner Bracket Bolts
eR emove [he oil pipe by taking out the banjo bolt.
eRemo ve thl! circlip and flat washer.
ePull the starter clutch gcar and take off the needle
bearing and fla t washer_
-Holding the starter clutch assembly with a vise, remove
the Allen bolts and take off the one-way clutch.
Starter Clutch Assembly Notes
-Se sure to ins.tall the one-way clutch so that the flange
of it fits on the holder dent.
A. Oil Pipe
e Holding the starter motor clutch, pull the alterna.tor
shaft with the ball bearing. And then , free the starter
motor clutch from the chain.
Alternator Shaft and Starter Clutch
Installation Notes
el f the starter motor idl e gear is removed, instan it so
that the small diameter gear side faces to the starter
motor side. Apply a non-permanent locking agent to
the threads o f the idl e ge~tr shaft holder bolr..
elf the alternator sh.Jft right t.:nd ball bearing was
removed, install it so tho:ll the shield side of it faces in
and press it until it stops by th~ bearing drivt'r se t
(special tool: PIN 57001·1129).
eApply a non-permancnr locking agent to tht' threads
of the- alternator shaft bearing holder bolts.
eLock the chain tensioner inserting a thin wire into the
hole on the tensioner push rod, and install rhe
tensioncr ass.embly.
A. One·w~y Clutch
c.
Holder Dent
8. flange
eAppl y. non-permanent locking 'gellt \0 1)1. threads of
the Allen bolts and tighten them to the specified
torque (see Exploded View) .
Alternator Shaft Chain Wear
eHold the alternator shaft chain so that it may be pulled
tight.
eMeasure the length of 20 links (21 pins) with a v~rnier
caliper.
8·20 CRANKSHAFT/TRANSMISSION
*If the 20 link length of the alternator shaft chain is
greater than the service limit, replace it.
Alternator Shaft Chain
Standard:
Service Limit:
20~ink
length
158.8 - 159.2 mm
161.2 mm
Chain 20·Links Length Measurement
2o-link Length
A. Turn freel y.
B. Locked.
*If the starter clutch docs not operate as it should or if
it makes noise, go to the nex t step.
eDisassemble the starter motor clutch, and visuall y
inspect the dutch parts.
*If there is any worn or damaged part, replace it.
NOTE
Chain Guide Wear
-Visuall y inspect the rubber on the guides.
*If the rubber is cut or damaged in any way, replace the
guide.
cExamine the starter clutch gear as well. Replace it if
it is worn or damaged.
Damper Inspection
-Visually inspect the rubber dampers of the coupling
between the alternator and the al lernator shaft.
*If the y appear damaged or deteriorated, replace them.
A. Inspect surface.
Ball and Needle Bearing Wear
A. Rubber Dampers
Startil Motor Clutch Inspection
eRem(H'e the starter motor ,
-Turn dIe starter motor idle gear by hand. When viewed
from the left side of the engine, the idle gear should
turn COlantcrclockwise freely I but should no t lurn
clockwi~.
-Check the ball bearings: alternator 'haft LH and RH.
c Since the ball bean"ng' is made to extremely close
toleran ces, the wear must be judged by fee~ rather than
measurement. Cleoan the bearing 1n a high flasb-point
solvent, dry it (do not spjn the bearing while it is dryl.
and oil it with ensine oil.
OSpin the bearing by hand to check its 90ndition.
*If the bearing is noisy, does not spin smoothly, or has
any rough spots, replace it.
-Check the follo.wing needle bearing: Starter motor
clutch.
CRANKSHAFT/TRANSMISSION 8·21
OThe 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, repla.ce it.
A. Neutral Positioning Lever
B. Gear Positioning Lever
Transmission
Transmission External Shift Mechanism:
External Shift Mechanism Removal
eRemove the front bevel gear case.
-Move the shift mechanism arm out of its position on
lho end of the shift drum, and pull out the shift shaft
with the arm, spring, and shaft return spring.
External Shift Mechanism Inspection
eExamine the shift shaft for any damage.
I
r
®
A. Splines
B. Return Spring
A. Neutral Positioning Lever
B. Gear Positioning Lever
C. Shift Mechanism Arm
D. Arm Spring
E. Return Spring
F. Shift Shaft
eRemove. the nuts and take off the neutral positioning
lever and gear positioning lever. Each lever has the
collar, spring, and washer.
External Shift Mechanism Installation Notes
eThe neutral positioning jevt!r spring is painted red.
eThe projected side of the coUar must fact! toward the
lever.
C. Arm Spring
D.Arm
CCheck the shift shaft for bending or damage to the
splines.
"If the shaft i, bent, ,t,.ighten or replace it. If the
splines are damaged, ,r eplace the shaft.
OCheck the return spring and arm spring for breaks or
distortion.
l'rlf the springs are damaged in any way, replace them.
cCheck the shift mechanism arm for distortion,
*If the shift mechanism arm is damaged in any way,
replace the arm.
-Check the return spring pin is not loose,
-If it is loose) unscrew it , apply a non-permanent locking
agent to the threads, and tighten it.
eCheck the gear positioning lever, neutral positioning
lever, and their springs for breaks or distortion.
*If [he levers or springs art! damaged in any way, replace
them.
8-22 CRANKSHAFT/TRANSMISSION
A. Gear Positioning Lever
C. Springs
8. Neutral Positioning Lever D. Return Spring Pin
-Visually inspect the shift drum pins) pin holder, and
pin plate.
*If they are badly worn or if they show any damage,
replace them.
A. Set Ring
B. Set Pin
C. Oil Passage Holes
eThe bearing set pins and rings must match properly
with the holes or grooves in the bearing outer races,
Wh en they are properly matched, there is no clearance
between the crankcase and the bt:.aring outer races .
Transmission Shafts, Shift Drum, Forks:
Transmission Shaft Removal
-Remove the engine.
-Split the crankcase,
eTake out the drive and output shaft assemblies.
-If the drive shaft assembly is to be disassembled ,
remove the clutch. If the output shaft assembly is to
be disassembled, remove the damper cam.
A. No Clearance (both left and right sides)
Transmission Shaft Installation Notes
-With a high ftash-point solvent, clean off the outer
circumferences of the transmission ball bearings and
needle bearings, and their beating housings, and wipe
dry.
e<::heck to see that the set rings and set pins are in place
in the transmission bearing housings, and blow the oil
passages in the bearing housings clean with compressed
air,
Transmission Shaft Disassembly
eRemove the transmission shafts.
-Using the circlip pliers (special tool : PiN 57001-144)
to r~move the c:irclips, disassemble the transmission
shafts.
-The 4th gear on the output shaft has three steel balls
assembled into it for the positive neutral finder
NOTE
Olf the standard set ringslPIN: 14013-1054) cannot be
put intD the crankcilSe and ball bearing grooves, use the
thin set rings (PIN:
standard sec rings.
14013-1055) instead of the
mechanism .
To re move this gear from the shaft,
quickly spin this gear in a vertical position while holding the 3rd gear, and pull off the gear upwards.
eThe ball bearings arc press-fit on the transmission
shafts . To remove the bearings, use the bearing puller
and adapter (special tools: 57001-158 and 57001-317).
CRANKSHAFTITRANSMISSION 8-23
Circlip Installation
Opening
A.4th Gear
eUsing the driver (special tool: 57001-137), install the
ball bearings. The ball bearing for the drive shaft must
be pressed on with the set ring groove toward the
clutch side. The bearing for the output shaft must be
pressed on with the set ring groove toward the opposite
side of the damper cam.
Transmission Shaft Assembly Notes
eWhen installing the 4th gear and steel balls on the
output shaft, do not apply grease to the balls to hold
th em in place. ,This will cause the positi ve neutral
finder mechanism to malfunction.
eWhen assembling the dri\'e shaft 5th gear bushing and
output shaft 3rd gear bushing to the shaft , align
their oil holes with the holes in the shaft.
Shift Drum and Fork Removal
-Remove the external shift mechanism.
-Split the crankcase.
eUnscrew the Allen bolts holding the shift drum ball
bearing holders.
If
,/'
.I
A. Align oil holes.
eReplace any circlip that were removed with new ones.
-Alwa ys install circlips so that (he opening is aligned
with a spline groove.
A. Shift Drum
-The transmission gears can be identified by size;
Drive shaft gears - the smallest diameter gear is 1st
gear, and the large.s t is 5th.
Output shaft gears - the largest diameter gear is 1st
gear, and thl' smallest is 5th.
ePul1 out the shift rods, and take off the shift forks.
ePul1 out the shift drum.
B. Shi ft Rods
8-24 CRANKSHAFT/TRANSMISSION
Transmission Gears
Drive Shaft
2nd
Output Shaft
2nd
5th
5th
3rd
4th
3rd
4th
1 sl
1st
5.5 mm -o>I~-l-- 3 mm
1. Long Pin
Shift Drum and Fork Installation Notes
Shih Drum Pin Plate and Overdrive Contact
elf the shift drum pin plate was removed , install it as
following.
cOne of the six pins is longer than the others. The long
shift drum pin must be installed in the correct position ,
and must be fit into the recess in the back of the
pin plate.
If these parts are assembled in the wrong
position, the neutral indicator light will not light when
(he gears. are in neutral.
Clnstall the overdrive switch contact with the tooth of
the contact fitting into the hole of the shift drum pin
plate.
Be careful not to bend the contact.
If the
contact is installed in the wrong position or is bent, the
overdrive indicator light will not light when the gcars
are in overdrive.
OApply a non-permanent locking agent to the threads of
the pin plate bolt and tighten it to the specified torque
(see Exploded View).
A. Long Pin
B. Overdrive Switch Contact
CRANKSHAFTITRANSMISSION 8-25
.The fingers of the drive shaft shift fork are shorte.r than
output shaft fork's.
The outpu t shaft forks are
identical.
A. 90'
A. Drive Shaft Fork
B. Output Shaft Forks
.Appl y a no n-pe rmanent locki ng agent to the threads
of the shift drum bea ring holder Allen bolts.
Shift Fork / Gear Groove Wear
Gear Backlash
.Split th e crankcase leaving the transmiSSion in place .
.Sl!t a dial gauge against the teeth on one gear, and move
the gear back and forth while holding the other gear
steady. The differe nce between the highest and the
lowest gauge readings is the amount of backlash.
*Replace both gears if the amount of backlash exceeds
the service limit.
.Measure the ' thickness of the ears shift .fork, and
mea sure the width of the shift fork grooves on
transmissio n gears.
*If the thickness of a shift fork ear is less than the
service limit, the shift fork must be replaced.
Shift Fork Ear Thickne ..
Gear Backlash
Standard:
Service Limi1 :
0.02 - 0.19 mm
0.25 mm
Standard:
Service Limit:
5.9 -6.0mm
5.Bmm
*If a gear shift fork groove is worn over the service limit ,
the gear mu st be replaced.
Gear Shift Fork Groove Width
Standard:
Service Limi1:
A. Move back and forth lightl y. B. Hold stead y.
Shi ft Fork Bending
.Vi~uJlIy
inspect the shift forks, and replace any fork
that is bent. A bent fork could cause difficulty in
shiftin g, or allow the transmission to jump out of gear
when und er power.
6.05 - 6.15 mm
6.3mm
8·26 CRANKSHAFT/TRANSMISSION
Shift Fork Guide Pin/Shift Drum Groove Wear
Gear Dog, Dog Hole, and Recess Damage
_Me .. ure the diameter of each shift fork guide pin, and
measure the width of each shift drum groove.
*If the guide pin on any shift Jork is less than the service
limit, the fork must be replaced.
-Visually inspect the gear dogs, and gear dog holes,
and recesses.
*Replace any gears that have damaged or excessively
worn dogs or dog holes.
Shift Fork Guide Pin Diameter
Standard:
Service Limit:
7.9-B.Omm
7.8 mm
®
...
. I!/ .
'
,. -
*If any shift drum groove is worn over the service limit,
the drum must be replaced.
Shift Drum Groo •• Width
Standard:
Service Limit:
B.05 - B.20 mm
B.3mm
..
A. Dog
B. Dog Hole
C. Recess
Bal/ and Needle Bearing Wear
A. Shift Fork Gu ide Pin
B. Shift Fork Ears
,~'
A. Shift Drum Grooves
.,.. @
I
-Check the following ball bearings: shift drum LH, drive
shaft RH, and output shaft LH.
cSi nee 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.
OSpin 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 following needle bearing: drive shaft LH and
output shaft RH, and LH.
OThe rollers in a needle bearing normally wear very
little, and wear is difficult to measure, Instead of
measuring, inspect the bearing for abrasion, eolor
change, or other damage.
*If there is any doubt as to the condition of a needle
beari ng, replace it.
WHEELS/TIRES
Wheels/Tires
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
Specifications ........ .. ... _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
Special Tools ....... . ..... ,. .. . ...... .. ......... .. .. . . . .. .
9-3
Wheels .................. " ...... . ... " ... . .. . . . . .. . .. . ..
Front Wheel Removal .................. .. .... .. ... _ . . . . .
9-4
9-4
Front Wheel Installation Notes ... _ . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Removal ............ _ .. . .. . _ . . . . . . . . . . . . . . .
9-4
9-5
R ear Wheel Installation Notes ............... _ . , . . . . . . . . . .
9-5
Wheel (Rim) Inspection. . . . . . . . . . .. . . . . ... . . . . .. . . . . . . . .
9-6
Axle Inspection .......................................
9-6
Wheel Balance ..... . ............ . ..... . ........ .... ...
Tires. . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6
9-8
Tire Removal ............ . ............ . ...... ...... ...
Tire Installation . ... .... . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . .
9-8
9-10
Tire Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-10
Tire Repair Recommendation ............... . .......... ..
9-11
Wheel Bearings and Grease Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bearing Removal Notes ....... ... ...... ,..... . . ....
9-11
9-11
Wheel Bearing Installation Notes. . . . . . . .. . .. . .... . ..... . ..
9-11
Wheel Bearing Inspection ........... . . . ... . ...... . ..... "
Grease Seal Inspection ... , . ..... .. , ., ........... . .. . .. ,.
9-11
9-11
Speedometer Gear Housing .. .... , .. .. ,', .... ', .......... ',..
9-11
Speedometer Gear Housing Disassembly Notes , ...... ,.......
9-11
Speedometer Gear Housing Assembly Notes " .. ... . ..... . . '.'
9-11
g.,
9-2 WHEELS/TIRES
.................
~~~i~d;;;; ' v"':
"" " ....
""" "" " " '" ·········· ......................,.......
..lew
_.....
....... ................. .. ........ ....... ............
~
G
®
G : Grease
M : Molybdonum .
St : Stake the f DISulfide G, ••••
aS1ener .
n ·. 1.5 N'm (0.15
T2 : 5.9 N.m (0.60 kg-m. 13 in-Ibl
T3 : 88 N.m (90 kg·m. 52 in·lbl
T4: 110 N.m (~ kg·m. 65 ft-Ibl
1.0 kg·m • 80 !t-Ibl
WHEELS/TIRES 9-3
Specifications
Service Limit
Standard
Item
Wheels:
Rim Runout:
Axial
Radial
Axle Runout/ l00 mm
-------
0_5mm
O.Bmm
0.2mm
0.7 mm : Repair Limit
Wheel Balance
Less than 109
Balance Weights
10 g, 20 g, 30 9
---- -
Front
4.5mm
1 mm
Rear
7.3mm
2 mm : Under 130 km/h
Tires:
Ti re Tread Depth:
3 mm : Over 130 km /h
Standard Tire:
Front
---
130/90-1667H
DUN LOP F21 Tubeless
Rear
- --
150/90-1574H
DUNLOP K425A Tubeless
Tire Air
Pr~ssure:
Front
Rea r
225 kPa 12.25 kg/em'. 32 psi)
Up to 120 kg (265Ib) Load
225 kPa (2.25 kg/em' . 32 psil
120 - 203 kg (265 - 448 Ib) Load
280 kPa (2.8 kg/em' . 40 psi)
Bead Breaker: 57001-1072
Special Tools
Along with common hand tools. the followin, more
specialized toolJ arc required for complete wheels/tires
serv ici ng.
Circlip Pliers : 57001-143
Bearing Driver Set: 57001-1129
Rim Protector: 57001-1063
9-4 WHEELS/TIRES
elnsert J wood wedge (4 - 5 mm thick) between the
disc brake pads. This prevents the pads from being
moved out of their proper position, should the brake
lever be squeezed accidentally.
Wheels
Front Wheel Removal
eDisconnect the speedometer cable lower end,
eRemove the both mounting bolts for one of the brake
calipers. Support the caliper so that it does not hang
by its brake hose.
Front Wheel Installation Notes
eApply grease to the ~eal lip~ for the grease seals on the
speedometer gear housing and the right end of the
wheel hub.
elmIal1 the speedometer gear housing so that it fits in
the speedometer gear drive notches.
A. Caliper Mounting Bolts
B. Speedometer Cable
C. Axle Nut
eRemove the axle nu t.
eLoosen the axle clamp bolt.
A. Fit in the gear drive notches.
eFit the speedometer gear housing tongue between the
stops on the left fork leg.
A. Axle Clamp Bolt
-Use a jack under the engine or other suitable means to
lift the front of the motorcycle .
• Pull out the axle and drop the front wheel out of the
forks.
A. Tongue
COo not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks under the
wheel so that the discs do not touch the ground.
elnsert the speedometer inner cable into the speed·
ometer gear housing while turning the wheel so that the
slot in the end of the cable will seat on the tongue of
the cable- will seat on tbe tongu e of the speedometer
pinion. Tighten the cable nut with pliers.
B. Stops
WHEELS!TIRES 9-5
eRem ove the brak e calip er hol der bolt.
ePull out the ax le and slide the ca lip er off til e disc.
Support the caliper so that it docs not hang by its
bra ke h o ~e .
eSlide the rear wheel toward the right to disengage the
wheel fro m the fin a l gear casco
eln sert a wood wedg~ (4 - 5 mm thick) between the
di~c brake pads.
Thi~ prevents the pad~ fr o m being
moved out of their proper positio n, ~hould the brake
pedal be sq uee7.ed accide nrally,
B. Turn the wheel.
-Tighten the following fasteners to the specified torque
(sec Exploded View).
Rear Wheel Installation Notes
eApply grease to the ~plines o n the rear wh ee l coupling
and the seal I ip~ of th e grease seal o n th e right end of
th e wheel hub.
AxleNut
Axl e Clamp Bolt (see Suspension chapter)
Bra ke Caliper Mo unting Bolb (see Brakt:s chapter)
-Completely clean o ff any grease that has gotten on
either side of Lh e brJke discs with a high nash point
solvent.
Do no t usc one which will leave an oil y
residue .
• Pump the brake lever several times until a full, firm
lev er "feel" is o btained.
I WARNING'
COo not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will not
function on the first application of the lever if this is
not done.
A. Grease.
eBe . . ure insert thc di . . tance collar between the final gear
ca~e and the left cnd of th e hUb .
Rear Wheel Removal
eR emo ve the foll owing parts.
Saddlebags
Rear Fender Rear and Bracket
Muffler,
eRemove the colter pin and ·ax!~ nut.
A. DisLlnce Collar
eTi ghten the following fasteners to the s.pecified torqut'
(see Exploded View).
;\xle Nut
Caliper Holder Bdl , (see Brakes chap'er )
A. Axle Nut
B. ca liper Holder Bolt
eComple te ly clean off any gcase that ha ... gotten on
either side of the brake d isc with a hig.h flash po int
sol v~nt.
Do not usc o ne which w(1I leJ \'c an oily
re, idue.
9-6 WHEELS/TIRES
.Pump the brake pedal several times until a full. firm
pedal "feel" is obtained.
_Carefully inspect the wheel for small cracks, dents,
bending, or warping.
_If there is any damage to the wheel, j[ must be replaced.
I WARNING'
I WARNING
000 not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will not
function on the first application of the pedal if this is
I
CNever attempt to repair a damaged wheel. If there is
any damage besides wheel bearings, the wheel must be
replaced to insure safe operational condition.
not done.
*If the rim has a scratch del'Pcr than 0.5 mm and/or
across the rim scaling surface, replace the wheel.
Wheel (Rim) Inspection
If there is any doubt as to the condition of the wheel
or if the wheel has received a heavy impact check the
rim runout as follows:
-Remove the tire and support the wheel by the axle.
-Set a dial gauge against the side of the rim, and rotate
the wheel to measure the axial runout. The difference
between the highest and fowest dial readings is the
amount of runout.
-Set the dial gauge against the outer circumference of
the rim, and rOLlte the wheel to measure radial runout.
The difference between the highest and lowest dial
readings is the amount of runout,
*If rim runout exceeds the service limit, check the wheel
bearings first.
Replace them if they are damaged.
_If the problem is not due to the bearings, the wheel
must be replaced. 00 not attempt to repair a damaged
wheel.
-To measure axle runout, remove the axle, place it in
V blocks that arc 100 mm apart, and set a dial gauge
on the axle at a point halfway between the blocks.
Turn the axle to measure the runuut. The amount of
runout is the amount of dial variation.
*If runout exceeds the service limit, straighten the axle
or replace it.
_If the axle cannot be straightened to within service
limit, or if runout exceeds the repair limit, replace the
axle.
Axle Runout/100 mm
Rim Runout
Service Limit
Axial
Radial
Axle Inspection
Service limit:
Repair Limit:
0.2 mm
0.7mm
0.5mm
0.8mm
Axle Runout
Rim Runout
l00mm
Wheel Balance
To check the wheel balance:
.Support the wheel so that it can be .pun freely .
• Spin the wheel lightly, ~nd .mark the wheel at the top
when the wheel stops.
WHEELS/TIRES 9-7
Wheel Balance Check
To install the balance weight:
-Check if the weight portion has any play on the bladcand-clip plate.
*If it does, discard it.
eLubrica tc the b;}[ance weight blade, tire bead, and rim
fiange with a soap and water solution or rubber
lubricant. Thi:o. helps the balance weight ~lip onto the
rim flange.
0 00 not lubricate the tire bead with engine oil or
gasoline because they will deteriorate the tire.
elnstall the balance weight on the rim.
c Slip the weight onto the rim flange by pushing or
I. Mark
eRepeat this procedure several times. If the wheel stops
lightly hammering the weight in the dir ection shown in
the figure.
CC heck that the bladt: and weight seat fully on the rim
flange, and lhal the clip is hooked over the rim ridge
and reaches the Oat portion of the rim .
of its own accord in various positions, it is well bal-
anced.
8alanCi! Weight Installation
To balance the wheel:
elf the wheel always stops in one position, provisionally
attach a balance weight on the rim at the marking using
(a) Press or lightly hammer the weight in _
adhesive tape.
.Rotate the wheel YI turn, and sec whether or not the
wheel stop s in this position. If it does, the correct
balance weight is being used.
*If the wheel rotat es and the weight goes UP. repL:1cc
the weight with the next heavier sileo If the wheel
rotates and the weight goes down, replace the weight
with the nex t lighter size. Repeat these steps until
the wht!el remains ~t rest after being rotated % turn .
eRotate the wheel ,mother ~~ turn an d then another
y. turn to sec if the wheel is correctly balanced.
eRepeat the entire procedure as many times as necessary
[0 .1chieve correct wheel hal a nc\!.
ePerm a nently install the balance weight.
Wheel Balonce Adjust
Rim Flange
Tire Bead
(b) In>lallation (Ompleted.
~ Weight
I. Bal.nee Weight
2. YI Turn
Clip
9-8 WHEELS/TIRES
I WARNING'
Tire Bead Breaker
\
Olf the balance weight has any play on the rim flange,
the blade and/or the clip have been stretched. Replace
the loose balance weight.
COo not reuse balance weights.
Balance Weight
Part Number
41075·1014
41075·1015
41075·1016
Weight ~gram')
10
20
30
1. Bead Breaker : 57001·1072
-Install the rim protectors (special tools) around the
valve stem. Lubricate the tire iron) and rim protectors
with a soap and water solution, or rubber lubricant.
-Step on the side of the tire opposite the valve stem,
and start prying the tir e off the rim near the valve
stem with tire irons (special tools) ,
Tires
Tire Removal
-Remove the wheel from the motorc yc le, and remove
the disc(s) from the hu b.
eTa maintain wheel bal ance, mark the valve slem posi ·
tion on the tire with chalk so th a t the tire can be
reinstalled in the same position.
-Take out the valve core to let out the air.
A. Valve Core
B. Chalk Mark
ellibrieale the lire beads and rim flanges. on both sides
with a soa p and water solution or rubber lubricant.
This helps the tire beads slip off the rim flanges.
ONever lubricate with mineral oil {engine oil) or gasoline
because they will cause deterioration of the tire.
-Break the beads away from both sides of the rim with
the bead breaker (s peci al tool ).
Tire Removal
1. Rim Protectors: 57001 ·1063
2. Tire Irons: 57001·1073
NOTE
OFor easier removal, always position rhe tire bead
opposite the valve stem ;n the rim well, and pry the rire
bead iJ little at a time.
o Be careful not to scratch the inner liner and air sealing
surface$ of the rim and tire with the tire irons. A
scratched inner liner or sealing surface may allow air to
leak .
WHEELS!TIRES 9-9
Air S•• lIng Surlaces
Air Valve
I.
2.
3.
4.
Locknut
Nut
Was her
Cast Wheel
5. Grommet
6. Val ve Stem
NOTE
G The
direction of the tire rotation is shown by an arrow
on the tire sidewall.
1. Air Sealing Surfaces
2. Inner Liner
eAfter removing the bead on one side, remove the other
bead from the same 'iidc.
eRemove the rim from the tift:.
-R emove the rim protectors from the rim.
A. Rotation Mark (Arrow)
B. Balanco Mark (Yellow Paint)
Tire Installation
elnspect the rim and tire, and replace them if necessary.
eclean the sealing surfaces of the rim and tire, and
smooth the sealing )urfaces of the rim with J. fine
emery cloth if necessary .
eReplace the valve with a new one. Tighten the mount·
ing nut and locknut to the spec ified wrque. (sec
Exploded View).
epOSilion the tire on the rim so tha t the valve is at
the tire balance mark (the chalk mark made during
removal, or the yellow paint mark on a new ti re).
eFit the rim protectors and tire irons to install the
remaining part of the tire bead which cannot be
installed by hand. For easy tire installat ion, position
the part of the bead wh ich is already over the rim
flange in the r im well .
eBy hand, slide as much as poss ible o f the lower side of
the tire bead over the rim flange, starting at the side
opposite the valve.
eApply a soap and water solution, or rubbt!r lubricant
to the rim flanges . rim protectors, tire beads , and life
irons.
-Check the life rotation mark on the rear tire and install
it on the rim accord ingly .
NOTE
OTo prevent rim damage, be sure to place the rim
protectors at any place the tire irons are applied.
9-10 WHEELSfTlRES
-'nstall the other side of the tire bead onto the rim in
the same manner.
-Lubricate the tire beads and rim flanges with a soap
and water solution or rubber lubricant to help sea t
the tire beads in the sealing surfaces of tile rim while
inflating the lire.
-Center the rim in the tire be.lds and inflate the lire
with compressed air until the tire beads seat in the
seal ing surfaces.
J
I WARNING I
-Remove any imbedded sto nes or other foreign particles
from the tread .
-Visually inspect Ihe tire for cra.cks and cuts, replacing
the Lire in case of bad damage . Swelling or high spots
indicate internal damage, requiring tire replacement.
-Measure the tread depth at the center of the tread with
a depth gauge. Since the tire may \\lear unevenly, take
measurements at seve ra l places.
*If any measuremem is Jess than the service limit,
replace the tir e.
OBe sure to inltall the valve core whens't'sr inflating
the tire, and do not inflate the tire to more than
390 kPa (4.0 kg/em'. 57 psi). Overinflation can
explode the tire with possibility of injury and loss of
life .
~
\
e(:heck to sec that the rim lines on both sides of the
tire sidewalls are parallel with the rim flanges.
Rim line
A. Depth Gauge
Tire Tread Depth
1. Rim Line
Front
Standard
Ser't'ice Umit
Rear
Standard
SerVice Limit
4.5mm
1 mm
7.3mm
2 mm lUnde, 130 km/h)
3 mm
elf the rim flanges and tire sidewall rim lines are not
parallel, remove the valve core. Lubricate the rim
flanges and tire beads. Install the valve core and inflate
the tire again.
eAfter the lire beads seat in the rim flanges , check for
a'ir leaks . Inflate the tire slightly above standard in·
flation. Use a soap and water solution or submerge
it, and check for bubbles that would indicate leakage.
-Adjust the air pressure to the specified pressure (see
Tire Inspection ).
-Install the brake disc(s).
-Balance the wheel.
I WARNING
10v.,
130 km/hl
I
e Ta ensure safe handling and stability. use only the reo
commended standard tires for replacement. inflated to
the standard preSlure.
NOTE
cCheck and balance the wheel when a tire is replaced
with a new one.
Standard Tire
Tire Inspection
As the tire tread wears dow n, the rire becomes more
susceptible the puncture and failure. An accepted
estimate is that 90% of all tire failures occur during the
1.15110% of tread life (90% wo rn). So it is false econom y
and unsafe to use the tires until th ey are bald.
Front
Size
Make, Type
Rear
Size
Make, Type
130/90-1667H
DUNLOP F21 Tubeless
150/90-1574 H
DUNLOP K425A Tub.I ...
WHEELS/TIRES 9·11
Tire Air Pressure (when cold)
Front
Rear
225 kPa (2.25
Up to 120 kg
(265 Ib) Load
120 - 203 kg
(2 65 - 448 Ib) Load
Wheel Bearing Installation Notes
kg/em', 32 psi)
225 kPa
(2.25 kg, 32 psi)
280 k?a
(2.8 kgJ cm' , 40 psi)
-Before installing the wheel bearings, blow any dirt or
foreign particles ou t of the hub with compressed air
[0 prevent contamination of the bearings.
.Pac k the front bearings (sin gle face shield t ype) with a
good quality bearing grease before installation .
-Install the wheel bearings using the bearing driver set
(special tool: PIN 57001-1129) so that the marked
sides face out. The front bearings (single face shield
type) should be insta lled with the sh ielded sides facing
out.
Tire Repair Recommendation
Current.ly two types of repair for tubeless rires
have come into wide use. One type is called a temporary
(extern al) repair which can be ca rr ied out without
removing th e tire from the rim. and t.he other type is
called permanent (internal) repair which requires tire
removal. It is generally und erstood that higher running
durability is obtained by permanent (internal) repairs
than by temporary (~x ternal ) ones. Also, permanent
(internal) repairs also have the advantage of permitting a
thorough examination for seco ndary damage not visjble
from external inspection of the tire. For these reaso ns,
Kawasaki does not reco mmend temporary (external)
repair. Only appropria te permanent (i nternal) repairs
are recommended. Repair methods may vary sl ightly
from make to make . Follow the repai r methods
indi ca ted by the manufacturer of the repair tools and
materials 50 that safe results can be obtained.
Wheel Bearing Inspection
- Turn the bearing back and forth while checking for
roughness of binding.
_If ro ughness or binding is found, replace the bearing.
- Ex amin e the bearing seal for tears or leakage .
-If th e sea! is torn or is leaking, repl ace the bearing.
Grease Seal Inspection
-Visually inspect the grease seal.
-Replace any if the lips are misshapen , discolored
(indicating that the rubber has deteriorated), hardened ,
or been otherwise damaged.
Wheel Bearings and Grease Seals
Speedometer Gear Housing
Wheel Bearing Removal Notes
Speedometer Gear Housing Disassembly Notes
Cl Oo not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc. Place
blocks under the wheel so the disc does not touch the
ground.
-Remove [he front whe el bearings.
c'lnsert a metal rod into the hub from the right side, and
remove the left side bearing by tapping evenly around
the bearing in ne r race . Th~ dis tance collar comes o ut
with the bearing.
o Removc the remaining bearing by tapping \!venl y
around the bearing inner race.
-Remove the rear wheel bearings.
Olnsert a metal rod into the hub from the left si dl:, and
remove the right side bearing by tapping evenly around
the bearing inner race. The distance collar comes out
with the bearing.
o Remo\'e the remaining bearing by tapping evenly
around the bearing inner race.
-If the speedometer cable bushing or speedometer
pinion needs to be removed, first drill the housing
th ro ugh the pin using a 1.0 to 1.5 mm drill bit. Drill
the housing from the under side using a 3.0 to 3.5 mm
drill bit. Using a suitable 3 mm rod, tap out the pin ,
and then pull out the speedometer cable bushing,
pinion, and washers .
NOTE
Olt is recommended that rhe assembly be replaced rather
than attempting to repair the components.
Speedometer Gear Housing Assembly Notes
-Aft!.:!r inserting a new ph1, stake the housing hole to
secure the pin in place.
-Pack the gear housing with a high tempe ra ture grease.
9·12 WHEELS/TIRES
Wheel Bearings
Front Wheel
1. Axle NUL
2. Speedometer Gear Homing
3. Speedometer Gear
4. Pinion
n
5. Speedometer Gear Drive
6. Grease Seal
7. Circlip
8. Bearing
9. Distance Collar
10. Rim
11 . Grease Seal
12. Collar
13. Axle
G : Grease.
i!
---------
-----------
G
G
Rear Wheel
1.
2.
3.
4.
II
n
~
II
I :"-..----:
Ii..-.. r
I(
:
-'-'
.J
'\ \
,\ \.
\'-,
\ l.
fl
fJ
c.0"
"/
,\ -
;
I
\,
,,
..
I
,
1
L
I
(4 QI,
Axle
Cover
Distance Collar
Bearing
5. Rear Wheel Coupling
6. Circlip
7. Rubber Damper
8. O-ring
9. Distance Collar
10. Rim
11. Circlip
12. Grease Seal
13. Collar
14. Axle Nut
1 S. Cotton Pin
G : Grea!e.
FINAL DRIVE 10-1
Final Drive
Table of Contents
Exploded View, , , . ' , . , , . , . , , , ' . , ...... , . , . , .. ' . , , .. , ' , .. , ,
10-2
Specifications, , , , , , , , . • ' , , ... , , . , . • , . , .. , , .. , . , ' . , .. . , .. ' .
10-3
Special Tools , .. ,',' ... . , ..... " .. _ , ' , ..• , , . . , ... . . . , . . . . .
lOA
Final Gear Case Oil .. , , , , . , . , , .. , , , , , . , , , , . . . , , ... . . , , . , , . , .
10-5
Final Gear Case Oil Level Inspection .. ,., .• " . " "
. . ".".,
10·5
Final Gear Case Oil Change " . " ... , ....... , ., . , . •. ', ., . ,
10-5
Final Gear Case " , . . ,.,., . . . . , . . , .... ,., .•. . ' _ .. .. . , . , , . . .
10-5
Final Gear Case Removal " .. ',." .. " , . . . , ... , ..•.... ,"
10-5
Final Gear Case Installation Notes , , ... , .. .•. , .. , . , . _ , , . , , ,
10-6
Final Gear Case Disassembly " .... , . . . .. . . ' ...... , ..... ,.
10.6
Final Gear Case Assembly Notes". , . .• ,., . .... ""
. • ,.,.,
10.7
Bevel Gear Inspection. , . . .. , . . ... , . . .... .. , . .... . .. . . , , .
10-B
Pinion Joint Inspection ... " .. • ,., . . . ,',................
10-B
Ball Bearing Inspection. , , . , .. , ... .. , . . . . . . . . . • . . . . . . . . . .
10.8
Needle Bearing Inspection .. . .. .• ... .. . ... . .......... . • ..
10-8
Oil Seal Inspection .. , . , .... , . ..•... . .. , ...... . , . . . . . . . .
10-8
Propeller Shaft ...... , , . , ... ........ . .... , . .. •. . . . •. .. . . .. ,
10-8
Propeller Shaft Removal . . , . , ..........•...... , . . . . . . . . . .
10-8
Propeller Shaft I nstallation Notes , ............ , . . . • . . . . . . • .
10-9
Propeller Shaft Joint Lubrication ..... _ . . .. , _ . ....... . , __. .
10-9
Propeller Shaft Inspection .. ,.,., . ... , .. • ' , ........ _ . , . . .
10-9
Propeller Shaft Sliding Joint Inspection ... . .... . , .. _.•. .. , . .
10-9
Front Bevel Gears ........... . . ,"
... , .. .. . ... . .. , . . . . •.. , ..
10-10
Front Gear Case Removal ... , .. , .. , . . . . . . . . . . . . . . . . . . . . ..
10-10
Front Gear Case Installation Notes ........... _ , . .. . . .. .. .. ,
10.10
Front Gear Case Disassembly . ... , . . , ......• ' . . . . . . . . . . . ..
10-11
Front Gear Case Assembly Notes."
..... , .... , .. "., ... ,.,
10-12
Driven Gear Disassembly , ... , .. " .. . .... .. ' . . , . " . , . .. ,'
10-12
Driven Gear Assembly Notes ...... " ... ,., _.. . . . _., ..• _, .
10-13
Damper Cam Removal, . , , .. , , ...........• , , .• .... .. . • . ,
10-13
Damper Cam Installation Notes .. " .... ,., . ... .... , .. , ....
10-13
Front Bevel Gear Adjustment ..............•... . , ......• ,.
10-13
Bevel Gear Inspection. , .... , .. . , , .... , . .. .... . ... . , , ....
10-1B
Cam Damper Inspection, .. , . , , .. . , , . , ... , . .. ... . , . , . . . ..
10-18
Ball Bearing Inspection .... " .... , . . .. ..... ,."
... , ......
10- lB
Tapered Roller Bearing Inspection ..... , ... .. . .. .... . . . , . ..
lo.1B
Needle Bearing Inspection " . ... ', ... , .. . , ... , . .. ,. , .....
10-lB
Oil Seal Inspection , .. , . . ..•..... . . , . . . • ,' . ... ', .... " ..
10-lB
Rear Wheel Coupling, .. , .. , . , .. , ... . .. . , .. ...... , . , .. . . .. ,.
10-18
Rear Wheel Coupling I nstallation Note , . .. .. , . . . . . . . . . . . . . . .
10-18
Damper Inspection , ... ... .. .... ... . , , . . . . . . . . . . . . . . . . ..
10-18
10-2 FINAL DRIVE
Exploded View
Vi ewed from Left
o
0
vo·
•
CD
Ii)/
~. %
~~
Ii)
®
CD
T9
T3
;1
G : Grease
L : Non·permanent Locking Agent
SS : Silicone Sealant
M : Molybdenum Disulfide Grease
St : Stake the fastener.
()
.®~~
~
vO ~@
D
1. Neutral and Overdrive Switch
~
()
®
0@
@
~~ J
T1 : 4.9 N ·m 1050 kg-m , 43 in ·lbl
T2: 9.8 N-m 11.0 kg·m, 87 In-Ibl
T3 : 12 N-m /1 .2 kg·m, 104 in·lb)
T4 : 16 N·m /1 .6 kg·m,ll .5 ft -Jb)
T5 : 24 N-m /2 .4 kg-m , 17.51t·lb)
T6 : 29 N-m 13.0 kg-m , 22 It ·Jb)
T7: 120 N-m /12 .0 kg-m , 871t·lb)
T8 : 225 N·m /23 kg-m, 165 ft4b)
T9 : 265 N-m /27 kg·m, 195 ft4b)
no: 540 N-m 155 kg-m , 400 ft ·Jb)
s
FINAL DRIVE 10-3
a
~~©
°c::noo
~~/
'I'
@
@r:?
Specifications
Item
Standard
Final Gear Case Oil:
Grade
Viscosity
Amount
Oil Level
API GL5 Hypoid Gear Oil
SAE80
210 mL
Bottom of filler opening
Final Gear Case:
Final Bevel Gear Backlash
0.06 - 0.10 mm (at gear shaft spline)
0.10- 0.15 mm (at gear tooth)
Front Bevel Gears:
Preload for Driven Gear Bearings
0.6 - 1.0 N·m (0.06 - 0.10 kg-m, 5 - 9 in-Ib)
Front Bevel Gear Backlash
0.13 - 0.18 mm (at gear tooth)
Q@
10-4 FINAL DRIVE
Dial Gauge Holder: 57001-1049
Special Tools
o
Along with common hand tools, the following more
specialized tools are required for complete final drive
servicing.
o
Bearing Puller: 57001-158
Adapter: 57001-317
Oil Seoland Bo.ring Remover: 57001-1058
Bearing Driver Set: 57001-1129
Driv",: 57001-382
Damper Cam Holder: 57001-1025
Pinion Gear Holder: 57001-1165
Drivon Gear Holder: 57001-1027
Drive Gear Holder: 57001-1226
..:..:~.:/
FINAL DRIVE 10-5
NOTE
Final Gear Case Oil
Final Gear Case Oil Level Inspection
-Support the motorcycle on its center stand.
eRemove the left saddlebag.
o The term "GL·5
rating. A "GL-6
used.
N
N
indicates a quality and additive
rated hypoid gear oil can also be
-Be sure the O-ring is in place,and Install the filler plug.
_Un scre w th e filler plug. The oil level should come to
th~
bottom of the filler opening,
Final Gear Case
NOTE
o This manual does not cOlier the pinion gear removal
because of the highly specialized equipment that is
required. If the pinion gear remollal is necessary, it
should be done by a properly equipped shop.
A. Filler Opening
B. Drain Plug
*If it is low, first check the final gear case for oil
leakage, remedy it if necess.ary, and add oil through
the filler opening. Use the same type and brand of oil
that is already in the final gear case,
-Install the filler plug.
Final Gear Case Oil Change
.Warm up the oil by running the motorcycle so that the
oil will pick up any sediment and drain easily. Then
stop it.
-Support the motorcycle on its center stand .
• Place an oil pan beneath the final gear caSt::, and remo ve
the drain plug.
Final Gear Case Removal
elf the final gear case is to be disassembled, drain the
final gear case oil.
eRemove the following.
Travel Trunk and Bracket
Rear Seat
Saddlebag:; and Brackets
Rear Wheel
eRemove the Idt shock absorber from its studs by
taking off the mount ing nuts.
eRemove th e final gear case by taking off the mounting
nuts. The spring comes off with the case.
NOTE
Glf the final gear caSe is full of oil, place the case so that
the breather hole is on top.
I WARNING.
C:: 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'3 high flash-point
sol~ent.
eAfter the oil has co mpletely drained out, install the
dra in plug with a new gaske t.
eFili the final gear case with the specified oil and quantity.
Final Gear Case Oil
Amount
210 mL
Grade
API G L-5 hypoid gear oil
Viscosity :
SAE 80
A. Final Gear Case Mounting Nuts
B. Breather Hole
,
I
10-6 FINAL DRIVE
Final Gear Case Insrallarion Nores
eL ubricate the propeller shaft joint (see Propeller Shaft
Joint Lub rication ).
elnstall the spri ng so that small diameter end faces
toward to final gear case ,
Final Gear Case Disassemblv
(ro replace rhe oil seals)
-Remo ve the final gear case cover mount ing bolts.
- Use the cover bolts to remove the ring gear assembly
from the gear case. The shim(s) comes off with the
assembly.
A. Small Diameter End
A. Jack the cover up with bolts.
-Fit the pinion gear splines into the propell er shaft joint
whit e turning the ring gear hub .
eTighten the final gear case mounting nuts to the
eTo remove the ring gear oil seal, soak the ring gear
assembly in oil and heat the oil to 120 - 150°C 1248
- J02"F), and then pr y out the seal. Be careful not to
scratch the sealing surface on the ring gt::ar hub.
specified to rq ue (see Ex ploded Vi ew).
elf the final gear case oil was drained, fill the case with
oil.
Final Gear Case
1. Pinion Gear Nut
2.
3.
4.
5.
Washer
Pinion Gear Joi nl
O-ring
Ring Gear Hub
6.
7.
8.
9.
10.
Oil Seal
Ball Bearing
Final Gear Case Cover
Cover Mounting Bolts
Rin g Gear Shim(s)
1l.
12.
13.
14.
15.
Ring Gear
Studs
Pinion Bearing Retainer
Oil Seal
Stud
16.
17.
18.
19.
20.
Ball Bearing (Four-point Contact)
Pini on Gear
Oil Seal
Needle Bca ri ng
Final Gear Case
FINAL DRIVE 10·7
( CAUTlO~]
COo not heat the case with a lorch. This will warp the
case.
-Remove the snap ring and pull out the nee dle bearing
outer race and oil seal together using the oil st:aj and
bearing remover (special tool:
PI N 57001-1058)_
-Remove the o il seal on the pinion bearing retainer
without th e pinion removal.
oUnscrew the pinion nut using the pinion gear holder
(spcc iallool),
A. Pre!is here.
eAlign the oil hole in the ne edle bearing outer race with
th e hole on the bearing housing (pinion gear side).
A, Pinion Gear Holder: 57001-1165
GRemo\'c the washer and pinion joint with the a ·ring.
c pull ou t the oil ')eal on the pinion bearing retainer using
a suitable puller.
A_ Oil Hole
eBlow the breather hole in [he final gear case cover
clean with compressed air.
Final Gear Case Assembly Notes
(to replace the oil seals)
eThe ring gear and pini on are lapped as a set in the
faclOry to get the best tooth contac.t. They must be
installed as a pair, never replac.e one without the other .
• Use a suitable driver to drive in the oil seals being
careful of installation direction a nd depth.
ePress the ring gear ass embl y slowly with a suitable
driver to firmly sea t the ball bearing if it may slide out
a liule by removal.
A, Breather Hole
10-8 FINAL DRIVE
OReinstal1 the original ring gear shim(s} to keep the gear
backlash and the too th contact unchangeiL
'Appl y a non-permanent locking agent to the threads of
the cover bolts, and tighten them to the specified
torque (see Exploded View).
-Replace th e pinion nut with new one,
-Using the pinion gear holder (special tool). tighten the
pinion nut to the specin ed torque (see E.plodcd
View).
_Stake the pinion nut with a punch.
{ CAUTlO:~]
GWhen staking the nut, be careful not to apply shock to
the pinion and its bearing. Such a shock could damage
the pinion and/or bearing.
Needle Bearing Inspection
.The rollers in a needle bearing normall y 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 condit io n of a neeqle
bearing, replace it.
Oil Seal Inspection
elnspect the oil seal.
*Rcplace it if the lips arc misshapen, discolored (indicating that the rubber has deterio rated), hardened, or
been otherwise damaged.
eApply a non-permanent locking agent to the threads of
each stud and install them to the case if the y were
removed.
Bevel Gear Inspection
-Visually check the bevel gears for scoring, chipping, or
other dam age.
*Replace the bevel gears as a set if ei ther gear is
damaged .
Propeller Shaft
Propeller Shaft Removal
Pinion Joint Inspection
_Visually inspect the splines of the pinion joint.
*If they are badly worn or chipped, replace the joint
with a new one. Also, inspect the propeller shaft
sliding joint.
eRemove the following.
Rear Wheel
Final Ge ar Case
Swing Arm
.Remove the propeller shaft fro m the front driven gear
joint.
c Turn the propellt.'f shaft so that the locking pin access
hole on the propeller shaft comes outside.
A. Check splined portion.
Ball Bearing Inspection
Since the ball bearing is made to extremely dose
tolerances, the wear must be judged by feel rather than
measurement.
-Spin the bearing by hand 10 chec.k its condition.
*If fhe bearing is noisy. does not spin smoothly, or
has any rough spots, replace it (as a gear set ).
A. Locking Pin Access Hol e
CPushing on the locking pi n J liule into the propeller
shaft, slip the propeller shaft off the driven gear joint.
•
•
FINAL DRIVE 10-9
Disengagement of Propeller Shaft from
Driven Gear Joint
Propeller Shaft Sliding Joint Lubrication
High Temperature Grease
.-
-
-
. -----4::8-
Propeller Shaft Inspection
e<::he ck that the uni versa l joint works smoothl y wi thout
ratt ling or sti ck ing.
*If it does not work smoothly ) the needl e bearings of
the uni versal joint are damaged. Replace the propeller
sha ft as sembly with a new one .
• Visually inspect the bearing of the shaft and the wear
of the splined section at the rear end o f th e shaft.
*If it is bent at all, repl.ace th e propeller shaft assembly.
00 not attempt to straighten a ben t shaft.
1. Propeller Shaft
4 . Spring
2. Universal Joint
5. Driven Gear Joint
3. Locking Pin
.Remove the drc!ip and washer from the rear end of th e
propeller shaft.
-Pull o ut the propeller shaft sliding joi nt off the propell er shaft.
Propeller Shaft Installation Notes
e<:heck the O-ring on the rear end of the propeller sh aft
for any kind of damage, and replace it if nece~sary .
-Lubricate the propeller shaft joint (see Propeller Shaft
Joint Lubrication).
A. Check univer sa l joinl.
. ...\fter con necting the propel ler shaft to the driven gear
joint, pull the propeller shaft rearward to check that
the shaft is secur ed in place by the locking pin.
B. In spect shaft and splined port ion .
Propeller Shaft Joint Lubrication
Propeller Shaft Sliding Joint Inspection
-Wipe off the old groase fro m th e propeller shaft slid ing
.Visual ly inspe ct the internal spli nes of the propeller
join t and pinion joi nt.
_Pac k the propeller shaft sl iding joint with 20 mL (16
grams) of high temperature grease.
shaft sli ding joint.
*I f they are badl y worn or chipped , repl ace the joi nt
with a new one.
10-10 FINAL DRIVE
Water Pump
Rear Wheel
Final Gear Case
eDisengage the front end of the propeller shaft from the
driven gear joint and slide back the propeller shaft (sec
Propeller Shaft Removal) .
• Place an oil pan beneath the front gear case,
-Unscrew the front gear case mounting bolts and remove
the front gear case. The cam follower and the damper
spring come off with the gear case,
A. Propeller Shaft Joint
B. Check the splined portion .
••
A. Cam Follower
Front Bevel Gears
Front Gear Case Removal
-Remove the front gear case cover by laking out the
mounting bolts. Each bolt has a flat washer and two
rubber dam pers.
eApply
d
-
B. Damper Spring
silicone sealant to the crankcase halves mating
sur face on th e front and rear si des of the
CdSI!
mount.
A. Apply silicone sealant.
B. Bolt requiring locking agent.
A. Front Gear Case Cover
-Remove the following.
Clutch Slave Cylinder
GUlCh Push Rod
Radiat",
Illume<' and Exhaust Pi pe,
-Tig hten the front gear ca!le mounting bolts to the
specified torque (se< Exploded View).
OApply a non-permanent locking agent to the threads
of the case bolt at the location shown .
-Install the Ihift pedal linkage and the left footpeg so
that the top end of the shift pedal levels with the top
of the footpog .
FINAL DRIVE 10-11
A. Cam Follower
B,90'
A Level
B. Damper Spring
C Oil Pipe Clamp Bolts
e lf the shift peda.l linkage was removal from the footpeg
bracket, apply a grease to the pivot shaft before in·
stalling it [0 the bracket.
e<::heck the engine oil level and add oil if necessary.
-Fit the rubber dampers and bolts onto the front gear
case, and then the screw in the bolts to mount the
Co\'er.
D. Driven Gear Assembly
Mounting Bolt,
-Remo\'e the drive gear.
o Unscrew the drive gear nut cap mounting boilS, and
remove the cap with the O-ring.
I.
Front Gear Case Cover Bolt and Rubber Dampers
CD (2' 3'
(4;
A. Drive Gear Nu t Cap
i
~)
1. Bolt
2. Wa,her
3. Rubber Damper
I
~
OPry open the drive gear nut with a small chisel.
OUn scrcw the drive gear n ul hold ing the drive gear shaft
with the holder (,pecial tool ).
4. Rubber Damper
5. Front Gear Case Cover
6. Fran t Gear Case
Front Gear Case Disassembly
(including drive gear removal)
A. Drive Gear Holder : 57001·1226
_R emove tht: cam follower and the damper spring.
-Remo\'c the driven gear asse mbly mounting bolts and
pull the assembly off the case.
-Unsc rew the oil pipe Clamp bolts from inside the case
and remove the oil pipe with the Q-ring.
o Pull off the drive gear shaft with the drive gear, collar,
and shim(s),
_Remove the drive gear shaft ball bearing using [h e
bearing drive r set (,pecial tool : PIN 5700'1·1129),
10·12 FINAL DRIVE
Front Gear Case Assembly Notes
(including drive gear Instal/ation)
eThe drive and driven gears are lapped as a set in the
factory to get the best tooth contact. They must be
replaced as a set.
.Press the drive gear and shaft assembly slowly with the
driver (special tool) to firml y seat the gear onto the
shaft.
A. Oil Holes
A. Driver : 57001·382
.If the neutral and o verdrive switch and collar were
removed, install them as following.
o;\pply a silicone sealant to the threads of the collar and
tighten it to the specified torque (see Exploded View).
oApply a non-permanent locking agent to the threads,
and install the neutral and overdrive switch so that the
terminal lead runs toward the front of the case.
Tighlell the switch to the specified torque (see Exploded View) .
• ,f the case outside oil pipe was removed, use a new flat
washer on each side of the fittings, and tighten the
banio bolts to th e specified torque (see Exploded
View).
eBe sure to check and adjust the bearing preload and the
bevel gear backlash and tooth contact, when any of the
backlash-related parts are replaced (see Front Be vel
Gear Adiustment).
eAfter completing all adjustment, re-assemble the front
gear case.
;J Replace the dri\'e gear nut with a new one.
OApply oil to the threads and seating surface of the nUl,
and tighten it to the specified torque (see Exploded
View).
OLoosen the nut completely and retighten it to the
Driven Gear Disassembly
specified torque.
GStake the nut to secure it in place.
.Holding the driven gear joint with t he driven gear
holder (special tool), unscrew the driven gear bolt.
::When staking the nut, be careful not to apply shock to
the shaft and its bearing. Such a shock could damage
the shaft and/or bearing.
:)Apply a non-permanent locking agent to the threads,
and tighten the cap mounting Allen bolts to the
specified torqu e (see Exploded View).
Olnstall the driven gear assembly so that the oil hole on
the housing aligns with the oi l hole in the case.
OTightcn the driven gear asst!mbly mounting bolts to the
specified torque (sec Exploded View ).
OApply a non-permanent locking agent to the threads,
and tighten the case inside oil p ipe clamp bolts.
A. Driven Gear Bolt
B. Driven Gear Holder: 57001·1027
FINAL DRIVE 10-13
eRemove the driven gear joint with th e O-ring.
eRemo ve the driven gear from the bearing housing.
eRemove the co llar and the spacer from the driven gear .
ePress the tapered roller bearing and oil seal o ut o f the
ho using using the bearing driver set (special tool:
57001-1129).
-Remove the tapered roller bearing which is pressed
onto the driven gear sha ft with the bearing puller and
adapter (s pecial tools : 57001-158 and 57001-317).
Driven Gear Assembly Notes
-The drive and driven gears are lapped as a set at the
factory to get the best tooth contact, They must be
replaced as a set. .
eBe sure to check and adjust th e bearing preload and th e
bevel gear backlash and tooth co ntact (see Front Bevel
Gear Adjustment).
-Drive the tapered roller bearing inner race onto the
driven gear shaft using the bearing driver (special tool).
B. Holder: 57001-1025
A. Damper Cam
Damper Cam Installation Notes
-Replace the damper cam nut with a new one.
-Tjght~n the damper cam nut to the specified torque
(see Exploded View).
o;\pply a small amount of oil (0 th~ threads and the
seating surface of the nut.
Front Bevel Gear Adjustment
A. Bearing Driver: 57001-382
- After completely the bearing preload adj ustment,
re-assemble the driven gear assembl y.
CU ,ing the bearing driver set (s pecial 1001 : 5700 1-1129),
press the oi l seal in unti l the face of the seal is level
with the end of the bearing housing hole.
OTighten the driven gcar bo lt to the specified torqu~ (see
Ex ploded View).
CStake the driven gear bolt to prevent it from lo osen ing.
In order to preve nt one gear from moving away from
the oth er gear under load, the tapered roll~r bearings
must be properly preloaded. Also the backlash (distance
o ne gear will move back and forth without moving the
o ther gear) and tooth contact pattern of the bevel gears
must be correct to prevent the gears from making noise
and b~ing damaged.
f-\ bove three adjustments are of critical importance
and must b~ carried out in the correct sequence and
method .
Front Bevel Gear Adjustment Procedure
I
,It
I
c..: When staking the nut. be careful not to apply shock to
the driven gear and their bearings. Such a shock could
damage the driven gear and/or bearings.
Damper Cam Removal
-Remo ve the retainer and needle bearing .
-Holdi ng the dampe r cam with the damper cam holder
(special tool ), unscrew the dam per cam nut.
I
Preload the driven gear bearings.
Adjust gear backlash_
I
,
I
,
I
Adjust tooth contact pattern_
I
\ It
I
Assemble the front gear case completly.
I
10-14 FINAL DRIVE
When the any of the baoklash-related parts arc
replaced, or the driven gear bolt is loosened; even if
the purpose is not to replace the parts, be sure to check
and adjust the bearing preload and the bevel gear baoklash and tooth contact by replacing shims.
Backlash-Related Parts
1. Drive Gear
2. Collar
3. Drive Gear Shim(s)
4. Ball Beari ng
5. Drive Gear Shaft
6. Front Gear Case
7. Driven Gear
8. T apered Roller Bcaring
9. Driven Gear Shim(s)
10. Driven Gear Bearing Housing
Parts which influence bearing
preload only
11. Collar (Preload Adjustment)
12. Spacer (Preload Adjustment)
13. Tapered Rollar Bearing
·14. Driven Gear Bolt
*Prcload adjustment is necessary whcn e ... er the bolt is
loos ened, even if the purpose is not to replace the parts.
Preload adjustment
-Assemble the driv en gear asse mbly , and li ghten the
driven gear nut to the specified torque (~te Ex ploded
View). Do not install the oil seal and do nor stake Ihr.:
bo lt until the correct bearing preload is oblained.
e Ta start With, choose a shim or collar so that the
bearings are just SNUG with NO play but also with NO
preJoad.
OAny over-preload on the bearings could damage the
bearings.
Preload for Driven Gear Bearing
USing Spring Scal.:
3 - 5 N (0.30 - 0.50 kg,0.7 -l.llb)
Using Torque Wrench:
0.6 - 1.0 Ni11 (0.06 - 0.10 kg·m, 5 - 9 in~b)
NOTE
CPrelo8d can be measured eirher with a spring scale or a
beam-rype torque wrench. When measured with a
spring scafe, the preload is designated by force (N, kg,
Ib), and when measured with a torque wrench , it is
designated by torque (N-m, kg-m, in-fbi.
-Apply a little engine oil to the bearings , and turn the
gear shaft more than 5 turns lo allow thl.! bearings to
sea t.
-Measure the bearing preload.
Bearing: preload is
defined as th e force or torque which is needed to start
the gear shaft turn ing.
OUsing Spring Scale:
Hook the spring scale on the handle ae a point 200
mm apart from the center of the gear shaft.
Hold the bearing housing in a vise so that the gear
shaft axis is vertical. Apply force to the handle
horizontally and at a right angle to it.
FINAL DRIVE 10-15
*If the pteload is out of the specified range, replace the
bearing collar andior spacer. To increase preload,
decrease the stack length of th e collar and spacer. To
decrease preload increase the slack length of the collar
and spacer .
..:rchange the stack length a little at a lime .
eRe-check the bearing preload, and re -adiust as neces-
sar y _
A. Spri ng Scale
B. Hole
C. Driven Gear Holder : 57001·1027
D. 200 mm
Bearing Prel08ding Mechanism
(A) Before Tightening
(8) Mter Tightening
Under
No Preload
Under
Pre load
Initial
Clearance
~--No
Under
No Preload
Under
Preload
1, Bearing Housing
2. Tapered Roller BeJri ng
3. Spacer
4. Col/ar
5. Tapered Roller Bearing
Collars for Preload Adjustment
Lengt~
(mm)
22.8
22.9
23.0
23.1
232
23.3
23.4
23.5
23 .6
23.7
23.8
23.9
24 .0
24.1
Clearance
Part Number
92027·1152
92027 ·1153
92027 ·1154
92027·1155
92027 ·1156
92027·1157
92027·1158
92027·1159
92027 ·1160
92027·1161
92027 ·1 162
92027·1163
92027 ·1164
92027 ·1165
Spacers for Preload Adjustment
Thickness (mm)
1 .70
1.72
1.74
1.76
1.78
1.80
Port Number
92025-1072
92025·1073
92025·1074
92025·1075
92025·1076
92025·1071
10-16 FINAL DRIVE
Backlash adjustment
-Clean any dirt and oil off bevel gear teeth .
-Install the drive gear with the primary shim (1.0 mm
thickness), and tighten the nut to the specified torqu e
(see Exploded View).
NOTE
8Do nor stake the head of the nut until both backlash
and tooch contact adjustments are finished.
-Install the driven gear
with the primary shim
the mo unting bolts
Exploded View).
c Check the backlash
assembly to the front gear case
(1.0 mm thickness), and tighten
to the spccifi~d torq ue (st:t::
d u ring the tightening o f the
mounting bolts, and stop tightening them immediately
if the backlash disappears. Then, change the 'him to a
thicker o ne ,
-In stall the dial gauge holder (s pecial tool) with 6 mm
bolts .and nuts o n the fro nt gear case to mount a dial
gauge .
- Set up a dial gauge against a drive gear tooth to check
gear backlash. The gauge stem must be in line with the
direction of tooth travel.
e T 0 measure the backlash, move the drive gear back and
forth while holding the driven gear steady with a
suitable tool. The difference between the highest and
lowest ga uge 'readings is the amount of back lash.
*If th e backlash is not within the limit, replace the gear
shim(s) at the dri\/c and/or driven gear. To increase
backlash, increase the thickness of the shim(s) . To
decreas e backlash f decrease the thickness of the
shim(s) .
' .change the thickness a little at a time.
e Re ·check ttie backlash, and re ·adjust as necessary .
NOTE
Olt is OK to use the pack of two shims. Do not use the
pack of three or more shims.
Front Bevel Gear Backlash (at the gear tooth)
0.13 - 0.18 mm
Shims for Drive Gear
Thickness (mm)
0.15
0.5
0 .6
0.7
0.8
0.9
1.0
1.1
1.2
Part Numbor
92025·1688
92025-1689
92025·1690
92025-1691
92025-1692
92025-1693
92025-1694
92025-1695
92025·1696
Shims for Driven Gear
Part Number
92025·1724
92025-1725
92025·1726
92025 ·1727
92025-1728
92025·1729
92025-1730
92025·1731
92025·1732
Thickness (mm)
0.1
0 .15
0 .5
0.6
0 .7
0 .8
0.9
1.0
12
Tooth contact adjustment
e(lean any d in and oil off the bevel gear teeth.
- Apply checking ccmpound to 4 or 5 teeth on the
driven gear.
NOTE
OApply checking compound to the teeth in a thin , even
coat with a fairly sriff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
;";The checking compound must be smooth and firm ,
with tIle consistency of tooth paste.
OSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear t ooth patterns and contact. Use this for checking
the bevel gears.
eT urn the driven gear for 3 or 4 revolutions in the drive
and rc\'erse (coas t) direct ions , while creating a drag on
the drive gear.
echcck 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 boltom of the tooth, and little closer to th e
toe of the tooth.
*,f the tooth contact pattern is incorrect, replace the
shim(s) at the drive gear and shim(s) at the driven gear,
following the exam ples shown . Then erase the tooth
contact palterns f and check them again. Als o check
the backlash ever y t ime the shims are replaced. Repeal
the shim change procedure as necessary.
NOTE
CIf t /'e backlash goes out of standard range after
A. Holder : 57001· 1049
B. Ho ld t he driven gear.
C. Move the drive gear.
changing shims, co" ect the backlash before checking
the tooth contact pattern.
Olt is OK to use the PliCk of two shims. Do not use the
pack of three or morfJ shims.
FINAL DRIVE 10.17
Correct Tooth Contact Pattern
Heel
rl'---+-"<--'T
,~~
t
>,6--+_-fu~e ,
Bottom
1. Drive Gear
2. Driven Gear
Incorrect Tooth Contact Patterns
Example 1: Increa se the thickness of [he dri ve gear
shim(s) by 0.05 mm , and/or increase the th ick ness of the
driven gear shim(s) by 0.05 mm to correct the pattern
stlO wn below. Repeat in 0.05 rnm steps jf nc(essary.
Exampl e 2: Decrease the thickness of the drive gear
shim(s ) by 0 .05 mm, and/or decre ase the th ic kness of
the driven gear shim (s) by 0 .05 mm to correct the
pattern sh own be lo w. Repeat in 0.05 mm steps if
nc(essa ry.
Heel
.
I ioe
Heel
\
.~TOP
T
_~TOP
Toe
Bottom
Bottom
Heel
\
Top \
n4-_-+-_..;T",,~~
"
1''' - - - I
'-'-'
\
Heel
Top
(! I-----1
-----'''' Bottom
\
TOH~.)
d-:9--->-----<n #
r
Bottom
2
/',"
~2
1. Drive Gear
2, Driven Gear
10-18 FINAL DRIVE
Bevel Gear Inspection
Oil Seal Inspection
-Visually check the bevel gears for scoring, chipping, or
elnspect the oil seals.
*Rcplacc it if the lips arc misshapen , discolored (i n dicating that the rubber has deteriorated), hardened, or
been otht:rwisc damaged.
other damage.
*Replace the bevel gears as a set if either gear is
damaged .
Cam Damper Inspection
.Visually inspect the damper cam, ca m follower spring,
J
and shaft.
.Replace the part if it appears damaged.
Rear Wheel Coupling
Rear Wheel Coupling Installation Note
0)
eAppl y grease to the G-r ing on the rear hub and install
the rear whee 1 coupl ing.
!
A. Cam
C. Spring
B. Cam Follower
D. Shaft
Ball Bearing Inspection
-5i nee the ball bearing is mad!! to extremely close
{Q l crance~J the wear must be judged by fee! ratht:r
than measurement. Clean the bearing in a high fla shpoint solvent, dry it (do not spin the bearing while it b
dry). and oi l it with engine oil.
eSpin the bearing by hand to check its condition .
*If the bearing is noisy, does not spin smoothly. or has
any rough spots, replac~ it.
A. Grease.
B. G-ring
Damper Inspection
eVisually inspect the rubber damper of the rear wheel
coupling.
*If it appear ... damaged or deteriorated, replace it.
Tapered Roller Bearing Inspection
eVi sually inspect the bearing for abrasion, color change,
or other damage.
*If there is any doubt as to the condition of a bearing,
replace it.
Needle Bearing Inspection
eThe rol1er~ in a needle bearing normally wear very
little, and wear 4S difficult to measure. In:itead of
mea'suring, inspect the bearing for abrasion, color
chang,e~ or other damage.
*If there is any doubt .as to the condition of a needle
bearing, replace it.
C. Rear Wh ee l Coupling
A. Rubber Damper
BRAKES 11-1
Brakes
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . • . . . . • . .
Specifications ..... _ .....• ... . _ ...............•......... _ . .
11-2
11-4
Special Tool ...... . ...........•..........•.........•... . _ .
11-4
Brake Fluid .................. .... ........•............. . .
11-5
Brake Fluid Requirement. . . . . . . . . . . . • . . . . . . . . . . . . . • . . . . .
11 -5
Brake Fluid Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . • . . . .
11-5
Brake Fluid Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 -6
Brake Line Air Bleeding. . .. . . . ... . . . .. . . .. . . . . . . . . . .. . ..
11-6
Master Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .
11-7
Front Master Cylinder Removal. . . . . . . . . . . . . . . .. ... . . .• . . .
11-7
Front Master Cylinder Installation Notes. . . . . . • . . .. . .. . . . . . .
11-7
Rear Master Cylinder Removal. . . . . . . .. . . . . . . . . . .. .. ... . • .
11-7
Rear Master Cylinder Installation Notes. . . . . . . . . . . . . . . . . . . . .
11·B
Front Master Cylinder Disassembly .......•.........•......
11-8
Front Master Cylinder Assembly Notes. . . . . . . . . .. .. . . . . . . . ..
11-9
Rear Master Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . .
11-9
Rear Master Cylinder Assembly Notes. . . .. . . . . . • . . . . .. . . . . .
11-9
Master Cylinder Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-9
Calipers ............ ... ...... . ...... . .......... _ •.. . •....
11-10
Caliper Removal ..............•.... _ . . . . . . . . . . • . . . . . . ..
11-10
Caliper Installation Notes . . . . . . . • . . . . . . . . . . . . . . . • . . . . • . ..
11-11
Caliper Disassembly Notes. . . . . . • • . . . . . . . . . • . . . . . . . . . . . ..
11-11
Caliper Assembly Notes . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . ..
Fluid Seal Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11-11
11-11
Dust Seal and Cover Damage ......................•...•..
11-12
Piston and Cylinder Damage. . . . . . • . . . . . . . . . . • . . . . . . . . . . ..
11-12
Caliper Holder Shaft Wear ............ . .... . ....... ... ...
11-12
Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . • . . . . . . . . . . ..
11 -12
Pad Removal .... ... ........ .. ............ ..... .......
11·12
Pad Installation Notes ......•.... .• ... . .................
11-12
LiningWear ........ .... . .. •..... . ... . •...•...........
11-13
Discs. . . . . . . . .. . . . . . . . . . . .. . . ... . . .. . .. . . .. . . .•. . . . .. . . ..
11·13
Disc Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . ..
11·13
Disc Installation Notes .... . . .. . . . . ...... . .. .... • . .......
11-13
Disc Wear ...................... . ..•.... .... . .. .......
11-13
Disc Warp. . . . . . .•. . . . . . . . . . . ... . . .. . . . . . . . . ..... . . ...
11-13
Brake Hoses ........ . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . ..
11 -14
Brake Hose Inspection ....... ..... ..................... .
11·14
Brake Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . ..
11 -14
11-2 BRAKES
Exploded View
o
1. Front Brake Light Switch
2. R.ar Brake Light Switch
G : Grea!e
T1 : 5.9 N-m (0.60 kg-m, 52 in-Ibl
T2: 7.8 N-m 10.80 kg-m, 69 in-Ib)
T3: 11 N-m 11.1 kg-m,95 in-Ib)
T4: 23 N-m 12.3 kg-m, 16.5 fHb)
T5: 25 N·m 12.5 kg-m, 18.0 ft-Ib)
T6: 32 N-m (3.3 kg-m, 24 ft-Ib)
T7: 98 N-m 110.0 kg-m, 72 ft -Ib)
BRAKES 11-3
@-""
11-4 BRAKES
Specifications
Item
Brake Fluid :
Standard
Grade
D.O.T.4
Brand (recommended)
Castro I Girling·Universal
Service Limit
Castrol GT (LMA)
Castrol Disc Brake Fluid
Check Shock Premium Heavy Duty
Pads:
Pad Lining Thickness:
5mm
1 mm
Discs:
Disc Thickness :
Front
4.8 - 5.1 mm
4.5mm
Rear
6.8 - 7.1 mm
6.0mm
Under 0.15 mm
0.3mm
Disc Runout
Special Tool
;-\Jong with commo n hand tools, th e fo ll owing more
specialized tool IS required for co mplete brake servicing.
Circlip Pliers: 57001 ·143
/
BRAKES 11·5
I WARNING I
Brake Fluid
Brake Fluid Requirement
Recommended fluids are given in the tabl e below. If
hone of the recommended brake fluids are available, use
CChange the fluid in the brake line completely if the
fluid must be refilled by the type and brand of the
fluid that already is in the reservoir are unidentified.
extra heavy-duty brake fluid only from a container
marked D.O.T.4.
Front Brake Fluid Reservoir
Recommended Disc Brake Fluid
Type:
Brand:
D.O.T.4.
Check Shock Premium Heavy Duty
Castrol Girting-Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid
I WARNING
I
c Never reuse old brake fluid.
COo not use fluid from a container that has been left
unsealed or that has been open for a long time.
COo 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.
GOon't leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
c Don' t add or change the fluid in the rain or when a
strong wind is blowing.
Olf any of the brake line fittings or the bleed valve
i. opened at any time, the AIR MUST BE BLED
FROM THE BRAKE.
A. Lower Level Line
B. Upper Level Line
Rear Brake Fluid Reservoir
::'Brake fluid quickly ruins painted surfaces; any spilled
fluid should be completely wiped up immediately.
A. Lower Level Line
B. Upper Level Line
e Apply a brake forGefully for a few seconds , and check
for fluid leakage around the fit t ings.
Brake Fluid Level Inspection
.Position the resen'oir hori zo ntal , and check that the
fluid leve l in the reservoi r is ht!;her than the lower level.
*I f the fluid leve l is lower th an the lower level, ch..:ck for
the fluid leakage of the brake fi ne , and add the nuid as
follows.
GRemove the reservo ir cap, and fill the reservoir to the
upper level line in the reservoir with the same type and
brand of the fluid that already is in the reservoir. And
then instal! the reservoir cap.
I WARNING I
Clf the brake lever or pedal has a soft or "sponge
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.
11-6 BRAKES
Brake Fluid Changing
Brake Line Air Bleeding
eRemove the reservoir cap. and remove 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
eRemove the reservoir cap, and check that there is
plent y of fluid in the reservoir .
container.
e{)pen the bleed valve (counterclockwise to open), and
pump the brake lever or pedal until all the fluid is
drained from the line.
0(1050 the bleed valve.
eFront brake: Since a dual disc brake is used, repeat the
o The fluid level must be checked several times during
the bleeding operation and replenished as necessary. If
above 4 steps one more time for the other side.
-Fill the reservoir with fresh brake fluid .
eopen the bleed valve, appl y the brake by the brake
lever or pedal, close the valve with the brake held
applied, and then quickly release the lever or peda/.
Repeat this operation until the brake line is filled
and fluid starts coming out of the plastic hose.
NOTE
NOTE
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.
-Connect a clear plastic hose to the bleed v.lve{s) at the
caliper(s), running the other end of the hose into a
container.
.With the reservoir cap off, slowl y pump the brake lever
or pedal several times until no air bubbles can be seen
rising up through the fluid from the holes at the
bottom of the reservoir. This bleeds the air from the
master cylinder end of the line.
OReplenish the fluid in the reservoir as often
sary to keep it from running completely out.
8S
neces-
eFront brake: Repeat the above 2 steps one more time
for th e other ·side .
eBleed the a ir from the lines.
Filling up the Brake Line
eFront brake line:
c Pump the brake lever a few times until it becomes hard
and then. holding the lever squeezed, quickly open
(turn counterclockwise) and close the bleed valve.
Then release the lever. Repeat this operation until no
more air can be seen corning out into the plastic hose.
ORe peat the previous step one more t ime for the other
side.
Bleeding the Brake Line
eJ l
1.
2.
3.
4.
Open the bleed valve.
Apply the brake and hold it .
Close t he bleed valve
Then quickly release the brake.
1. Hold the brake applied.
2. Quickly o pen and clo se the "Ive.
3. Re lease the brake.
BRAKES 11-7
eRear brake line :
oPump the b'rake pedal a few times until it becomes hard
and then, holding the pedal pushed down, quickly open
(turn counterclockwise) and close the bleed valve.
Then release the pedal. Repeat this operation until no
more air can be seen coming out into the plastic hose.
eWhen air bleeding is finished, check that the fluid is
filled to the upper level line marked in the reservoir
Rear Master Cylinder Removal
-Remove the reservoir mounting bolt.
-Remove the banjo bolt to disconnect the brake hose
from the master cylinder, and temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum. There is a flat washer on each side
of the hose fitting.
fluid that spills.
Immediately wipe up any brake
(see Brake Fluid Level Inspection).
elnstall the reservoir cap.
eTighten the bleed valve(s) to the specified torque (see
Exploded View).
eApply the brake forcefully for a few seconds, and
check for fluid leakage around the fittings.
............................................................................
Master Cylinders
A. Reservoir
B. Banjo Bol t
C. Master Cylinder Bracket Bolts
Front Master Cylinder Removal
eDisconnect the front brake light switch wires from the
switch .
eRemove the front master cylinder clamp bolts and
eRemove the brake pedal bolt and take off the brake
pedal.
clamp , and take the master cylinder off the handlebar.
bolts.
e Free the brake light switch spring and brake pedal shaft
_Remove the rear master cylinder bracket mounting
lever return spring.
Front Master Cylinder Installation Notes
eThe master cylinder clamp must be installed with the
arrow mark upward.
eTighten the upper clamp bolt first and then the lower
clamp bolt to the specified torque (sec Exploded
View) . There will be a gap at the 10IVer part of the
clamp after tightening.
A. Master Cylinder
B. Brake Light Switch Spring
D. Clevis Pin
E. Lever Return Spring
C. Colter Pin
eRemove the cotter pin from the clevis pin and pull out
the clevis pin.
eRemove the maHer cylinder mounting bolts and take
A. Tighten upper clamp bolts first.
B. Arrow Mark
off the cylinder.
11-8 BRAKES
Rear Master Cylinder Installation Notes
elf the brake pedal shaft is' removed from the bracket,
wipe the old grease off the shaft and apply a grease to
the shaft.
elf the push rod clevis nut or locknut was loosened,
adjust the clevis position to obtain the correct pedal
position.
eTa adjust the clevis po sition so that th e push rod
protrusion is 4 - 5 mm below the cl evis nut, the pedal
position will be the correctly.
-Ti ghten the rear ma ster cylinder mounting bolts to the
, pecified torque (see Exploded View),
e Use a new nat washer on each >idc of the brake hose
fitting, and tighten th e banjo bolts to he specified
torque (>ee Exploded View), Be ,ure that the metal
pipe i, properl y fitted into the U-shaped notch in the
ma>ter cylinder.
-Install the brake pedal to the pedal 'haft aligning the
marks on the pedal and shaft.
Push Rod Protrusion
...\. Align marks.
A, 4 - 5 mm
_Check and adjust th e rear brake light switch (see
Electrical System chaprcr).
eSleed the brake line after ma>t er cylinder in>tallation .
e<:heck the brake for weak braking power, brake drag,
and fluid leakage,
Pedal Position
Front Master Cylinder Disassembly
A. Level with top of footpeg,
ePull back the dust cover, and remove the banjo bolt to
disconnect the upper brake hose from the master
cylinder. There is a flat washer on eac h side of the
hose fitting. Immediatel y wipe up any b rake fluid that
spill"
eRemo ve the reservoir cap and diaphragm. and empty
o ut the brake fluid,
eRemove the locknut and pi'v'ot bolt, and remove the
brake lever .
eSlide the dust cover out of plac e.
eRemove the retaine r with circlip plier> and pull out the
piston with the secondary cup, and take off the
primary cup and spring.
NOTE
OJ{
the correct pedal position cannot be obtained by
adjusting the push rod clevis~ the pedal may be
deformed or incorrectly installed.
CAfter adjusting the cfevis, tighten the locknut to the
specified torque (see Exploded View) .
COo not remove the secondary cup from the piston since
removal will damage it.
BRAKES 11-9
Front Masler Cylinder
I . Primary Cup
2. Secondary Cup
3. PiSion
Rear Master Cylinder
1. Primary Cup
2. Secondary Cup
3. Piston
4. Brake Hose
5. Retai ner
6 . Push Rod
-Remove the retainer with ci rciip pliers and pull out [he
brJke hose conn eCtor and O-rin g from th e master
cyli nder .
Front Master Cylinder Assembly Notes
-Before Jssembly, clean all parts in clud ing the master
cy linder with brake fluid or alcohol, and app ly brake
fl uid to the pa rts removed and to th e inner wall of the
cylinder.
CUse only brake fluid, isopropyl alcohol, or elhyl
alcohol, for cleaning brake parts, Do nOI use any other
fluid for cleaning these parts. Gasoline, motor oil, or
any other petroleum distillate will cause deterioration
of the rubber paru . Oil spilled on any part will bit
d ifficult to wash off completely, and will eventually
deteriorate the rubber used in the disc brake .
-Tigh ten the brake lever pivo t bo lt and tighte n the
locknut to the specified torqut': (sec Ex plo d ed Vie w).
- Use a new flat washer on each side of the brake hose
fiuing, a nd tighten the banjo bolt to the specified
torque (see Exploded View).
-Bleed the brake line after master cylinder ins Lll1 ation.
-Ch~ ck th e brake for weak braking po wer, brake drag,
and fluid leakage.
Rear Master Cylinder Disassembly
-RemOVe! the retainer with drcli p pli ~rs , and pull out the
pis to n stop and push ro d, as a set. Then remove the
pisto n and secondary cup , and the spring and prima ry
(U p .
0 00 not remove the secondary cup from the piston since
removal will damage it.
Rear Master Cylinder Assembly Notes
eBe fore assembly) clean all parts includ in g [he master
cylinder with brake fluid or alcohol, and to appl y brake
fl uid to the parts re moved and to the inn er wall of the
cylinder .
OUse only brake fluid, isopropyl alcohol, or ethyl
alcohol, for cleaning brake parts . Do not use any other
fluid for cleaning these parts . Gasoline, motor oil, or
any other petroleum distillate will cause deterioration
of the rubber parts . Oil spilled on any part will be
difficult to wash off completely. and will eventually
deteriorate the rubber used in the disc brake.
Master Cylinder Inspection
( Visual Inspection)
eCh eck that th ere a.re no scratches, rust or pitting on
the in si de of the ma ster CY linder and o n the ou tside
o f th e pi ston .
*I f the master cyli nder or piston shows an y damage,
replace them .
- Inspect the primary cups and seco ndary tvps.
* If a cup is worn, damaged, softe ned (ro tted). or swollen,
rep lace i t.
*If fluid leakage is noted at the bra ke lever, (he pistOn
assembly should be replaced to renew the cup.
eCheck [he dust covers for damage.
"If they are damaged , replace them.
e(heck that the relief and supply ports are Oa t plugged.
*I f the small relief port becomes plugged , the brake pad,
will drag o n the dis c. Blow the ports clean wIth
co mpressed air ,
-Chec k the piston return springs for any damage.
*If the spring is damaged, rcplace it.
11-10 BRAKES
Front and Rear Master Cylinders
(i)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10 .
11.
12.
13 .
14.
(0
Reservoir
Diaphragm
Relief Port
Supply port
Cylinder
Return Spring
Primary Cap
Piston
Secondary Cu p
Dust Cover
Brake lever
Push Rod
Clamp
Hose
Calipers
Caliper Removal
eRemove th e caliper mounting bolts an d take the caliper
off th e disc.
A. Caliper Mounting Bolts
A.
Caliper Mounting Bolts
BRAKES 11·11
Caliper Installation Notes
Caliper Assembly Notes
eTighten the caliper mounting bolts to the specified
torque (see Exploded Vi ew ),
-Check the brake for wea.k brakin g power, brake drag,
.Before assembly, clean all pans including the caliper
with brake fluid or alcohol / and apply brake fluid to
the parts removed and to the inn er wall of the caliper
and fluid leakage.
cylinder.
WARNING.
COo not attempt to drive the motorcycle until iii full
brake lever or pedal is obtained by pumping the brake
lever or pedal until the pads are against the disc. The
brake will not function on the first application of the
lever or pedal if this is not done.
OExcept for the disc pads and disc; ule only disc brake
fluid, isopropyl alcohol, or ethyl alcohol, for cleaning
brake parts. Do not use any other fluid for cleaning
these parts.
Gasoline, motor oil, or any other
petroleum distillate will cause deterioration of the
rubber parts. Oil spilled on any part will be difficult to
wash off completely. and will eventually deteriorate
the rubber used in the disc brake .
• Apply a thin coal of PBC (Pol y Butyl Cuprysi l) grease
to the caliper holder shafts and holder ho les . (PBC is a
Caliper Disassembly Notes
elf the caliper is to be disassembled after removal and if
compressed air is not available, remove lhe pisron using
the following two st eps before disconnecting the brake
hose from th e ca liper.
o Rcmove the pads.
oPum p the brakl: lever or ped al to remo ve the ca liper
piston.
o lmmediately wipe up any brake fiuid that spills .
• Remove the brake hose banjo boll and disconnect the
hose from the caliper. There is a flat washer on each
side of the hose fitting, Immediatel y wipe up any
special high tem perature, water-resistant grease:).
.'nstall rhe an ti -rattle spring in the calipers as shown.
brake fluid that spills .
• Using compressed air, remove the piston.
c Cover the caliper opening with a dean, heavy cloth.
~) Remove the piston by lightly applying compressed air
to where the brake line fits into the caliper.
I WARNING I
GTo avoid serious injury. never place your fingers or
palm inside the caliper opening. If you apply compreued air into the caliper, the piston may crush your
hand or fingers.
A. Anti-rattle Spring
econncct the brake hose to the caliper putting a new
flat washer on each side of the brake hose fitting.
Tighten the brake hose banjo bolt to the specified
torque (sec Exploded View) .
• Blced the brake line after caliper installation.
Piston Removal
Fluid Seal Damage
The fluid seal around the piston maintains the proper
pad /disc clearance. If this seal is not satisfactory, pad
wear will increase, and cons tant pad drag on the disc will
raise brake and brake fluid temperature .
• Replace the fluid seals un.der any of the foHowing
conditions: (al fluid leakage around the pad; (b) brakes
1. Apply compressed air.
2. Cloth
overheat; (c) there is a
pad wear; (d) the setll
fluid seal is replaced,
Also, replace all seals
changed,
large difference in left and right
is stuck to the piston. If the
replace the dust seal as well.
every other time the pads are
11·12 BRAKES
Caliper
-Check to see that the cali per holder shafts are not
badly worn or stepped. or the rubber friction boots are
not damaged.
*If th e rubber fric tio n boots are damaged, replac e {he
rubbe r friction boots, and the cali per ho lder.
Pads
Pad Removal
.Remove the caliper. The brake hose di scon ne ction is
not required.
eTake the piston-5 idc pad oul of the caliper holder .
ePu sh the caliper holde r forward the piston, and then
remove the pad from the caliper ho lder shafts.
1.
2.
3.
4.
Caliper
Brake Pad
Brake Pad
Cali per Holder
5. Dust Cover
6. Piston
7. Anti·Rattle Spring
8 . DUH Seal
9. Fluid Seal
10. Friction Boot
Dust Seal and Cover Damage
B. Caliper Holder
A. Pad
e<:he ck that the du st sea ls and covers are not cracked,
worn, swollen, or o th erwise damaged.
*If they ~how any damage, replace them.
Pad Installation Notes
-Before insLallation, clean the pads with a high flash
Piston and Cylinder Damage
point
-Vi suall y inspect the piston and cy linder su rfaces.
"'Re place the cylin der and piston if they are badl y
scored or rust.,., .
Caliper Holder Shaft Wear
The caliper body mu st sl ide smoot hly on the caliper
holder shafts. If the body does not slide smoothly, one
pad will wear more than the other, pad wear will
solv~nt.
I WARNING.
OWhen 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 !JeU 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.
in~
crease, and con stant drag on the disCawili raise brake and
brake fluid temperature.
.Push the cali pN piston in by hand as fa r as it will go,
and then instdll the pads.
BRAKES 11-13
Lining Wear
-Ch eck the lining thic knc i) o f the pads in eac h caliper.
*If th~ linin g thickn ess of ei ther pad i:i less tha n the
service limit, re pla ce both pad s in the calipe r as a se t.
Brake Pad
A. Min imum Thi ckness 1'¥1arkin g
eTi ghten the d isc mo unt in g All e n bo lt s to th e
s pec;fj~d
lorque (see Exploded View).
1. Li ning Th ickness
1 . Service Lim it
Disc Wear
eM easure th~ thick ness o f each di sc at the po int where
it has worn the most.
*Replace the disc if it has wo rn past the se rvice limit.
Pad Lining Thickness
Standard
Service Limit
5 mm
1 mm
Disc Wear Measurement
Discs
Brake Disc
Disc Removal
Measuring Area
-Remo ve th e fro nl or rear wheel .
eRe mo vt: th e di sc mo un ting Allen bolts and tak e o ff the
disc.
[CAUTlO~]
:::00 not lay the wheel down on one of the discs. This
can damage or warp the di5C. Place blocks under the
wheel so that the discs do not touch the ground.
Disc Installation Notes
-Th e minimum thickn ess. of th e disc is mark l;: d on the
di sc. Instilll th e di sc w ith the marked side fa cing o ut.
Front Disc Thickness
Standard
Service Limit
Rear Disc Thickness
Standard
Service Limit
4.8 - 5.1 mm
4.5 mm
6.8 - 7 .1 mm
6.0mm
Disc Warp
-Se t up d dial gauge again st the disc at the point as
sh o wn in th e figure, and mea sure d is c run o ut.
.,f runout t: xccl'-d s the serv ic e limit , re place th e disc.
11-14 BRAKES
Disc Warp Measurement
1. Bra ke Disc
2. Mcasuring A rea
Disc Runout
Standard
Service Limit
Under 0.15 mm
O.Jmm
Brake Hoses
............................................................................
Brake Hose Inspection
The high pressure inside the brake line can cause fluid
to leak or the hose to burst jf the line is not properl y
maintained.
-Bend and twisl the rubber hose while examining il.
*Rcp lace it if any cracks or bu lges are noticed.
Brake Hose Replacement
. Pump the brake fluid ou t of the line as explained in the
Brake Fluid Changing.
eRemove the banjo bolts at both ends of the brake hose,
and pull the hose off the motorcycle. Especially, for
the brake hose between the rear master qljinder and
the reservoir, loosen the clamps at both ends of the
hose, and take off the hose.
-I nstall the new brake hose in its place putting a new
flat wash~r on each side of Ihe brake hose fitting.
eTighten the brake hose banjo bolts to thl! specified
torque (sec Exp loded View).
SUSPENSION 12-1
Suspension
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . • . . . . . . . . . .
12-2
Specifications. . . . . . • . . . . . . . • . . . . . . . . . • . . . . . . . . . • . . . . • • . . . .
12-3
Special Tools .......•..................•.. •• ... ... ...•....
12-4
Front Fork _ . .. ..... . .. ... . . . . ... • . .... ..... _. . . .. .. . . . . . .
12-5
A ir Pressure Adjustment .. . . .....• . ..•. _. _. . . . . . . . . . . . . . .
12-5
Fork Oil Change . . . . . . . . . • . . . . . • . . . . • . . . . . . . . . • . . . . . . . .
12-5
Front Fork Removal . . . .... .. ... . .. ................... .
12·6
Front Fork Installation Notes ...........•................
12·6
Fork Leg Disassembly ..................................
12·6
Fork Leg Assembly Notes ... . . . ....•........ . .... .. . . ...
12· 7
I nner Tube Inspection ... .... . . . . . . • .... •.. ..... . .••. ...
12-8
Guide Bush Inspection. . . . . . . . . . . . . . . . . . .. . . . . . . .. .•. . . .
12·8
Oil Seal and Dust Seal Inspection . . . . . . . .. . . . . . . . . . . .. . . . . .
12·8
Rear Shock Absorbers . . ...... . . . ... ..... .. ...... .. . . . ......
12·8
Air Pressure Adjustment . . . . . . . . . . . . . • . . . . . . . . . • . . . . . • . . .
12·8
Damping Force Adjustment. . . . . . . . . . . . . . . • . . . . . . . . . . . • . .
12·9
Rear Shock Absorber Removal. . . . . . . . . . . . . . • . . . . . . . . . . . . .
12-9
Rear Shock Absorber Installation Notes ...... . • • ...• •.. .. . "
12·10
Rear Shock Absorber Oil Filling ....... , . . . .. . . . . . . . . . . . . ..
12·10
Rear Shock Absorber Inspection ..................•.......
12-11
Rear Shock Absorber Scrapping. . . . . . . . . . . . . . . . . . . . • . . . . ..
12-11
Swing Arm ........................•..........•...........
12-11
Swing Arm Removal. . . . . . . . . . . . . . • . . . . • . . . . • . . . . . . . . . ..
12· 11
Swing Arm Installation Notes .. . . . . . .. .. .•... .. . ....• .... .
12·12
Swing Arm Bearing Removal. . . . . .. • . . . . . • . . . ... . . .. . . . ..
12-12
Swing Arm Bearing Installation .... . .......... . .. . ... . .. ..
12- 13
Swing Anm Bearing Inspection . . . . . . . . .. .. . . . . .... . .. . . . . .
12· 13
Swing Arm Bearing Lubrication ................. '"
12·13
. ... . ..
12-2 SUSPENSION
...................................................................................
Exploded View
...................................................................................
o
,
10
o
8
e
C:'l
(9
©l
~ .
8
10
I
8
i1
~
='
~l
""
~
~
~,
,
\1
~
B ----------<TsJ
g-
©
6l
L : Non -permanent Locking Agent
M : Molybdenum Disulfide Grease
T1 : 11 N'm (1.1 kg·m, 95 in~bl
T2 : 12 N ·m (12kg·m, 104in·lb)
T3 : 14 N·m (1 .4 kg·m , 10.0 ft~bl
T4 : 18 N ·m (1.8 kg·m. 13.0 ft·lbl
T5: 20 N-m (2.0 kg..", 14.5 ft -Ibl
T6: 30 N 'm (3.1 kg·m , 22 ft·lbl
T7 : 53 N-m (5.4 kg·m, 39 h·lb)
SUSPENSION 12·3
~
r~
."
I
I
I
@&,
~
Cif
\., ~I
@
Specifications
Item
Standard
Front Fork:
Air Pressure
50 kPa (0,5 kg/em' , 7,1 psi)
Usable Range: 40 - 60 kPa (OA - 0,6 kg/em', 5,7 - 8,5 psi)
Fork Oil:
Viscosity
SAE10W20
Amount/Side
391 ±2,5 mL
Oil Level
160 ±2 mm (Fully compressed)
Rear Shock Absorbers:
Air pressure
150 kPa (1,5 kg/em' , 21 psi)
Usable Range: 150 - 250 kPa (1,5 - 2,5 kg/em', 21 - 36 psi)
Damping Force
No, 2 of 4 positions
Shock Absorber Oil:
Viscosity
SAE5W
Oil Capacity/Side
230 mL
Air Chamber Capacity/ Side
160 mL
124 SUSPENSION
Fork Outer Tube Weight: 57001-1218
Special Tools
Along wi th common hand to ols, the followin g
rr.ore specialized tools are requ ired for complete
suspension servici ng.
Front Fork Cylinder Holder Handle : 57001-183
Fork Oil Seal Driver: 57001 -1219
Adapter: 57001-1057
Socket Wrench Holder: 57001 -1225
Oil Seal and Bearing Remover: 57001-1058
Be.ring Oriver Set: 57001 -1129
-""'-C.',
,,''"
,,
','.
,,
SUSPENSION 12-5
Fork Oil Change
Front Fork
Air pressure Adjustment
• Put the motorcycle on its center stand, and raise the
eRemove the front fork legs.
eRemove the cap, retaining ring, and top plug from the
fork leg.
ePushing the top plug down, remove the retaining ring .
front wheel off the ground using a jack or other
suitable stand under the engine.
-Check and adjust the air pressure when the front fork is
cold (room temperature).
NOTE
000 not use tire gauges for checking the air suspension is
air pressure.
They may not indicate the correct
pressure because at air leaks chat occur when the gauge
is applied to the valve.
o Lower air pressure is (or comfortable riding, but it
should be increased for high spetJd riding, or riding on
bad roads.
A. Top Plug
Olnject air little by little so that air pressure does not rise
rapidly. Air pressure aXC89ding 250 kPa (2.50 kg/em',
36 p,i) may damage the oil ,eol.
I WARNING I
CBe sure to adjust the air pressure within the usable
range. Pressure too high or too low can produce 8
hazardous riding condition.
c Only air or nitrogen gas can be used. Never inject
oxygen or any kind of explosive gas.
0 00 not incinerate the front fork.
0 00 not remove the springs and rely on compressed air
only. Correct springs must be used in this suspension
system. Use without springs can lead to a condition
causing accident and injury.
B. Rel<!ining Ring
-Pull out the collar, oil filter, and spring.
ePour out the fork oil into a suitable container, pumping
as necessary to empty out all the oil.
ePour in the specified type and "amount of oil.
-Pump the fork enough times to expel the air from the
upper and lower chambers.
-With the fork fully compressed and held upright, insert
a tape measure or rod in the inner tube, and measure
the distance from the top of the inner tube to the oil.
*If the oil is above or below the specified level , remove
or add oit and recheck the oil level.
Fork Oi' Leve' Measurement
Oil
Level
A. Air Valve
Front Fork Air Pressure
Standard:
Usable Range:
50 kP. (0 .5 kg/em', 7 .1 psi)
40 - 60 kPa (0.4 - 0 .6 kg/em ' ,
5.7 - 8.5 psil
12·6 SUSPENSION
fCAUTION]
-Remo ve the connecting pipe retaining ring toward the
fork leg top, and slide the fork leg off the stem base.
o The operation of air front forks is especially dependent
upon correct oil level. Higher levef than specified
may cause oil leakage and seal breakage. So be sure to
maintain the specified level.
elnspect the O-ring on the top plug, and replace it with
a new one if it is damaged.
eln )ull the !:Ipring, oil filter , and collar. Thl.! spring
must be installed with the small diameter end of it
down.
elnstall the top plug with the retaining ring.
the cap.
Install
echange the oil of the other fork leg in th e same
-Stick a piece of tape over the air hole to keep the oil
from running out of the fork.
Front Fork Installation Notes (each fork leg)
_Ro ute the control cables, clutch and brake hoses, and
electrical wirings correctly.
-The conn ecting pipe is between the stem head and the
rctain ing ring on the fork leg.
elnstall the fork leg so that the top of the inner tube is
aligned with the upper surface of the stem head.
manner.
Fork Oil
Viscosity
SAE10W20
Amount per side
When changing oil:
330mL
After disassembly and
completely dry:
391 ±2.5 mL
Level
160 ±2 mm
(fully compressed)
Front Fork Removal (each fork leg)
A. Inner Tube Top
B. Upper Surface of Stem Head
eRelease the air pressure from the fork.
eRemo ve the follow ing .
Front Wheel
-Tighten the upper and lower clamp bolts to the spe-
Front Fender
cified torque (sec Exploded View).
Fairing
- Adjus t
.Remove the caliper from the fork leg to be, removed,
and fest th e C.lli per on some kind of stan d so that it
doesn't dangle.
-Loosen the upper and lower fork cla mp bolts.
-Holding the co nne ctin g: pipe. work the fork leg down
and out of the Stem head and con nectin g pipe with a
twisting motion.
th~
Fork Leg Disassembly
-Remove the cap, retai n ing ring, and top plug.
c Pushing the top plug down, remove the retaining r ing.
_Pull o ut the collar, o il filter, and spring.
®
A. Upper Clamp Bolt
B. Lower Clamp Bolts
C. Co nnecting Pipe
D. Retaining Ring
fron t fork air press ure .
A. Col lar
=8',
'~
B. Oil Filter
C. Spring
SUSPENSION 12-7
·Pour out the fork oil into a suitable container.
eRemove the axle clamp bolt and nut if it is the right
fork leg.
_Stop the cylinder from turning by using the front fork
cylinder hold er handle and adapter (s pecial too ls ).
Unscrew the Allen bolt and take the bolt and gasket
•
A
@~
\\
out of the bottom o f th e outer tube.
Front Fork Cylinder Removal
A. Inner Tube Guide Bush
B. Outer Tube Guid e Bush
C. Washer
D. Oil Seal
eThere is the cylinder base, valve, and spring at th e
outer tube bottom.
®
1. Front Fork Cy linder Holder Hand le: 57001-183
2 . Adapter: 57001-1057
3 . Front Fork Cylinder
I
eRemove the cylinder unit and the short spring from th e
top of the front fork tube .
eSeparate the inner tub e from the outer tube.
CRemove the dust seal and retainer from the outer tub e
top.
e Mount the weight (special tool) on the top of the outer
tub e, by fitting [he step of the weight to the top corner
of the outer tube .
CHolding the inner tube by hand in a vertical pos ition,
stroke the outer tube several times and pull it down.
A. Cylinder Base
B. Valve
C. Spring
Fork Leg Assembly Notes
-Inspect the guid e bushes (see Guide Bush Inspection),
and replace them with new ones if necessary.
------------------
echeck the top plu g O-ring fo r damage. Replace it with
new one if damaged.
eApply a non-permanent locking agent to the threads of
the Allen bolt. Tighten th e Allen bolt to the specified
torq ue (see Exploded View), using the front fork
cyli nder holder handle and ada pter (special tools) to
stop the cylinder from turning .
-Use th e fork oil sea l dri ver (special tool) to install
the guide bush and the oi l sea l in the front fork.
Olnstall the guide bush (with a used guide bush or
washer on it) by tapping th e used guide bush or washer
with the driver until it stop s. The slit of the bush must
be faced toward the left or ri ght.
A Fo rk Outer Tube Weight: 5 700 1-1218
ORemove the oil seal, wasner, and outer tube guide bush
fro m the inner tube,
el f the drain screw was removed, check the gask et for
damage. Replace th e damaged gasket with a new one,
Before installing the drain screw, apply a nonpermanent locking agent to the threads of the sc rew,
and lighten the screw securel y.
ePour in the type and amount of fork oil specified and
adjust the oil level.
elnstall the long spring with the smal l diameter end of it
down.
I
12-8 SUSPENSION
Guido Bush Installation
Rear Shock Absorbers
Air Pressure Adjustment
CD
.Put the motorcycle up on its center stand to raise the
rear wheel off the ground.
-check and adjust the air pressure when the rear shock
absorbers are cold (room temperature).
NOTE
000 not use tire gauges for checking air pressure. They
may not indicate the correct air pressure because of air
leaks that occur when the gauge ;s applied to the valve.
o Lower air pressure is for comfortable riding for an
average-built rider with no accessories. Ordinarily, the
heavier the rotal load becomes, the higher the air
pressure should be set.
1. Driver: 57001-1219
2. Used Guide Bush
3. Slit (toward the left or right)
4. New Guide Bush
5. Tap
Inner Tube Inspectian
-Visually inspect the inner tube, and repair any damage.
• Nicks or rust damage can sometimes be repaired by
using a wetstone to remove sharp edges or raised areas
which cause seal damage.
*If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
Clnject air little by little so that air pressure does not rise
rapidly. Air pre.. ure exceeding 500 kPa 15.0 kglem',
71 psi) may damage tho oil ••• 1.
I WARNING'
a Be sure to adjust the air prnsure wit.hin the usable
range. Pressure too high or too low can produce a
hazardous riding condition .
COnly air or nitrogen gas can be used. Never inject
oxygen or any kind of explosive gas.
COo not incinerate the rear shock absorber.
replace the oil seal whenever the inner tube is repaired
or replaced .
Clf the inner tube is badly bent or creased; replace it.
Ex.cessive bending, followed by subsequent straightening. can weaken the inner tube.
Guide Bush Inspection
-Visually inspect the guide bushes.
*Replace them if necessary.
Oil Seal and Oust Seal Inspection
-Inspect the oil seal and dust seal for any signs of
deterioration or damage.
*Replace them jf necessary. Replace the oil sea.l with a.
new one whenever it has been removed.
A. Air Valve
Rear Shock Absorber Air Pressure
Air Pressure
Usable Range
kPa (k g/em', psi)
Setting
Load
Road
150 (1.5, 21)
Soft
Light
Good
250 (2.5, 36)
Hard
t
J 1 J
Heavy
Bad
SUSPENSION 12-9
NOTE
OThe recommended air pressure is 150 kPa (1,5 kg/cm
21 psi) for average rider with no accessories.
2
,
Damping Force Adjustment
eTurn the adjusters to the desired number until you feel
a click. The numbers on the adjuster show the setting
eRe move the following.
Travel Trunk and Bracket
Rear Seat
Saddlebags and Brackets
eRemove the nuts and bolt holding the rear shock
absorbers.
ePull the shock units off their mounting studs and disconnect the air hose from the oil separator. Plug the
hose fitting hole on the right shock unit to keep the oil
from running out of the unit.
position of the damper.
eBe sure to turn both adjusters to the same setting
position.
A. Disconnect th is hose.
A. Damper Adjuster
elf the oil separator and air valve are to be removed,
remove the following.
Fairing
Dummy Tank Cover
Front Seat
B. Position Number
I WARNING.
o rf both adjusters are not adjusted equally, handling
may be impaired and II hazardous condition may
result.
NOTE
o The damping force can be left soft for average riding.
But it should be adjusted harder for high speed riding
or riding with a passenger. If the damping feels too
soft or too stiff, adjust it in accordance with the
follOWing table:
l
GThe recommended setting position is the No.2 position
lor one rider with no accessories.
Damper Force
Setting
Position
Damping
Force
Soft
1
2
3
4
Setting
Load
Road
Speed
Light Good
Low
1 1 1 1 i
Stronger
Hard
Heavy
Bad
~
High
Rear Shock Absorber Removal
eSupport the motorcycle on its cent er stand.
eRe lease the air pressure from the rear shock absorbers.
A. Oil Separator
B. Air Valve
NOTE
000 not compress only one 01 the shock units. If this is
done, the damper oil may flow out through the connecting hose to the other shock unit, 8trd the ail levels
will change.
CAlter removal, place the shock units so that the correct
side is up. If they are left upside down or in other
incorrect conditions, the oil in the shack unit may flaw
through the connecting hose and the oil level may
change.
12-10 SUSPENSION
Placing Methods of Rear Shock Absorb ...
GA
.
I
I
~
I
I
I
I
Down
WV
(A) GOOD: Correct side up.
Down
(C) BAD: Upside down.
Bottom
Top
Top
-,-~
-~
'.\ ,a,
\, \ IJ'
~
Block
, ,;»
(B) GOOD: Top is higher.
>?'»,.
(D) BAD: Top is lower.
Rear Shock Absorber Installation Notes
-Before installing the rear shock absorbers, connect the
air hose from the oil separator if it was disconnected.
Tighten the hose filling to the specified torque (see
Exploded View).
-Install each ~hock un it with the damper adjuster faced
oul.
(E) BAD: Oil flows.
elnstall the shock absorber mounting nuts and bolt.
Each nut has a large flat washer , and each upper nut
has lockwasher additionally.
eTighten the mounting nuts and bolt to the specified
torque (see Ex ploded View).
e ;.\ djusl the air pressure and damping forcc_
R.ar Shock Absorber Installation
®~
Rear Shock Absorber Oil Filling
eDisconnect the air hose from the shock unit.
-Fill the shock un it with the specified oil from the hose
fitting hole,
Shock Absorber Oil (per one unit)
A. Front
Oil Vi,easily:
SAE5W
230 m L
Oil Capacity:
Air Chamber Capacily: 160 mL
SUSPENSION 12-11
Rear Shock Absorber Inspection
-Since the rear shock absorbers are sealed units which
cannot be disassembled, only external checks are
necessary.
*If one unit is damaged, replace both shock absorbers as
a set. If only one unit is replaced and the two arc not
balanced, motorcycle instability at high speeds may
result.
-Check the rubber bushings.
*RcpJace any that arc worn, cracked, hardened , or
otherwise damaged.
Rear Shock Absorber Rubber Bushings
1. Hose Fitting Hole: Fill the shock unit with the
specified oil.
.Drain the oil until the removed oil volume comes to the
specified air chamber capacity,
1. Rubber Bushings
Rear Shock Absorber Scrapping
eBefore a rear shock absorber is scrapped, release any air
pressure and oil completely by removing the air hoses.
I WARNING I
2. Removed Oil
not incinerate 8 shock absorber without first
removing the air hose or it may explode.
0 00
eStop to remove the oil when the removed oil volume
becomes equal to the specified air chamber volume.
c The shock unit should have a specified amount of oil.
Swing Arm
Swing Arm Removal
3 . Removed Oil (equal to air chamber volume)
4. Specified Air Chamber Capacity
5. Specified Oil Capacity
eRemove the following.
Travel Trunk and Bracket
Saddlebags and Brackets
Rear Wheel
Final Gear Case
eRemove the mounting bolt from the 100\'er end of the
right shock absorber.
eFree the brake hose from the clamps on the swing arm.
ePry off the s\ving arm pivot caps.
eUnscrew the ;\!Ien holts to remove the shaft retainers
on bOlh sides.
12-12 SUSPENSION
eAlign the swing arm as the following sequence .
Olnstall the left shaft rct.:liner and tighten the Allen
bolts to the specified torque (see Exploded View)_
Clnstall the spacer and right shaft retainer. Temporarily
tighten the retainer mounting Allen bolts.
A. Retainer
B. Bolts
-While holding the swing arm, pull out the swing arm
shahs usinga suitable bolt or screw.
A. Spacer
C. Adjuster
8. Retainer
D. Locknut
it stops and tighten it to the
specified torque (see Exploded View).
OScrew in the adjuster until
OUsing the socket wrench holder (special tool)' tighten
the adjuster locknut to the specified torque (see
Exploded
turning.
View)
while
keeping
the adjuster from
A. A Suitable Bolt or Screw
B. Swing Arm Shaft
.Pull back the swing: arm and take
it off.
Swing Arm Instal/ation Notes
(including Swing Arm Alignment)
eGrease the swing arm shaft holes with a molybdenum
disulfide grease and install the swing Jrm shafrs.
f\. Socket Wrench Holder: 57001-1225
oTightcn the right shaft retainer mounting Allen bolts to
the spccified rorque (sce Exploded View ),
eMove the swing arm up and down to check for
abnormal friction, and push and pull it fro m side to
side to check for bearing play (see Swing Arm Bearing
A. Swing Arm Shaft Hole
B. Grease.
Inspection) .
SUSPENSION 12-13
Swing Arm Bearing Removal
.Pull (Jut th e grease seals and Tapered roller bearing
inn er races .
• Pull out the ouler races of th e tapered roller bearings
using the oil seJI and bearing remover Cspecial lOol: PIN
57001-1058)
Swing Arm Bearing Installation
- Lubr icate the 'iwing arm bearings before installation
(see Swing Arm Bearing Lubr ica ti on).
- U'ie rht: bearing driwr set (special t.oo l: PiN 57001 ·
1129) to press in the tapered roller beari ng ou ter races
and grea se seals.
Swing Arm Bearing Inspection
- Remove the rea r wheel, both r~<H shock absorbers , and
final gear case.
eMov(.:' the swing arm up and do wn to check for
abnormal friction, a nd pu sh and pull it from side to
si de 10 check for bea(ing play,
*If abnormal frict io n is felt, the bearings arl: damaged .
Rep lace both left and right bearings and g:reasc st.'a ls.
*Th ~ play developed during use ma y indicate beari ng
damage. In this case, remOVl! the swing arm and inspect
th e bearings. Repl ace both Icft and right bearings if
onc of the beMings is damaged .
Swing Arm Bearing Lubrication
-Remove the o;wing Jrm, dnd remove th e grease st'als
from bo th sides of the swing arm.
e(;kan o ul the o ld grease from the bea ri ngs. and apply a
mo lYbdenum disu lfide grcast: : to them.
A. Grease.
- In stall the new grease seals, smearing [hem with a th in
coat of molybdenum disulfide grease.
- Install the swing arm .
STEERING 13-'
Steering
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . .. . . • . . . . . .• . . . . . . . . . . . .
13-2
Special Tools .. ....... .. .....•...... . ........•............
13-3
Steering Adjustment ........ _........ _ . . . . . . . . . . . . . . . . . . . . . .
13-4
Steering Inspection .........•..... _. . . . . . . . . . . . . . . . • . . . .
13·4
Steering Adjustment. . . . . . . . . • • . . . . . . • . . . . . . . • . . . . . . . . . .
13-4
Handlebar ................. .... • . ..... . ....... _ • . . . . . . • . . .
13-5
Handlebar Removal . ...... .. .. .............. ... ... . •...
13-5
Handlebar Installation Notes ... . •.....................•..
13-5
Steering Stem and Bearings ............... . .•................
13-6
Steering Stem and Bearing Removal' . . . . . . . . . . . . . . • . . . . . . . . .
13-6
Steering Stem and Bearing Installation Notes . . . . . . . . • • . . . . . ..
13-7
Steering Stem Bearing Inspection and Lubrication. . . . . . . . . . . . .
13-B
Grease Seal and G-ring Inspection ................ • •. .. .. ..
13-8
Steering Stem Warp ................. . . . . ...............
13-8
13·2 STEERING
.........
......................
~~~;~d;;;;'~:
........
lew
" ...... ..... .... .
................... .
.......... ...... ...... .......... .............. ....... ...... ...
~
1. LH Switch H
.
ou"ng
witch Haus'
3 . Ignit ion Sw Itch
'
'"9
2. RH S '
A
. Agent
L :. Adhe Slye
.
. Non ·po rmanent l
M : Molybdenum D ' ocklng Agent
T
Isulfide Grea
1 ; 11 N·m 11 1 k
T2 ; 27 N.m 12' g· m. 95 in·lb)
T3 : 42 N'm 14'~ kg·m. 20 ft·lb)
T4 ; 44 N-m 14' kg·m.31 h·lbl
.5 kg·m , 33 h·lbl
5'
STEERING 13·3
Special Tools
Stem Nut Wrench : 57001·1100
Al ong with common hea d too ls, the fo llowing more
speci ali zed too ls are required for co mple te steerin g
servi ci ng.
Stem Bearing Driver: 57001 ·137
Adapter: 57001·1074
Stem Bearing Remover: 57001 ·1107
Bearing Puller: 57001·158
Adapter: 57001·317
Driver Pre .. Shaft : 57001·1075
Driver: 57001·1077
Driver: 57001 ·1106
13-4 STEERING
Steering Adjustment
When the steering bearings are properly adjustt:d, the
handlebar will turn freely from side to side with no
looseness of the ste ering stem within the frame. In other
words, the bearings will ha ve little or no free play and
abwlutely no preload . Inspect the steering according to
the Periodic Maintenance Chart or if the following
symptoms an: noticed.
Symptoms :
(Tight)
I. The motorcYc!1;) wanders while being ridden.
2. The stee ring feels light.
3. The bearing races becomes notch ed.
(Loose)
1. The forks "clu nk" or "click" when the brake is
applied or when the motorcycle is ridden over a
pothole.
2. The handlebars seem to "ibrate more than normal.
Steering Inspection
Steering Adjustment
- Set the motorcycle up un its center stand.
-Remove the following parts.
Dumm y Tank Cover
Battery
Ste m Head Cover
Fairing
-Loosen the front fork lower clamp bolts and stern head
nu t.
- Using a jack under the engi ne, lift th e front wheel off
the ground.
_Loosen the stem locknut all the way with the stem nut
wrench (special tuol).
_Set the motorcycle on its center stand.
-Use a jack under the engine to lift the front wheel off
the ground.
Checking for steering too tight:
-With the front wheel pointing straight ahead, alternatel y nudge each end of the handleba r. The fro nt
wheel shou ld swing fully left and right from the force
of gravity until th e fork hits the stop.
*If the wheel binds or catches before the stop , the
steering is too tight.
NOTE
o The wires and cables will have some effect on rhe
motion of the fork which must be taken into accounr.
Be sure the wires and cables are properly routed.
o The bearings must be in good condition and properly
lubricated in order for any rest to be valid.
Checking for steering too loose:
-St.and in front of the motorcycle and grasp the lower
ends of the fork near the ax le .
_Feel for steering looseness by pushing and pul ling the
forks.
*tf you feel looseness, the steer in g is LOa loose.
A. Stem Head Nut
B. Stem Locknut
C. S tem Nut Wrench : 57001-1100
elf the steering is LOa tight, loosen the stem locknu t a
fraction of a turn ; jf the steering is too loose, tighten
th e lockn ut a fraction of a turn. Turn the lock nut 1/8
turn at a time maximum.
-Ti ghten the steeri ng stem head nut LO the specified
torque (see Exploded View).
-Tighten th e front fork lower clamp bo lts LO the specified torque (scc Exploded View in Suspensi on
chapter ).
-Check the steering again.
*I f the steering is st ill too tight or tou loose, repeat the
adjustrn ent.
_In stall the removed parts.
STEERING 13-5
Handlebar Installation Notes
(including Handlebar Position AdiustmentJ
Handlebar
-Handlebar position can be adjusted to change height, to
Handlebar Removal
-Remove the handle grip bars.
o Remove the dut.ch and front brake master cylinders
with their hoses connected by taking out th e clamp
be inclined the handlebar forwards and backwards, and
to be bent the grip bars inwards and outwards.
I WARNING I
bolts, and I"tthem hang free.
COpen the handlebar switch housings by taki ng out their
screws, an d let them hang free.
c Remov e the grip bars by t.lking out the caps and Allen
bolts.
CWhen adjusting handlebar position out of the standard,
always check that the handlebar does not contact the
fairing or windshield, by turning the handlebar to
either side. If the handlebar contacts anything, the
handlebar position must be adjusted again.
-To set the handlebar into the standard pos ition J
observe the following.
OAlign the angle of the handleb ar with the angle of the
front fork.
A. Handle Grip Bar
B. Cap
C. Weight
-Remove the handlebar.
ORemow th e straps to free th e cables and wires from the
handlebar.
ORem ove the stem head cover by taking out the scre\\o"S.
A. Parallel
o Remove the handlebar by taking out the clamp bolts,
stem head cover hra.cket. and damps.
OAlign the marks on the handlebar and the handle grip
bars.
.c\. Handl ebar
C. Clamp Bolts
B. Clamps
D. Stem Head Cover Brack et
f\. Marks
13-6 STEERING
elnstall the handl ebar clamps with the arrow marks on
them pointing forward,
-Tighten the front clamp bolts first, and then the rear
cla mp bolts to the specified torque (see Exploded
View). There will be a gap at the rear part of the clamp
after tightening.
A. Arrow
C. Even Gap
B. No Gap
eTighten the handle grip bar Allen bolts to the specified
torque (see Exploded View) .
eApply a non-permanent locking agent to th e threads of
the screws, and install the weights with them.
-Route the cables and wires correctly. The c.ables and
wires must not hinder handlebar movement.
e The upper or lower half of the switch housings has a
small projection. Fi t the projection into the small hole
in each handle grip bar.
Steering Stem and Bearings
..............................................................................
Steering Stem and 8earing Removal
eRe move th e following parts.
Handlebar
Fairing
Dummy Tank Cover
Battery
Front Wheel
Front Fork Legs
eRe move the mounting bolts, free the brake hose joint
from the stem base, and remove the front brake
assembly as a set.
-Remove the stem head nut, and take off the Oat
washer, stem head, and lockwasher .
ePush up on the stem base, and remove th e steering stem
locknut with the stem nut wrench (special tool: PIN
57001-1100), th en remove the steering stem and stem
base (single unit).
-Remove the steering stem cap and upper tapered roller
bearing inner race and O-ring.
-To remove the outer races pressed into the head pipe,
install th e stem bearing remover (special tool) as shown
below, and hammer the stem bearing remo\'cr to drive
it out.
NOTE
olf either steering stem bearing is damaged, it is
recommended that both the upper and lower bearings
(including outer races) should be replaced with new
ones,
Outer Race Removal
A. Projecti on
B. Hole
echeck and adjust th e following.
Throttle Grip
Choke Coble
Front Brake
Clutch
I. Stem Bcaring Remover: 57001-1107
eRemove th e lower inner race {with its grease seal}
which is pressed onto the steering stem, with the
bearing puller and adapter (special to o l,).
STEERING 13-7
A. Bearing Puller : 57001-158
B. Adapter: 57001-317
C. Bcaring Inner Race
A. Stem Bearing Driver: 57001-137
B. Adapter : 57001-1074
eLubricate the steering stem bearings with grease,
-Insull the stem locknut so that the stepped side faces
down.
Steering Stem and Bearing Installation Notes
.Apply grease to the outer races) and then drive them
into th e head pipe using the drivers and the driver press
shaft (special tools).
Outer Race Installation
A. Stepped Side
B. Cap
.,f the stem bearing outer races was reinstalled, perform
the following four steps to sett.le the bearings in place.
OUsing the stem nut wrench, lighten the stem locknut to
39 N·m (4.0 kg·m, 29 ft·lb) of torque. (To tighten the
~teering ste m locknut to the specified torque, hook the
wren ch on the stem locknut, and pull the wrench at the
hole by 215 N (22 kg) force in the direction shown.)
Torquing Stem Locknut
<i;----
- - - - j 80 mm
-----~
1. Driver Press Shaft: 57001-1075
2. Driver : 57001-1106
3. Dr iver : 57001-1077
eApply grease to the tapered roller bearing, and drive it
onto the steering stem usjn~ the stem bearing driver
and adapter (speci.1 tools ).
215 N
(22 kg)
1. Stem Nut Wrench : 57001-1100
13-8 STEERING
QCheck that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem
bearings may be damaged.
OAgain back out the stem locknut a fraction of a turn
until it turns lightly.
o Turn the stem loc knut lightly clockwise until it just
becomes hard to turn.
Do not overtighten, or the
steering will be too tight.
eRoute the cables and wires correctly. The cables and
wire:; mu:.t not hinder handlebar mo ... cmcnt.
e<:heck and adjust the steering after installation.
A. O-ring
Steering Stem Bearing Inspection
and Lubrication
-Using a high fl ash-point solvent, wash the upper and
lower tapered roller bearings in th e cages, and wipe the
upper and lower outer races, which arc press-fitted into
the frame head pipe, clean of grease and dirt.
.Visually check the outer races and the rollcrs.
*Rcplacc the beari ng assemb lies if they shown wear or
damage.
.Pack the upper and lower tapered roller bearings in the
cages with grease I and apply a light coat of grease to the
upper and lower outer races.
•
A. Tdpcr Roller Bearings
B. Grease Seals
Grease Seal and D-ring Inspection
eVisually inspect the grease seal and Cori ng for any signs
of deterioration or damage.
*Replace the gre.lse seal , O-ring, or bearing (assembl ed
with grease seal) if it shows any signs of damagt:.
Steering Stem Warp
eWhenever the steering is remo ved, or if the steering
canno t be adjusted for smooth actio n, check the
steering stem for suaightness.
*If the steering stem shaft is bent , replace [he steering
stem.
~ --
FRAME 14-1
Frame
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . .. . . . . • . . . . . .
14-2
Fair ing. . . . . . . . . . . . . . . . . • . . . . . . . . . • . . . . . . . . . . . . . . . . . . .. . .
14-6
Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14·6
Fair ing Installation Notes. . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . .
14·9
Travel Trunk and Saddlebags . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . ..
14-10
Travel Trunk Remova l Notes .. . .. . ..•.... . . . ...•.. . . .. .. .
14· 10
Travel Trunk Installation Note. . . . . . . . . . . . . . . . . • . . . . . . . . ..
14- 11
Saddlebag Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14- 11
Saddlebag Installation Notes
(including Tail End Alignment)
14·11
Bracket Removal Notes ... . ... ... . . .. .. .. .. . .... .... ... .
14-12
Bracket Installation Note . . . . . . . . . . . . . . . . . . . .. . . . . . . . . •..
14- 13
Front Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .• . . . . . . . . . . . . .
14· 13
Front Fender Install ation Note ... .. ...•.. .. .. .... .. .. ....
14-13
Rear Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..
14· 13
Rear Fender Remova l Notes . . . . . .• . . . . . . . . . . . . . . . . . . . •. ..
14· 13
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . • . . . . . . . . . . . ..
14· 13
Seat Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14·13
Rear Frame . . ..... .... ... . .. . .. .. . ... . ... .. . . . . .. . . . . . . . .
14· 14
Rear Frame Removal Notes . . . . .. . .. .. .. ..... .....• ... .. .
14-14
Rear Frame Installation Notes .. . . . . . ... .• .. .. .. . . . .•.. . . .
14· 14
14-2 FRAME
.........................................
E~~;~~;;d·v·i·~~·················· ...................................
.
p ,p
...............................................
r
"
~
1 Relay Assembly
.
2 . Turn S I'9"al Control Unit
.
' hting Device
3 . Reserve L Ig
4: Power Amplifier
A : Adh.,i.e Agent
FRAME 14-3
~
~
~<>
f'
~A
'-<7
~
~.
~
1~
63'
'"
~
~
"
:~
JJ
'">!.
~~
.
14-4 FRAME
k Room Light
5.
Trun
m Light Switch
6 Trunk Roo
7·
8·
9'
10 ·
11.·
Turn S',g08' Relay
Starter Motor Relay
Relay Assembly
Ra d 'o
, Antenna. h
Side St. nd SWlte
G : Grease
L : Non· pe rmanent
Locking Agent
T1 : 57 N'm {S .S k g·m, 42 ft·lb)
FRAME 14·5
••
• ..,.
1
~.
~
~~
0.-
~
--~
I
..-""
1
(~?
tf~
1
"
I
'~~~
I
i;
.~
"
~~
--~
-- -,---@- - --- '
1
~~
I
I
~
..,
~
~
/
~
,
t~ '
I
,
~~!);
J
: I 7/~~ ~
I.
I
I
I
-
/ ..'
: J/
I
I
I
I
"-
I
G I
I
I
_ _ ...JI
"
--
~--
,
/
'-/
"
-- "
""
14-6 FRAME
Fairing
Fairing Removal
eRemove the windshield as the following sequence.
A. Rear View Mirrors
A. Lower Cover
B. Screws
A Upper Cover
B. Screws
C. Screws
B. Windshield Cover
A. Wind,hield
C. Remo ve this screw.
B. Loosen these screws .
• Remove the fai ring outer covers.
A. Air Duct,
eRemove the headli ght unit with the remote ca ble.
oTa free th e remote cable from the fairinp; inner cover,
remove
A. Headlight Cover
B. Screws
the
mounting nut.
headlight
beam
adjuster
and .:..1blc
FRAME 14·7
A. Headlight Unit
B. Remote Cable
C. Adjuster
D. Moun t ing Bolts
A , Air H oses
E. Screw
F. Cable Mounting Nut
_ Remove the speaker') and meter assembly .
•
~
A. Inncr Cover
A. Speaker Cover
B. Allen Bolts
B. Screws
C. Speaker
D. Screws
e Remove the electrical components from the fairing
brac.kcl.
,
,
.~ .
Meter Assemb ly
8 . Mounting Nuts
e Remove the fairing inner covers.
o To r~movc the right inn~r cover, free the suspension
air hoses from the cover,
A. Speaker Housing
B. BoilS
14-8 FRAME
A. Turn Signal Control Unit
A. I nsid e Cover
B. Screws
B. Reserve Lighting Device
.Remove lh c radiator shoulder covers.
A Power Amplifier
A. Radiator Shoulder Cover
B. Screws
A. Radiator Shoulder Cover
B. Screw:;
_Remove th e fairing inside covers.
A. Inside Cover
B. Screws
C Clamps
.Remo ve the fairing bracket.
C. Clamps
FRAME 14-9
®
•
.~
I ~ j
I
f\ . Fairing Bracket
B. Bolt,
A. Louver
8. Arrow
eB e sure to cover the radio and cassette player with the
watenigh1 sea t.
A. Fairing Bracket
B. Bolt,
A. Watertight Seat
eR cmm'e the radiator fron t cover,
B. Radio."d Cassette Player
elnsta ll the windshield a, the fo llowi ng.
OBefore in, tailing the wind,hiel\! on the fairing. route a
string around the groove o f the seal trimming.
A. Radiator Front Cover
B. Screws
A. Seal Trimming
Fairing Installation Notes
eR oute
t.he
cables,
wirings,
and
hoses
correc tl y,
elf the ventilation louvers were removed, install them
with the arrow pointin::; up.
B. String
oPlacc the windshield onto the fairi ng so that ib dented
po rtions
fit between the collars and the fairin g.
14·10 FRAME
Windshield Installation
'f1--P-_c----\~~
~I-k-----c(j)
(1'
A. End Trimming
C. i\dhesive Agent
B. Windshield Covcr Trimming D. Clamp
1.
2.
3.
4.
Fairing
Windshield Cover
Rubber Damper
Windshield
5.
6.
7.
8.
Mounting Bolts
Flanged Collar
Collar
Bracket
o Pul1 up the string which has been routed around the
groove of the seal trimming so that the upper end of
the trimming properly fits to the inside of the windshield.
Travel Trunk and Saddlebags
Tra vel Trunk Removal Notes
eMove the travel trunk rearward as far as it will go, and
disconnect the wiring conne-c tcrs from the trunk and
passenger switches.
A. String
B. Seal Trimming
COo not use any tools iUch ilS a screwdriver to prevent
the black-printed area of the windshield from being
damoyod.
oPrcss the sea l trimmi ng against the windhsicld with
your fingers to make watertight contacts at them.
.. it the end trimmings onto the left and right ends of
the windshield lower portion.
OA pply an adhesive agent to the area shown to fix the
end trimming onto the windshield cover trimming.
A. Connectors
8. Passenger Switches
.Remove the wing screws at the bottom of the travel
trunk.
FRAME 14-11
Saddlebag Installation Notes
(including Tail End Alignment)
eHoo k the saddlebag o nt o the saddlebag bracket, and
push in the lo cking pin .
A. Wing Screws
Travel Trunk Installation Note
.Place th e travel trunk on the bracket so that the
holders on its bo tto m
fi t into
A. Lock ing Pin
B. Red Line
the bracket ho les.
I WARNING.
CWhen installing the saddlebags, be sure the locking pin
is all the way in. If you can '$e' 'he red line on the
locking pin, it is not securely latched. Be sure the red
line is out of sight. If the saddlebag is not secure. it
could fall off while you art riding the motorcycle
possibly causing a crash.
A. Ho lders
B. Ho les
. Align the ta il ends of the rear fender rear an d
saddlebags if the par t' which relate to the tai l end
alignment were han dled.
Saddlebag Removal Note
eRemove th e li d fro m t he saddl eba g, pu ll the knob and
unhoo k the saddlebag from th e brac ket.
A. Kno b
A. Level
B. Even Clearance
14-12 FRAME
Saddlebag Leg
I.
2.
J.
4.
Mounting Bolt
Saddlebag
· --I4.V· Lcg
"
Bracket
5. Adjuster
-' 6. Nut
'''II
"5;
GLaasen the rear fender rear mounting bults and slide it
back and forth to align the fender tail end with the
A. No Step
saddle bag end.
cLoosen the saddlebag leg mounting bolts and nuts, turn
the adjusters to raise or lower them, and align the
saddlebag tail end with the fender tail end.
cSlide the saddlebag and equalize the left and right
saddlebag side clearances.
A. Rear Fender Rear Mounting Bolts
OTighten the bolts and nuts after adjustment.
Bracket Removal Notes
-Remove the tra vel tran k bracket together with the
saddlebag brackets.
A. Saddlebag Leg Mounting Bolts
OBefore removing the travel trank bracket, free the
antenna bracket from the trank bracket.
,
©
A. Adjusters
B. Nuts
A. Travel Trank Bracket
B. Saddlebag Bracket
C. Antenna Bracke t
FRAME 14-13
Bracket Installation Note
-Remove the rear fende r front.
eTighten the rcar shock absorber upper mounting nuts
to the specified torque (see Exploded Vicw in the
Suspension chaptcr).
Front Fender
Front Fender Installation Note
.I nstall the (rant fender brac:e with the arrow pointing
forward.
A. Rea.r Fender Front
B. Mounting Bolls
Seats
Seat Removal Note
eMove the rear seat forward as far as it will go.
A. Front Fender
B. Brace
C. Arrow
..............................................................................
Rear Fender
..............................................................................
Rear Fender Removal Notes
eRemove the rear fender relr and its bracket.
A . Rear Fender Rear
B. Fendcr Mounting Bolts
A. Rear Seat
B. Mounting Bolts
1-\ . Front Seat
B. Mounting Bolts
C. Bracket
D. Bracket Mounti ng Bolts
14·14 FRAME
Rear Frame
Rear Frame Removal Notes
IBefore removing the rcar frame, rem ove the fuel in the
fuel tank as possible using a suitable pu mp.
IRemove the rear shock absorbers. I t is not required to
remove the air hoses from the shock absorbers.
eR emove the followine.
Travel Trank and Bracket
Saddlebags and Brackets
Rear Fender and Bracket
Mufflers
SealS
Rear Shock Absorbers
Side Covers
Footboards Jnd Bumpers
A. Footboard
B. Bumper
C. Mounting Bolts
eHolding the fuel tank, remove the rear frame.
A. Rear Frame
B. Moun ting Bol h
C. Damper Rubbers
Rear Frame Installation Notes
eSe sur. to install the damper rubbers in place.
eTighten the rear frame mounting boilS to th e spedii ed
torque (;ec Expl ode d View).
eR ou te the wirings and hom correc tl y.
ELECTRICAL SYSTEM 15-1
Electrical System
Table of Contents
15-2
15-3
Wiring Diagram (Audio) . . . . . . . . .
15-4
15-S
Exploded View " , " " " "
Specifications' , . . . . . . . . . . . . . . . . . . .. . 15-8
Special Tools, , , , , , , , ,
_ , _ . ____ _ IS-9
Battery . .... . ... . . . . . . .
IS-9
Precautions . . . . . . . . . . . . . . . . .. ... . 15,9
Electrolyte ..
. ....... .
15-9
Electrolyte Level Inspection, , , . ' ,
IS-9
BatteryCharging . " . , " ' , .. _, . ," ,15-10
Battery Condition ,_, _""
,_IS-10
Battery Initial Charging, , , _
, _15-10
Battery Ordinary Charging, , , . , _,
_IS-II
Battery Test Charging
, ______ , , ,IS-II
Alternator, , . , , , , , . , ' , _ , , , _ ,
, , ,IS-12
Alternator Removal Note . .
, . ,IS-12
Alternator Installation Notes ...
, , ,IS-12
. ............... .
Brush Spring Inspection . . . . . . . . . . . . 15-23
Wiring Diagram (Main) . . . . . . , . . . . . . .
Precautions, .
Commutator Cleaning and Inspection . . . 15·23
Alternator Disassembly Notes, . . . . . . . 15-13
Alternator Assembjy Notes, "
_"" IS-13
Armature Inspection . . . . . . . . . . . . . . 15·23
Field Coil Inspection _ , , , ' , , , , , ' , , ,IS-24
Brush Plate Inspection, , ' , , , , , , , , , _IS,24
Starter Motor Relay Inspection . . . . . . . 15-25
Lighting System, , , , , . _ .. , , ' ... , .. _ . _15-25
Headlight Circuit _, _ . , .. _ . , , , . , , , _ , 15-25
Headlight Beam
Horizontal Adjustment . . , . , . . . . . . 15-25
Headlight Beam
Vertical Adjustment . . . . . . . , . , , .15-25
Headlight Reserve Lighting
System Inspection
,..
. . . . . . ,15-27
Turn Signal Circuit _ , ' , , , , , , ' , ' , . ' _ .15-27
Turn Signal Control Unit Inspection, .. . 15-27
Turn Signal Relay Inspection """,,15-29
, IS-29
Bulb Replacement
, , _ , , ,IS-29
Bulb Replacement Notes ..
Fuel Pump "_" _
, ' , ,15-31
Alternator Operational Inspection . , .. . 15-15
Fuel Pump Internal Resistance . . . . . . . 15·31
Carbon Brush Length . _ , _ , , ___ . _ , _15-16
BrushSpringTension . _ , . ... . ,'" _15-16
Cooling Fan Circuit . . . . . . . . . . . . . . . . . . . 15-32
Rotor Co il Inspection . . . . . . . . . , .. . 15-16
Fan Motor Inspection . , .. , ... . ... . 15-32
Fan Switch Inspection . . . . . . . _ , .. . . 15-32
Slip Ring Cleaning _, .. ' . ,., . •. , _ ,15-16
Slip Ring Diameter, ,
,15,16
Stator Coil I n,pection
,15-16
Rectifier Inspection
.... ,.,., ..... 15-17
Ball Bearing Inspection
,15-17
Ignition System ., _ _
_""" _" ,IS-17
IC Igniter Installation Note, , , , , , , , , ,15,17
Cooling Fan Circuit Inspection . . . . . . . 15·23
Meters and Gauges ... , . . . .
, _ , __ , ,15-33
Meter Assembly Removal!
, _ ' __ 15-33
Installation Notes
Meter Assembly Separation/
, , _ , _15-33
Assembly Notes
Meter and Gauge Replacement Notes . . ,15-34
Ignition Coil Installation Notes . . . . . . . 15-17
Tachometer Inspection
Spark Plug Removal Note, _
, 15-18
Spark Plug Installation Note, , , . _, ,_15-1B
IC Igniter Inspection, , , , , , , , , _ , , , ,15-18
Fuel Gauge Operation Inspection . . ... ,15-36
Water Temperature Gauge
Pickup Coil Inspection . ..
. . . . . . .. . 15-19
Indicator Light Self-check
Ignition Coil Inspection. .
. . . . . . . . 15-20
., . . . . . . . . . ,15-36
Operation Inspection, , .. , , . . . , , .15-36
Spark Plug Cleaning and Inspection . .. . 15-20
Unit Inspection ., .... , ... . " _ .15-36
AV lAC Signal Unit Inspection " ... __ 15-37
Spark Plug Gap
Distance Sensor Inspection . . . . . . . . . . 15·37
Electric Starter System
Starter Motor Removal Note.
Starter Motor I nstallation Note
, , , 15-20
, __ lS-22
, , ,IS-22
,15-22
AV Control Circuit Inspection
AC Control Circuit Inspection
Electrolyte Level Sensor Inspection . .. ,15-38
Starter Motor Disassembly Note . . . . . . 15-22
Fuel Level Sensor I nspectior)
Starter Motor Assembly Note, '"
Carbon BrUSh Length " " " _ ,
Water Temperature
_ , _ , 15-22
, , ,IS-23
.. . 15·37
. . 15·38
. . . . . . . . 15·38
Sensor Inspection, .. , . . . . ... .. . 15-38
15-2 ELECTRICAL SYSTEM
Switches . . . . . . . . . . . . . . . . . . . .... •.. 15·39
Rear Brake Light Switch
Adjustment .. . ..........• . ... 15·39
Switch Inspection .. . .. . . . • .... . .. 15·39
Relays ..... . . ..... ..... _ .•....... 15-42
Relay Inspection . . . .. . _ . •..•. . .. 15·42
Diodes .. ..... . .. ... . • • . . .. ..... .. 15-42
Diode Inspection . . •. .. . .•.... ... 15·42
Fuses . .. .. _ . _ .. . ... . . •. . .. .. . . . .. 15-43
Fuse Inspection . ... ..... . .. .. ... 15-43
Electrical Wiring . . . . . . . . . . • .... • ..... 15-43
Wiring Inspection. . . . . . . . . . . •. .. 15-43
o Electrical
Precautions
Conncctor~
Female Connectors
There arc numbers of important precautions that ar~
musts when servicing electrical systems. Learn and
observe all the rules below.
000 not reverse th~ battery lead connections. This
will burn o ut the diodes in the electrical parts.
oAlways check battery condition befor!.": condemning
other parts of an electrical system. A fully charged
battery is a must for conducting acc urate electrical
system te::as.
oThe electrical parts should never be struck sharply, as
with a hammer , or allowed to fall on a hard surfac~.
Such a ~hock to the parts c.m damage them.
c;To prevent damage to the audio system, do not
connect or disconnect the battery leads without
removing the 3;.\ audio fu~e in the fuse c.lse,
aTo pr~\'ent damage to electrical parts, do nor disconnect the baltery !cads or any other electrical
connections when the ignition ~witch is on, or whih:
the engine is running,
c Becausc of the large amount of current, never keep
the starter switch pushed when the starter motor
will not turn ov~r, or th e current may burn out the
starter motor windings.
000 not use a meter illumination bulb rated for o ther
than voltage or wattage spccified in the wiring di agram, as the meter or gauge panel could be warped
by excessive heat radiated from the bulb .
oTake care not to short the leads that are directly
connl.'cted to the battery positive (+) terminal to the
chassis ground.
oTroubles may involve one or in some cases al l itl:m s.
Never re place a defective part with out det ermin ing
Male Connectors
OCo lo r Codc~:
BK
BL
BR
Bl ack
Blue
Browll
CH
Chocolate
DG
G
Dark gree n
Green
GY
LB
LG
If th e failure was brough
o
Gray
Light blue
Light green
on by so me other item o r items, they too mu st be
repaired or replaced, or the new repla cemen t will
soon fai l again.
c,\1ake sure all connectors in the circuit are dean .1nd
tight, and examine wires for signs of burning. fraying,
etc. Poor wires and bad connections will affect ~Iec ­
trical sys tem operation.
P
Pink
Purpl e
Red
what CAUSED the failure.
PU
Orang!!
R
IV
White
Y
Yellow
C:Vleasure coil arid wind ing resis tance when the pan is
co ld (at room temperature ).
_C-,r-- -
ZG1200-Al Main Wiring Diagram
:
I
o
~
1
i
••
I
~HH;H
~--
II ... ....
r-----,_, :::::--~:;:tI
.~
111111
.f
_ _ _ L.,..
i
E=ii
L-11!.~~
iI==:;o(P-
,_ ~ :r= iH . wr~-=­
~ vi~ , . 1i1f Ii f ~~ ~­
: :1:~1 ID,1lW H "f 7iif
7MtJtr
I
.,,, ...
- - - - - -- -- .....I
1.--------------'
-- ....... ,..,
"",..
-
~H~HU
~
o~
j ,
of
•
~,u·
--
t _ _ , _ , _, ..
:;-;tt:"_L_:"
~
~'-.-..­
'7V~' .
--....
~
','I II.
::.
~~;:-- ,_.
,,a
•
-I
-_. -..
.
~
---
J
IC )-
-l.!:l_
"
1
"".
' _
~
~
"....
~
'I"" ·
~
'--
-"
-.,,,,.,.,...
",
M
.~
I( 1::::::
- ~,
II ... , • •
~
~-~
I'J
@aF-~-=
T _~
...._ _
L.,.. "'C' 'I" a....
-'-
~.
nk_---------------.:.-;--,U , ~ =~f"T:":r-:;.
_________________ .J
~
L
ELECTRICAL SYSTEM 15-3
_----
•
'"
..
_
""
..a:.
o-~
i
I
••
~
,
!
:~a!
1
!
-
I
ir
-
I
I ,
l'j~
- ,II
~,
s
" Ii '
i .
I~
Ii
it'
I,.
~.
I
I1
I~
::
II
Ii
II
•
~
.. -
~
•IS•
I
1•
~
!~
Ii
II• !I
,I
h :r•
ZG 1200·A1 Audio System Wiring Diagram
15-4 ELECTRICAL SYSTEM
Left Hand lebar Sw itches
Volume Control
Swi tch
Auto Seek Switch I
Program Change
Sw itch
Muting Switch
Radio/Tape
Button
:c?
-l:,
,,O-.. .
A"=
\l Jool
--
0-
I
GY-
---
R
-,o
BR
BA·
-
G
BlGY-
r:::t
--
f-!B l
~(G Y
Y-~~ Y
Y-:,:r
Passenger Switches
Volume Control
Switch
Auto Seek Switch/
Program Change
Switch
Mut!ng Switch
Radio/Tapo
:c?
0:
'f '" 'i'
--
:~
--
r1
A- -;:J~IA
R
-i~
11
I
'---
~B l
Bl
GY
1-6 Y
Y-
Button
I
~(G
G-
--
III '"
f-e
~Io
BA
I
--
... ,. ,.
.=r-'Y
Leh Handlebar Switches
CB Channel
Select
Switch
;:"'0:
"'Ill
«
M
CB Ta lk
Switch
~
,.",,.1
Passe nger Switches
CB Channel
Select
Switch
ca
T alk
SwitCh
I
i 'I
rl
~:J
GY-
I
h
~
~
~
~~
«
-
~
~
~
u..
l P....Q!N
u
CB Module
A
-
---
r'-----------------------
Speakers
M
<i
r--GY~~
_
<i
~GY/BK~W/BK
1-
Le tt
AM / FM A ntenna
t - - -- -- - - - - - - -CB Rad io
(Op!ion al )
---,1- - - -
----- - - - - - --
- - --
Helmet Sound System
(Optional )
C8 Antenna
5P OIN
r-1.
5P DIN
-
NOTE
8P D IN
~
5P DIN
C8 ContrOl
Unit
oConnectors @ through @ are connec ted to
the Connectors of the same reference lerrer in
the main wiring diagram .
ELECTRICAL SYSTEM 15-5
....... .....
Explod~~ ·~·;~~ ······-· .. ··· ··············
.... _................................ -.......................................... .
... ... ..... ... ....... ..... ........
...
+
...
n
' Agent
L : Non .p ermanent Lock Ing
T1 :
T2 :
T3 :
T4 :
4.9 N -m (050
9 .8 N .m (1 '0 kg -m. 43 in-Ib)
14 N .m (1 . kg -m. 87 in-Ib)
25 N.m (2 ': kg -m. 10.0 It·lb )
. kg -m. 18 .0 It·lb )
15~
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 15-7
...
ff
~
ff
~
..,
II'!
q
~
~
I ·
I ':'
rrl
II- i;ll ~ ~
IlftJ
Replacement Parts
!l
~
•
...
•
.,
~
•
:;
~
•
tJ .y,
I
~' 1~
1., Ik·
e l I I
,~
~
~~
11
.,R
~(§~
I
0
15-8 ELECTRICAL SYSTEM
Specifications
Standard
Item
Battery:
Type
Specific Gravity
Alternator:
Type
12 V 20 Ah
1.2BO@20'C (6B'F)
Rated Output
Charging Voltage
Charging Amperage
Regulated Voltage
Three-phase AC, regulator and rectifier
contained in the unit
35 A @7500 r/ min (rpm), 13.5 V
13.5 V Night @4000 r/ min (rpm)
19 A Night @4000 rIm in (rpm)
14.7 ±0.5 V
Carbon Brush Length
Brush Spring Tension
Rotor Coil Resistance
Slip Ring Diameter
16.5 mm
310 - 430 g (with new brush)
3.5 - 5.01].
23 mm
Ignition System:
Ignition Timing
Pickup Coil Resistance
Ignition Coil:
3·needle Arcing Distance
Primary Winding Resistance
Secondary Winding Resistance
Spark Plug:
Standard
Option: Low Speed, Cold
High Speed
Plug Gap
NGK DPRBEA ·9 or ND X24EPR·U9
NGK DPR7EA·9 or ND X22EPR·U9
NGK DPR9EA·9 or ND X27EPR·U9
O.B- 0.9 mm
Electric Starter System:
Starter Motor:
Carbon Brush Length
Commutator Groove Depth
12.0 - 13.0 mm
0.5 - O.Bmm
Cooling Fan Circuit:
Fan Switch
Meters and Gauges:
Electrolyte Level Sensor Resistance
Fuel Level Sensor Resistance
Water Temperature Sensor Resistance
Switches:
Rear Brake Light Switch
Service Limit
Bmm
210 g
22.2 mm
10' BTDC @BOO rIm in (rpm)
360 -4401].
7 mm or more
1.B-2.BI].
10 - 16 kl].
ON: above 94 - 100°C (201 - 212' F)
OFF: below 91 ' C (196°F)
about 6BO I].
Full Position: 3 - 12 I].
Empty Position: 70 - 120 I].
BO°C (176° F): about 52 I].
100° C (212'F) : about 27 I].
ON after about 15 mm pedal travel
6mm
0.2mm
ELECTRICAL SYSTEM 15-9
Special Tools
Along with common hand tools, the following
more specialized too ls are required for complete
electrical system servicing.
Hand Tester: 57001·983
c Ncyer let a good battery stand for more than 30 days
without giving it a supplemerHal charge, and never let
a discharged battery stand without charging it. If a
battery st..lnds for any length of lime, it slowly selfdischarges . Once it is discharged, the plates sulphate
(turn white), and the battery will no longer take a
charge.
o Keep the battery well-charged during cold weather so
that the ell.!ctrolyte does no t freeze and crack open the
battery. The more discharged thl.! battery becomes, the
more easily it freezes.
OAlways keep the battery vent ho se free of obstruction,
and make sure it doe~ not get pinched, crimped, or
melted shut by contact with the hal muffler.
If
battery gases ca nnot escape through this hose, t.hey will
explode the battery.
c DON'T INSTALL THE BATIERY BACKWARDS.
The negative side is grounded.
Spark Plug Wrench: 57001·1024
Electrolyte:
Electrolyte Level Inspection
.Remove the battery .
• Visually check the electrolyte level in the battery.
*1 f the level of electrolyte in any cell is below the !ower
level line on the battery case, add distilled water only
to that cell.
elnstall the battery.
Bearing Driver Set: 57001 ·1129
A. Level Lines
Battery
Precautions:
Following a few simple rules will greatly extend the
life of the battery.
OWhcn the level of IhL! electrolyte in 'he battery is low,
add
onl~f
distilled water to each cell', until the le ve l is
at the upper level line marked on tne outside of (he
baItery. Ord inar v tap wat~r is nO[ it substitute fo r
di sti lled water and will sh o rten the life of the battery.
eN ever add sulphuric acid sol ution to the ba ttery , This
will make the electrolyte solution too strong and will
ruin the battery within a very short time.
OAvoid Q,uick<harging t he battery . A quick-charge will
dama ge t'he batter y plates.
A. Electro ly te Level Sensor
B. Arrow shows 5ensor positio n.
15-10 ELECTRICAL SYSTEM
Battery Charging:
Battery Condition
NOTE
eBefore charging. check battery condition by te sting the
specific gravity of the electrolyte in each cell with a
hydrometer.
Hydrometer
OThe speci fic gravity of the electrolyte varies with
changes in temperature, so the specific gravity reading
must be corrected for the temperature of
electrolyte.
CCelsius: Add 0.007 poinrs to reading for each lOoe
above 20°C or subtract 0.007 points for each 10°C
below 20°C.
OFahrenheit: Add 0.004 points to reading for each 10° F
aboye 68°F Or !>UUUd<.:l 0.004 po;nu for each 100 F
below6SoF.
me
• ,f th e specific gravity of any of the cells is more than
0 .050 away from any other reading, the battery will
probab~y not accept a charge. If it generally best to
replace a b,lltery in this condition.
*If the specific gravity of all the cells is 1.280 or more
th e battery is fully charged.
Read
here
Battery Initial Charging
Befo re being placed in service, a new battery should
be given an initial charging .
• Cu t off the scaled en d o f the batter y vcnt hose and
remove the filler caps a nd electrolyte level sensor .
• Fill each ce ll to the upper Jevcllinc on the battery case
with fresh el ec trolyte at a temperature of 30°C (86 ° F)
or less. Let the battery stand for abo ut 30 minutes
before charging.
NOTE
Olf me electrolyte level drops, add electrolyte to me
upper level line before charging.
eLoo k for sediment and white su lfation inside the cells
on th e bottom of the plates.
• LC3ving the caps off the cells, connect the battery to a
charger, set the charging rate at 1/10 thl;: battery
c.apacity. and charge it for 10 hours. For example, j f
the battery is ra led at 1BAh, the charg ing rate would
be 1.8 A.
WARNING
I
CKeep 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 prevenu
sparks at the battery terminals which could ignite any
battery gases.
A. Sulfation here
B. Sediment here
_S ee th e Battery Troub les hooting Guide in Battery Test
Charging.
*If the spe cific gravity is below 1.200 the batter~' need s
to be c.harged.
c Oo not use a high rate battery charger, as is typically
employed at automotive service stations, unless the
charger rate can be reduced to the level required.
Charging the battery at a rate higher than specified may
ruin the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higher·than -normal charging rates also cause
the plates to shed active material. Deposits will accu·
mulate. and can cause internal shorting.
ELECTRICAL SYSTEM 15-11
I WARNING I
Glf the temperature of the electrolyte rises above 4SoC
o
(llS F) during charging, reduce the charging rate to
lower the temperaturs and increase charging time
proportionately.
OKeep the battery away from sparks and open flames
during charging, since the battery gives off an eXplotlve
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 ga.e •.
l
-Turn the charger off, then disconnect it from the
battery.
-Check battery volt.lge . Battery voltage should be 12
- 13 V.
-Check the specific gravity of each cell with. hydrom·
eter (see Battery Condition).
*If the voltmeter o r hydrometer readings are below
those specified, additional charging is necessary before
the battery can be installed,
-Sot the charge rate and time according to the battery
con dition previously determined (see Battery Condition), using the tab le .
Batterv Ordinary Charging
-Remo ve the battery.
[CAUTlO~
COo not use a high rate battary charger, as is typically
employed at automotive service stations, unless the
charger rate can be reduced to the level required.
Charging the battery at • rate higher than .pecified may
ruin the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higher-than -normal charging rite. lisa cause
the plates to shed active material. Deposits will accumulate, and can cause internal shorting.
Clf the temperature of the electrolyte riles above 45°C
(115'F) during charging, reduce the charging rate to
lower the temperature, and increase charging time
proportionately.
I
OAlways remove the battery from the motorcycle for
charging. If the battery i. charged while still in.talled,
battery electrolyte may spill and corrode the frame or
other parts of the motorcycle.
-Clean off the battery using a baking soda-and·water
solut ion.
The terminals must be especially clean.
-If any of the cells are low, fill them to th e LOWER
level line with distilled water only. The electrolyte will
expa nd during charging, and the level will rise .
-Connect a charger to the battery BEFORE plugging it
in or turning it on.
-Turn the charger off or unplug it, then dis connect it
from the battery.
-Check battery condition (See Ba ttery Condition),
*If the battery condit ion indicates that it is not fully
charged, additional cha rging time is necessary.
Battery Charging Rate/Time Table (12V 20Ah)
1.280 Fully Charged
1.28
1.24
1.20
1.16
u
""-
VI
1.1 2
1 08'
~ :~~
at 1 A charge rate
1.140
t- - - - S;;';pl-;; - ...... , . , J
....
l'
' ,'
....
S
at 3A charge rate
'.'.' ,
.............
•• 10
2
,
1
,
...
,
,
3
. ..
".
,
10
4
6
5
4
3
:i
:1
2
',' , , ,
20
15
.5
2
1
,
,
•
at 4A charge rat e
at 6A charge rate
••
::,,::,::::::.:.::.::::::,.::. i:'::::::: i:':::':: i'~~u~~~.I, i::::::, ·:~:~t~~Yd:~Ch~;g~d:.:: i: ii,:::·::::',:':' i.:'.:
at 2A charge rate
at SA charge rate
• , • , •••• •• , •
.
'.' '.'
25
15
8
5
,
6
4
,
3
Hou rs of Charging Time at Rates Sh own
,
30
,
7
.
4
9
10
,,
5
7.5
6
5
..
,
....
,
.
, ,
..
, ,
.
15-12 ELECTRICAL SYSTEM
Battery Troubleshooting Guide
Good Battery
(+) chocolate color
Suspect Battery
Action
white (,ulphated); + plate.
bro ken or corrodl!o
Replace
Replace
Plates
H
Sediment
none, or small amount
sediment up to plates, cau')ing sh o rt
Vo ltage
above 12 V
below 12 V
Electrolyte Level
above plates
below lOp of plates
Specific Gra lli ty
above 1.200 in all cells; no two
cells more than 0.020 ditferent
below 1.100, or difference of more
[ha.n 0.020 belW~t!n lwu Lt:'lb
gray
Test charge
, Fill and test charge
Test charge
Battery Test Charging
elf the battery is suspec ted of being defective, sulfated,
0( unable to tak e a char$c, consult the table.
eTo test (;harge a battery. perform the ordinary charging
procedure and monitor the battery voltage dnd other
signs as men tioned below.
*If the battery voltage suddenly jumps to o ver 13 V just
after the start of charging, th e plates arc probably
sulfated. A good battery will risc to 12 V immeditel),
and then gradually go up to 12.5 or 13 V in about 30
min to an h ou r after th e start of charging.
*If one cell produces no gas bubbles or has a very low
specific gravity, it is probabl y sh orted.
*1 f there does not appear to be enough sediment in a cell
to short the plates, but that cell ha s a very low specific
gral'ity after the battery is full y charged, the trouble
may be that there is not enough acid in that one cell.
A. Alternator
B. Mounting Bolts
In this case only, sulfuric. acid solution mdY be added
to correct the specific gravity.
*I f a fully charged battery not in usc loses its charge
after 2 to 7 days; or if the specific gravity drops markedly. the battery is defective. The 'ielf-discharge rate of
a good battery is only about 1% per da y .
. Alternator Installation Notes
- Cheel..: that the rubber dampers Me in place before
instal ling the alternator.
- Clean the alternator legs and crank case where the
al ternator is grounded .
.............................................................................
Alternator
.............................................................................
The alternator contains the following: electrical
components in its co mpact housing :
Alternator Stator and Rotor
Recti ficr
Regulator
A. Clean here.
Alternator Removal Note
.Remov~
the alternator.
B. Rubber Damper;
eAppl ya non-permanen t lock ing .lgent to the threads of
th e alternator mounting bolts.
ELECTRICAL SYSTEM 15-13
Alternator Disassembly Notes
-Unso ld er the stator coil leads from the rectifier
e Separate the alternator LH and RH housings.
\,;Mark the housings before separation so that the
housings can be assembled in the same
terminals.
pOSItion .
Olf necessary. heat the left end of the LH housing to
a bout 50 - 60°C (120 - 140° F).
Alternator Assembly Notes
.Press (he LH bearing onto the rotor shaft with the
bearing long end from the ring groove facing out.
eSolder the carbon brush lead end with the brush holder
so that the brush projects as shown.
Carbon Brush Installation
A. LH Housing
B. RH Housing
D. Coupling
E. Heat here.
C. Housing Screws
eRemove the rotor from the RH housing.
A. Carbon Brush
C. Solder.
B. 3 - 4 mm
D. Thi n Wire
.Push the brushes into the holder, and ho ld them in
A.R otor
B. Bearing Holde r Screws
their positions with a thin wire running through the
holes on the LH housin g) brush ho lder, and brushes .
• Posi ti on the retainer on th e L H bear ing groove so that
the protruding: port ion of tht: retainer comes to the
deeper side of th e groove.
• Rem ove the stator, rectifier, regulator, and carbon
brush assembly together from the LH hou sing.
A. Retainer (Pro truding Portion)
B. Groove (Deeper Side)
A. Rectifier Mounting Screws
B. Regulator ,\lounting Screws
C. Terminal
NUl
. After assembling the alternator, be surt: lh e rOLDr turns
freely.
15-14 ELECTRICAL SYSTEM
Charging System Circuit
1. LH Bearing
2. Carbon Brushes
3. Rotor
4. Stator
5.
6.
7.
8.
Alternator
O-ring
RH Bearing
Oil Seal
Spring Was her
9. Retainer
10. Rectifi er
11. Slip Ring
12. LH Housing
13. RH Housin g
14 . Regulator
15. Allernalor
16. Ignition Switch
17. Main Relay
18. Fuse Case
19. 10 A Fuse
20. 30 A Fuse
21. Battery
Alternator Intarnal Circuit
(17)
-
::
1 - - - BK / Y --~
IV
1
BR
WI'~
BK / Y
1[81
"-'~
r---R-
W/ BK
'---B R
,
IV / BK,
BR
,,
+
--
(;j'.
~ -'
ELECTRICAL SYSTEM 15·15
Alternator Operational Inspection
For any cha.rging system problems, always check the
chargi ng system wiring first, and then chec k the system
with the foilowing tests shown in th e tes t guide.
Test Guide
Trouble
Ba ttery disch arged
Battery overcharged
Bt.'ginning Test No.
T est No. I
Test No.6
Test No.1 - Charging Voltage
eReplace the disc harged battery with a good battery_
. Check the charging vo ltage at the alternator B termina l
wi lh the engine idling and run ning at 2000 rlmin (rpm).
_I f the voltage at 2000 rl min (rpm ) is higher than the
vo lt age at idle speed, go to Test No.3.
*1 f the vo ltage at 2000 r Imin (r pm ) is the same as the
voltage at idle speed (vo ltage docs no t changeL go to
Test No.2.
Te.t No.3 - Regulated Voltage
_R emove th e lOA fuse for the headlight in th e fuse case.
_Check th e charging voltage at the B terminal with the
engine running at 4000 - 5000 r l min (rpm ).
* If the vo ltage is within 14.2 - 15.2 V, the regulator i,
OK. Go to T es t No . 4 .
-If the voltage is less than 14.0 or more than 15.5 V,
th e alterlliltor is d efe cdve. Chock the alternltor unit.
Test No.4 - Charting Amper.
-Disconnec t the lead fr o m the B terminal.
-Check the charging amperage between, the B terminal
and the lead whh the enigne running at 2000 r/ min
(rpm) . Turn on the hoadlight , tail/ bra ke lights, turn
signal tights,
during the test.
The trouble is in the other pa rt s.
A. B T .rmi nal
A. B Terminal
CI C.
·a'lf the am perage is less than 15 A, the alternator is
defective.
*I f the a mp erage is 15 - 20 A, go to Test No. 5.
* Jf ' he amperage is more [han 20 A, the alternator is OK.
B. Ammeter
B. Voltmeter
Test No.2 - Battery Power Supply
- Check the voltage at the IF termin al with the ign ition
switch turned on but engine stopped.
*I f the ba ttery voluge appea" at lh ~ f \ermina r, go to
Test No.3 .
_I f the voltage is OV, c heck the main harn ess si de.
Test No. 5 - Charging Amperage (Review)
_Discharge the battery a little or rdnstallth e discharged
ba t tery.
.Check the wiri ng betvveen the B terminal and the battery
( + ) termir1dL
-Check the charging amperage a t 2000 rlmin (rpm )
again .
*I f the amperage is less than 20 A, check the alternator
unit.
*If the amperage is m o r~ than 20 A, th e allc:rnator is
OK. The troub le is in the other part.s.
A. F Terminal
B. Vol tmeter
Test No. 6 - Charging Voltage
- Rep lace the overCharged ballery with a good battery.
_ Check the charging vol tage at the B t.erminal with ihe
cns ine running.
Increase th e engi ne spt\..~ sJowly
dur ing the tesl.
*If the voltage docs no t r ise more than 15.5 V, go to
Test No.7.
*I f the voltage rises morc than 15.5 V, tht:: alternalOr
(regulato r) is defective.
15-16 ELECTRICAL SYSTEM
Rotor Coil Inspection
eMeasure the rotor co il resistance between the slip rings.
*If the resistance is not as specified, re place the roto r.
Rotor Coil Resistance
3.5 - 5.0 Q
-Using the highest ohmmeter range, measure the resistance between he rotor shaft and each of the slip rings.
*If there.: b any rcadi n~ ,.II (111, the rotor I;oil has a short
and must be re placed.
A. B Terminal
B. Voltmeter
Slip Ring Cleaning
Test No.7 - Regulated Voltage
e!<.emove the 10 A fuse for t he headlight in the fuse
case,
_Visually in ~ pect the slip ring for dirt or pitting.
*If necessary, smooth the slip ring with lathe or fine
emery cloth.
e<:heck the charging vo lLage at the B terminal with the
engine running at 4000 - 5000 rlmi n (rpm).
*If the voltage is within 14.2 - 15.2 V, the alternator
(regulator) is OK. The trouble is in other parts.
Slip Ring Diameter
*If the voltage is more than 15.5 V, the alternator is
dcfcctiye.
Slip Ring Diameter
Standard:
Service Limit:
23mm
22.2mm
Carbon Brush Length
Carbon Brush Length
Standard:
Service limit:
16.5 mm
8mm
Carbon Brush Length
[AJ
5 en'ice Limit
Brush Leng th
A. Slip Rings
B. Stator Coil Windings
Brush Spring Tension
.Push the carbon brush into th e holder until th e protrusion of it come) to 2 mm from the holder, and then
measure the spring tension at this ins tart.
*If the tensi on is less than the service limit, repla ce the
spring.
Brush Spring Tension
Standard:
Service limit:
310 - 430 g (with new brush I
210 g
Stator Coil Inspection
eUsing an Ohmmeter, che<:k the stuor coil windings for
continuity ("lose to 0 !2).
*Ii the meter shows. no continuity, the Sialor coi l winding
has an open lead .nd m~'t be replaced .
-Using the highC"Sl ohmmeter range. measure the resistance between the stator co il (or:c and each of th e coil
windings .
• If there is any reading at all, the stator coil winding ha s
J sho rt and mu st be replaced.
ELECTRICAL SYSTEM 15-17
Rectifier Inspection
Ignition System
-Set an ohmmeter to the x I kQ range.
_Connect the ohmmeter to the ends of each diode, and
check the resislJ.nce in both direction. Th e resistance
should be low in one direction and more than len times
as much in the o ther direction.
*If an y diode shows low or high in both directions, the
diode is defective and the rectifier must be replaced.
I WARNING.
c The ignition system produces extremely high voltage.
Do not touch the spark plugs, high tension coils, or
spark plug leads while the engine is running, or you
could receive a severe electrical shock.
NOTE
CThe actual meter reading varies with the meter used
and the individual diode, but, generally speaking, the
lower reading should be from zero to the first 1/2 of
the scale.
!CAUTlO~]
0 00 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 Ie
igniter damage.
COo not install the battery backwards. The negative side
is grounded. This is to prcvel'lt damage to the diodes
and Ie igniter.
Clf a megger or a meter with a large-capacity battery is
used, the rectifier will be damaged.
IC Igniter Installation Note
Rectifier Inspection
-Connect the filter to the vacuum hoses so that the
marked side of the filter faces to the opposite side of
the IC igniter.
Rectifier
--,
A. IC Igniter
B. Filler
A,
C,
A,
C,
Ball Bearing Inspection
.Turh e~ch bearing b.lcl\ and forth while check ing for
r.oughneis Of binding.
*If roughne» or binding is found, replace thiJ bearing,
eExami,ne the bearing >eai for tears or leakage.
*If [he seal is torn or is leaking, rt!place the bearing.
C. ,\1arked Side
Ignition CoN Installation Notes
eConnect the primary wires to the primary coil terminab as follows:
o Bl ack and rcd wi res - #1 & 4 ignition coil (Left)
cCreen an d red wires - #2 & 3 ignition coil (Right)
eThe + and - mark ings n~xt to the prim.uy coil termi nals on the ignition coil body indicate the polarity of
the terminals. The polarity of the two spark. plug leads
are as shown when the primary le'ads are connL'Clcd as
indicated in the figure. But both the primary wtrcs
(pos itive red , .and negati ve bl.ack and green) ca n be
connected with either terminal on the ignition coil
without changing the cngine performance.
15-18 ELECTRICAL SYSTEM
Polarity of Ignition Coil
Spark Plug Installation Note
(-) #1 or #2 spark plug lead
-Tighten the spark plug to the specified torque (see
Expl oded View ).
c==r':;
: J::I: :r: Gl~°I!J=: ===.J;:2J~ ~;;~:i:
Ie Igniter Inspection
_Check the IC igniter in according to the IC Igniter
Troubleshooting chart.
eTo inspect the Ie igniter internal resistance, perform
green lead
the following.
-Set the ohmmeter to the x 1 kU range and make the
measurements shown in th e table.
*If the meter readings arc not as specified, replace the Ie
(+) #4 or #3 spark plug lead
igniter.
[CAUTIO~]
CUse only Hand Tester 57001·983 for this test. A tester
other than the Kawasaki Hand Tester may show
different readings,
0 1f a megger or a meter with a large-capacity battery is
used, the Ie igniter will be damaged.
Terminal No. of
Ie Igniter
.... Ignition Coil (#1 & 4)
Spark Plug Removal Note
-Remoye the battery before remoying the #2 and #4
spark plugs. If necessary , usc the spark plug wrench
(special tool: PIN 57001·1024).
Ie
Igniter Internal Resistance-
Tester (+) Lead Connection
Terminal
Number
1
2
c
c
.;:;
u
u
c
c
3
4
0
u
~
~
-'
2
"" ""
00
00
C
00
00
00
5
6
00
00
00
00
00
C
~
7
8
9
10
00
-
-
-
-
00
00
-
-
-
-
D
A
-
-
-
-
~
~
-
-
-
-
A
B
E
-
-
-
-
-
-
-
-
-
-
00
6
B
00
7
-
8
-
.~
~
4
~
F
3
3
""
5
I
~
1
00
0
F
E
~
-
-
-
Infinity
-
A
0.9 - 1.5
B
2 - 3.8
-
-
-
-
~
C
C
C
C
C
C
~
9
-
-
-
.-
-
-
C
C
10
-
-
-
-
-
-
C
C
""
c
Value (kU)
00
C
C
3.6 - 5.5
D
E
8 - 12
9 - 13
F
13 - 24
I~
"'Me.asured with hand tester 57001 ·983. A tester other than the Kawasaki Hand Tester may show different readings.
ELECTRICAL SYSTEM 15-19
IC Igniter Troubleshooting
Engine operates poorl y.
There is no trouble in the ignition
system except fo r the IC ignit er.
Inspectio n of IC ignitcr
internal resiSliH1ce proves th c
igniter is good?
No
Replace Ie
ignitt:r.
Yes
Replace Ie
No
ignit ~r.
Engine o perates
Sli II poorly ?
Yes
Replace the Ie
igniter with the
original o ne.
No
Engin!;) o p ~ra tcs
still poorly?
/'
Trou ble is in Ie igniter
and should be caused by
the oth er parts o r engine
itself.
Yes
Engine operates
still poorly ?
"-
No
T ro uble should be caused
by the o ther parts or
engine itself.
"
Yes
Tro uble is in Ie
igni tcr.
Pickup Coil Inspection
ei\1~a 5ure
the pickup coil wind ing resistance.
*If the resi stance is no t as specified, replace the pickup
coil assemb ly.
Pickup Coil Resistance
360 - 440
n
el\·leasure the resi stance between th e pickup coil leads
and the co il mounting plate.
*If th e resi stance is less than infinity, replace the pickUp
coil asc;embly.
15-20 ELECTRICAL SYSTEM
Ignition Coil Winding Resistance
Primary windings:
Secondary windings:
1.8 - 2.8 n
10 -16 kn
A. Pickup Coils
Ignition Coil Inspection
-Check the spark plug leads for visible damage.
*1 f any spark plug lead is damaged, replace the coil.
l\t1easuring arcing distance:
A. Measure primary winding resistance.
B. Measure secondary winding resistance.
C Spark Plug Cap (removed)
The most accurate test for determining the condition
of the ignition coil is made by measuring arcing distance
with a suitable tester for the 3-needle method.
-Connect the ignition coil (with the spark plug cap left
installed at each of the spark plug leads) to the tester,
and measure the arcing distance.
I WARNING I
OTo avoid extremely high voltage shocks, do not touch
the coil or leads.
Spark Plug Cleaning and Inspection
-Cle~n
the spark plug, preferably in a sandblasting
device, and then clean off any abrasive particles. The
plug may also be cleaned using a high flash-point
solvent and a wire brush or other suitable tool.
*1 f the spark plug electrodes are corroded or damaged,
or if the i nsu lator is cracked, replace the plug. Use the
standard spark plug or its equivalent.
*If the distance reading is less than the specified value,
the ignition coil or spark plug caps arc defective.
Ignition Coil Arcing Distance
7 mm or more
Spark Plug Gap
eMeasure the gap with a wire-type thickness gauge.
*If the gap is incorrect, carefully bend the side electrode with a suitable tool to obtain the correct gap.
Spark Plug Gap
eTa determine which part is defective, measure the
arcing distance again with the spark plug caps removed
from the ignition coil.
*If the arCing distance is subnormal as before, the
trouble is with the ignition coil itself. If [he arcing dis[a nee is now normal, the trouble is with the spark plug
0.8 -0.9 mm
Spark Plug Gap
cap~_
Measuring coil resistance:
If the arcing tester is not available) the coil can be
checked lor a broken or badly shorted winding with an
ohmmeter. However, an ohmmeter cannot detect layer
shorts and shorts resulting from insulation breakdown
under high voltage.
eMeasure the primary winding resistance and the
,econdary winding resistance.
*If the resistance is not as specified, replace the ignition
coil.
1
1.
2.
3.
4.
Insulator
Center Electrode
Plug Gap
Side Electrode
Ignition Circuit
I.
2.
3.
4.
5.
IC IgniiCr
Pickup Coil (#2 & 3)
Pick up Coi l (#1 & 4)
Timing Rotor
Ignitio n Coil (#1 & 4)
6. I~n i t io n Coil (#2 & 3)
7. Spark Plugs
8. Engine Stop Switch
CD
@
.....
~
~
?-
'" "
P/ BL--.,
' - - - BK/Y
L..:::r
"0
Lf
Y/G
P/ BL
>-
Ignition Switch
Diode Assembly
Starter Lockout Swi tch
N~utral Switch
Side Stand Switch
FuseCase
30 A Fuse
Battery
BR/ R
LG
I ... ,
9.
10.
11 .
12.
13.
14.
15.
16.
'"
>-
~
r4 "
Tf~
P/ BL
P/ BL
~
~.
co
. - - - - BK
0
Tl1
r
h
'I
I
~...J~>­
~
co
"P
'"
(5'.
,j
I I (§) '
""
,
Y/ R
BK/R ...j
(J)
~~i~~~ I Uj
~BRI R _
,
e:.>
>- _
cttr
r
>-
' "$
3:
O? co
~Cl
LL_
I
fJ4)
'-or
,,~
r----',
,,@
,
L ____ .J
"
BK Y
>-
'"
"
co"..
@
/
m
m
o
-4
r-
:Il
(';
l>
r-
en
~
-4
m
~
....U1
N
....
15-22 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal Note
eRemove the starter motor.
A. Brush Plate
B. (+) Side Carbon Brush
A. Starter Motor
B. Mounting Bolts
C. Screw
Starter Motor Assembly Notes
ePush the brush plate into place with the tab in the
notch.
Starter Motor Installation Note
-Clean the starter motor legs and crankcase where the
starter motor is grounded.
A. Tab
B_ Notch
elnstall the brush end cover so that the long vertical tab
on the brush plate aligns with the key slot in the cover.
A. Clean here.
Starter Motor Disassembly Note
eRemove the (+) side carbon brush lead screw, and take
off the brush plate.
A Tab
B_ Key Slot
ELECTRICAL SYSTEM 15-23
Carbon Brush Length
Carbon Brush Length
Commutator Groove Depth
Standard :
0.5 - 0.8 mm
Service Limit : 0.2 mm
Commutator
Good
A
t
Groove
Depth
MiC.J.
Commutator
C<lrbon Brush Length
12.0 -13.0 mm
Standard :
Service Limit: 6 mm
Brush Spring Inspection
- Check thal the brush sprin gs are in place and snap the
bru shes firml y into place.
*J f not , reinstall or replilc~ th e sprin g.
Armature Inspection
Commutator Cleaning and Inspection
- Smooth the co mmut a to r surfac ~ if necessary wi th fine
e mery cloth, and clean out the grooves as illustrated .
.M ea~urc t he rc) islan ce between each segment and all
the others.
*1 f the resistance is too high o r even in finite, th e
armature wi nding has an o pen circui t . Rep lace the
starter moto r.
e Measure the resi stance between the commutato r and
the armature shaft.
* If the resistance is less than infinite, the armature is
shorted. Rep/ace the sta rter motor.
A Comm uta tor
. D e te rmin~ as accuratel y as possibl e the dept h of the
grooves between commutator segments.
*Replacc th e slan er molor with d new one if the groove
depth is less than the service limit.
A. Segme nts
B. Sha ft
15-24 ELECTRICAL SYSTEM
Field Coil Inspection
Brush Plate Inspection
.Measure the resistance between the starter motor
terminal and the (+) side carbo n brush terminal lead.
• If the resistance is greater than 0 n, the field coils have
an open. Replace the starter motor.
.Measure the resistance between the yoke and the
starter motor terminal or (+) side carbon brush
terminal lead.
*If the resistance is less than infinite, the field coils are
eMeasure the resistance between the (+) side c.arbon
brush holder and the metal pl ate .
*1 f the resistance is less than infinite, the holder has a
short. Replace the starter motor.
_Measure the resistance between the (- ) side carbon
brush and the mewl plate.
*If th e resistance is greater than O!1: , the brush assemb ly
has an open. Rep lace the starter motor.
"hart",d to ground. Re pl:tcC' th (! <;u rtf'.r mntnr.
A. (+)Side Carbon Brush Holder
B. (- ) Side Carbon Brush
C. Metal Plate
A. Starter Motor Terminal
B. (+) Side Carbon Brush Termi nal Lead
C. Yoke
Electric Starter Circuit
1. Engine Sto p Switch
2. Starter Button
3. Starter Relay
4. Starter Lockou t Switch
5. Neutral Switch
6. Ignition Switch
7. Fuse Use
8. 30 A Fuse
9. S14rter Motor
10. Starter Motor Relay
11. Banery
BKiR-[D-LG
>'L
C§)
~
7'
r-----.,
\.oj
g-BK/Y
""
C
'L
co,r-.
I
I
@ I
I
I
I
L _____ -.l
+
1\1)
ELECTRICAL SYSTEM 15-25
Starter Motor Relay Inspection
-Connect an ohmmeter and 12 V battery to the starter
motor re lay as shown.
*1 f the rclay does no t work as specified, the re lay is
defective.
Testing Relay
Meter Range: x 1 n range
Criteria:
When battery is connected """ 0 n
When battery is disconnected - )
00
n
Testing Relay
A. Adjuster
B. Adjuster Guide
C. Left
D. Right
. lnst.11 the headlight cover.
Headlight Beam Vertical Adjustment
NOTE
.~.
oOn high beam, the brightest point should be slightlY
below horizontal with the motorcycle an its wheels and
the rider seated. Adjust th o headlight to the proper
angle according to local regulations.
Starter Motor Re la y
• Turn the adjuster to the di rection " UP" or "DOWN ", to
adjust the hea dlighl vertically.
Lighting Sys tern
Headlight Circuit :
Headlight Beam Horizontal Adjustment
e Re move the headl ight cover.
A. Ad juster
Vertical Adjustment
A. Headlight Cove r
B. f\"ounti ng Screws
.Put a Phillips screwdriver into the adjuster guide.
eTurn the adjuster in or out until the beam points
strai~ht
ahead.
B. UP
C. DOWN
...
Headlight Circuit
U'1
1. Head light
2. High Beam Indicator Light
3.
4.
5.
6.
7.
8.
9.
Failure In dicator Light
Dimmer Switch
Resen'e Lighting Device
Starter Circuit Relay
Starter Circuit
Headlight Relay
Main Relay
ihlofl
~
,, ®
',I
I
15 A Fu,e
30 A Fuse
Starter Motor
Starter Motor Relay
Battery
13.
14.
15 ,
16.
17.
®
®
10. Ignition Switch
11, Di ode A,<cmbly
12, Fu seC.,.
...../
..j
3" ...../
coco -
~
~
~ !:
>-'
co
_
!:
---~ a!
a! co
>-
et:
I
en
m
rm
(')
-I
:II
~
r-
:.: CIl>-
i'J)
N
en
-<
en
t!:
-I
m
~
-' :.:
CD
R / BK
BK/ Y
R/ Y
~
I ,
L
~T
I
CIl >- >-
O? O?::J
@
R/ BKiitR/B K
.ill
~BK/Y .fIf.BK/Y
'c:::T-+- G/ R
@
--
-'
CIl -'
CIl
>- et:
I +
:.:'
et: et: -'
. CIl
LG/ R
::J
1-4
~
'" CIl !: Q
t
~3
--,
0~~U
BL/Y - -
L ___ _
" 4'
'''rL'
I
_J
BL/O
r::::: 'h
I
CIl
(ID
>-
~
>-
I
I
I
>-
-- H ¢
~>-
:.::.:
CIlCIl
0<
(""
~
>:.:
CIl
0<
l..bJ
@
I
I
®
®
..
ELECTRICAL SYSTEM 15-27
Headlight Reserve Lighting System Inspection
If either high or low beam burns out, the reserve
lighting system switches over to the remaining filament
automatically, and lights th e white headlight failure
indicator light to show that th e headlight bulb must be
replaced . If the high beam filament burns out, the low
beam is automatically turn ed on; ir low beam burns out,
the high beam is turned on but more dimly than normal.
The US and Canadian models contain a relay in the
head light goes on on l:e the st.1rter butt on is pushed to
start th e engi ne, and stays on until the ignition switch is
turned off. But the headlight goC'j out whenev e r the
starter button is pushed ro restart the engine after engine
':!ta1!ing.
*1 f a ll wirings and comp onents other than the rever se
lighting device check out good , the device is defeaive.
Turn Signal Circuit:
Turn Signal Control Unit Inspection
When the turn signitl switch is in ON position, a
solenoid turns off the turn signal after it has been on fo r
4 seconds, plus the time that the motorcycle has traveled
an additional 50 meters. The cancelling sys tem cons ists
of th e battery (power source), lurn sign al comrol unit,
distance sensor, solenoid, and turn signa l switch. When
the turn signal ~wjtc h is pushed to the left or right, the
turn signal s start flashing and the cont rol unit starts
co unting off 4 seconds. At th e end of this time , the
control unit starts ca lculating distan ce traveled usi ng
pulses from the distance sensor at {he rear of the
spe edometer.
When the motorcycl e has traveled 50
meters, the control unit o perates the solen oid, which
rt"turns the turn signal switch to the OFF position .
• If all wirings and components ot her thitn the turn signal
control unit check o ut good, the unit is defecrive.
A, Reserve Ligh ti ng Device
B, Turn Signal Control Unit
Reserve Lighting System Operation
Headlight
Dimmer Sw itch
Position
Both high and low
HI
bea m filame nts
arc normal
LO
High beam filam ent
burned out
Lo w beam filament
burned ou t
HI
LO
HI
LO
Headlight Failure
Indica tor Light
Reserve Lighting
Goes on
(hardly vi si ble)
Goes on
(hardly \'isible)
Goes on
Low beam comes on .
Goes on
(hardly visible)
Goes o n
(hardly visible)
~oe s
on
High beam co mes on dimly.
Turn Signal Circuit
ITI
~~W
~
:t ~
~. ~
~
;r _ '
GY ,
,
-
;r
>- - -,
m",
G
VG'
~
~
10
I
KIY
I
.
~~
l ®
L..B KI Y
GY
G, .
·,t,
".
" I
""
,
'"
;r _.
0
~
I
-;
CI)
<
~
m
I
3::
~:~;;~ ~ :h 't,~ ,,~."'OO"",.
. ,,",",",
tJ°~~
vrr ~ if\~ . Lcf~:~ n al~ndica tor
"
~.
~
,,~U"
~, ,""
OOOI~ ~~,;r
Co~tro
Front RightTurn Signa !
0
•
_.
'"
lh
.r -,
0
P
I
""
h
;r "
_
0
I
<ll
"', '''""
2. Front L.ft . u t
- I- -,
I
I
"/C
(')
l>
r
o - ~-
_ _
-!
-l
:0
I
(L?)
-W/ R
.'.
;r ""-
•
"
L,
•...
1,5.:
m
(')
¥
(.4)
o
m
r
¥;r",
~
;DJ: GY~
U1
N
c:o
__ ::;. __ :::to-~ -
:;;:.. -. ':¥. ~
,,J J-, t"'".
~"
::::->
~
GY
~
~
-- ~illp
~ -""'L
lJj
~
l ~, ~' p
",
I
;r
;r t
- 0
'I I)
'.'
,J
~
19 0 ~
(8 1
BK ! Y -----"~'
G
·ro.,
:}.ii
'",,,,,,",,.
H '.15;
J.
"I LighT
Si nal Light
4. ,,,
Rcar
Light
C '"',
5. Meter
Right
1and
u Signa
. g I Ind" icator Light
7.
Gauge
"f Turn
l' rn Signal. Rela
'"
" y
L - - - - - "- - -
_ , ',
i:
S'
. ht 1 urn Ign,.
3. Rcar Rig
7
9. Hazard SWITC
""" n.
,.,,,"
"". ".," ",./
••
1-I . IOAFu,"
I I,
"
?;
'16\
o
o
' ... - ---
1"t
':!.. _ ----
.:0
@
--
\
;0 " " "
6: Turn Signal
17 . Turn Signal SW itch
l B. Battery
'" "
n
ELECTRICAL SYSTEM 15-29
Turn Signal Relay Inspection
-Remove the turn signal relay.
- Con nect o ne 12 V batt ery an d turn signa l lights as
in dicated in the figu re, and count how many times th e
lights fl as h for o ne minute.
*If the ligh ts do no t flash as specified, re pl ace the turn
signa l re lay.
Testing Turn Signa' Relay
(Example : Two lighu are connected.)
Bulb Replacement :
Bulb Replacement Notes
!CAUT!:O~J
:.:': 00 not use bulbs rated for greater wattage than the
specified value, as the meter or gauge panel could
become warped by excessive heat radiated from the
bulb •.
eRemove and insta ll the head light bulb.
Turn Sing. 1
Re l.y
!CAUTI~~J
GWhen handling quaru·halogen bulbs, never touch
the glan with bare hands. Always use a clean cloth.
Oil contamination from hands or dirty rags can reduce
bulb life or cause the bulb to explode.
Turn
Signal
Ug_h lS
e Fi t th e d ust cover ont o the headl ight bu lb firmly as
shown.
12 V Ba ttery
Testing Turn Signal
Load
•
The Nu mber
of Turn
Sig n.1 Ligh ts
Wattage (IV)
1
21 - 2 3
2
42 - 46
3
63 - 69
4
84 - 92
Flashing
Ti m e~
(c /m'\')
More th a. 150
A. To p Mar k
B. Dus t Cover
75 - 95
Dust Cover Installalion
: Cycle(s) per m in ute
Bad
Good
A. Turn Signal Re lay
I . Dus t Cover
2. Headl ight Bulb
15·30 ELECTRICAL SYSTEM
eRemove the wedge·base type bulbs.
oPul1 out th e bulbs and sockets, and/or pull the bulbs
off the s:ockets.
A. Tail/Brake Light Bulbs
A. Indicator Bulbs
B. Illumination Bulbs
A. Side Marker Light Bulb
A. Tail /Brake Light Bulbs
B. License Plate Light Bulb
A. Trunk Room Light Bulb
.Remove the lock pin type bulbs.
c Pull out the bulbs and sockets.
oPush the bu lb in, turn it counterclockwise, and pull it
out of the socket.
A. Turn Signal/Running Posi tion Light Bulb
ELECTRICAL SYSTEM 15-31
Fuel Pump Internal Resistance
-Set the ohmmeter to the x I kU range and make the
measurements shown in the table.
*If the meter readings are not as specified} replace the
fuel pump.
Fuel Pump Internal Resistance
Tester (+) Lead Connection
Lead
"
~
BK
c
0
_-' u
"
I "
-2
0
A Turn Signal Light Bulb
, ~
BK
~
BL
~
BK/Y
~
~~
~
f--
BL
BK/ Y
~
~
More than
20 kU
..............................................................................
~
~
~
Fuel Pump
..............................................................................
The fuel pump does not operate wh en the ignition
switch is turned on only. The pump operates when the
starter button is pushed on or thl! engine is running.
Fuel Pump Circuit
If
',
\. . ../
--g ®
BKR-qL_ _--'
o
~---L,
1. Engine Stop Swilch
2. Starter BUllon
3. Fuel Pump
4. Ignition Coil (#1 & 4)
5. Ignition Circu it
6. Ignition Switch
7. Fuse Case
8. 30 A Fuse
9. Battery
o
'\!..)
"7"
r-----,
IV
I
+
o
15-32 ELECTRICAL SYSTEM
Fan Switch Inspection
Cooling Fan Circuit
.Remove the fan switch, and check the internal resistance of the fan switch across the switch terminal and
the bod y.
-Suspend the switch in a container of water so ,t hat the
temperature-sensing projection and threaded portion
are submerged.
*The fan switch resistance should change as shown in
the Lable. If it does not, replace the switch.
Cooling Fan Circuit Inspection
If the fan doe~ not run while the water temperature
gauge hand is in the hot range, check th e water tem·
perature gauge, or the cooling fan circuit.
-Visually inspect the radiator fan .
*1 t the fan blJ.lh:'!I or )hroud arc damaged, replace: the f:t.n
assembly .
• Pull off the fan switch lead, and ground it with a
suitable lead.
*If the fan turns, inspect the fan switch.
the fan does not turn, check the fan, fan relay or
wiring as follows.
Fan Switch Resistance
Resistance Change
Temperalure
.,f
Atmospheric
temperature
~n
Raise 94 -100°C
(201 - 212°F)
00 .....
91°C
(196°F)
~<- O.S
~
WARNING.
cBe careful not to touch the fan blades to avoid injury.
Lower
0.5 Q
~
n
Fan Motor Inspection
.Pull out the fan connector and connect it to 12 V
battery as follows.
Fan connector (male)
Battery 1-)
Battery (+)
G
BL
*1 f the fan does not turn, replace the fan assembly.
Cooling Fan Circuit
I.
2.
3.
4.
5.
6.
"3
--~
'=)
Cooling Fan
Fan Switch
Fan Relay
Fuse Case
10 A Fuse
Battery
r
,J)
.6:r1-G
~Bl-I--l
BK j Y
Bl-+----....l
BK / Y
®
,------,
lI'iBl
I
I
I
I
,'5'
,-,<)
I
I
I
l ____ .J
,~
n
ELECTRICAL SYSTEM 15-33
Fan Sw itch Inspection
Thermometer
Fan
Swi tch
~l
/
A. Radio and c.sscttc Player
B. Mo unting Bolts
They must no t louch
the container sides or
bOllom.
Meters and Gauges
Meter Assembly Removal/ Installation Notes
eThe meter Jssembly is removed and installed during the
fairing removal and installation.
C. Watertight Scat
B. Louvers
ICAUTIO~ I
CPlace the meter or gauge so that the face is up.
A. Mounting Bracket
If a
meter or gauge is left upside down or sideways for any
length of time it will malfunction.
eRemove the meter and gauge a~sembly.
Meter Assembly Separation/Assembly Notes
eRemove the radio and cas)cltt! player.
f\. Radio and Cassette Player
B. Player From Panel
C. Mounting Screws
A. Meter and Gauge Assembly
B. Mounting Brack et
C. Rubber Dampers
D. Mounting N~ts
E. Mounting S.crew\
15-34 ELECTRICAL SYSTEM
Meter and Gauge Replacement Notes
COo not remove a meter pointer unless the meter is to
be replaced. The pointers cannot be reinstalled. The
pointer mounting is different from replacement meten.
eTa disassemble the meter case, remove all the sc rew'i
and wiring from the back side of the case,
.Pull the po inter off the meter shaft of th e bad meter
A. Meter and Gauge A"embly
C. Seal Trimming
B. Meter Assembly Cover
only, and remove th e meter unit from the dial face.
eAfter mounting the meter unit on the dial face, put on
the pointer so that it fit s on the me te r s.haft notch.
elnstall the rc tainer, and tighten the ca p while holding
the pointer.
A
A. Pointer
A. Panel Cover
B. Trip Re.et Knob
C. Lower Case
D. Screws
elf the venti lation louvers w ere removed, install them
with the arrow pointing up.
;..\ . Louver
B. Arrow
B. Cap
C. Retainer
Meter and Gauge Circuit
II
1, Indicator Light Self·check Unit
I
(1)
~
~ I
_
ct:
m
I
I ~ I
CO-- o...
_::IiCCC-1-1
:;:
~
I
~co
'"
IX)
-"
co
_
~
P
"cw
-.
(q :
~cL
a..
(iwl
-"
ii:l
I
I
3:
::L '"
L
7)
IX)
?!
~
-'"
>-
Qj
I
(IZi
I
11
BRUB
P
G/ L
E L/ R
BL ~
(- f-
I
,
,
l -f(
,VjY
W,
LB
L
BK/Y
BK
/W
-
[
I
I-
'-
~ r ""-c>e=t"'"
'--''I
BK / W
~
'"8"
"=,'
RK!W
~lt1
r
'(
B
®
c
Y
BL~
12.
13,
14.
15,
16,
17 .
18.
19.
20.
21.
22.
-, 23.
: 24.
-
",
R
-
I
\?~
"_~>-
B:~)1J'
I
I
.
~
co>->-
Q)>->-
,.:; - >2
'"
~-"
!2P
o
'"
::J
;;- -
-"
0<
-"
IX)
:;:
'"
~ !2~
m
1 -" l
f
~ ~~ ~e (f2)~
- ,~_:;:
ru
-
10,
Battery Indicator Light
Oil Pressure Warning Light
Fuel L ~ve l Warning Light
Fuel Gauge
Tachometer
Water Temperature Gauge
Distance Sensor
,W/ AC Signal Un it
AV: Auto Volume (Aud io )
AC: Auto Cancel (Signal)
Meter Assembly Side
Ignition Coil (#1 & 4)
Ignition Circuit
Main Relay
Ignition Switch
Fuse Case
10 A Fuse
30AFusc
Turn Signal Circuit
Audio Circuit
Water Temperature Sensor
Fuel Level Sensor
(Low Fuel Level Sensor)
Oil Pressure Switch
Electrolyte Level Sensor
Battery
'6! --- 1'JV.
Y
L G/BK
(-
( -
(
B ---"
BK
-
M
I
8,
9.
11.
I
I
R
2.
3.
4.
5,
6.
7.
::L
r-
m
BK Y
/
(')
-I
::0
(')
>-
»
r-
::L
en
<
IX)
(?}j
~
m
...==
~L~
U1
W
U1
15-36 ELECTRICAL SYSTEM
Tachometer Inspection
NOTE
oThe tachometer inspection is explained on the assumption that the ignition system operates normally.
. Check to sec that the rub ber dampers at the mete r
mounting bracket are in goo d conditio n. They should
not be hard or cracked.
• '{eplacc an y dama.ged rubbt:r dampers ~"jlh new U fl e).
e<:heck to see that all mete r mounting bolts and nuts are
ti gh tell ed·sec ure ly.
*Tighten the loose fasteners.
_Check the tach ome ter circui t wiring.
*1 f all wiri ng and components o th er than th e tac hometer unit check o ut good, the un it is suspect. Check
th e un it as shown.
eTurn the ign i tion switch ON.
.With the BK/ Y and the BR I.ad conn ec ted, open o r
connect the BK lead to the BR lead re peat ed ly. T hen ,
the meter hand sho uld flick.
*I f the hand does not fl ick, replace the tacho meter
un it.
Water Temperature Gauge Operation Check
Ignition Switch Position: ON
Wire Location:
Female, Sensor Connector
(dioconnected)
Gauge should r.ad C when
Results:
connector wire is opened.
Gauge should read H when
connector w ire is grounded to
engine.
COo not ground the wiring longer than necessary. After
the needle swings to the H position, stop the test.
Otherwise the gauge could be damaged.
*I f the gauge readin gs are correct, the water temperature
senso r is bad. If these readings arc no t ob tained, the
trouble is with the gauge and /or wiring.
-Chec k th e water temperature gauge circuit wiring.
*If all wiring and co mponents o ther than the water tem perature gauge unit chec k out good, the un it is
defective.
Fuel Gauge Opeartion Inspection
.Prepare an auxiliar y wire , and check the operatio n of
th e gauge.
Fuel Gauge Operation Check
Ignition Switch Pos ition :
ON
Female 3-pin sensor connector
Wire Location:
(disconnected)
Results:
Gauge should read E wh en W/Y
and BK/Y wires are opened.
Gauge ,hould read F when W/Y
and BK / Y wires are shorted.
Indicator Light Self-check Unit Inspection
COo not short-circuit the leads longer than necessary.
When the hand swings to the "F" position, stop shortcircuiting. Otherwise a good meter could be damaged.
*If the gauge readings are correc t, the fuel level sensor is
bad. If these readings are not obtained, the tro ubl e is
with the gauge and /or wiring.
-Che, k the fuel gauge circuit wiring.
* If a ll wiring and com ponent s other [han the fuel gauge
unit check o ut good, the u ni t is defective.
Water Temperature Gauge Operation Inspection
.Prepare an auxiliary wire, and check the o pera t ion of
the gauge.
.Pre pare four auxiliary wires and 12 V battery .
• Disconnect th e 9- pin connectors fro m the meter
assemb ly.
-Connect the battery (+) terminal to the BR meter lead,
and the battery (-) term inal to the BK / Y me ter lead .
The battery indicato r light shou ld turn o n at this time.
*If th e indicator light do es no t turn on, check the wiring
and bu lb. If th ey are OK, the self-c hec k u nit is
defective. Replace the meter assem bly.
-Co nnect th e battery (+) term inal to the P meter lead.
T he battery indicator light should turn o ff a t th is time.
*If the indicator light does not turn uff, the self·check
uni t is defective. Replace the meter assembly .
-Connect the ba ttery (- I terminal to th e BU R meter
lead. The ba llery, oil, and fue l indicator ligh ts should
turn on at thj~ time.
*I f any li ght docs not turn on. check thl.! wiri ng and
bu lb. If they arc OK, the self·check unit is defective.
Rep la ce the meter asse mbl y.
*If th e above teSIS prove that th e left-c heck unit is good,
chec k the main wiring harn ess side.
ELECTRICAL SYSTEM 15·37
Indicator Light Self·check Operation
Ignition
Switch
and
Sensor
Battery
(Electrolyte Level)'
Fuel Level
(Low Fuel)-Oil Pressure'""**
Battery
Indicator
Light
Fuci Level
OFF
.
~
, ,
OFF
OFF
,,
,
,,
,
,,
,,
,,
[
[
,
Fl
fl
,
, ,
>0; ..
Low Fuel Level Sensor:
..... "Oil Pressure Swi tch:
fOOl
! ,
-.fONt
I
ON
L
: I
ON
L
[ONlJ
ON
L
ON
L
[
,,
[
[
,
I
Oil Pressure
"Electrolyte Level Sensor:
L
ON
OFFi
OFF - Less than 2 V
ON - More than 4 V
OFF -+ Fuel level is above the sensor.
ON - Fuel level is below the sensor.
OFF -,. Engine is running.
ON - Engine is stopped.
AV/AC Signal Unit Inspection
.Prepare an auxiliary wire.
eDisconnect the AV/AC signal unit BK/W lead from the
distance sensor.
.. -:.®
eTurn an the ignition switch and audio power switch.
eMeasure the voltage between the Y lead (+) and the BL
lead (- ). The VOltage should be 8 V.
*If the volt.tgc is not as specified, check the AV control
circuit. If the f\ V control circuit is good , the signa l
unit is defective. Replace the meter assembly.
eGround the signal unit BK/W lead with an auxiliary
wire and measure the voltage again. The voltage should
be 2 V.
*If the voltage is not as specified. the signal unit is
defective. Replace the meter assembly.
.. Turn on (L or R) the turn signal switch.
eMeasure the voltage between the LG/BK lead (+) and
the BKjY lead (-). The voltage should be 6 V when
th e signal unit BK/W lead is grounded, and 0 V when
the BK/W lead is opened.
*If it does not as specified, check the AC control circuit.
If the AC control circuit is good, the signal unit is
defective. Replace the meter assembly.
*If the above tesb prove that the AV/AC signal unit is
good, check the distance sensor, audio system, and /or
turn signal circuit.
A
A.
Indicator Light Self·check Unit
B.
AV/AC Signal Unit
C
Distance Sensor
A V Control Circuit Inspection
Distance Sensor Inspection
-Olsconnect the distance sensor leads.
-M e::asure the resistance between the stnsor leads while
turning the front wheel slowly. The meter should show
con tinuity and then open periodicall y as the wheel
revolutions.
*I f it does not, replace the distance sensor.
-Disconnect the 2-pin connector from the meter
assembly.
_Turn on the ignition switch dnd audio power switch.
e~'lcasure the vollJge between the Y lead (+) and the BL
lead (-) in the female 2'pin connector. The voltage
should be 8 V.
*If the voltage is not as specified, the trouble is in the
audio system.
15-38 ELECTRICAL SYSTEM
A C Control Circuit Inspection
Fuel Level Sensor
eDisconnect the 9-pin white connector from the meter
assembly.
eTurn o n the ignition swi tch and turn signa l switch.
eMeasure t he voltage between the R lead (+) and the
BKi Y lead (-) in the female 9-pin conneCtor. The
voltage should be 6 V.
*If the voltage is not as specified, the trouble is in the
turn signal circuit.
Electrolyte Level Sensor Inspection
eDisconn ect the electrolyte level sensor lead.
eMeasure the voltage between th e sensor lead (+) and
the battery (- ) termina l.
*If the vo ltage is lower than the specified value, first
check the electrolyte level in the cell where . the sensor
is installed. If the level is lower than th e lower level
line, add disti ll ed water. If the level is high enough, remove th e se nsor from the battery to check for an open
lead and to check the sensor lead stick for corrosion or
other damage. If any trouble is found in th e lead or
stick, re pai r or replace it.
Electrolyte Level Sensor Voltage
More than 6 V
eMeasure the resistance of the electrolyte leve l sensor.
*1 f the resistance is not as specified, replace the sensor.
Electrolyte Level Sensor Resistance
about 680
1. Float in Full Position
2. Float in Empty Posit ion
3. Float Arm Stop
4. Low Fuel Level Senso r
Water Temperature Sensor Inspection
-Remove th e water temperature sensor, and check the
internal resistance of the sensor across the sensor
terminal and the body.
-Suspend the sensor in a container of water so that the
temperature sensi ng projection and threaded portion
are submerged.
*If the resistance is not as specified, replace the sensor.
Water Temperature Sensor Resistance
80"C (176"F):
100"C (212"F):
About 52
About 27
n
n
n
Water Temperature Sensor Inspection
Fuel Level Sensor Inspection
.Remove the fu el level sensor.
e<:heck that the noat moves up and down smoolhly
without bindi ng. It should go down under its own
we ight.
*If the float does not move smoothly, replace the
sensor .
• Insp ec t th e leads and 3-pin connector.
*If th~ y show an y signs of damage, replace th e sensor.
.i\.·leasure the resistance between the WjY and I3KjY
sensor leads.
*If the resista nce is not as specified, or t he resistance
values do not change smoothly as the float moves up
and down, replace the sensor.
Fuel Level Sensor Resistance
Full Position :
Empty Position:
3 -12 n
70 - 120
n
Water
Temperature
Sensor
Thermometer
/
,~
\/
They mu st not touch
the conL:li ncr sides or
boltom.
ELECTRICAL SYSTEM 15-39
*If it does not, adjust the rcar brake light switch up or
down,
To change the switch po sition, turn the
Switches
adjusting nut.
Rear Brake Light Switch Adjustment
-Check the operation of the rcar brake light switch by
depressing the brake pedal. The brake light should go
on after abou t 15 mm of pedal trave l.
oro avoid damaging the electrical connections inside the
switch, be sure that the switch body does not turn
during adjustment.
Switch Inspection
- Usi ng an ohmmeter, check to see that only the connections shown in the table have continuity (about
lero ohms).
*If the switch has an open or short, repair it or replace it
wi th new o ne.
A. Rear Brake Light Switch
B. Adjusting Nut
C. Ligh ts sooner.
D. Lights later.
E. 15 mm
Ignition Switch Connections
W
YIR
BL(W
R
BR
IV
OIG
OFF, LOCK
ACC
ON
P(Park)
Starter Lockout Switch Connections
Dimmer Switch Connections
BK/ Y
BK/ R
BK
BL/ Y
When du tch le vcr is pu lied in
When clu tch lever is re leased
BL/O
R/Y
RIBK
HI
LO
Horn Button Connections
BKJW
BK/Y
c
)
Push on
Volume Control Switch Connections
..
R
UP
." DOWN
Turn Signal Switch Connections
GY
0
G
BLIIV
\VIR
BKIY
WIG
r
"
R
N
L
')
GY
BR
15-40 ELECTRICAL SYSTEM
Auto Seek Switch/Program Change
SWitch Connections
Rear Brake Light Switch Connections
BR
BL
BK/ R
BK/V
BR/W
BRjW
o
c
When brake pedal is pushed down
Side Stand Switch Connections
Muting Switch Connections
When side stand is up
OFF
When side stand is down
ON
Trunk Room Light Switch Connections
Radio!Tape Button Connections
V
Push on
I
C
GV
I
When tru nk is opened
When trunk is closed
")
Oil Pressure Switch Connections·
Engine Stop Switch Connectons
OFF
RUN
51'.'. Terminal
Ground
When engine ;s slOpped
When engine is running
I : I V: I
... : Engine lubrication system is in good condition.
Starter Button Connections
Neutral Switch Connections
Gear Position
SW. Terminal
Ground
BK
Ground
Neutral
Others
Push on
Hazard Switch Connections
Overdrive Switch Connections
Gear Position
OFF
Overdrive (5th gear)
ON
Others
Front Brake Light Switch Connections
BK
When brake lever is pulled in
BK
ELECTRICAL SYSTEM 1&41
A. Ignition Switch
8. Starter Lockout Switch
C. Ho rn Bu tto n
D. Turn Signal Switch
A. Rear Brake Light Switch
B. Side Stand Switch
E. Dimmer Switch
A. Volume Control Switch
B. Auto Seck Switch / Program Change Switch
C. Muting Switch
D. Radio!Tape Button
A. Engine Stop Switch
C. Hazard Switch
8. Starter Button
D. Front Brake Light Switch
A. Trunk Room Light Switch
A. Oil Pressure Switch
B. Neutral and Overdrive Switch
15·42 ELECTRICAL SYSTEM
Relays
Relay Inspection
NOTE
oFor inspections of the starter motor relay and turn
signal relay, fefer to the appropriate sections for
them .
.connect an ohmm eter and 12 V battery to the re lay
as shown.
*I f the rclay does not work as specified, the relay is
defective.
Testing Relay
A. Relays
n.
Meier Range:
x1
range
Criteria: When battery is connected -~ 0
When battery is disconnected -
(~Iain,
Starter Circuit, Headlight)
n
OQ
n
Testing Relay
Ohmmeter
Diodes
Rela y
Diode Inspec tion
_ Zero the oh mmeter, and connect it to each pair of
terminals to check the resistance in both direction s.
*The resistance should be low in o ne direc ti on and more
th an ten times as much in the other directi on . If any
d iode shows low or high in both directions, the diode is
defec tive and the d iode asse mbl y mUSI be re placed .
+
12 V Battery
<D and @ : Relay Coil Terminals
@ and @) : Relay Switch Termina ls
A. Relays (Fan , Brake Light, ACC)
NOTE
oThe actusl merer reading 'Iaries with the merer used
and the individual diode, but, generally speaking, the
lower reading should be from zero to the first ~ of the
scale.
A. Diode Assembly (Ignition)
ELECTRICAL SYSTEM 15-43
A. Diode Assembly (Headlight)
A. Fuse Case
Fuses
......... ,.................................................................. .
A. Fuse Cases for Audio System
Fuse Inspection
elnsepct the fuse element.
*If it is blown OUI, replace th e fuse. Before replacing J.
blO\vn fuse, always check th~ amp~rage in the affected
circuit.
If the arnpl::ragc is equal to or greater than the
fuse rating, check the wiring and related components
for a short circuit.
CWhen 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.
Fuse (Wedge Typel
Fuse Elemenr
Blown Element
fHl
Terminals
Electrical Wiring
Wiring Inspection
-Visually inspect the wiring for signs of burning, fraying,
etc .
*If any wiring is poor, replace th e damaged wiring.
.Pull each connector apart and inspec t it for corrosion,
dirt, and damage.
*If the connector is corroded or dirty, c lean it carefully.
If it is damaged, replace it.
-Check the wiring for continuity.
o Use the wiring diagram to find the ends of the lead
whic.h i'i ')U'ipected of being a problem.
:J,"'casure the resistance bt!twt!en the ends of the Icads.
*1 f the resistance is nut 0 n, thl.! lead is defective.
Replace the lead or the wiring loom if necessary.
APPENDIX 16-1
Appendix
Table of Contents
Additional Considerations for Racing . . . . . . . . . . . . . . . . . . . . . . . . . . .
16·2
Carbu retor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16-2
Spark Plug ... .. . .. . . . . .•. .. . ... . ............ . . .... •. . ..
16-2
Spark Plug Inspection. . . . . . . . . . . . . • • . . . . . . . . . . . . . . . . . . . .
16-2
Troubleshooting Guide . . . . . . . • . . . . . . . . . .. . . . . . . . . . . . . . . . • . . .
16·4
General Lubrication . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . • . .
16-8
Lubrication . ............. ............. ... ... . .• ......
16-8
Nut, Bolt, and Fastener T ightness . ... . .. .. . . . . .... . .. . . .. . . • • .
16-8
Tightness Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .
16-8
Unit Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
16- 10
16-2 APPENDIX
Additional Considerations for Racing
Thi'5 motorcycle has been manufactured (or use in
a reasonable and prudent manner and as a vehicle only_
However, some may wish to subject this motorcycle lO
abnormal operation, ~uch as wuuld be experienced under
racing condition.. KAWASAKI STRONGLY RECOM·
MENDS THAT ALL RIDERS RIDE SAFELY AND
OBEY ALL LAWS AND REGULATIONS CONCERN·
ING THEIR MOTORCYCLE AND ITS OPERATION.
Racing should be done under su pervised conditions,
and recognized sanctioning bodies should be contacted
for (u rther details. For those who desire to participate
in competitive racing or related use, the following
technical information may prove useful.
However,
please nOle the following important points.
.You are entirely responsible for the use of your motorcycle UndL'f abnormal conditions such as rae.jng. and
Kawasaki shall not be liable for any damages which
might arise from such usc .
eKawasaki 's Limited Motorcycle Warranty and Limited
E(l1ission Control Systems Warranty specifically (:xelude motorcycles which arc used in competitive or
related uses.
Please read the warranty carefully.
eMotorc ycie racing b a very sophisticated sport, subject
to many variables,
The following information is
theoretical only, and Kawasaki shall not be liable for
any damages which might arise from alteration~ utilizin~ this information.
eWhen the motorcycle is operated on public roads, it
must b~ in it::. original state in order to ensure :kifety
and compliance with applicable regularions.
When a plug of the correct heat range is being used,
the electrodes will stay hot enough to keep all the
carbon burned off, but cool enough £0 keep from
damaging the engine and the plug ilself. This temperature is .bout 400 - 800°C (750 - 1,450°F) and can
be judged by noting the condition and color o( the
ceramic in sula lOr around the center electrode. I f the
ceramic is clean and of a light brown color, the plug is
operating at the right temperalUre.
A spark plug (or higher operating tcmperature~ is
used for racing. Such a plug is designed rur vetter
cooling efficiency so that it will not overheat and thus
is often called a "colder"· plug. If a spark plug with too
high a heat range is used ,- thar is, a "co ld" plug that
cools itest:lf too well - Ihe plug will stay too cool to
burn off the carbon, and the carbon will collect on the
electrodes and th e ceramic insulator.
The carbon on the electrodes conduct'5 electricity,
and can short the center electrode to ground by either
coating the ceramic insulator or bridging across the gap.
Such a short will prevent an effective spark. Carbon
build-up on the plug can also cause other troubles. It
can heat up red-hot and cause preignition and knocking,
which may e\lcntually burn a hole in the top of the
piston ,
Spark Plug
Carburetor:
Sometimes an alteration may be desirab le for improved performance under special conditions when
proper mixture is not obtained after the carburetor has
been properly adjusted, and a/l pans cleaned and found
to be functioning properly .
If the engin e still exhibits symptoms of overly lean
carburetion after all maintenance and oidjustments are
correctly performed, the main jet can be replaced with it
smaller or larger one. .At smaller numbered jet gives a
leaner mixture and a larger numbered jet a richer mixture.
Reach
Spark Plug:
The spark plug ignites the fuel /air mixture in thl!
combustion chamber, To do this effectively and at the
proper time, the correct spark plug must be used, and
the spark plug must be kept clean and adjusted,
Test have shown the plug listed in the "Electrical
System" chapter LO be the best plug for general usc.
Since spark plug requirements change with the igni ·
tion and carburetion adjustments an.d wi th riding condi·
tions, whether or not a spark plug of a correct heat range
is used should be de termined by removing and inspecting the plug.
Plug gap
1. Terminal
4. Gasket
2. Insulator
5. Center electrode
3. Cement
6. Side electrode
Spark Plug Inspection
eRemovc the spMk plug and inspect the ceramic insulator.
APPENDIX 16-3
Spark Plug Condition
Carbo n fouling
O il fou ling
*Wht, ther or no t the ri ght tem pe ratu re pl ug is being u sed
ca n be ascerta in ed by not ing th e cond iti o n of t he
ceram ic insul ato r around t he electrode. A light bro wn
color indi ca tes. the correc t p lug is being used. If the
ceram ic is white , th e plu g is o perati ng a t too high a
tem pera ture and it shou ld be rep laced wi th the nex t
col der type,
{CAUTlO~ I
Clf the spark plug is replaced with a type other than the
standard plug, make certain the replacement plug has
the same thread pitch and reach (lenqth of threaded
portion) and the same insulator type Iregular type or
projected type) as the standard plug.
Cif the plug reach is too short, carbon will build up on
the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert the
conect spark plug later.
e ll the reach is too long, carbon will build up on the ex posed spark plug threads causing overheating,
preigniton, and possibly burning a hole in the piston
top. I n addition, it may be impossible to remove the
plug without damaging the cylinder he.d.
Plug Reach
Too sh o rt
Co rrect reach
Carbon
bu ilds up here
Standard Spark Plug Threads
Diameter :
Pitch :
Reach :
12 mm
1.25 mm
19 .0 mm
Nor mal o perati o n
Overheating
NOTE
OThe heat range of the spark plug functions like 8
thermostat for the engine. Using the wrong type of
spark plug can make the engine run too hot (resulting
in engine damage) or too cold (with poor performance,
misfiring, and stalling).
16-4 APPENDIX
Troubleshooting Guide
NOTE
OThis is not an exhaustive list, giving every possible
cause for each problem listed. It is meant simply as a
rough guide to assist the troubleshooting for some of
the more common difficulties.
Piston ring bad (worn, weak, bro ken, or sticking)
Piston ring/land clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or
carbon accumulation on the seating surface)
Hydraulic las h adjuster damaged (worn, seizure, or
spring broken)
Hydraulic lash adjuster oil passage clogged
Engine Doesn't Start, Starting Difficulty:
Starter motor not rotating:
Starter lockout or neutral switch trouble
Surter motor trouble
Battery voltage low
Relays not contacting or operating
Starter button noc contacting
Wi ri ng open or shorted
Ignition switch troubl e
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn't turn over:
Starter motor clutch trouble
Engine won't turn over:
Val vc seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small (!nd seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camsha ft seizure
Alternato r shaft bearing seizure
Balancer beari ng seizure
No fuel II ow:
Fuel tank air ve nt obstructed
Fuel pump troubk
Fuel line clogged
Float valve clogged
Engine flooded:
Fud level in carburetor float bowl too high
Float valve worn or stuc k open
Starting technique faulty
(When flooded, crank the cngi ne with the throttle
fully open to allow more air to reach the
engine,)
No spark; spark weak;
Elattery voltage low
Spark plug dirt y, bro ken, or maladjush.:d
Spark plug cap or high tensi on wiring trouble
Spark plug cap not in go od conLlct
Spark plug incorrect
IC igniter trouble
Neutral, staner loCkout, or side stand switch
tro uble
Pickup coil trouble
Ignilion coil trouble
Ign ition or engine stop switch shorted
Wiring shorted or ope n
Fuse blown
Compression low :
Spark plug loose
Cylinder head not sufficiently Lightened down
Cylinder, piston worn
Poor Running at Low Speed:
Spark weak:
Battery voltage low
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
IC igniter trouble
Pickup coil trouble
Ignition coil trouble
Fuel/air mixture incorrect:
Pilot screw maladj usted
Pilo t jet, or air passage clogged
Air bleed pipe bleed holes clogged
Pilot passage clogged
Air cleaner clogged, poorly scaled , or missi ng
Starter plunger stuck open
Fuel level in carburetor fl oat bowl too high or too
low
Fuel lan k air vent obstructed
Carburetor hold~r loose
Air cleaner or surge tank duct loose
Fuel pump trouble
Comprenion low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/la nd clearance excessi ve
Cylinder head warped
Cylinder head gasket damaged
Engine not sufficie.ntly warmed up after lash
adjuster install atio n
Hy draulic lash adjusler dam~ged (worn, seizure, or
spring broken)
Hydraulic lash adjuster o il passage clogged
Valve spring broken or weak
Valve not seating properl,! (valve bent, worn, or
carbon accumulalion on the seating surface)
Backfiring when deceleration:
Vacuum switch valve broken
Air suction valve trouble
Other:
IC igniter trouble
Carburetors no t synchronizing
Carburetor vacuum piston doesn't slide smoothly
Engine oil viSCOSity too high
Driw train t(ouble
Final gcar case 011 viscosity too high
Brake draggi ng
Air suction valve troubl e
Vacuum switch val ve trouble
APPENDIX 16-5
Poor Running or No Power at High Speed :
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug cap shorted Of not in good contact
Spark plug incorrect
Ie ignite r trouble
Pickup coil trouble
Ignition coil trouble
Fuel/ai r mixture incorrect:
Starter plunger sWt,,:k open
Main jet clogged or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level in carburetor float bowl too high Of toO
low
Bleed holes of air bleed pipe or needle jet clogged
Air cleaner clogged, poorly sealed, or missing
Air cleaner or surge tank dUCl poorly scaled
Water of foreign matter in fuel
Carburetor holder loose
Fuel unk air vent obstructed
Fuel line clogged
Fuel pump trouble
Compression low:
Spark plug loose
Cylinder head nOl sufficiently lightened dow n
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or stiCking)
Piston ring/land clearance excessive
Cyl inder head sa,ket damaged
Cylinder head warped
Hydraulic lash adjuster damaged (worn, sdzure, or
,pring broken)
Hydraulic'lash adjuster oil pa>sage clogged
Valve spring broken or weak
Valve not seating properly (valve bem, worn, or
carbon acc umul ation on tile scating surface.)
Knocking:
Carbon built up in combustion chamber
Fuel poor ~uality or incorrect
Spar/... plug im:orrcct
Ie igniter trouble
Backfiring when deceleration :
Vacuum swi t...:h valve broken
Air suc tion va lve tro uble
Miscellaneous :
Thro ttle \'a l v~ won't fully open
Vacuum piston don't slide smoothly
Brake draggi ng
Clutch slipping
Overheating
Engine oi l level too high
Engine oil viscosity too high
Drive train trouble
Final 2,ear case oil viscosity too high
Air suction valve trouble
Vacuum switch valve trouble
Balancer mechaoism mal funct ioning
Overheating :
Firing incorrect:
Sp"k plug dirty, broken, or maladjusted
Spark plug incorrect
IC igniter trouble
Fuel/air mixture incorrect :
Main jet c logged or wrong size
Fuel level in carburet or float bowl lOa low
Carb u retor ho lder loose
Air cleaner poo rly sca led, o r missing
Air cleaner o r surge tank duct poorly sealed
A ir cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Clu tch slipping
Engine o il level too high
Engine o il viscosity too h igh
Driv/: train trouble
Fi nal gear case o il viscosity too high
Brake dragging
Lubrication inadequate:
Engine oi l level too low
Engine o il poor quality or incorrect
Gauge incorrect:
Water temperature gauge bro ken
Water temperature se nsor broken
Coolant incorrect :
Coola nt levd too low
Coolant d e teriorated
Cooling system component incorrect :
Radiator clogged
Th ermos tat trouble
Rad iator cap troub le
Thermost.atic fan switch troubl e
Fan rel:<I' trouble
Fan motor broken
Fan hlade d.lmaged
Water pump not lurning
\Va rer pump impeller damaged
Over Cooling :
Gauge incorrect :
Waler temperature gduge brok~n
Wal er temperat ure sensor broken
Cooling system component incorrect ;
Thermostatic fan switch trouble
Th e rmostat trouble
Clutch Operation Faulty:
Clutch slipping:
Fric tio n plate worn or warp ed
Steel pl ate worn o r warped
Clut.ch sp ring broken or weak
Clutc h rlollcas~ mt:chanism trouhle
Clutch hub or housing unevenlv worn
Clutch not disengaging properly :
Clutch plate warped or too rough
Clutch spring tension uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oillevd too high
Clutch ho usi ng fro zen on drive shaft
Clutch release mechilnism trouble
Clutch hub locknut loose
Air in the clutch fluid lint'
Clu tch fluid leak
16-6 APPENDIX
Clutch nuid deterio ra ted
Primar y or secondary cup damaged
Master cyli nd er scra tched in side
Gear Shifting Faulty:
Doesn 't go into gear; shift pedal does't return:
Clutch not disengaging
Shift fork bent or seiled
Gear s tuck o n the shaft
Gear position lever binding
Neutral positioning lever binding
Shift return spring: weak or broken
Shifl
Shift
Shift
Shift
return spring pin loose
mechanism arm spring broken
mechanism ar m broken
pawl broken
Jumps out of gear:
Shift fork worn
Gear groove worn
Gear dogs Jnd/or dog holes worn
Sh ift drum gro ove worn
GeM position ing lever spri ng weak or broken
Sh ift fork pin worn
Drive shaft, output sha ft, and/or gear splines worn
Overshifts :
Gear pos itioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal Engine Noise:
Knocking:
IC igniter trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug intOrrecl
Overheating
Piston slap :
Cylinder/ pisto n clearance exces~ivc
Cylinder , piston worn
Connecting rod ben t
Piston pin, piston holt'S worn
Valve noise:
Engine not su fficiently warmed up after las h
a.djus ler instalJali o n
Hydraulic Ia.sh a.djuster damaged (worn, seizure, or
;pring broken)
Air in hydraul ic lash adjuster
~' c tal chips or dust jammed in hydraulic lash
adjuster
Engine o perated in rcd zone
Va lve spring broken or weak
Camshaft bearing worn
Other noise:
Connecting rod small end clearance ex cessivl!
Connecting rod big end clearance C!xcessive
Piston ring worn, broken or stuck
Piston seizure , damage
Cylinder head gasket ledking
Ex ha ust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mo unts loose
CrdnkshJft bearing worn
Primary gear worn o r chipped
Camshaft chain tensioner troub le
Camshaft chain, sprocket, guide worn
Air suction va lve damaged
Vacuum switch valve damaged
Balancer gear worn or chipped
Balancer shaft positio n ma ladjusted
Bala ncer bearing worn
Balancer or alt ernator shaft co upling rubber
damper damaged
Alternator shaft chain tens io ner troubl e
Alternator shaft chdin, sprocket, guide worn
Abnormal Drive Train Noise:
Clutch noise:
Weak or damaged rubber d.tmper
Clutch housing/ friction plate cJeardncc excessive
Clutch housing gear worn
Transmission noise :
Bearings worn
Tr;msmission geMS worn or chipped
t\.k tal chips jammed in geM teeth
Engine oil insufficient
Drive line noise:
Beve! gear bearings worn
Bevel gears worn or chipped
Bevel gears malad justed
Rear wheel coupling damaged
Insufficient lubricant
Abnormal Frame Noise:
Front fork noise :
Oil insufficient or 100 thin
Spring weak or broken
Rear shock absorber noise:
Shock Jb;orber damaged
Disc brake noise :
Pad installed incorrectl y
Pad ,urface gl aze d
Disc warped
Caliper trouble
Other noise :
Bracket , nut , bolt , etc . not properly mounted or
tightened
Oil Pressure Warning Light Goes On:
Engine oi I pump damaged
cngine oil screen clogged
Engine oil filter clogged
Engine oil level too low
Engine o il visco5,ity too low
Camshaft bearings worn
Crankshaft bearings worn
Oil pressure swi tch dam.lged
Wiring damJged
Reli ef valve stuck open
Q-ring at the oil pipe in the crJnkc.J~c damaged
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damased
APPENDIX 16-7
Valve guide worn
Engine oil level tOO high
Black ,moke :
Air cleaner clogged
Main jet too large or fa llen off
Starter plunger stuck open
Fuel level in carburetor float howl too high
Brown smoke:
Mai f'i jet too small
Fuel II;.'vei in carburetor float bowl too low
Air cleaner or surge tank duct loose
Air cleaner poorly sealed or mi ssing
Handling and/or Stability Unsatisfactory ;
Handlebar hard to turn:
Steering stem locknut too tight
Bearing damaged
Steering bearing lubrication inadequalt:
Steering stem bent
Tire <lir pressure too low
Handlebar shakes Dr excessively vibrates :
Tire worn
Swing arm pivot beari ng worn
Rim warped, or nO[ balanced
Wheel bearing worn
Handlebar clamp loose
Steering stL'nl head nut loose
Handlebar pulls to one side:
Frame bent
Wh eel misalignment
Swing arm bent or twisted
Steering maladjusted
Front fork bent
Righ t/left fork legs unbalanced (oi l level, air
pressure)
Shock absorption unsatisfactory:
(Too hard)
Front fork oi l excessive
Front fork oil viscosity too hi gh
From fork air pressure too high
Rear shock absorber air pressurt! too high
Tire air pressure too high
Front fork bent
(Too soft)
Front fork oil insufficient and/or leaking
Front fork oil viscosi ty too low
Front fork air pressure too low
Rear shock absorber dir pressure too low
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaki ng
Brake Doesn't Hold:
Air in the brake line
Pad or disc worn
Brake Ouid leak
Di« warped
Contaminated pad
Brak. fluid deteriorated
Primary or secondary cup damaged
,\ l aslCr cyl inder scralched inside
Battery Discharged:
Battery fau lt y (e.g., plate! lulphated, shorted
through sedimentati o n, electro lyte lewl too
low)
Batterly It!ads making poor contact
Load excessive (e.g., bulb of excessive wattage)
Ignition switch troub le
Altern ator trouble
Wiring faul lY
Battery Overcharged:
Ahernaror tro ubl e
16-8 APPENDIX
Nut, Bolt, and Fastener Tightness
General Lubrication
Lubrication
Tightness Inspection
eBefore lubricating each PJrt, clean off any rusty spots
with rust remover and wipe off any grease, oil, dirt, or
e<:heck the tightness of the bolts and nuts li,ted here.
Also, check to st;)i! that each cotler pin is in place a.nd in
good condition.
grime.
eLubricate the points listed below with indic.atcd
NOTE
lubricant.
NOTE
CWhenever the vehicle has been operated under wet or
rainy conditions; or especially after using a
high·pressure spray water, perform the general
lubdcation.
Pivots: Lubricate with Motor Oil.
Center Stand
Side Stand
Clutch Lever
Brake Lever
Brake Pedal
Rear Brake Rod Joint
Points:
Lubricate with Grease.
Throttle Inner Cable Upper End s
Speedometer I nner
Cablc~
*Grease the lower part of the inner cable sparingly.
Cables: Lubricate with Rust Inhibitor.
Choke Cable
Throttle Cables
uFor the engine fasteners, check the tightness of them
when the IJngine is cold (at room temperature).
*If
lher~
specified
are
loos~
fasteners, retorque them to [he
torque following the specified tightening
sequence. Refer to the appropriate chapter for torque
specifications. If torque specifications are not in the
appropriate chapter, see the basic torque [able (see
Torque and Locking Agent in the General Information
chapter).
For each fastener, first loosen it by % turn, then
tighten it.
*If cotter pins are damaged, replace them with new
ones.
Nut, Bolt, and Fastener to be checked
Wheels:
Front Axle Nut
Front Axle Clamp Bolts
Rear Axle Nut
Rear Axle Nut Cotter Pin
Brakes:
Front Master Cylinder Clamp Bolts
Front Caliper Mounting Bolts
Rear Master Cylinder Mounting Bolts
ReM Caliper Holder Mounting Bolt
Rear Caliper Mounting Bolts
Brake Lever Pivot Nut
Cable Lubrication
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Front Fender Mounting Bolts
Rear Sh ock Absorber Mounting Bolt and Nuts
Swing Arm Pivot Shaft Nuts
Steering:
Stem Head Nut
Handlebar Clamp Bolts
Handle Grip Bar Bolts
Engine:
Engine Mounting Bolts
Cylinder Head Bolts
Exhaust Pipe Mounting Nuts
1. Pressure Cable Luber: KS6019-021
2. Lubricate cabks with a penetrating rust inhibitor.
Muffler Mounting Bolts
Exhau>t Pipe and Muffler Connecting Clamp Bolts
Clutch Master Cylinder Clamp Bolts
Clutch L~ver Pivot Nut
Radiator Mounting BoilS
Shift Pedal Bolt
Other"
Center Stand Bolts
Side Stand Nut
Rear Frame (I.·lounting Bolts
APPENDIX 16·9
Right Down Tube Mounting Bolts
Footpeg Bracket Mounting Bol ts
Footboard Bracket Mount ing Bolts
Final Gear Case Mou nting Nuts
Engi ne Guard Mounti ng Bolts
Bumper Mounting Bolts
Grab Bar Mounting Bolts
Travel Trunk Mounting Bolts
Dummy Tank Cover ,\ lo unting Screws
16-10 APPENDIX
Unit
Conve~ion
Units of Length:
Table
km
Prefixes for Units:
Symbol
M
k
e
m
Prefix
mega
kilo
eenti
milli
micro
1,000,000
1,000
0.01
0.001
0.000001
mile
ft
in
Units of Torque:
Units of Mass:
2.205
0.03527
x
x
~
Power
x
x
x
x
x
!1
kg
g
0.6214
3.281
0.03937
x
x
x
m
mm
N·m
N·m
N·m
x
x
x
kg·m
kg·m
kg·m
x
x
x
0.1020
0.7376
8.851
9.807
7.233
86.80
kg·m
ft·lb
in-Ib
~
~
N·m
ft·lb
in-Ib
~
~
Ib
oz
Units of Pressure:
Units of Volume:
x
x
x
x
x
x
x
x
x
L
L
L
L
L
L
mL
mL
mL
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
~
~
~
~
kPa
kPa
kPa
x
x
x
kg/em'
kg/em'
em Hg
x
x
x
0.01020
0.1450
0.7501
98.07
14.22
1.333
x
0.6214
~
~
~
kg/em'
psi
em Hg
kPa
psi
kPa
Units of Speed:
km/h
cu in
Units of Force:
mph
Units of Power:
N
N
x
x
kg
kg
x
x
0.1020
0.2248
9.807
2.205
~
~
kg
Ib
kW
kW
x
x
N
Ib
PS
PS
x
x
1.360
1.341
0.7355
0.9863
~
~
PS
HP
kW
HP
Units of Temperature:
5 (OF +40)
9 (OC+401_40~ of
5
OF
AO
~4
°C
32
63
~20
:0
20
: 40
60
I
I,I
I
I I
I
I
~40
9
-20:
-17.8
0
:
4.4
,,
104
80
I II
20
26.7
140
160
I
I
I
40
60
100:
212
176
120
I'
"
4B.9
I:
: 180
.I
I
80
71.1
200
I
I ,,
,
93.3
,
240 I
: 220
,
I
100
OF
248
I
I
I I
: 120
""
2S4
260
I
280:
300
I, I
I
I
:140
133
320
I
160
°c
!
'.
MODEL APPLICATION
Year
Model
1986
ZG1200·Al
&ginning Frame No.
I KAZG9A 1IOGAOOOOOI . or
JKAZG9A lOGB500001
0: This dicit in the frame number changes from one machine
another .
-
~Kawasaki
KAWASAKI HEAVY INDUSTRIES, LTD,
Consumer Products Group
Part No. 99924-1064-01
to